Engine: Service Precautions
WM 1001AW The most important working regulations and warning notes
Folder 1
Group 1 - Engine
DANGER
Suspended load.
- Risk of serious crushing and injury
-> Do not work at or under a suspended load.
-> Never reach in between the engine and components during installation or removal.
-> Wear protective safety gear.
CAUTION
Leaks due to components being at too low a temperature or at different temperatures.
- If components that are cold or at different temperatures are sealed together by the application of sealant, adhesion problems and leaks can arise due to the build-up of condensation water or component distortion.
-> Components must have reached at least 17°C throughout.
-> Components must not be too hot (distortion).
-> Spare parts that are stored in the cold or heat (strong sunlight), must be brought to room temperature or the same temperature as other parts before installation.
Group 10 - Crankcase - suspension
DANGER
Danger of injury from incorrect use of tools and from falling loads.
- Danger of crushing from heavy loads.
-> When working on the engine suspension, the engine must be appropriately secured against falling or lowering.
-> Never use defective lifting equipment (bent or damaged tools must not be used or repaired. Always replace these tools). Check tools for signs of damage before use.
-> Only use lifting equipment tested and approved by Porsche. Home-made and auxiliary constructions result in improper use and are dangerous.
-> The transport eyebolt can only bear vertical traction with no side or transverse forces. Side loads (e.g. from chains or cables) will damage the transport eyebolt, which must then be replaced. Extreme cases of improper use can break the transport eyebolt.
-> Tools and lifting equipment must always be used properly. Improper use or dangerous home-made constructions can break tools and result in falling loads.
-> Wear protective gloves.
DANGER
Danger of poisoning from silicone, grease and oil.
- Danger of poisoning and damage to skin
-> Do not consume food or drink while working (danger of mixing).
-> Silicones, greases and oils are toxic and must not be swallowed or handled without protection.
-> Observe the specifications on the containers. If swallowed, seek medical advice and show the information on the containers.
-> Wear gloves.
Information
- When working on the crank mechanism, absolute cleanliness is essential.
- Any seals which have been removed must always be replaced.
- Only the auxiliary and assembly equipment recommended for the repair job may be used for the particular assembly work.
- Only the auxiliary materials recommended by Porsche (such as lubricants or sealants) may be used.
- All screw fittings must be tightened according to the prescribed torque or torque angle.
Group 13 - Crank drive, pistons
DANGER
Danger of poisoning from silicone, grease and oil.
- Danger of poisoning and damage to skin
-> Do not consume food or drink while working (danger of mixing).
-> Silicones, greases and oils are toxic and must not be swallowed or handled without protection.
-> Observe the specifications on the containers. If swallowed, seek medical advice and show the information on the containers.
-> Wear gloves.
DANGER
Danger of injury from rotating components and belt drive.
- Risk of severe hand injuries.
-> Never reach into running belt drives or rotating components.
-> Switch off engine.
WARNING
Do not remove the drive belt when the engine is warm.
- Risk of damage or deformation.
-> Drive belts should only be removed when they have cooled down.
DANGER
Danger of injury from running radiator fans (electric fans).
- Risk of severe hand injuries.
-> The vehicle fans can continue running or start up when the ignition is switched off.
-> The power supply to the fans must be disconnected before starting work on the radiator or radiator fans. (Remove fuse => Fuse carrier).
Information
- Work on the crank mechanism/pistons must be carried out very carefully and in clean conditions.
- A dirty engine should be cleaned before opening.
- No dirt may enter the engine when opened.
- During work interruptions, the open engine or components must be covered to protect them from dirt.
- Any seals which have been removed must always be replaced.
- Only processing materials (silicones, oils, greases, etc.) approved by Porsche may be used.
- All screw fittings must be tightened according to the prescribed torque or torque angle.
Information
- Only processing materials (silicones, oils, greases, etc.) approved by Porsche may be used.
- All screw fittings must be tightened according to the prescribed torque or torque angle.
- Never remove the drive belt when it is hot.
Group 15 - Cylinder head, valve drive
DANGER
Danger of poisoning from silicone, grease and oil.
- Danger of poisoning and damage to skin
-> Do not consume food or drink while working (danger of mixing).
-> Silicones, greases and oils are toxic and must not be swallowed or handled without protection.
-> Observe the specifications on the containers. If swallowed, seek medical advice and show the information on the containers.
-> Wear gloves.
Information
- Work on the valve drive must be carried out very carefully and in clean conditions.
- A dirty engine should be cleaned before opening.
- No dirt may enter the engine when opened.
- During work interruptions, the open engine or components must be covered to protect them from dirt.
- Any seals which have been removed must always be replaced.
- Only the auxiliary materials recommended by Porsche (such as lubricants or sealants) may be used.
- All screw fittings must be tightened according to the prescribed torque or torque angle.
Group 17 - Lubrication
WARNING
Engine oil is toxic.
- Danger of poisoning.
-> Do not consume food or drink while working (danger of mixing).
-> If swallowed, observe the warning information on the containers, contact a doctor if necessary and show the information on the containers.
WARNING
Danger of scalding with hot engine oil.
-> Allow engine and components to cool down.
-> Avoid contact with the skin and eyes.
-> Wear suitable protective clothing.
WARNING
Oil is combustible.
- Risk of fire due to oil and hot components (exhaust manifold, etc.)
-> Do not pour engine oil over very hot components (e.g. turbocharger).
-> Never place cloths soaked with oil on hot engine components.
-> In case of fire, use CO2 or dry powder fire extinguishers.
Information
- Only oils with the appropriate viscosity and approved by Porsche may be used.
- A mixture of different oils is not permitted.
- During an oil change, the old oil must be drained from the engine via the drain plugs provided. Extraction by suction is not recommended.
- Engine oil and oil filters must be disposed of according to the respective, applicable national laws.
- Seals in the oil circuit must be replaced by new ones following disassembly.
- Observe the specified torques.
Group 19 - Cooling
CAUTION
Danger of poisoning.
- Coolant additives and cleaning liquids are toxic.
-> Swallowing coolant additives and cleaning liquids must be urgently avoided.
-> Do not consume any food or drink while working (danger of accidental mixing).
-> If swallowed, observe the warning information on the containers and contact a doctor. If necessary, show the doctor the warning information on the packaging.
CAUTION
Danger of scalding with hot coolant.
-> Never open the cooling system when it is hot. Emerging coolant may be very hot and can cause scalding.
-> The cooling system must be depressurised before being opened.
-> Allow engine to cool down.
DANGER
The vehicle fans can continue running or start up automatically.
- Injuries which can lead to the loss of body parts.
-> The power supply to the fans must be disconnected before starting work on the radiator, radiator fans or belt drive. Disconnect the => fuse carrier or battery => Work instructions after disconnecting the battery
-> Allow engine to cool down.
CAUTION
Risk of damaging the cooling system.
-> Do not relieve the system pressure of the cooling system and then run the engine.
-> Relieving the system pressure and subsequently starting the engine can cause severe damage to components in the cooling system. If the cooling system must be opened when it is hot, allow the cooling system to cool down before starting the engine again.
Information
- The coolant filled in at the factory is intended to suffice for the entire service life. As long as the coolant is not contaminated by foreign bodies or other fluids it need not be changed.
- Different coolant additives must not be mixed and doing so may damage the cooling system. Only use original Porsche coolant additives.
- The coolant must be set to antifreeze protection of -37 °C. This corresponds to a mixing ratio of 50 : 50 (coolant additive : water). This mixing ratio provides optimum corrosion and antifreeze protection.
- Coolant additives, coolants and cleaning agents must be disposed of according to the respective, applicable national laws.
- Seals in the cooling system must be replaced by new ones following disassembly.
Information
Group 20 - Fuel supply, control
WARNING
Toxic substances
- Danger of poisoning or suffocation
-> Ventilate the work area well.
-> Never ingest or inhale.
-> Read specific information on the Hazard Sheet.
-> Wear personal protective gear.
WARNING
Highly inflammable or explosive materials
- Danger of fire or explosion
-> Avoid contact with hot parts or sources of ignition.
-> Use suction to remove ignitable vapours.
-> Attach warning sign in a clearly visible position.
Information
- Absorb any escaping fuel using a suitable binding material or a cloth.
- Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
- The fuel system must be depressurised before starting work on it.
- Only work on the fuel system in well-ventilated rooms.
- Any seals which have been removed must always be replaced.
- Do not use any sealant containing silicone or silicone spray when the injection system is open. Traces of silicone drawn in by the engine are not combusted and damage the oxygen sensors.
Group 21 - Exhaust system, turbocharging
CAUTION
Danger of burns from very hot components (turbocharger, exhaust manifold).
-> Components of the exhaust system can be extremely hot.
-> Allow the parts to cool down first and wear protective gloves.
Information
- After the connecting clamps in the exhaust system have been released, they must always be replaced.
- During assembly work on the exhaust system, ensure that the components are aligned and installed correctly.
- Seals must be replaced by new ones following removal.
- Observe the correct tightening sequence and tightening torques.
Group 24 - Fuel system, electronic injection
DANGER
Danger of poisoning from fuels.
-> Gasoline is toxic.
-> Inhaling vapours can cause irritation of the mucous membranes and eyes.
-> It can be carcinogenic. It represents a serious risk to health when inhaled, touched or swallowed over longer periods.
-> Only work on the fuel system in well-ventilated rooms.
-> Wear protective gloves that are fuel-resistant.
-> Wear a breathing mask with active charcoal filter; do not breathe in any fuel vapours.
-> Ensure that there is adequate ventilation and extract all fuel vapours.
-> Before opening the fuel lines or fuel hoses, relieve the fuel pressure.
-> Collect escaping fuel, absorb it if necessary with a suitable binding material and dispose of properly.
-> Pay attention to cleanliness when working on the fuel system.
DANGER
Danger of fire from fuel.
-> Keep clear of ignition sources.
-> Do not smoke.
-> Disconnect battery.
-> Danger of fire due to naked flames and sparks, e.g. during welding or grinding work.
-> Danger of fire due to escaping fuel, e.g. on hot engine components or due to electrostatic charge. Allow engine to cool down.
-> Secure the vehicle, e.g. with a warning sign.
-> Change any clothing soaked with fuel immediately.
-> In case of fire, use CO2 or dry powder fire extinguishers.
CAUTION
Dirt on injection system components (intake manifold injection and direct fuel injection system)
- Material damage
- Rough-running engine
- Bad exhaust emissions
-> Thoroughly clean connection points and adjacent areas before loosening them. If the engine is very dirty, wash it before starting disassembly work.
-> Lay removed parts on a clean surface and cover them. Do not use fibre-shedding cloths.
-> Carefully cover components or seal them if repair work will not be carried out immediately. Place rubber caps on connections. Seal intake openings with film or adhesive tape.
-> Only install clean parts. Do not take spare parts out of the packaging until just before installation.
-> Never use compressed air when the system is open. Do not move the vehicle.
CAUTION
Danger of fire from leaking high-pressure lines.
- Fuel can leak out if high-pressure lines are bent or damaged.
- Fuel can leak out if threaded joints are not fitted correctly.
- Fuel can leak out if the tightening specifications are not observed.
-> Never bend high-pressure lines.
-> The high-pressure distribution pipe (rail) or other fuel feed components in the high-pressure area must always be completely removed.
-> Perform a visual inspection to ensure that connection points are undamaged and perfectly clean.
-> Check that threaded joints at connection points are not seized up or corroded. Make sure the thread is not damaged.
-> Fit union nuts on all connection points by hand before screwing in screws or bolts.
-> Pay attention to cleanliness. Remove dirt on the ball/conical joints.
-> Check or inspect connection points for leaks following assembly.
Information
- The ignition must be switched off when working on the fuel system.
- Absorb any escaping fuel using a suitable binding material or a cloth.
- Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
- The fuel system must be depressurised before starting work on it.
- Only work on the fuel system in well-ventilated rooms.
- Any seals which have been removed must always be replaced.
Precautionary measures when handling oxygen sensors
CAUTION
The oxygen sensor may be damaged if handled incorrectly.
- Change in engine emissions.
- Damage to the environment.
- Check Engine lamp may come on.
-> Do not remove the plastic cap on the thread until just prior to fitting the oxygen sensor. The thread grease must never come into contact with the connector.
-> Protect sensors - before and after fitting - against mechanical shocks.
-> Sensors that were dropped on the floor must not be used owing to the risk of a broken ceramic insulator.
-> The cables must not be twisted or kinked when the sensors are screwed in. Avoid pulling on the cable and connector.
-> Cleanliness in the housing of the plug connections is of utmost importance for the oxygen sensor to function properly. Particles of dirt can impair the function of the oxygen sensor. The connector must therefore be protected against any and all types of soiling.
-> Sensors with a soiled or damaged connector must no longer be used.
-> Protect the cables and plugs when carrying or moving the exhaust system with the sensors already fitted.
-> High-pressure cleaning equipment must not be used in the area of the sensors and plug connections.
-> Contact and corrosion agents, e.g. Stabilant, must not be applied to the plug contacts of the oxygen sensors.
Group 26 - Exhaust system
CAUTION
Heavy components
- Risk of squashing
-> Wear personal protective gear.
-> Get someone to help if necessary.
CAUTION
Hot components
- Risk of burns
-> Let hot components cool down.
-> Wear personal protective gear.
CAUTION
Engine exhaust gas.
- Danger of poisoning.
-> Only operate the engine with an appropriate exhaust gas extraction system.
CAUTION
Danger of burns from very hot components (turbocharger, exhaust manifold).
-> Components of the exhaust system can be extremely hot.
-> Allow the parts to cool down first and wear protective gloves.
Information
- After the connecting clamps in the exhaust system have been released, they must always be replaced.
- During assembly work on the exhaust system, ensure that the components are aligned and installed correctly.
- Seals must be replaced by new ones following removal.
- Observe the correct tightening sequence and tightening torques.
Group 28 - Ignition system
CAUTION
High-voltage ignition system.
- Danger of electric shocks.
- This can cause cardiac irregularities.
-> When working on the ignition system, the ignition key must be removed from the ignition lock.
-> The ignition system must be disconnected from the power supply before starting work on it.
-> Only connect/disconnect lines or plugs when the ignition is switched off.
-> Only connect measuring devices when the ignition is switched off.
Information
- The ignition system must be disconnected from the power supply before starting work on it.
- Observe the specified torques.
- Spark plug threads must not be greased.