Removing and Installing Bearing Cover For Intermediate Shaft (2003)
Removing And Installing Bearing Cover For Intermediate Shaft
CAUTION:
- After removing the chain tensioner under no circumstances must the crankshaft be turned, otherwise the timing chain may Jump over.
- Danger of damage to engine.
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 (reuse oil drain plug with new aluminium sealing ring and tighten with a tightening torque of 50 Nm (37 ftlb.)).
Removing Bearing Cover
1. Unscrew drive belt.
2. Release box for B+ connector. To do this, unscrew the two hexagon-head screws on the crankcase and set the box to one side.
3. Remove supply tank of the power steering system. To do so, suck fluid (Pentosin) out as much as possible. 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 the holder for the air conditioning compressor. To do this unscrew the two M8 hexagon-head bolts and remove the holder.
8. Turn engine clockwise on the hexagon-head bolt (a/f 24) of the crankshaft belt pulley to TDC and fix with special tool dowels pins No. 9595/1 (use short dowel pin).
NOTE: After removing the chain tensioner under no circumstances must the crankshaft be turned, otherwise the timing chain may jump over.
9. Remove the chain tensioner for cylinders 4-6 -arrow-. To do this undo the chain tensioner with a socket wrench insert for hexagon socket a/f 14 and remove.
Tiptronic:
10. Remove the torque-converter drive plate. To counter, fit toothed segment No. 9538/1 special tool using an M12 x 50 bolt. Unscrew the eight M10 x 25 x 1 internal Torx 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. Undo the six M8 pan-head screws in several stages in diametrically opposite sequence and remove.
12. Remove double-mass flywheel (DMF). To counter, fit toothed segment No. 9538/1 special tool using an M12 x 50 bolt.
Unscrew the eight M10 x 50 internal Torx screws and remove DMF.
13. Remove primary chain tensioner and chain tensioner for cylinder bank 1-3 (hexagon socket a/f 32).
-A- Primary chain tensioner; -B- Chain tensioner for cylinder bank 1-3
14. Unscrew hexagon M8 collar nut on bearing cover of the intermediate shaft using special tool socket wrench No. 9110, countering with a suitable screwdriver at the slotted threaded pin of the intermediate shaft -see figure-.
15. Unscrew the three hexagon-head screws M6 x 20 (micro-encapsulated) on the intermediate-shaft flange. Replace screws on installation.
NOTE: Lever out bearing cover carefully so as not to damage the sealing surfaces.
16. Lever out the bearing cover carefully, for instance with two angle screwdrivers. To make levering out easier, turn the bearing cover to the left and right several times.
Fitting Bearing Cover
NOTE: Fit a new the bearing cover.
1. Before fitting the new bearing cover, check the fitting bore on the case for burrs and sharp edges. These should be removed with an oilstone or polishing cloth. Remove any residues and clean the bore using a clean cloth soaked in solvent naphtha or acetone.
NOTE: Renew the hexagon collar nut M8 x 1 and micro-encapsulated screws for the bearing cover.
2. Grease the fitting bore and new bearing cover with Optimally MP3 special grease (obtainable from Porsche Parts Service) and position the bearing cover. Screw the new hexagon nut M8 x 1 on the threaded pin of the intermediate shaft.
3. Screw the three hexagon-head screws M6 x 20 (micro-encapsulated) on the crankcase and tighten.
Tightening torque 10 Nm (7.5 ftlb.)
4. Tighten the hexagon collar nut M8 using special tool socket wrench No. 9110 with tightening torque. At the same time, counter with a suitable screwdriver in the slotted threaded pin -see Figure- (assistance of a second person advisable).
Tightening torque 12 + 1 Nm (9 + 0.5 ftlb.)
5. Fit primary chain tensioner and chain tensioner for cylinder bank 1-3 with new aluminium sealing ring (hexagon socket a/f 32) and tighten with tightening torque.
-A- Primary chain tensioner; -B- Chain tensioner for cylinder bank 1-3
Tightening torque 80 Nm (59 ftlb.)
NOTE: New fastening screws for the torque-converter drive plate or double-mass flywheel (DMF) must be used.
6. Fit double-mass flywheel or drive plate for the torque converter using new screws. To counter, fit special tool toothed segment No. 9538/1 -Figure- using an M12 x 50 bolt.
Tightening torque 25 Nm (19 ftlb.) + 120 degrees 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 the six M8 pan-head screws with tightening torque.
Tightening torque: 23 Nm (17 ftlb.)
8. Install the chain tensioner for cylinders 4-6 -arrow-. Tighten chain tensioner to tightening torque with a socket wrench insert for hexagon socket a/f 14.
Tightening torque 80 Nm (59 ftlb.)
9. Fit holders for air conditioning compressor and servo line. Fix both holders using two M8 hexagon-headed screws and tighten with tightening torque.
Tightening torque: 23 Nm (17 ftlb.)
10. Pull dowel pin out of the fixing bore.
11. Install Tiptronic transmission.
12. Install air conditioning compressor with pipes connected. Ensure that the spacer sleeve is seated correctly.
Tightening torque for M8 hexagon-head bolts 23 Nm (17 ftlb.)
13. Install supply tank for power steering system. Turn the bayonet lock counter-clockwise until the markings line up.
14. Fit box for B+ connector with two hexagon-head bolts to the crankcase.
Tightening torque 10 Nm (7.5 ftlb.)
15. Fit and tension drive belt.
16. Fill up with engine oil.
17. Fill up with Pentosin.
18. Fit the engine compartment lid and the maintenance cover in the passenger compartment.
Engine compartment lid
Maintenance cover in passenger compartment
19. Connect the battery.
20. Close convertible top.
Tightening Torques
