Removing and Installing Bearing Cover For Intermediate Shaft
WM 152119 Removing and installing bearing cover for intermediate shaft
Preliminary work for bearing cover for intermediate shaft
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
Removing bearing cover for intermediate shaft
Caution: Timing chain may jump over.
^ Risk of engine damage
-> Following removal of the chain tensioner, the crankshaft must not be turned under any circumstances.
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.
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 (or vibration damper) clockwise to overlapping TDC of cylinder bank 1-3 and fix it with special tool fixing 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 x 12 hexagon-head bolts on the coolant pipe (heating) at cylinder side 4 - 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 screwed river.
8. Unscrew the three M6 x 20 hexagon-head bolts (coated) on the intermediate-shaft flange. Replace screws during installation and clean thread.
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 anticlockwise.
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), for example. Move the bearing cover frequently to the left and right to make the levering easier. Do not damage the sealing surfaces.
Installing bearing cover for intermediate shaft
Installing bearing cover for intermediate shaft
Note: Clean working area of bore for bearing cover and crankcase thoroughly using acetone or solvent naphtha.
Note: Replace bearing cover or sealing ring for bearing cover.
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.
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 x 1 and coated M6 screws for bearing cover.
3. Position three new, coated M6 x 20 screws on the crankcase and pull in the bearing cover by screwing in the screws uniformly. Tighten screws -> Tightening torque: 7.5 ftlb.
4. Position new M8 x 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: 9 ftlb. + 0.5 ftlb.
5. Insert primary chain tensioner with new aluminum sealing ring (hexagon a/f 32) and tighten to the specified torque. -> Tightening torque: 59 ftlb.
6. Insert chain tensioner for cylinder 1 - 3 with new aluminum sealing ring (hexagon a/f 32) and tighten to the specified torque. -> Tightening torque: 59 ftlb.
7. Fasten coolant pipe (heating), cylinder side 4 - 6, with two M6 x 12 hexagon-head bolts. -> Tightening torque: 7.5 ftlb.
8. Fit two new closure caps on cylinder head cover.
9. Pull fixing pin out of the crankshaft belt pulley.
Subsequent work for bearing cover for intermediate shaft
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 clutch.
5. Install double-mass flywheel.
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.