Removing and Installing Bearing Cover For Intermediate Shaft (2002)
Removing And Installing Bearing Cover For Intermediate Shaft
CAUTION:
- 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
Preliminary work:
NOTE: Note the work instructions for disconnecting and reconnecting the battery.
- Move convertible top to service position.
- Remove the engine compartment lid and the maintenance cover in the passenger compartment.
- Disconnect the battery.
- Remove Tiptronic transmission.
- 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.).
Removing Bearing Cover
1. Release drive belt.
2. Release box for B+ connector. To do this, unscrew the two hexagon-head bolt screws on the crankcase and set the box to one side.
3. Remove supply tank of the power steering system. To do so, remove fluid (Pentosin) as much as possible using suction. Then open the bayonet lock -arrow- on the bottom of the expansion tank and remove the tank. Collect emerging Pentosin with a cloth. Close the opening in the servo pump with a clean plug.
NOTE: The air conditioning circuit must not be opened to release the air conditioning compressor.
4. Loosen air-conditioning compressor. To do this, unscrew the two hexagon-head bolts at the front -arrows- on the side of the maintenance opening (in the passenger compartment).
5. Unscrew the fastening screw at the back -arrow- from the engine compartment side. This is positioned between the intake manifolds of the fourth and fifth cylinders.
6. Disconnect the ground connection cable plug. Lever the air conditioning compressor with the connected leads out of the engine compartment and set them on a support.
7. Remove holder for air-conditioning compressor. To do so, undo the two M8 hexagon-head bolts and remove the holder.
8. 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).
NOTE: After removal of the chain tensioner, the crankshaft must not be turned under any circumstances, because otherwise the timing chain may jump over.
9. 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:
10. 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.
11. Remove thrust plate and drive plate. Release and unscrew 6 M8 pan-head screws gradually and in diametrically opposite sequence.
12. Remove double-mass flywheel (DMF). Fit special tool toothed segment No. 9538/1 for countering using an M 12 x 50 screw. Unscrew 8 M10 x 50 Torx socket screws and remove the DMF.
13. Remove primary chain tensioner and chain tensioner, cylinder bank 1 - 3 (hexagon socket a/f 32).
-A- Primary chain tensioner; -B- chain tensioner, cylinder bank 1 - 3
14. 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 -see Figure-.
15. 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.
16. 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.
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 Optimally 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 -see Figure- (help from a second person recommended).
Tightening torque 12 + 1 Nm (9 + 0.5 ftlb.).
5. Install both primary chain tensioner and chain tensioner cylinder bank 1 - 3 with a new aluminium sealing ring (hexagon a/f 32) and tighten to the correct tightening torque.
-A- Primary chain tensioner; -B- chain tensioner, cylinder bank 1 - 3
Tightening torque 80 Nm (59 ftlb.)
NOTE: Fastening screws for drive plate for the torque converter or the double-mass flywheel must be replaced.
6. 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 M12 x 50 screw.
Tightening torque 25 Nm (19 ftlb.) + 120 degree torque angle
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.
7. Manual transmission: Install thrust plate and drive plate. Tighten 6 M8 pan-head screws to the prescribed torque.
Tightening torque: 23 Nm (17 ftlb.)
8. 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.)
9. 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.)
10. Pull fixing pin out of the fixing bore.
11. Install Tiptronic transmission.
12. Install the air-conditioning compressor with the leads connected. Ensure correct seating of the spacer sleeve.
Tightening torque for M8 hexagon-head bolts 23 Nm (17 ftlb.)
13. Install supply tank for power steering system. Turn the bayonet lock clockwise until the markings line up.
14. Fit box for B+ connection on the crankcase with 2 hexagon-head bolts.
Tightening torque: 10 Nm (7.5 ftlb.)
15. Fit and tension drive belt.
16. Fill engine oil.
17. Fill Pentosin.
18. Install the engine compartment lid and the maintenance cover in the passenger compartment.
Engine compartment lid
Maintenance cover in the passenger compartment
19. Connect the battery.
20. Close convertible top.
Tightening Torques
