Removing and Installing Sealing Ring For Intermediate Shaft
Removing and installing sealing ring for intermediate shaft
Engine installed (flywheel side)
Remove sealing ring for intermediate shaft
- Remove manual transmission.
- Remove Tiptronic 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.
1. Remove the clutch pressure plate, including the drive plate.
2. Remove drive plate for the torque converter or the double-mass flywheel (DMF). Fasten special tool toothed segment 9538/1 for countering on the right crankcase half (cylinder bank 1 - 3) with an M10 x 50 screw. Undo and remove drive plate or DMF.
3. Drain engine oil. After a dripping time of 20 minutes, insert oil drain plug with new sealing ring and tighten.
Tightening torque 50 Nm (37 ft. lbs.)
4. Turn the engine on the crankshaft belt pulley clockwise until the bore 1 TDC (top dead centre) in the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with special tool fixing pins 9595/1 -see Figure-. Use short fixing pin.
5. Remove camshaft closure caps from cylinder bank 1 - 3. The closure cap of cylinder bank 1 - 3 is located on the flywheel side. Drive small screwdriver into centre of the closure cap and lever off the cap.
6. Check basic camshaft adjustment -arrow-. If the position is not correct, remove the dowel pin and turn the crankshaft a further 360° in clockwise direction. Fix belt pulley again with fixing pin.
View from the flywheel side
7. Turn primary chain tensioner out of the crankcase, cylinder bank 4 - 6.
8. Turn secondary chain tensioner out of the cylinder head 1 - 3.
9. Undo intermediate shaft flange. Unscrew the three fastening screws M6 x 20 on the intermediate-shaft flange. Undo the M8 x 1 lock nut with the socket wrench 9110 -see Figure-. At the same time, counter with a suitable screwdriver in the slotted threaded pin.
10. Position and align special tool retaining device 9642 -see Figures-.
Tensioning the retaining device
11. Carefully press the intermediate shaft off, for instance with two angle screwdrivers -see Figure-. Proceed carefully so as not to damage the sealing surfaces.
Install sealing ring for intermediate shaft
1. Check crankcase bore for sharp edges. Break off (deburr) any sharp edges on the crankcase bore (intermediate shaft flange) with polishing cloth or an oilstone.
2. Grease the new sealing ring slightly with Optimoly MP3 (available from Porsche Parts Service) and insert in the groove of the intermediate shaft flange.
Note;
- The sealing ring must not be twisted and must not be pulled over sharp edges of the flange.
3. Position intermediate shaft flange on the bore and affix with new micro-encapsulated hexagon-head bolts.
Note;
- Do not exert any pressure on the threaded pin when pushing in the intermediate shaft flange, as the threaded pin might otherwise be pressed inward into the intermediate shaft.
- As soon as the threaded pin projects at the intermediate shaft flange, screw the new lock nut into position.
4. Position and align special tool retaining device 9642 -see Figure-. Centre intermediate shaft and intermediate shaft flange by turning the crankshaft to and fro a little (max. 2° to 3°, remove dowel pin from the belt pulley first).
Note;
- It must be possible to insert the intermediate shaft flange almost completely into the intermediate shaft bore by hand.
5. Tighten the three micro-encapsulated M6 x 20 hexagon-head bolts evenly -see Figure-.
Tightening torque 10 Nm (7.5 ft. lbs.)
6. Tighten lock nut M8 x 1 with the socket wrench 9110. At the same time, have a second person counter with a suitable screwdriver in the slotted threaded pin -see Figure-.
Tightening torque 11 Nm (8 ft. lbs.)
7. Equip both chain tensioners with new sealing rings, screw in and tighten.
Tightening torque 80 Nm (59 ft. lbs.)
8. Fill in engine oil.
Note;
- Replace screws for the double-mass flywheel and drive plate for the torque converter.
9. Fit double-mass flywheel or drive plate for the torque converter.
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.
10. Fit the clutch pressure plate with drive plate.
11. Install manual transmission or Tiptronic transmission.
