Installing
Installing crankshaft
Overview of connecting rod bearing position
1. Fit gearing carrier half 4-6 on special tool retaining device 9607 using two M1 0 x 25 hexagon-head bolts.
2. Ensure that the dowel sleeves are seated correctly in gear carrier half 4-6.
3. Insert three oil spray jets in the take-up bores in each of the gear carrier halves, press in gently to the stop using a plastic mandrel (no.4 mm).
4. Insert two thrust washers onto the center thrust block (no. 4) of gear carrier half 4-6; when doing so, the oil pockets -arrows- must always point outwards (to the belt pulley side or flywheel side).
5. Insert seven new bearing shells for the crankshaft and coat with new engine oil. Pay attention to the installation position: the fixing lugs of the bearing shells in gear carrier half 4-6 point towards the dowel sleeve side, the fixing lugs of the bearing shells in gear carrier half 1-3 face the opposite side.
Twist lock of bearing shell
6. Insert crankshaft. Check that the thrust washers are seated properly.
7. Carefully position gear carrier half 1-3 on the crankshaft and gear carrier half 4-6. Fix the gear carrier halves by tapping them carefully with a plastic hammer.
8. Position 14 M9 x 127 thrust-bearing screws manually. Pre-tighten screws to the required tightening torque in accordance with the tightening sequence. Then tighten to the required torque angle. Initial tightening 11 ft. lbs.; Torque angle 120°
9. Check axial play of crankshaft. Fit dial gauge and dial gauge holder on gear carrier (flywheel side) and place against crankshaft flange. Press crankshaft manually against probe of dial gauge and set dial gauge to '0'. Press crankshaft away from dial gauge. Repeat process several times and note measured value.
10. Insert connecting rod bearing in connecting rod and connecting rod cap. Coat sliding surface with Optimol Optipit (available from Porsche Parts Service: 000.043.204.17).
Note: Connecting rod bolts must always be replaced.
11. Fit each of the connecting rods of cylinder 4-6 with the allocated connecting rod cap at the bearing surfaces of cylinders 4, 5 and 6. Position new screws manually. Pay attention to the installation position of the connecting rods: The recesses of the connecting-rod bearing twist lock face the oil pan (when the gear carrier is installed in the crankcase).
12. First, screw in connecting rod bolts to the required torque and tighten to the specified torque angle. Then loosen the bolts again. The final tightening is performed again with an initial tightening per the torque and the final tightening is performed with the torque angle wrench. Initial tightening 15 ft. lbs.; Torque angle 110
Installing crankshaft, touching up
1. Fit oil guide with new seals. Tighten six new M6 x 16 (micro-encapsulated) Torx screws. Tightening torque 7.5 ft. lbs..
Note: Fix the intermediate shaft to the crankshaft using old O-rings, for example, to secure it.
2. Insert intermediate shaft with timing chains.
3. Install tensioning rail and guide rail. Tighten three M6 x 40 hexagon-head bolts for guide rail -1-. Fit tensioning rail -3- with new circlip and shim -2-. Tightening torque 7.5 ft. lbs..
4. Secure engine support 9589 engine assembly support.
5. Fit crankcase half 1-3 with two mounting parts 9590 to the engine support 9589. Check sealing face to gear carrier for damage. Carefully clean sealing face with a clean cloth that has been soaked in solvent naphtha or acetone.
Use only dowel sleeves whose dimension 'B' = 26.5 mm for fixing the gear carrier.
6. Check dowel sleeves to ensure that they are seated correctly or insert two new dowel sleeves in crankcase -arrows-.
7. Replace seals for coolant ducts -arrows-.
Note: It is advisable to get a second person to assist in inserting the gear carrier into crankcase half 1-3.
8. Insert gear carrier in crankcase half 1-3 with retaining device.
9. Screw in and tighten two additional screws for fastening the gear carrier to cylinder side 1-3, replace O-ring. -arrows-. Tightening torque 16 ft. lbs.
10. Screw in and tighten another cylinder-head screw with spacer sleeve 9613-arrow- on the belt pulley side. Tightening torque 15 ft. lbs.
11. Unscrew special tool retaining device 9607 from gear carrier.
12. Install piston.