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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Installation and Conversion Instructions

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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
•

May 31, 2016
Page 10 of 31

Do not use steel stamping numbers to mark the engine number on direct fuel injection
engines.

Tequipment

Installation and Conversion Instructions
•
2.2

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ENU

1001

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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Installation and Conversion Instructions

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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

May 31, 2016
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)
45/12

ENU

1001

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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Installation and Conversion Instructions

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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

May 31, 2016
Page 14 of 31

– 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)
45/12

ENU

1001

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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Installation and Conversion Instructions

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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