Removing and Installing Bearing Cover For Intermediate Shaft
Removing And Installing Bearing Cover For Intermediate Shaft
CAUTION:
- Pentosin Is hazardous to the health.
- Wear protective gloves and goggles. If the eyes or skin come into contact with the fluid, wash immediately with water.
- Collect emerging Pentosin.
- Protect the leads against soiling and damage with caps.
- Clean hoses which come Into contact with Pentosin thoroughly.
- After removal of the chain tensioner, the crankshaft must not be turned under any circumstances, because otherwise the timing chain may jump over.
- Danger of engine damage.
NOTE:
- As from model year 2002, it will only be possible to remove the bearing cover with the engine installed in manual transmission vehicles.
- In Tiptronic vehicles, the complete engine/transmission unit must be removed.
Preliminary work
NOTE:
Note the work instructions for disconnecting and reconnecting the battery.
- Disconnect the battery.
- Drain engine oil (insert the oil drain plug again with a new aluminium sealing ring and tighten with a tightening torque of 50 Nm (37 ftlb.).
Tiptronic:
- Remove and install the engine.
- Remove transmission.
Manual transmission:
- Remove transmission.
Removing Bearing Cover
1. Remove air cleaner housing (engine installed).
2. In vehicles with air conditioning, the following work steps must be performed on the installed engine:
a. Remove the drive belt from the belt pulley of the air-conditioning compressor. Mark the running direction of the belt with a coloured pen. Slacken belt by turning the tensioning pulley (wrench size 24) clockwise, hold still and simultaneously take the drive belt off the belt pulley of the air-conditioning compressor. Carefully allow the tensioning roller to turn back into tensioning position.
b. Disconnect battery positive lead -1- at B+ disconnection point. Unscrew the hexagon nut M8 and remove the positive lead. Then unscrew the hexagon-head bolt M6 x 12 -2- at the holder and lay the holder and box to one side.
c. Extract Pentosin fluid from the servo-tank with a pump. Dispose of extracted Pentosin according to the relevant regulations. Lay a cloth under the tank to collect any emerging Pentosin. Open the bayonet lock anti-clockwise and remove the tank. Immediately seal the lower tank opening with a plug (dia. approx. 30 mm).
d. Remove the air-conditioning compressor. Tool recommendation: 1/4 inch -Figure d3-. 3 hexagon-head bolts M8: Unscrew 2 at rear -1-, 1 at front -2-. For better access to the front threaded part -2-, remove the engine compartment temperature sensor with the rubber sleeve at the right intake distributor. In order to lift the compressor out, pull the front fastening screw upwards out of the spacer sleeve. Disconnect the ground cable at the plug connection.
Front threaded part, air-conditioning compressor
Figure d3: recommended 1/4 inch tool for the front compressor screw
e. Lay the air-conditioning compressor with the leads connected to one side on a protective support. Also secure against falling down (tie wraps).
3. Turn the engine at the hexagon-head bolt (a/f 24) of the crankshaft belt pulley clockwise to TDC and then fix it with special tool fixing pins No. 9595/1 (use short fixing pin).
4. Remove holder for air-conditioning compressor. To do so, undo the two M8 hexagon-head bolts and remove the holder.
NOTE: After removal of the chain tensioner, the crankshaft must not be turned under any circumstances, because otherwise the timing chain may jump over.
5. Remove the chain tensioner, cylinder bank 4-6 -arrow-. To do so, release and unscrew the chain tensioner with a socket wrench insert, hexagon socket a/f 14.
Tiptronic:
6. Remove the torque-converter drive plate. Fit special tool toothed segment No. 9538/1 for countering using an M12 x 50 screw. Unscrew 8 M10 x 25 x 1 Torx socket screws and remove drive plate.
Manual transmission:
NOTE: In order to avoid deforming the thrust plate housing, always loosen the pan-head screws on the clutch pressure plate in several stages and in diametrically opposite sequence.
7. Remove thrust plate and drive plate. Release and unscrew 6 M8 pan-head screws gradually and in diametrically opposite sequence.
8. Remove double-mass flywheel (DMF). Fit special tool toothed segment No. 9538/1 for countering using an M12 x 50 screw. Unscrew 8 M10 x 50 Torx socket screws and remove the DMF.
9. Unscrew 2 M6 x 12 hexagon-head bolts on the coolant pipe (heating) cylinder side 4 - 6.
10. Remove primary chain tensioner -arrow- (hexagon socket a/f 32).
11. Remove chain tensioner, cylinder bank 1 - 3 (hexagon socket a/f 32).
12. Unscrew M8 hexagon collar nut on the bearing cover of the intermediate shaft with special tool socket wrench No. 9110, at the same time countering at the slotted threaded pin on the intermediate shaft with a suitable screwdriver.
13. Unscrew the three M6 x 20 hexagon-head bolts (micro-encapsulated) on the intermediate-shaft flange. Replace screws during installation.
NOTE: Lever the bearing cover out carefully so as not to damage the sealing surfaces.
14. Lever the bearing cover out carefully using, for instance, two angle screwdrivers. Move the bearing cover frequently to the left and right to make the levering easier. Do not damage the sealing surfaces.
Installing Bearing Cover
NOTE: Replace bearing cover.
1. Before installing the new bearing cover, check the fitted bore on the crankcase for sharp edges and burrs. They should be removed with an oilstone or a polishing cloth. Remove any existing residue and clean the bore with a clean cloth soaked in solvent naphtha or acetone.
NOTE: Replace hexagon collar nut M8 x 1 and micro-encapsulated screws for bearing cover.
2. Grease fitted bore and new bearing cover with special grease Optimoly MP3 (available from Porsche Parts Service) and place bearing cover in position. Position new M8 x 1 hexagon nut on the threaded pin of the intermediate shaft.
3. Position and tighten 3 new M6 x 20 hexagon-head bolts (micro-encapsulated) on the crankcase.
Tightening torque 10 Nm (7.5 ftlb.)
4. Tighten M8 hexagon collar nut with special tool socket wrench No. 9110 with the correct tightening torque. At the same time, counter with a suitable screwdriver in the slotted threaded pin of the intermediate shaft (help from a second person recommended).
Tightening torque 12 + 1 Nm (9 + 0.5 ftlb.).
5. Install both primary chain tensioner -arrow- and chain tensioner cylinder bank 1 - 3 with a new aluminium sealing ring (hexagon a/f 32) and tighten with the correct tightening torque.
Tighten chain tensioner cylinder bank 1 - 3 with torque wrench
Tightening torque 80 Nm (59 ftlb.)
6. Fasten coolant pipe (heating), cylinder side 4 - 6, with 2 M6 x 12 hexagon-head bolts.
Tightening torque 10 Nm (7.5 ftlb.)
7. Install chain tensioner, cylinder bank 4-6 -arrow-. Tighten the chain tensioner with a socket wrench insert, hexagon socket a/f 14, with the correct tightening torque.
Tightening torque 80 Nm (59 ftlb.)
8. Install holder for air-conditioning compressor and servo line. Fasten both holders with 2 M8 hexagon-head bolts and tighten with the correct tightening torque.
Tightening torque: 23 Nm (17 ftlb.)
9. Pull fixing pin out of the crankshaft belt pulley.
NOTE: Fastening screws for drive plate for the torque converter or the double-mass flywheel must be replaced.
10. Install double-mass flywheel or drive plate for torque converter with new screws. Fit special tool toothed segment No. 9538/1 -Figure- for countering using an M 12 x 50 screw.
Tightening torque 25 Nm (19 ftlb.) + 120 degree torque angle
Tiptronic vehicles:
11. Refit transmission.
12. Install the engine. Then perform work steps 15 to 22.
Manual transmission vehicles:
NOTE: In order to avoid deforming the thrust plate housing, always tighten the pan-head screws on the clutch pressure plate in several stages and in diametrically opposite sequence.
13. Install the clutch pressure plate, including the drive plate.
14. Install transmission.
15. Install the air-conditioning compressor with the leads connected (connect ground cable and pull up front fastening screw or, for instance, fasten to the air-conditioning line with adhesive tape). Tighten three M8 hexagon-head bolts with the correct tightening torque. Ensure correct seating of the spacer sleeve.
Tightening torque for M8 hexagon-head bolts 23 Nm (17 ftlb.)
16. Install supply tank for power steering system. Turn the bayonet lock clockwise until the markings line up.
17. Install box for battery positive lead.
18. Install drive belt.
19. Install air cleaner.
20. Fill in engine oil.
21. Fill in Pentosin.
22. Connect the battery.
Tightening Torques
