122-L7V6H-03

Installation and Conversion Instructions
911 (991)
45/12
ENU
1001
1
Power Kit (I-no. X51)
Revisions:
This bulletin replaces bulletin Group 1, #45/12, dated October 20, 2015.
Model Year:
As of 2012 up to 2016
Vehicle Type:
911 Carrera S (991)/911 Carrera 4S (991)/911 Targa S (991)/911 Targa 4S (991)/911 “50
Years” (991)
Information:
Subsequent performance increase to 316 kW (430 HP)
Engine Type:
Standard engine MA103 with engine power of 294 kW (400 hp)
General:
A parts kit is available for increasing the performance of the standard engine.
Increased performance is achieved by implementing the following measures on the engine:
•
•
•
•
New cylinder heads with flow-optimized intake ports, valves and valve springs.
New intake camshafts.
New resonance intake manifold with switching flaps (material: aluminum sand cast).
Modified maps for the DME control unit.
The following additional modifications are also required and the following preconditions must be met on
the vehicle side:
•
•
•
New engine cover with carbon inserts, painted Titanium Grey.
Sports exhaust system incl. tailpipes (if not already fitted).
Radiator –middle– (I-no. 153).
The higher-performance engine is also available as factory installed option for the new vehicles
mentioned above under Exclusive option No “X51”.
Software:
•
Minimum version 11.200 (updated on September 27, 2012)
Engine run-in:
Engine speeds greater than 5,000 rpmare not permitted over a distance of 310 miles (500 km). The
maximum engine power of 430 hp (316 kW) depends on the total mileage of the engine at the time of the
retrofit and is achieved from a total mileage of approx. 6,250 miles (10,000 km) or higher.
Warranty:
Information
In order to provide a warranty for the retrofit, the dealer must create "Power Kit (I-no. X51)" documentation for the relevant vehicle in the "Porsche Quality Information System = PQIS".
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Installation and Conversion Instructions
Retrofitting:
Warranty in accordance with the Repair Conditions and the Warranty Conditions for Original Porsche
Parts.
If the engine to be converted has a mileage of over 25,000 miles (40,000 km), the crankshaft main
bearings and connecting-rod bearings must also be replaced.
If there is obvious wear on the connecting-rod bushings (scores), the connecting rods must also be
replaced.
New vehicle with Power Kit (I-no. "X51"):
Vehicle warranty in accordance with Porsche guidelines.
Diagram:
Figure 1
A
B
C
D
E
Technical
Description:
–
–
–
–
–
Torque (Nm)
Engine speed (rpm)
Power (kW)
Standard engine
Engine with increased performance – 430 hp (316 kW at 7,500 rpm and 440 Nm at 5,750 rpm
Standard-production engine
Increased performance engine
MA103
MA103 S
6
6
Bore:
102 mm
102 mm
Stroke:
77.5 mm
77.5 mm
3,800 ccm
3,800 ccm
12.5 : 1 (-0.5)
12.5 : 1 (-0.5)
Engine type:
No. of cylinders:
Displacement:
Compression ratio:
May 31, 2016
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Installation and Conversion Instructions
Max. engine power
at engine speed:
911 (991)
45/12
ENU
1001
294 kW (400 hp)
7,400 rpm
316 kW (430 hp)
7,500 rpm
Max. torque
at engine speed:
440 Nm
5,600 rpm
440 Nm
5,750 rpm
Max. power output per litre:
77.4 kW/l
83.2 kW/l
Engine speed limitation at:1
7,800 rpm
7,800 rpm
Idle speed:
680 ± 25
680 ± 25
:2
304 km/h (188 mph)
308 km/h (191 mph)
vmax
1
Engine speed at operating temperature
2
Value for 911 Carrera 2 Coupé (manual transmission)
1
Information
Please inform your sales staff and customers about the engine “break-in” precautions.
Copy the first three pages of these Installation and Modification Instructions and give them to your
customers!
Parts Info:
991.044.100.003
 Power Kit, 316 kW (430 hp), set
991.044.100.014
 Power Kit, 316 kW (430 hp) incl. sport exhaust system (I-no.
176), set
 Power Kit, 316 kW (430 hp) incl. sport exhaust system (I-no.
176), set
991.044.100.025
3
ONLY for vehicles with sports exhaust system (I-no. 176)!
4
ONLY for Japan/Porsche Asia Pacific (= PAP) vehicles!
5
ONLY for RoW/USA and Canada vehicles!
Order the following as required for set “Power Kit WITHOUT sport exhaust system (991.044.100.00)”:
991.111.481.01
2x
 Clamp for muffler
997.111.520.00
2x
 Clamping sleeve for main muffler
ONLY order for vehicles WITHOUT connector (6-pin, see Step 5.4) in the vehicle:
991.612.957.00
1x
 Dummy connector, 6-pin
ONLY order for vehicles from model year 2015 (see Step 5.5):
991.612.944.00
1x
 Adapter wiring harness
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Parts List:
Figure 2
Parts included for engine ( Figure 2):
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999.170.151.90
6x
Spark plug FGR 5NQE  Figure 2 -1-
9A1.607.167.41
1x
9A1.607.091.00
1x
9A1.110.061.46
1x
Holder for wiring harness on lower part of intake-air distributor
(cylinder 4–6)  Figure 2 -2Wiring harness for engine (with connection for transmission input
shaft sensor for manual transmission = I-no. 487)  Figure 2 -3Vent line (fuel tank)  Figure 2 -4-
991.504.990.00
1x
———
1x
Engine compartment cover with carbon badges, painted Titanium
Grey  Figure 2 -5Intake-air distributor (ASSemblY = ASSY)  Figure 2 -6-
9A1.107.506.45
1x
Vent line to cylinder head 1–3  Figure 2 -7-
9A1.107.017.45
1x
Engine oil filler neck  Figure 2 -8-
9A1.107.505.47
1x
Crankcase vent line  Figure 2 -9-
991.107.264.45
1x
Oil filling hose  Figure 2 -10-
9A1.106.550.45
1x
Cooling water compensation line  Figure 2 -11-
9A1.110.092.41
1x
9A1.110.859.41
1x
Pressure line (connecting line for fuel collection pipe, ASSY) 
Figure 2 -12Fuel collection pipe for cylinder 1–3  Figure 2 -13-
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9A1.110.860.41
1x
Fuel collection pipe for cylinder 4–6  Figure 2 -14-
9A1.104.911.45
1x
9A1.105.275.45
1x
Cylinder head 1–3, complete, ASSY (incl. valves and bearing
saddles for camshafts)  Figure 2 -15Intake camshaft for cylinder 1–3  Figure 2 -16-
9A1.105.403.02
2x
Washer, 34.0 x 0.1 (exhaust camshaft sprocket, not shown)
9A1.105.403.10
2x
Washer, 33.4 x 0.5 (camshaft controller, not shown)
9A1.105.276.45
1x
Intake camshaft for cylinder 4–6  Figure 2 -17-
9A1.104.912.45
1x
Cylinder head 4–6, complete, ASSY (incl. valves and bearing
saddles for camshafts)  Figure 2 -18-
1
Figure 3
Parts included for vacuum and fresh-air system (engine area  Figure 3):
9A1.110.666.00
1x
Connecting piece (angled pipe)  Figure 3 -1-
999.239.045.40
3x
Hose, 3.5 x 2.0 x 60  Figure 3 -2-
999.239.042.40
1x
Hose, 3.5 x 2.0 x 75  Figure 3 -3-
948.110.126.00
1x
Connecting piece (elbow)  Figure 3 -4-
06E.133.794
9x
T-piece  Figure 3 -5-
928.574.717.05
5x
Moulded hose (protective tube, bent)  Figure 3 -6-
928.573.727.05
3x
Y-piece  Figure 3 -7-
999.507.866.40
2x
Line bracket, 5.0 x 5.0 (Raymond)  Figure 3 -8-
900.918.005.40
4m
Pipe, 5.0 x 1.0 x 4 m (running meter)  Figure 3 -9-
999.181.445.40
6x
Protective tube, 5.0 x 200  Figure 3 -10-
000.043.205.01
1m
Pipe, 4.0 x 1.0 x 1 m (running meter)  Figure 3 -11-
7PP.906.283.B
2x
Change-over valve (not shown)
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Gaskets/seals and small parts (not shown):
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900.385.041.01
4x
Torx screw, M6 x 12
999.073.535.01
18 x
Torx screw, M8 x 21
9A1.104.141.04
1x
Cylinder-head gasket (cylinder 1–3)
9A1.104.140.04
1x
Cylinder-head gasket (cylinder 4–6)
9A1.105.731.03
1x
Cylinder head cover seal (cylinder 1–3)
9A1.105.732.03
1x
Cylinder head cover seal (cylinder 4–6)
999.707.446.40
2x
O-ring, 18 x 2.5 (camshaft control valve actuator)
900.331.057.40
2x
O-ring, 11.2 x 2.65 (valve lift adjustment actuator)
999.707.576.40
1x
O-ring, 7.0 x 2.5 (oil pipe for cylinder 4–6)
999.707.346.40
6x
O-ring, 15.0 x 3.0 (screw for chain tensioner tensioning rail)
900.123.106.30
1x
Sealing ring, A 18 x 24 (oil drain plug)
9A1.105.339.00
1x
Seal for crankcase cover (positive crankcase ventilation)
999.707.636.40
2x
O-ring, 44.0 x 3.5 N (positive crankcase ventilation)
999.701.504.40
1x
O-ring, 10.0 x 2.5 (vacuum pump)
999.701.505.40
1x
O-ring, 54.0 x 2.5 (vacuum pump)
999.701.789.40
1x
O-ring, 12.0 x 2.0 (vacuum line)
999.707.639.40
2x
O-ring, 24.0 x 2.5 N (crankcase vent line)
999.707.657.40
2x
O-ring, 31 x 3 (water tube)
999.707.658.40
2x
O-ring, 23 x 3 (water line)
999.707.643.40
1x
O-ring, 55.25 x 2.62 (high-pressure pump)
999.704.020.90
6x
Sealing ring, 6.3 x 2.8 (high-pressure injector)
999.701.112.41
6x
O-ring, 7.52 x 3.51 (high-pressure injector)
997.111.107.31
2x
Exhaust manifold seal
991.111.482.00
2x
Seal for front muffler
999.072.841.01
2x
Combination screw, M10 x 50 (transmission mount)
999.072.866.01
4x
Hexagon-head bolt, M12 x 1.5 x 95 (cross member)
999.072.930.01
2x
Hexagon-head bolt, M12 x 1.5 x 100 (lower control arm)
999.073.517.01
12 x
Cheese head bolt, M10 x 1.0 x 46.5 (rear drive shaft)
999.084.445.01
4x
Lock nut, M12 x 1.5 (rear-axle trailing arm)
997.331.217.02
2x
Eccentric screw, M12 x 1.5 x 83 (lower rear-axle trailing arm)
900.910.003.03
6x
Hexagon nut, M8 (front muffler/strut)
999.073.458.01
6x
Screw, M8 x 16 (automatic clutch)
N 908.484.05
2x
Hexagon nut, M12 x 1.5 (hydraulic mount)
999.513.076.40
20 x
Tie-wrap, 1.5 - 85
900.123.111.21
3x
Sealing ring, 14 x 20
948.107.222.00
1x
Oil filter
948.107.322.00
1x
Sealing ring, 91.0 x 4.0
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Installation and Conversion Instructions
911 (991)
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1
Figure 4
Parts included for radiator –middle– (I-no. 153  Figure 4):
Materials:
991.106.237.01
1x
Retaining frame  Figure 4 -1-
999.084.638.01
4x
Hexagon nut, M6  Figure 4 -2-
991.106.537.01
2x
Rubber mounting, upper  Figure 4 -3-
991.106.538.01
2x
Rubber mounting, lower  Figure 4 -4-
991.106.638.02
1x
Water supply hose  Figure 4 -5-
991.106.639.01
1x
Water return hose  Figure 4 -6-
991.106.137.02
1x
Radiator (middle)  Figure 4 -7-
991.106.337.01
1x
Sealing frame  Figure 4 -8-
991.575.141.00.1E0
1x
Air guide (centre)  Figure 4 -9-
991.505.569.01.1E0
1x
991.505.989.02.1E0
1x
Retaining frame, center, Black (standard front apron)  Figure 4
-10Retaining frame, center, Black (front apron I-nos. XAA/XAT/XAS,
not shown)
000.043.301.476
Xx
Antifreeze, BASF Glysantin G40–91 EF; 1-liter container
000.043.204.68
1x
000.043.205.93
1x
000.043.303.27
1x
“SYNTHESO GLEP” grease; 50g tube (for fitting O-rings, moulded
seals, etc.)
“KLUEBERPLUS S 06-100” grease; 100g tube (for fitting O-rings in
cooling system)
Lubricant for injection line, 50-ml container
000.043.301.196
7.5 l Engine oil, EXXON Mobil 1 0W-40, 1-liter container (see also
Manufacturer's Certificate  Manufacturer's Certificate '170100
Overview of approved Porsche A40 engine oils (04/12)')
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Installation and Conversion Instructions
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Quantity, as required.
Tools:
Information
Only work tools that were not described in the Workshop Manual are listed here. For details of special
tools, e.g. for removing and installing the engine, please refer to the relevant description!
Nr.197 - Pneumatic marking pen
9900 - PIWIS Tester 3
Template, 0.5 (5 mm)
Shop light
Drill
Drill bit, ∅ 8 mm
Tenon saw
File
Work Procedure: 1
Preparatory work
1.1
Remove engine (  Workshop Manual '100119 Removing and installing engine - section on
"Removing"').
1.2
Remove transmission (  Workshop Manual '343527 Removing and mounting transmission'
or  Workshop Manual '373427 Removing and mounting Porsche Doppelkupplung (PDK)').
1.3
Carry out subsequent work on the engine assembly support (  Workshop Manual '1001IN
Tools for removing units and working on the engine assembly support').
1.4
Remove intake-air distributor (  Workshop Manual '244619 Removing and installing
intake-air distributor').
1.5
Remove generator (  Workshop Manual '272219 Removing and installing generator').
1.6
Remove camshafts (  Workshop Manual '150520 Removing and installing camshafts
(includes setting timing)').
1.7
Remove cylinder head (2 x) (  Workshop Manual '157019 Removing and installing cylinder
head - section on "Removing"').
1.8
Carefully inspect the cylinder walls, pistons and re-used parts for wear and clean them ( 
Workshop Manual '1310IN Piston wear, weight groups and identification markings').
If signs of wear are detected on the components, these must also be replaced.
2
Convert engine
2.1
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Install new cylinder head (2 x) (  Workshop Manual '1001Z2 Assembling engine').
2.1.1
Check that all stoppers are fitted on the new cylinder head. If not, fit missing
stoppers.
2.1.2
Install new cylinder head (2 x) with the relevant new cylinder-head gasket (2 x) ( 
Workshop Manual '157019 Removing and installing cylinder head').
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2.1.3
Fit oil supply valve for vacuum pump (brake booster) with a new O-ring on the
cylinder head and suspend timing chain at the valve (  Workshop Manual '1001Z2
Assembling engine').
2.1.4
Secure guide rail in the cylinder head (1–3 and 4–6) with bearing pins (2 x) ( 
Workshop Manual '1001Z2 Assembling engine').
2.1.5
Remove solenoid hydraulic valve
for camshaft control (one on
each cylinder head, cylinder
1–3:  Figure 5 -1-) from the old
cylinder head and install on the new
cylinder head with a new O-ring
(  Workshop Manual '153719
Removing and installing solenoid
hydraulic valve for camshaft
control').
1
2
3
4
– Solenoid hydraulic valve
for camshaft control
Figure 5
(cylinder 1–3)
– Solenoid hydraulic valve for valve lift control (cylinder 1–3)
– New intake camshaft (cylinder 1–3)
– Exhaust camshaft (cylinder 1–3)
2.1.6
Remove solenoid hydraulic valve for valve lift control (one on each cylinder head,
cylinder 1–3: Figure 5 -2- ) from the old cylinder head and install on the new
cylinder head with a new O-ring (  Workshop Manual '155519 Removing and
installing solenoid hydraulic valve for valve lift adjustment').
2.1.7
Install new intake camshaft (one on each cylinder head, cylinder 1–3:  Figure 5
-3-) and old exhaust camshaft (one on each cylinder head, cylinder 1–3:  Figure
5 -4-) with a new washer (34.0 x 0.1) for the camshaft controller (  Workshop
Manual '150520 Removing and installing camshaft - section on "Installing"').
Set the timing.
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2.1.8
Unclip guide rail (one on each
cylinder head  Figure 6 -1-) from
upper part of bearing saddle on the
removed cylinder head and install
it on the new upper part of bearing
saddle (new cylinder head, cylinder
1–3:  Figure 6 -2-) (  Workshop
Manual '150520 Removing and
installing camshaft – section on
"Installing"').
1
2
2.1.9
– Guide rail
– New upper part of bearing
saddle (cylinder 1–3)
Position new seal in each cylinder
head cover and install cylinder head
cover (cylinder head 1–3 and 4–6)
(  Workshop Manual '158219
Removing and installing cylinder
head cover - engine removed').
Figure 6
Information
•
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Page 10 of 31
Do not use steel stamping numbers to mark the engine number on direct fuel injection
engines.
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Installation and Conversion Instructions
•
2.2
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1
Due to the material composition, the engine number must be engraved using the
specified tool.
Add the letter “S” to the engine type on the
standard engine
1
2
3
4
–
–
–
–
Clip
Lower coolant pipe
Engine type “MA103”
Engine type “MA103 S”
2.2.1
Loosen clip on lower coolant pipe
( Figure 7 -1-) and swivel the
coolant pipe aside (  Workshop
Manual '195019 Removing and
installing coolant pump').
2.2.2
Turn the engine 90° to the right.
2.2.3
Engrave the letter "S" immediately
after the engine type MA103 (
Figure 7 -4-;  Workshop Manual
'1001IN Position and marking of
engine number').
2.2.4
2.3
911 (991)
Figure 7
Position and secure lower coolant pipe (  Workshop Manual '195019 Removing
and installing coolant pump').
Convert or install positive crankcase ventilation, ignition system and fuel supply
1
2
2.3.1
– Fuel high-pressure pump
– Positive crankcase ventilation cover,
cylinder 1–3
Install fuel high-pressure pump
( Figure 8 -1-) with a new
O-ring (  Workshop Manual
'246319 Removing and installing
high-pressure pump').
Figure 8
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2.3.2
Fit cover for positive crankcase
ventilation (2 x, cylinder head 1–3
 Figure 8 -2-/cylinder head
4–6  Figure 9 -1-) with a new
O-ring and new moulded seal (
 Workshop Manual '150520
Removing and installing camshaft section on "Installing"').
1
2
2.3.3
– Positive crankcase ventilation cover, cylinder 4–6
– Vacuum pump (solo pump)
for brake booster
Figure 9
Install vacuum pump (solo pump) for brake booster with new O-rings (2 x) on
cylinder head 4–6 (  Workshop Manual '477619 Removing and installing vacuum
pump',  Figure 9).
Fit coolant pipe for vacuum pump (solo pump) for brake booster with new O-rings
(2 x) in the vacuum pump and secure it to the bottom of the coolant guide.
2.3.4
Install new spark plugs (  Workshop Manual '287020 Removing and installing
spark plugs').
2.3.5
Install ignition coils (  Workshop Manual '282020 Removing and installing ignition
coils').
2.3.6
Convert coolant temperature
sensor (cylinder 3) with a new
sealing ring (  Workshop Manual
'197819 Removing and installing
coolant temperature sensor
(cylinder 3)').
1
2
2.3.7
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Page 12 of 31
– Coolant temperature
sensor (cylinder 3)
– Coolant compensation line
Remove old coolant compensation
line ( Figure 10 -2-) and install
new coolant compensation line (
Figure 11 -2-).
Tequipment
Figure 10
Installation and Conversion Instructions
2.3.8
911 (991)
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1
Remove lower part of oil filler neck
(  Workshop Manual '171519
Removing and installing oil filler
neck').
1
2
3
4
5
6
– Coolant temperature
sensor (cylinder 3)
– New coolant compensation line
– New engine oil filler neck
– New fuel collection pipe,
cylinder 1-3
– New fuel collection pipe,
cylinder 4-6
– New pressure line (highpressure connecting line
for fuel collection pipe)
Coat O-ring (underside of
connection piece) with Klüber
Syntheso Glep.
Figure 11
Position and fit new oil filler neck on the crankcase ( Figure 11 -3-).
2.3.9
2.4
Install fuel collection pipe and fuel injectors (6 x) with new Teflon seals (6 x) ( 
Workshop Manual '243019 Removing and installing fuel collection pipe with fuel
injectors',  Figure 11).
Convert or install engine electrics, exhaust system holder and positive crankcase ventilation.
2.4.1
Install generator (  Workshop Manual '272219 Removing and installing
generator').
2.4.2
Convert bracket for silencer holder (2 x).
Tightening torque 23 Nm (17 ftlb.)
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2.4.3
Install lower part of heat shield (2
x,  Workshop Manual '261219
Removing and installing heat
shield') and rear silencer holder (2
x,  Workshop Manual '2601IN
Components and arrangement of
exhaust system') ( Figure 12).
1
2
3
4
5
Figure 12
2.4.4
Position new engine wire harness on the engine (  Workshop Manual '975219
Removing and installing wire harness for engine').
2.4.5
Connect plug connections to ignition coils (6 x) and sensors/senders/hydraulic
valves (engine body/cylinder head area) ( Figure 12).
2.4.6
Fit new crankcase vent line (
 Workshop Manual '1001Z2
Assembling engine' Figure 13)
1
2
3
4
5
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– Lower part of heat shield,
cylinder 4–6
– Rear silencer holder,
cylinder 4–6
– Engine wire harness
– Ignition coil, cylinder 6
– Hall sender, cylinder 4–6
– Crankcase vent line
– Retaining clip for air-conditioning compressor
– Connection for engine oil
filler neck
– Connection for oil-filter
housing
– Connection for positive
crankcase ventilation
cover, cylinder 4–6
Tequipment
Figure 13
Installation and Conversion Instructions
2.4.7
911 (991)
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1
Route new engine wire harness to
the starter, secure it to existing
lines and connect it to the starter
(  Workshop Manual '276019
Removing and installing starter').
1
2
3
– B+ line terminal
– Line 50 terminal
– Cap on starter
Fit cap on the starter.
Figure 14
2.5
Install and complete new intake-air distributor.
1
2
3
4
5
– New intake-air distributor (ASSY)
– Holder for wiring harness on
distributor tube (pre-fitted)
– Holder for wiring harness on lower
part of intake-air distributor (cylinder
4–6)
– Torx screw, M6 x 12
– Connection piece for vent
connections (cylinder head 1–3)
2.5.1
Grease connection piece (vent
connections on cylinder head
1–3,  Figure 15 -5-) on the new
intake-air distributor with Optimol.
2.5.2
Fit new engine wire harness holder
( Figure 15 -3-) on the new
lower part of intake-air distributor
(cylinder 4–9) using Torx screws (M6 x 12).
Tightening torque 10 Nm (7.5 ftlb.)
Tequipment
Figure 15
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Information
Do NOT remove plastic locks (color: red) on the 12 screws (M6 x 25) on the lower
part of the intake-air distributor flange. They are used to center the intake-air
distributor on the cylinder heads.
2.5.3
Fit new intake-air distributor
complete with restraining strap,
new seals (6 x) and pre-fitted
screws (M6 x 25, 12 ea.) on the
cylinder heads.
1
2
3
– New intake-air distributor
– Restraining strap
– Torx screw, M6 x 12
Figure 16
2.5.4
Connect new crankcase vent line
to the ventilation adapter (cylinders
1–3) ( Figure 17).
1
2
2.5.5
– Crankcase vent line and
cylinders 4–6
– Connection piece for
intake-air distributor
Secure new intake-air distributor to
the cylinder heads with M6 x 25
screws (12 x) according to the
specified tightening sequence
(  Workshop Manual '244619
Removing and installing intake-air distributor').
Figure 17
Tighten pre-fitted M6 x 12 screws (2 x for tabs on distributor tube  Figure 16 -3-).
Tightening torque 10 Nm (7.5 ftlb.) +1 Nm (+0.5 ftlb.)
Open restraining strap ( Figure 16 -2-) and pull it out to the side.
May 31, 2016
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Tequipment
Installation and Conversion Instructions
2.5.6
2
3
4
2.5.8
1001
1
– Vent line for cylinder head
1–3
– Connection piece for
intake-air distributor
– Connection piece for ventilation, cylinder head 1–3
– Holder for engine wire
harness (side, cylinder
1–3)
Fit new fuel tank vent line on holder
for intake-air distributor for cylinder
1–3 and connect plug connections
( Figure 19).
3
4
– New fuel tank vent line
– Holder for intake-air
distributor, cylinder 1–3
– Resonance tube
connection
– Electric plug connection
Adapt and connect vacuum system
•
ENU
Figure 18
Fit holder for engine wire harness
(2 x, side) on lower part of intake-air distributor for cylinder 1–3 ( Figure 18
-4-)/cylinder 4–6 (  Workshop Manual '975219 Removing and installing wire
harness for engine').
1
2
2.6
45/12
Fit new vent line for cylinder head
1–3 ( Figure 18).
1
2.5.7
911 (991)
Figure 19
Vacuum system; top view:  Figure 20
Tequipment
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1
2
3
4
10
11
14
15
A
B
C
D
E
F
G
H
J
K
•
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Installation and Conversion Instructions
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–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
Figure 20
T-piece
Angled pipe
Protective tube
Molded hose (protective tube, bent)
Pipe, 5.0 x 1.0 x 30.0
Pipe, 5.0 x 1.0 x 85.0
Pipe, 5.0 x 1.0 x 185.0
Line bracket, 5.0 x 5.0 (Raymond)
Connection for air cleaner control valve
Connection for vehicle thermal management control valve
Connection for engine thermal management vacuum unit
Connection for thermal management control valve
Connection for sports exhaust system control valve
Vacuum unit for resonance tube switching flap
Connection for vacuum unit on switching flap shaft, cylinder 1–3
Connection for vacuum unit on switching flap shaft, cylinder 4–6
Connection for transmission control valve
Connection for vehicle
Vacuum system; side view (cylinder 4–6):  Figure 21
Tequipment
Installation and Conversion Instructions
1
2
3
4
5
6
7
8
9
11
12
13
14
15
16
17
A
B
C
D
E
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
911 (991)
45/12
ENU
1001
1
Figure 21
T-piece
Angled pipe
Protective tube
Molded hose (protective tube, bent)
Y-piece
Hose, 3.5 x 2.0 x 75.0
Pipe, 4.0 x 1.0 x 230.0
Pipe, 5.0 x 1.0 x 350.0
Pipe, 5.0 x 1.0 x 280.0
Pipe, 5.0 x 1.0 x 85.0
Pipe, 4.0 x 1.0 x 75.0
Pipe, 5.0 x 1.0 x 510.0
Pipe, 5.0 x 1.0 x 185.0
Line bracket, 5.0 x 5.0 (Raymond)
Protective tube, 5.0 x 200.0
Protective tube, 5.0 x 300.0
Connection for air cleaner control valve
Connection for vehicle thermal management control valve
Connection for engine thermal management vacuum unit
Thermal management control valve
Connection for sports exhaust system control valve
Tequipment
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F
G
H
J
K
L
M
–
–
–
–
–
–
–
Vacuum unit for resonance tube switching flap
Connection for vacuum unit on switching flap shaft, cylinder 1–3
Connection for vacuum unit on switching flap shaft, cylinder 4–6
Connection for transmission control valve
Connection for vehicle
Vacuum unit control valve on switching flap shaft, cylinder 1–3 and cylinder 4–6
Vacuum unit control valve for resonance distributor switching flap
Information
Specified lengths are minimum lengths!
Remove any additional parts you need from the standard vacuum/fresh-air system,
which are no longer required.
Cut pipelines off the relevant pipe (provided = running meter) as shown in  Figure
20 and  Figure 21.
2.6.1
Attach 300-mm length for protective tube 5.0 x 300 ( Figure 21 -17-) from the
parts provided.
Connect vacuum system as shown in  Figure 20 and  Figure 21.
2.6.2
2.7
Adapt and connect fresh-air system
•
Fresh-air system; side view (cylinder 4–6):
Figure 22
1
2
3
4
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–
–
–
–
Pipe, 5.0 x 1.0 x 220.0
Pipe, 5.0 x 1.0 x 30.0
Protective tube, 5.0 x 200.0
T-piece
Tequipment
Installation and Conversion Instructions
5
6
7
8
9
10
A
B
C
D
E
F
G
–
–
–
–
–
–
–
–
–
–
–
–
–
911 (991)
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ENU
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1
Connecting piece (elbow)
Pipe, 5.0 x 1.0 x 70.0
Pipe, 5.0 x 1.0 x 350.0
Line bracket, 5.0 x 5.0 (Raymond)
Y-piece
Molded hose (protective tube, bent)
Connection for vehicle
Connection for vehicle thermal management control valve
Connection for engine thermal management control valve
Connection for sports exhaust system control valve
Connection for tuning flap control valve
Connection for resonance induction manifold control valve
Connection for transmission
Information
Specified lengths are minimum lengths!
Remove any additional parts you need from the standard vacuum/fresh-air system,
which are no longer required.
2.7.1
Cut pipelines off the relevant pipe (provided = running meter) as shown in  Figure
22.
2.7.2
Connect vacuum system as shown in  Figure 22.
NOTICE
Risk of damage to lines and/or hoses (vacuum)
•
due to incorrect routing.

Maintain a sufficient distance from components exposed to high temperatures while driving.

Avoid using small bending radii.
2.8
Install vacuum/fresh-air system on the engine
Tequipment
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A
B
C
D
1
2
3
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Installation and Conversion Instructions
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–
–
–
–
–
–
–
Figure 23
Engine thermal management control valve
Installation position of sports exhaust system control valve
Vacuum unit control valve on switching flap shaft, cylinder 1–3 and cylinder 4–6
Vacuum unit control valve for resonance tube switching flap
Line bracket
Vacuum system (green)
Fresh-air system (blue)
2.8.1
Secure lines in the line bracket ( Figure 23 -1-) on the intake-air distributor for
cylinder 4–6.
2.8.2
Clip control valves ( Figure 23 -A / B / C / D-) into the intake-air distributor
holders.
2.8.3
Fit vacuum system and fresh-air system on the engine and secure in holders
( Figure 23).
Tequipment
Installation and Conversion Instructions
2.9
911 (991)
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1001
1
Concluding work for converting engine
1
2
3
2.9.1
– Drive belt
– Lower cover
– Upper cover
Install drive belt (  Workshop
Manual '137819 Removing and
installing drive belt') and drive
belt cover (  Workshop Manual
'138419 Removing and installing
drive belt cover') ( Figure 24).
Figure 24
2.9.2
Install upper part of heat shield (2
x) (  Workshop Manual '261219
Removing and installing heat
shield').
1
2
3
4
3
– Upper part of heat shield,
cylinder 4–6
– Exhaust manifold with
catalytic converter,
cylinder 4–6
– Engine carrier
– Vacuum line (sports
exhaust system)
Figure 25
2.9.3
Install exhaust manifold with catalytic converter (left/right:  Figure 25 -2-)
with a new seal (  Workshop Manual '261019 Removing and installing exhaust
manifold').
2.9.4
Install engine carrier ( Figure 25 -3-) with front muffler holder (  Workshop
Manual '103019 Removing and installing engine carrier').
2.9.5
Secure vacuum line (sports exhaust system  Figure 25 -4-) to the engine carrier
with a clip (  Installation and Conversion Instructions '260100 Sports exhaust
system, 3.8 l (I-no. 176)')
Install exhaust system on engine side
3.1
ONLY for vehicles WITHOUT sports exhaust system (I-no. 176), see also:  Installation and
Conversion Instructions '260100 Sports exhaust system, 3.8 l (I-no. 176)':
3.1.1
3.2
Install new front muffler with new seals (2 x) and new M8 hexagon nuts (6 x) ( 
Workshop Manual '262519 Removing and installing front silencer').
ONLY for vehicles WITH sports exhaust system (I-no. 176):
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Installation and Conversion Instructions
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3.2.1
Install front muffler with new seals (2 x) and new M8 hexagon nuts (6 x) ( 
Workshop Manual '262519 Removing and installing front silencer').
3.2.2
Install rear silencer (left/right) (  Workshop Manual '263319 Removing and
installing rear silencer').
ONLY for vehicles WITHOUT –middle– radiator (I-no. 153):
Install –middle– radiator
4.1
Preparatory work for –middle– radiator area
4.1.1
Remove front apron (  Workshop Manual '631519 Removing and installing front
apron').
4.1.2
Remove air guide on side radiators
(left/right;  Workshop Manual
'192419 Removing and installing
air guide') and pedestrian
protection (  Workshop Manual
'697019 Removing and installing
pedestrian protection').
1
2
3
– Air guide, right
– Air guide, left
– Pedestrian protection
Figure 26
4.1.3
Fit retaining frame (for radiator)
at the threaded bolts on the front
panel using M6 hexagon nuts (4 x).
1
2
– Retaining frame (for
radiator)
– Hexagon nut, M6
Figure 27
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1
WARNING
Caustic fluid
•
Danger of chemical burns

Avoid contact with caustic fluid.

Wear personal protective gear.

Ensure that there is good ventilation.

If you do come into contact, wash off immediately with plenty of warm water and
contact a doctor if necessary.
4.1.4
Place a suitable container underneath the side radiators.
Remove dummy plugs on side radiators (bottom) and collect coolant.
4.2
Install –middle– radiator (  Workshop
Manual '198019 Removing and installing
middle radiator',  Figure 28).
1
2
3
4
5
–
–
–
–
–
Retaining frame
Radiator (middle)
Sealing frame
Air guide (center)
Water hose (supply)
Figure 28
4.3
Replace closed retaining frame (center) for
front apron with a new open retaining frame
(centre) in accordance with the vehicle variant
(WITH/WITHOUT I-no. XAA/XAT/XAS) ( 
Workshop Manual '660519 Removing and
installing radiator grille').
1
2
– Retaining frame (center), open
(vehicles with I-no. XAA/XAT/XAS)
– Front apron (vehicles with I-no.
XAA/XAT/XAS)
Figure 29
Tequipment
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4.5
5
Installation and Conversion Instructions
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ONLY for vehicles WITHOUT I-no.
XAA/XAT/XAS:
Adapt front apron
4.4.1
Make air opening (4 x,  Figure 30
-arrows-) on underside of the front
apron.
4.4.2
Drill a hole at the radius of each of
the markings/impressions.
4.4.3
Cut out air opening (4 x) using a
tenon saw.
4.4.4
Remove burrs from cut edges.
Concluding work for –middle– radiator area
4.5.1
Install pedestrian protection (
 Workshop Manual '697019
Removing and installing pedestrian
Figure 30
protection') and air guide on side
radiators (left/right;  Workshop Manual '192419 Removing and installing air
guide').
4.5.2
Install front apron (  Workshop Manual '631519 Removing and installing front
apron').
Concluding work for engine area
5.1
ONLY for vehicles WITHOUT sports exhaust system:
Install combined switch (switch console);  Installation and Conversion Instructions
'260100 Sports exhaust system (I-no. 176)'.
5.2
Mount transmission (  Workshop Manual '343527 Removing and mounting transmission
- section on "Removing and mounting"') or Porsche Doppelkupplung (PDK) (  Workshop
Manual '373427 Removing and mounting Porsche Doppelkupplung (PDK)').
WARNING
Working on the vehicle electrical system
•
Risk of short circuit and fire.

Disconnect and cover the battery.

Route electric wires without tension so that no chafing occurs.

Secure electric wires to existing wires/components using tie-wraps and/or wrapping tape.
5.3
May 31, 2016
Page 26 of 31
Install engine (  Workshop Manual '100119 Removing and installing engine - section on
"Removing"').
Tequipment
Installation and Conversion Instructions
5.4
911 (991)
45/12
ENU
1001
1
Fit connector (6-pin, connection close to DME
control unit connector) for transmission input
shaft sensor
1
2
3
5.4.1
– Engine wire harness
– Connector for DME control unit
– Connector for transmission input
shaft sensor (6-pin)
ONLY for vehicles WITH manual
transmission (I-no. 487):
Check whether a mating connector
( Figure 31 -2-) is fitted in the
vehicle.
Yes: Connect plug connection and
fit it to existing holder.
No: Protect connector from
spray water using a dummy plug
991.612.957.00 if necessary and
fit to existing holder.
5.4.2
Figure 31
ONLY for vehicles WITH Porsche Doppelkupplung (PDK) (PDK transmission = I-no.
250):
Protect connector from spray water using a dummy plug 991.612.957.00 if
necessary and fit to existing holder.
5.5
ONLY for vehicles from MY 15:
Also use wiring harness (991.612.944.00)
for plug connection for engine thermal
management control valve/vehicle wiring
harness.
1
2
3
5.6
– wiring harness
– Engine thermal management control
valve connector
– Engine wire harness holder,
cylinders 4–6 (right-hand side)
Check all operating fluid levels and top up if
necessary.
Figure 32
5.6.1
Fill in coolant and bleed the cooling system (  Workshop Manual '193817
Draining and filling coolant (includes bleeding)').
5.6.2
Fill in refrigerant (  Workshop Manual '87031700 Draining and filling refrigerant').
5.6.3
Check engine-oil level and top up with new engine oil if necessary (  Workshop
Manual '170101 Checking engine-oil level').
Tequipment
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6
Installation and Conversion Instructions
45/12
Install new engine compartment cover with
carbon badges ( Figure 33).
5.7.1
Install fan motors for
engine-compartment blower (
 Workshop Manual '198119
Removing and installing
engine-compartment blower').
5.7.2
Clip in new engine compartment
cover with carbon badges.
Code/program “Power Kit ( I-no. X51)” and “sports
exhaust system (I-no. 176)”, if not already installed
6.1
Preparatory work
6.1.1
6.1.2
Connect battery charger ( 
Workshop Manual '2X00IN Battery
trickle charging') and connect
9900 - PIWIS Tester 3 to the
vehicle and switch it on.
Figure 33
Check PIWIS Tester software version (at least 11.200) on the Start screen (above
Copyright).
Information
The 9718 - PIWIS Tester instructions take precedence and in the event of a
discrepancy these are the instructions that must be followed. Deviations may
occur with later software versions.
The procedure described here has been structured in general terms; different text
or additions may appear in the 9718 - PIWIS Tester.
6.1.3
Switch on ignition in the vehicle.
Select vehicle “911” and type “991” in the "Diagnostics" menu on 9900 - PIWIS
Tester 3. PIWIS Tester Diagnostics starts.
WARNING
Sudden voltage interruption of the power supply to the control module.
•
Destruction of the control module.

During programming, it is essential to guarantee the power supply for the PIWIS Tester. It
is essential to connect a battery charger with a current rating of at least 40 A to the vehicle
battery.

Prior to disconnecting the control module, switch off the ignition and remove the ignition key.
May 31, 2016
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Installation and Conversion Instructions
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ENU
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1
NOTICE
Control unit programming will be aborted if the Internet connection is unstable.
•
An unstable Internet connection can interrupt communication between PIWIS Tester III and the
vehicle communication module (VCI). As a result, control unit programming may be aborted.

During control unit programming, always connect PIWIS Tester III to the vehicle communication module (VCI) via the USB cable.
6.2
Enter the new vehicle equipment in the vehicle data
(see also:  Workshop Manual '247055 Replacing DME control unit')
6.2.1
Select “DME” in the control unit overview. Press •>>“ to continue.
Take note of the Porsche part number before programming, e.g. 991.618.626.08
(for EU5/manual transmission – model year D vehicle).
Press •<<“ to go back to the higher-level menu.
6.2.2
Press •F7“ in the control unit overview to switch to the “Additional menu”.
6.2.3
Select the “Maintenance of vehicle data” function. Press •F12“ until “X numbers”
appears in the Value group column.
6.2.4
Select the option “X51 – CARRERA POWER KIT” in the “Value group = X numbers”
column and wait until a tick appears in the “Installed” column.
6.2.5
ONLY for vehicles WITHOUT sports exhaust system before conversion:
Press •F12“ to go to the “Value group = M numbers” page.
Scroll to the “176 – SPORTS EXHAUST SYSTEM” row here, select the option
“176 – SPORTS EXHAUST SYSTEM" and wait until a tick appears in the “Installed”
column.
6.3
6.2.6
Press •F12“ to go to the end of the menu and then press •F8“ to save the
selected option(s).
6.2.7
Wait until the message “Creation of vehicle order has been completed.” appears.
Continue to Log management by pressing •F12“.
6.2.8
Press •F10“ to open the log. Check that the selected vehicle equipment has been
entered and close the log.
Code/program the new vehicle equipment.
6.3.1
Select all control units in the control unit overview (•CTRL+A“) and switch to the
“Codings/adaptations” column.
6.3.2
Select "Automatic coding" in coding mode. Press •F12“ to continue.
6.3.3
Once “Automatic coding” (takes approx. 8 minutes) is complete, switch to the
control unit overview and select DME control unit.
Tequipment
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6.3.4
Once the control unit is displayed, e.g. “DME V6 naturally aspirated EU 3.8 (X51)”,
press •F8“.
The message “Performing programming …” will appear and two progress bars will
be displayed at the bottom of the screen.
6.4
6.3.5
When programming is complete (after approx. 6 minutes), press •F12“ to switch
to the control unit overview.
6.3.6
Press •F8“ to display all control units containing faults.
6.3.7
Check any faults that are present, work through them if necessary and then delete
them by pressing •F8“.
Check that the DME control unit was programmed successfully by reading out the new part
number7.
Porsche Part No.7
991.618.640.02
EU5/PDK transmission
991.618.641.02
EU5/manual transmission
991.618.642.02
Low Emission Vehicle = LEV/PDK transmission
991.618.643.02
Low Emission Vehicle = LEV/manual transmission
991.618.644.02
EU4 –not restricted–/PDK transmission
991.618.645.02
EU4 –not restricted–/manual transmission
991.618.646.02
EU4 –restricted–/PDK transmission
991.618.647.02
EU4 –restricted–/manual transmission
991.618.648.02
EU4 –Porsche Asia Pacific (PAP)–/PDK transmission
991.618.649.02
EU4 –Porsche Asia Pacific (PAP)–/manual transmission
991.618.650.02
EU5 –Porsche Asia Pacific (PAP)–/PDK transmission
991.618.652.02
Ultra Low Emission Vehicle (ULEV) –Porsche
Asia Pacific (PAP)–/PDK transmission
7 Version:
6.5
7
May 31, 2016
Page 30 of 31
Emission standard and country or
region/transmission type
PIWIS Tester, release version: 11.200 for model year 2013 = D vehicles
Adapt DME control unit (  Workshop Manual '247055 Replacing DME control unit').
Concluding work
7.1
Disconnect the battery charger (  Workshop Manual '2X00IN Battery trickle charging').
7.2
Lower the lifting platform and remove the vehicle.
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1001
1
7.3
Perform a test drive or adaptation drive (DME control unit [  Workshop Manual '247055
Replacing DME control unit'] and transmission control unit [  Workshop Manual '373055
Replacing PDK transmission control unit']).
7.4
Read out the fault memory of all systems, work through any existing faults and erase the fault
memory (  Workshop Manual '0X03IN Diagnostic maintenance: Diagnostic system and
maintenance inter...').
7.5
Switch off ignition and disconnect 9900 - PIWIS Tester 3.
10 01 31 00:
–Engine (1 x) for 911 Carrera S (991), increased performance– ONLY for
vehicles WITHOUT sports exhaust system
Includes:
Engine removed and installed; replacing cylinder heads,
intake-air distributor, oil filler neck and engine compartment
cover.
Installing rear silencer for sports exhaust system and
connecting vacuum lines.
Adding the letter S to the engine number.
–Middle– radiator installed and air openings made on
underside of front apron
Programming DME control unit; reading out all control units
and erasing fault memories.
Filling with operating fluids. Sound function test on sports
exhaust system.
Without:
Measurement of performance and test drive.
Labor time: 2720 TU
10 01 31 03:
–Engine (1 x) for 911 Carrera S (991), increased performance– ONLY for
vehicles WITH sports exhaust system
Includes:
Engine removed and installed; replacing cylinder heads,
intake-air distributor, oil filler neck and engine compartment
cover.
Adding the letter S to the engine number.
–Middle– radiator installed and air openings made on
underside of front apron
Programming DME control unit; reading out all control units
and erasing fault memories.
Filling with operating fluids. Sound function test on sports
exhaust system.
Without:
Measurement of performance and test drive.
Labor time: 2610 TU
Important Notice: Technical Bulletins issued by Porsche Cars North America, Inc. are intended only for use by professional automotive technicians who have attended Porsche service training
courses. They are written to inform those technicians of conditions that may occur on some Porsche vehicles, or to provide information that could assist in the proper servicing of a vehicle. Porsche special
tools may be necessary in order to perform certain operations identified in these bulletins. Use of tools and procedures other than those Porsche recommends in these bulletins may be detrimental to the
safe operation of your vehicle, and may endanger the people working on it. Properly trained Porsche technicians have the equipment, tools, safety instructions, and know-how to do the job properly and
safely. Part numbers listed in these bulletins are for reference only. The work procedures updated electronically in the Porsche PIWIS diagnostic and testing device take precedence and, in the event of a
discrepancy, the work procedures in the PIWIS Tester are the ones that must be followed.
© 2016 Porsche Cars North America, Inc.
Tequipment
May 31, 2016
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