Component Changes For Engines Produced As of Model Year 2009

WM 1001IN IMPORTANT component changes for V8 engines as of October 2008














Information

Component changes for engines produced as of model year 2009, calendar week 42/2008

Information:
Component changes implemented as of the following engine numbers:

M4801 905541
M480IG 904965
M4851 901689
M4851S 900562
M4851T 901788

Information:
At present, aluminum screws are used for the cylinder head cover, timing case cover, lower part of crankcase and oil guide housing. Observe modified tightening specifications as instructed.
In addition, the new timing case cover can only be retrofitted (on older engines) in conjunction with aluminum screws and the new chain tensioner.
The joint flange behind the vibration balancer is secured to the timing case cover with aluminum screws.
In addition, the crankcase can only be retrofitted (in older engines) with a new starter and modified primary catalytic converter support.
New sealant in conjunction with aluminum screws for the crankcase and oil guide housing. Old sealant must not be used if sealant is likely to come into direct contact with aluminum screws!
The crankshaft mount now has four conventional bearings (one more color classification). Install new crankshaft only with new modified bearing shells.
Lower part of crankcase (outer cross bolt connection) with aluminum screws and new sealant
Oil guide housing with aluminum screws and new sealant
Cylinder heads with new spark plugs. If a cylinder head is replaced on an older engine, the spark plugs on the opposite cylinder head must be changed (replaced).
Modified camshafts only in conjunction with modified screws for sprockets and camshaft controllers. Install new camshafts only with modified screws (external Torx) for the camshaft controller and sprocket (screw length!).
Modified ignition rod modules with aluminum screws and engine wire harness.
Modified valve cover with aluminum screws and modified cap on solenoid valves for camshaft controllers.
Eyelets still have steel screws.
Modified valve cover and cylinder head on cylinder bank 1 to 4 have an additional M8 thread bore and M8 screw (aluminum). If the cylinder head is replaced (on older engines), the valve cover must also be replaced. Modified valve cover must be installed on the old cylinder head using an M6 screw when retrofitting the valve cover on older engines.
Countersunk screws for securing auxiliary unit brackets and engine carrier to the crankcase. The tightening torque remains unchanged.
Crash support (support bracket) on generator with aluminum screws.
Always check component pairings!
Always check specific engine numbers!

Information on aluminum screws

Information:
Aluminum screws and steel screws have different properties!
Most aluminum screws are identified on Porsche V engines by an internal Torx screw with internal pin. Aluminum screws can be identified differently on transmissions, on the chassis and on engines from other manufacturers.
Another differentiating feature is that aluminum screws are lighter than steel screws of the same size (e.g. screws used in bar ignition modules).
The aluminum screws used at present have the additional marking RIBE (manufacturer) and AL9 (strength) on the screw head.
Screws with an internal pin can be loosened and tightened using commercially available bit inserts with a hole (safety bits).





Aluminum screw on V engines

Aluminum screws must be used only once. Replace the screws whenever they have been loosened.
Aluminum screws must always be tightened in two steps (torque and torque angle) or require a special yield point wrench Electronic torque wrench 9768. The specified tightening torques and torque angles must always be observed. The extent to which a screw is tightened can be limited using a yield point wrench.
Sealants that can come into contact with aluminum screws in threaded bores must be approved for use with aluminum screws by Porsche - if this is not observed, there will be increased friction in the screw thread and the aluminum screw will break.
Aluminum screws must not be fitted using tightening parameters for steel screws - the aluminum screw will break.
Screw threads must be perfectly clean. Sealant residue or chips increase the friction coefficient - the aluminum screw will break. Blow out thread holes.

Aluminum screws





Overview of repair relevant component changes as of model year 2009, calendar week 42/2008

Information:
The eyelets must not be inadvertently secured using aluminum screws! - Aluminum screws would break and the suspended engine would fall down!





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 replace aluminum screws; observe tightening sequence as for steel screws - Tightening torque: 10 Nm (7.5 ftlb.)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





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 Y Yellow; B Blue, R Red; N Green - (example: YYYYY-BBBB; 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)





Tightening sequence for timing case cover

A - Aluminum screw, M6 x 30; timing case cover to crankcase and cylinder head; always replace aluminum screws; - Tightening torque: 4 Nm (3 ftlb.)90°
B - Aluminum screw, M6 x 55; inner timing case cover to upper part of crankcase and cylinder head; always replace aluminum screws; - Tightening torque: 4 Nm (3 ftlb.)90°; Inner timing case cover to cylinder head - Tightening torque: 4 Nm (3 ftlb.)90°
C - Aluminum screw, M8 x 55; timing case cover (chain tensioner position) to upper part of crankcase and cylinder head; always replace aluminum screws; - Tightening torque: 10 Nm (7.5 ftlb.)90°
D - The timing case cover must be level with the lower part of the crankcase (use steel rule or dial gauge)





Chain tensioner, sealing flange

1 - Joint flange (oil sealing lip with engine oil); align with sleeve or vibration balancer
2 - Aluminum screwM6 x 20; always replace aluminum screws; - Tightening torque: 4 Nm (3 ftlb.)90°
3 - Aluminum screwM6 x 55; always replace aluminum screws; - Tightening torque: 4 Nm (3 ftlb.)90°
4 - Sealing ring
5 - Chain tensioner - Tightening torque: 60 Nm (44 ftlb.)





Bar ignition modules and valve cover, cylinder bank 1 to 4

1 - Valve cover for cylinder bank 1 to 4 (align over bar ignition modules)
2 - Bar ignition module
3 - Aluminum screwM6 x 20; bar ignition module; always replace aluminum screws; - Tightening torque: 4 Nm (3 ftlb.)90°
4 - Aluminum screwM6 x 30; always replace aluminum screws; - Tightening torque: 4 Nm (3 ftlb.)90°
5 - Cap
6 - Aluminum screw, M8 x 35 (on torque support); always replace aluminum screws; - Tightening torque: 10 Nm (7.5 ftlb.)90° Steel screw on eyelet!
7 - Eyelet (with steel screw) - Tightening torque: 23 Nm (17 ftlb.)
8 - Sheetmetal holder
A - Direction of travel
- Not shown; design cover on bar ignition modules - Tightening torque: 4.4 Nm (3.0 ftlb.)





Bar ignition modules and valve cover, cylinder bank 5 to 8

1 - Valve cover for cylinder bank 5 to 8 (align over bar ignition modules)
2 - Eyelet
3 - Eyelet (with steel screw) - Tightening torque: 23 Nm (17 ftlb.)
4 - Aluminum screwM6 x 30; always replace aluminum screws; - Tightening torque: 4 Nm (3 ftlb.)90°
5 - Bar ignition module
6 - Aluminum screwM6 x 20; bar ignition module; always replace aluminum screws; - Tightening torque: 4 Nm (3 ftlb.)90°
7 - Sheetmetal holder
8 - Cap
A - Direction of travel
- Not shown; design cover on bar ignition modules - Tightening torque: 4.4 Nm (3.0 ftlb.)





Valve cover seals, cylinders 1 to 4

1 - Valve cover for cylinders 1 to 4 (align over bar ignition modules)
2 - Oil cap
3 - Aluminum screw, M6 x 20; hall sender (phase sensor); always replace aluminum screws - Tightening torque: 4 Nm (3 ftlb.)90°
4 - Hall sender
5 - O ring
6 - Valve cover seal
7 - Valve cover seal, inner
8 - Seal for hydraulic valve for camshaft control





Valve cover seals, cylinders 5 to 8

1 - Valve cover for cylinders 5 to 8 (align over bar ignition modules)
2 - Hall sender
3 - Aluminum screw, M6 x 20; hall sender (phase sensor); always replace aluminum screws - Tightening torque: 4 Nm (3 ftlb.)90°
4 - O ring
5 - Valve cover seal
6 - Valve cover seal, inner
7 - Seal for hydraulic valve for camshaft control





Oil guide housing with accessories

1 - Guide tube
2 - O ring
3 - Screw, M6 x 16 - Tightening torque: 10 Nm (7.5 ftlb.)
4 - Oil dipstick
5 - O ring
6 - Timing case cover to oil guide housing, aluminum screw; always replace aluminum screws - Tightening torque: 4 Nm (3 ftlb.)90°; oil level sensor to oil guide housing (steel screw) - Tightening torque: 12 Nm (9 ftlb.); oil guide housing to lower part of crankcase, aluminum screw; always replace aluminum screws - Tightening torque: 4 Nm (3 ftlb.)90°
7 - Oil level sensor
8 - O ring
9 - Sealing flange
10 - Screw, M6 x 20 - Tightening torque: 10 Nm (7.5 ftlb.)
11 - Screw, M6 x 16 - Tightening torque: 10 Nm (7.5 ftlb.)
A - Direction of travel





Applying sealant to oil guide housing

1 - Sealant application (geometry, 1-mm bead of sealant)
2 - Sealant application - Doboseal 224N (999.915.573.43, status 09/08)
A - Direction of travel





Auxiliary units

1 - Air conditioning compressor
2 - Screw, M10 x 100
3 - Screw, M8 x 10
4 - Holder
5 - Screw, M8 x 20; tandem pump to bracket for auxiliary units - Tightening torque: 23 Nm (17 ftlb.); power-steering pump to bracket for auxiliary units - Tightening torque: 23 Nm (17 ftlb.)
6 - Tandem pump
7 - Screw, M8 x 35; power steering pump to adapter bracket - Tightening torque: 23 Nm (17 ftlb.); tandem pump/adapter bracket to bracket for auxiliary units - Tightening torque: 23 Nm (17 ftlb.)
8 - Power steering pump
9 - Aluminum screwM8; always replace aluminum screws - Tightening torque: 10 Nm (7.5 ftlb.)90°
10 - Support bracket
11 - Dowel sleeve