Removing and Installing Injection Valves - Engine Installed

Removing And Installing Injection Valves - Engine Installed

WARNING:
- Observe the general safety instructions when working on the fuel system and when handling petrol and other fuels.
- The battery must be disconnected when working on electrical components.

Preliminary work
1. Read out the fault memory with the Porsche System Tester.
2. Find out the radio code.
3. Disconnect the battery and cover terminal or battery.
4. Remove rear spoiler.
5. Remove air cleaner housing.

Removing injection valves of cylinder bank 1 - 3
1. Pull off the connecting hoses between the charge air coolers and the Y-shaped pressure pipe. To do this, unclip the retaining clips using a screwdriver and pull out the hose. Refit the retaining clips immediately.
2. Detach the holder over the air-conditioning compressor. Unscrew the M6 screw on the holder for this purpose.
3. Undo the hose of the Y-shaped pressure pipe. To do so, undo the hose clamp -arrow- and pull the hose off the Y-shaped pressure pipe.







4. Remove the Y-shaped pressure pipe. To do so, undo the hose clamps -3 and 5- and the hexagon-head bolts -1 and 2-. Pull off pressure sensor plug -4-.







5. Remove the three-phase generator.
6. Remove box for connector. Unscrew the two M6 screws and lay the box to one side.







CAUTION:
- u Do not lower engine too far:
- To avoid damage to the hoses, leads and engine, the engine must only be lowered by approx. 30 mm - 40 mm:

7. Lower engine. Secure the engine against falling down with a workshop jack. Undo the two hexagon nuts on the right and left of the engine mount. Lower engine by max. 30 mm - 40 mm.
8. Undo the hose -arrow- on the left pressure pipe. To do so, undo the hose clamp and pull the hose -arrow- off the pressure pipe.







9. Disconnect the connector of the overrun air valve module -arrow- and pull off the two vacuum hoses -arrow-.







10. Undo the hose clamp on the left pressure pipe and remove the entire overrun air valve module -Figure-.







11. Pull the vent line off the coolant expansion tank.
12. Remove fuel filter.
13. Loosen and unscrew the three fastening screws -arrows- at the front intake pipe connector.







14. Remove hose clamp and pull off ventilation hose from the intake pipe.







15. Undo the upper fastening screw -right arrow-. Lift the intake pipe out of the shaft bolt -left arrow- and remove towards the rear of the vehicle. Remove the seal.







16. Disconnect the activated carbon filter lead. To do so, disconnect the coupling -arrow-.







17. Pull off the connector -1- of the camshaft adjustment valve.

NOTE: With all fuel lines, always counter with a second open-ended wrench:







18. Disconnect the fuel return line -2- (a/f 14 and 17). Unscrew the M6 screw in the holder -3-.







19. Disconnect the fuel supply line -4- (a/f 17 and 19).
20. Disconnect the fuel line -5- (a/f 17 and 19) to the fuel collection pipe, cylinder bank 4 - 6.
21. Unclip the cable duct on the fuel collection pipe and lay it as far as possible to the side.
22. Undo the fuel collection pipe. Unscrew the two M6 screws -arrows- on the fuel collection pipe for this purpose.







23. Remove connectors of the injection valves.
24. Carefully pull out the fuel collection pipe with the injection valves.
25. Pull off the tab washers of the injection valves -A- and pull the injection valve -B- out of the fuel collection pipe.







Removing injection valves of cylinder bank 4 - 6
1. Remove rear right wheel housing liner.
2. Remove charge air cooler module.
3. Remove rear right heat insulation plate.

CAUTION:
- Do not lower engine too far:
- To avoid damage to the hoses, leads and engine, the engine must only be lowered by approx. 30 mm - 40 mm:

4. Lower engine. Secure the engine against falling down with a workshop jack. Undo the two hexagon nuts on the right and left of the engine mount. Lower engine by max. 30 mm - 40 mm.
5. Disconnect the connectors of the ignition coils of cylinders 5 and 6.
6. Pull off the connectors for the valve lift adjustment valve and the hall sender.
7. Remove the pressure hoses on the left and right of the Y-shaped pipe to the charge air cooler. To do this, unclip the retaining clips using a screwdriver and pull out the hose. Refit the retaining clips immediately.
8. Detach the holder over the air-conditioning compressor. Unscrew the M6 screw on the holder for this purpose.
9. Remove the Y-shaped pressure pipe. To do so, undo the hose clamps -3 and 5- and the hexagon-head bolts -1 and 2-. Disconnect pressure sensor plug -4-.







10. Disconnect the connectors of the main wiring harness -arrows- in the engine compartment on the right and lay to one side.







11. Remove the secondary air pump.
12. Pull off the vacuum hose on the fuel pressure regulator and lay it to one side.







13. Disconnect the fuel supply line -1- (a/f 19 and 22) and the fuel return line -2- (a/f 17 and 19).







14. Undo the cable duct at the fuel collection pipe.
15. Undo the fuel collection pipe. Unscrew the two M6 screws -3- for this purpose.

NOTE: When removing the fuel collection pipe, lever it up very carefully and pay attention to all leads in order to avoid any damage:







16. First raise the fuel collection pipe carefully at cylinder 4, then at cylinder 6.







17. Raise the cable duct as far as possible, pull off the connectors of the injection valves and remove the fuel collection pipe.
18. Remove the tab washers of the injection valves and pull the injection valves out of the fuel collection pipe.

Installing injection valves
1. Always fit new sealing rings on the injection valves.
2. Coat the sealing rings of the injection valves slightly with Vaseline.
3. Press the injection valves into the fuel collection pipe -A- and then install the tab washers -B-. Align the injection valves so that the lugs on the valves and the lugs on the fuel collection pipe lie directly above one another. Ensure that the tab washers are seated correctly.







NOTE: When installing the fuel collection pipe, make sure that the injection valves are not damaged or soiled.

4. Place the fuel collection pipe with the injection valves of cylinder bank 4 - 6 in position on the right intake distributor. Connect connectors of the injection valves. Carefully insert the injection valves into the openings in the intake pipe.
5. Fasten the fuel collection pipe. Put on and tighten the two M6 screws -3- for this purpose.
Tightening torque of M6 screws = 10 Nm (7.5 ftlb.)

NOTE: With all fuel lines, always counter with a second open-ended wrench:







6. Position and tighten the fuel supply line -1- (a/f 19 and 22).
Tightening torque 30 Nm (22 ftlb.)







7. Connect the vacuum hose to the fuel pressure regulator.







8. Position and tighten the fuel return line -2- (a/f 17 and 19). Tightening torque 30 Nm (22 ftlb.)







9. Connect the cable duct to the fuel collection pipe. Ensure correct seating.
10. Connect hall sender connector.
11. Fit the connectors of the main wiring harness -arrows- in the engine compartment on the right.







12. Connect the connectors of the ignition coils of cylinder 5 and 6 and the connector of the valve lift adjustment valve.
13. Place the fuel collection pipe with the injection valves of cylinder bank 1 - 3 in position on the left intake distributor. Connect connectors of the injection valves. Carefully insert the injection valves into the openings in the intake pipe.
14. Fasten the fuel collection pipe. Put on and tighten the two M6 screws -arrows- on the fuel collection pipe for this purpose.
Tightening torque of M6 screws = 10 Nm (7.5 ftlb.)







15. Connect the cable duct to the fuel collection pipe. Ensure correct seating.

NOTE: With all fuel lines, always counter with a second open-ended wrench:
16. Position and tighten the fuel line -5- (a/f 17 and 19) to the fuel collection pipe, cylinder bank 4 - 6.
Tightening torque 30 Nm (22 ftlb.)







17. Position and tighten the fuel supply line -4- (a/f 17 and 19).
Tightening torque 30 Nm (22 ftlb.)







18. Position and tighten the fuel return line -2- (a/f 14 and 17). Position the M6 screw in the holder -3- , but do not tighten yet.
Tightening torque, return line 30 Nm (22 ftlb.)







19. Connect plug of camshaft adjuster -1-.

NOTE: In order to check the fuel system for leaks, the following operations must be carried out:







20. Install fuel filter.
21. Connect together the plug connection of the activated carbon filter lead. The plug must engage audibly. Pull slightly to ensure that the connection is properly locked.







NOTE: None of the electrical connections of the three-phase generator nor any of the other plug connections may come into contact with the body or any other components:

22. Install the B+ lead and the plug connection on the three-phase generator. Lay the three-phase generator aside. Make sure that the connections do not come into contact with the body or any other components.
23. Connect the battery.
24. Connect the Porsche System Tester and switch on the ignition.
25. Then activate the fuel pump with the Porsche System Tester and allow the pump to run for approx. 2 - 3 min.
26. Disconnect battery.
27. Remove the three-phase generator. To do this, disconnect the B+ wire and the plug.
28. Remove fuel filter.
29. Install secondary air pump.
30. Install the rear right heat insulation plate.
31. Install charge air cooler module.
32. Install rear right wheel housing liner.
33. Insert new seal at the intake pipe connector.
34. Place the intake pipe in position on the shaft bolt -left arrow-.







35. Connect the vent hose. Tighten hose clamp -arrow-.







36. Position and tighten the three screws at the front intake pipe connector.
Tightening torque of M6 screws = 10 Nm (7.5 ftlb.)







37. Position and tighten the upper screw -right arrow-.
Tightening torque of M6 screw = 10 Nm (7.5 ftlb.)







38. Tighten the M6 screw in the holder -3-.
Tightening torque of M6 screw = 10 Nm (7.5 ftlb.)







39. Tighten the hose -arrow- on the left pressure pipe. To do so, push the hose -arrow- on and tighten the screw-type hose clamp.







40. Install the overrun air valve module -Figure-.







41. Connect the connector of the overrun air valve module -arrow- and push on the two vacuum hoses -arrow-.







42. Install fuel filter.
43. Connect the vent line of the coolant expansion tank. Fasten hose clamp.
44. Fasten the engine to the engine mounts again. To do so, raise the lowered engine with the workshop jack to its final position, position and the tighten both the collar nuts.
Tightening torque of collar nuts 85 Nm (63 ftlb.)
45. Install box for connector. Put on and tighten the two M6 screws -arrows- for this purpose.
Tightening torque of M6 screws = 10 Nm (7.5 ftlb.)







46. Install three-phase generator.
47. Press the Y-shaped pressure pipe into the air cowl of the throttle body, connect the hoses -3 and 5- and fasten the hose clamps. Connect the connector of the pressure sensor -4- and position and tighten the M6 screws -1 and 2-.
Tightening torque of M6 screws = 10 Nm (7.5 ftlb.)







48. Install the holder over the air-conditioning compressor. Position and tighten the M6 screw in the holder for this purpose.
Tightening torque of M6 screw = 10 Nm (7.5 ftlb.)
49. Connect hose to the Y-shaped pipe and fasten with the hose clamp -arrow-.







50. Install the connecting hoses between the charge air coolers and the Y-shaped pressure pipe; the connecting hoses must engage audibly.
51. Install air cleaner housing.
52. Install rear spoiler.
54. Read out the fault memory with the Porsche System Tester.
55. Enter radio code.
56. Perform a function test.