Removal and Replacement
Removing and installing bearing cover for intermediate shaft - M96/05Tools
Preliminary work for bearing cover for intermediate shaft
Note: Note the work instructions for disconnecting and reconnecting the battery.
1. Disconnect the battery.
2. Drain engine oil.
3. Remove air cleaner housing.
Tiptronic transmission:
4. Remove engine.
5. Remove Tiptronic transmission.
6. Remove drive plate for converter.
Manual transmission:
7. Remove manual transmission.
8. Remove clutch.
9. Remove double-mass flywheel.
Removing bearing cover for intermediate shaft - up to engine number 695 07 475
ATTENTION: Timing chain may jump over.
^ Risk of engine damage
^ Following removal of the chain tensioner, the crankshaft must not be turned under any circumstances.
ATTENTION: Risk of damage due to particles of dirt.
^ Oil bores/oil ducts can become blocked up.
^ When working on the engine, absolute cleanliness is essential.
^ Lay removed engine parts on a clean base and cover them without fail.
^ Use the cover for dust protection when fitting the engine NR.165 on the engine assembly support.
Note:
^ It is only possible to remove the bearing cover with the engine installed in vehicles with manual transmission.
^ In Tiptronic vehicles, the complete engine/transmission unit must be removed.
Note: Always observe specified engine number range.
Bearing cover up to engine number 695 07 475
1. Lever out two green closure caps on pulley side of cylinder bank 1 -3.
2. Turn the engine at the hexagon-head bolt (a/f 24) of the crankshaft belt pulley clockwise to overlapping TDC of cylinder bank 1 -3 and fix it with special tool locating pins 9595/ 1.
Note: For checking with the adjusting gauge, the timing adjustment must be correct.
3. To check the camshaft adjustment, insert adjusting gauge 9686 for camshaft into the camshaft slots (pulley side) (inscription on gauge pointing towards cylinder head cover). If the gauge cannot be inserted, rotate the crankshaft a further 360° and secure it again.
4. Unscrew two M6 12 hexagon-head bolts on the coolant pipe at cylinder side - 6.
5. Remove primary chain tensioner (hexagon socket a/f 32).
6. Remove chain tensioner, cylinder bank 1 -3 (hexagon socket a/f 32).
Note: To make it easier to remove the bearing cover, spray the sealing surface with anti-rust agent.
7. Unscrew M8 hexagon collar nut on the bearing cover of the intermediate shaft with special tool socket wrench 9110, while at the same time countering the slotted threaded pin on the intermediate shaft with a screwdriver.
8. Unscrew the three M6 20 fastening screws (coated) on the intermediate-shaft flange. Replace screws during installation and clean thread in crankcase.
Note:
^ Remove bearing cover using special tool puller 9673.If this is not available, lever the bearing cover out carefully with two screwdrivers so as not to damage the sealing surfaces. Turning several times to the left and right loosens the bearing cover.
^ After removing the bearing cover, do not press the threaded bolts of the intermediate shaft.
9. Position special tool puller 9673 at the bearing cover grooves and secure by turning the locking lever anti-clockwise.
10. Pull the slide hammer on the puller a number of times against the stop nuts while countering the tool at the same time with the other hand.
11. If the puller is not available, lever the bearing cover out carefully using two screwdrivers (or angle screwdrivers). Move the bearing cover a number of times to the left and right to make levering easier. Do not damage the sealing surfaces.
Removing bearing cover for intermediate shaft - from engine number 695 07 476
ATTENTION: Timing chain may jump over.
^ Risk of engine damage
^ Following removal of the chain tensioner, the crankshaft must not be turned under any circumstances.
ATTENTION: Risk of damage due to particles of dirt.
^ Oil bores/oil ducts can become blocked up.
^ When working on the engine, absolute cleanliness is essential.
^ Lay removed engine parts on a clean base and cover them without fail.
^ Use the cover for dust protection when fitting the engine NR.165 on the engine assembly support.
Note:
^ It is only possible to remove the bearing cover with the engine installed in vehicles with manual transmission.
^ In Tiptronic vehicles, the complete engine/transmission unit must be removed.
Note: Always observe specified engine number range.
Note:
^ The same sealing ring and installation/removal procedure applies as for the "old" bearing cover.
^ The new bearing cover can only be retrofitted along with the new intermediate shaft up to model year 2002 (M96/03).
Overview of bearing covers for intermediate shaft.
^ A - Bearing cover 996.105.024.01
^ B - Bearing cover 996.105.024.06
^ C - New collar nut, M12 1.25
Rear of bearing cover
^ A - Rear of bearing cover 996.105.024.01
^ B - Rear of bearing cover 996.105.024.06
Use the special tool assembly tool P 9673/ 1 for bolting the new bearing cover.
1. Lever out two green closure caps on pulley side of cylinder bank 1 -3.
2. Turn the engine at the hexagon-head bolt (a/f 24) of the crankshaft belt pulley clockwise to overlapping TDC of cylinder bank 1 -3 and fix it with special tool locating pins 9595/ 1.
Note: For checking with the adjusting gauge, the timing adjustment must be correct.
3. To check the camshaft adjustment, insert adjusting gauge 9686 for camshaft into the camshaft slots (pulley side) (inscription on gauge pointing towards cylinder head cover). If the gauge cannot be inserted, rotate the crankshaft a further 360° and secure it again.
4. Unscrew two M6 12 hexagon-head bolts on the coolant pipe at cylinder side - 6.
5. Remove primary chain tensioner (hexagon socket a/f 32).
6. Remove chain tensioner, cylinder bank 1 -3 (hexagon socket a/f 32).
Note: To make it easier to remove the bearing cover, spray the sealing surface with anti-rust agent.
7. Loosen M12 hexagon collar nut (a/f 22) on bearing cover for intermediate shaft with special tool assembly tool P 9673/ 1 and screw it off - Threaded joint with collar nut on bearing cover for intermediate shaft.
8. Unscrew the three M6 20 fastening screws (coated) on the intermediate-shaft flange. Replace screws during installation and clean thread in crankcase.
Note:
^ Remove bearing cover using special tool puller 9673.If this is not available, lever the bearing cover out carefully with two screwdrivers so as not to damage the sealing surfaces. Turning several times to the left and right loosens the bearing cover.
^ After removing the bearing cover, do not press the threaded bolts of the intermediate shaft.
9. Position special tool puller 9673 at the bearing cover grooves and secure by turning the locking lever anti-clockwise.
10. Pull the slide hammer on the puller a number of times against the stop nuts while countering the tool at the same time with the other hand.
11. If the puller is not available, lever the bearing cover out carefully using two screwdrivers (or angle screwdrivers). Move the bearing cover a number of times to the left and right to make levering easier. Do not damage the sealing surfaces.
Installing bearing cover for intermediate shaft - up to engine number 695 07 475
ATTENTION: Risk of damage due to particles of dirt.
^ Oil bores/oil ducts can become blocked up.
^ When working on the engine, absolute cleanliness is essential.
^ Lay removed engine parts on a clean base and cover them without fail.
^ Use the cover for dust protection when fitting the engine NR.165 on the engine assembly support.
Note: Clean working area of bore for bearing cover and crankcase thoroughly using acetone or solvent naphtha.
1. Before installing the new bearing cover, check the fitted bore (axial attachment surface, bore chamfers) 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 bearing cover or sealing ring for bearing cover.
Note: Always observe specified engine number range.
2. Grease fitted bore in crankcase and new bearing cover (with new sealing ring) with special grease Optimoly MP3 (available from Porsche Parts Service) and place bearing cover in position.
Note: Replace collar nut M8 1 and coated M6 screws for bearing cover.
3. Position three new, coated M6 20 screws on the crankcase and pull in the bearing cover by screwing in the screws uniformly. Tighten the screws. Tightening Torque: 10 (7.5 ft. lb.) Nm
4. Position new M8 1 collar nut on the threaded pin of the intermediate shaft. Then tighten the nut using special tool socket wrench 9110. At the same time, counter with a screwdriver in the slotted threaded pin of the intermediate shaft. Tightening Torque: 12 (9 ft. lb.) Nm +1 (0.5 ft. lb.) Nm
5. Insert primary chain tensioner with new sealing ring (hexagon a/f 32) and tighten to the specified torque. Tightening Torque: 80 (59 ft. lb.) Nm
6. Insert chain tensioner for cylinder 1 - 3 with new sealing ring (hexagon a/f 32) and tighten to the specified torque. Tightening Torque: 80 (59 ft. lb.) Nm
7. Secure coolant pipe on cylinder side - 6 with two M6 12 hexagon-head bolts. Tightening Torque: 10 (7.5 ft. lb.) Nm
8. Fit new closure caps on cylinder head cover.
9. Pull locating pin out of crankshaft belt pulley.
Installing bearing cover for intermediate shaft - from engine number 695 07 476
ATTENTION: Risk of damage due to particles of dirt.
^ Oil bores/oil ducts can become blocked up.
^ When working on the engine, absolute cleanliness is essential.
^ Lay removed engine parts on a clean base and cover them without fail.
^ Use the cover for dust protection when fitting the engine NR.165 on the engine assembly support.
Note: Always observe specified engine number range.
New bearing cover.
^ B - Bearing cover 996.105.024.06
^ C -Collar nut, M12 1.25
Note: Clean working area of bore for bearing cover and crankcase thoroughly using acetone or solvent naphtha.
1. Before installing the new bearing cover, check the fitted bore (axial attachment surface, bore chamfers) 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 bearing cover or sealing ring for bearing cover.
2. Grease fitted bore in crankcase and new bearing cover (with new sealing ring) with special grease Optimoly MP3 (available from Porsche Parts Service) and place bearing cover in position.
Note: Replace collar nut M12 and coated M6 screws for bearing cover.
3. Position three new, coated M6 20 screws on the crankcase and pull in the bearing cover by screwing in the screws uniformly. Tighten the screws. Tightening Torque: 10 (7.5 ft. lb.) Nm
4. Position new M12 1.25 collar nut on the threaded pin of the intermediate shaft. Then tighten the nut using special tool assembly tool P 9673/1. At the same time, counter with an angle screwdriver in the slotted threaded pin of the intermediate shaft. Tightening Torque: 20 (15 ft. lb.) Nm +/ -1 (0.5 ft. lb.) Nm
5. Insert primary chain tensioner with new sealing ring (hexagon a/f 32) and tighten to the specified torque. Tightening Torque: 80 (59 ft. lb.) Nm
6. Insert chain tensioner for cylinder 1 - 3 with new sealing ring (hexagon a/f 32) and tighten to the specified torque. Tightening Torque: 80 (59 ft. lb.) Nm
7. Secure coolant pipe on cylinder side - 6 with two M6 12 hexagon-head bolts. Tightening Torque: 10 (7.5 ft. lb.) Nm
8. Fit new closure caps on cylinder head cover.
9. Pull locating pin out of crankshaft belt pulley.
Subsequent work for bearing cover for intermediate shaft
Tiptronic transmission:
1. Install drive plate for converter.
2. Refit Tiptronic transmission.
3. Install engine.
Manual transmission:
4. Install double-mass flywheel.
5. Install clutch.
6. Install transmission.
7. Filling in engine oil.
8. Install air cleaner housing.
Note: Note the work instructions for disconnecting and reconnecting the battery.
9. Connect the battery.