Removing and Installing Oil Pump With Coolant Guide Housing - Engine Removed
Removing And Installing Oil Pump With Coolant Guide Housing - Engine Removed
CAUTION:
- When working on the engine, absolute cleanliness is essential. An engine cover should be used on the engine assembly support. Lay removed engine parts on a clean base and cover them without fail. Even the smallest particles of dirt can block up oil bores.
- After removal of the chain tensioner, the crankshaft must not be turned under any circumstances, because otherwise the timing chain may jump over.
Removing Oil Pump
1. Place pan under the engine to collect any remaining engine oil and coolant which runs out.
2. Drain engine oil. Unscrew the oil drain plug (hexagon socket a/f 8) and drain emerging oil into an oil collection container. Insert plug with a new sealing ring and tighten.
Tightening torque 50 Nm (37 ftlb.)
3. Remove engine carrier by undoing the four hexagon-head bolts M10 (a/f 15) -arrows-.
4. Turn engine at the hexagon-head bolt (a/f 24) of the crankshaft belt pulley clockwise to the TDC mark -arrow-. Fix belt pulley -see figure- 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, otherwise the timing chain may Jump over. By altering the timing, damage to the engine may occur.
5. Remove the chain tensioner, cylinder bank 4-6 -arrow-. To do so, release and unscrew with a socket wrench insert (hexagon a/f 14).
6. Remove chain tensioner, cylinder bank 1 - 3 (hexagon socket a/f 32) -arrow-.
7. Remove primary chain tensioner arrow (hexagon socket a/f 32, oil filter area).
8. Remove cable plug of the coolant temperature sensor -arrow-. Next unscrew eight M6 x 20 and two M6 x 80 hexagon-head bolts -see figure-.
9. Carefully remove the oil pump.
10. Remove old metallic gaskets. Cut through the old seal between the coolant pump and oil pump housing at the connecting webs -arrows-.
Installing Oil Pump
NOTE: Replace 0-rings on oil pump flange and metal gaskets.
1. Clean and degrease the sealing surfaces on the oil pump housing -see figure- and on crankcase (e.g. with acetone or solvent naphtha). Replace 0-rings on the oil pump flange -arrow-. Grease oil pump flange and bore on crankcase with special grease Optimally MP 3 (obtainable from Porsche Parts Service).
2. Cut new metal seal (combination seal for coolant pump and oil pump housing) at the connecting webs -see arrows- and fit the seals for the oil pump and the coolant guide housing -figure below-.
Metal seals for oil pump and coolant guide housing
NOTE: Do not use force when fitting the oil pump (risk of fracturing housing or damaging oil pump drive). Carefully remove any burrs on the crankcase bore or oil pump drive flange with an oilstone.
3. Fit the oil pump. To do this, fix the oil pump on the stud bolts of the engine engine carrier. Insert the oil pump driver (external hexagon) into the drive flange of the oil pump and turn so that it fits in the internal hexagon of the intermediate shaft. At the same time carefully press the oil pump against the crankcase. The drive flange must slide in the crankcase bore of the intermediate shaft (do not tilt).
4. Push on cable plug of the coolant temperature sensor -arrow-. Next screw in evenly the eight M6 x 20 and two M6 x 80 hexagon-head bolts -see figure- for the oil pump and coolant guide housing and tighten.
Tightening torque 10 Nm (7.5 ftlb.)
5. Insert primary chain tensioner with new sealing ring and tighten to the specified torque (hexagon a/f 32).
Tightening torque 80 Nm (59 ftlb.)
6. Insert chain tensioner, cylinder bank 1-3, with new sealing ring and tighten to the specified torque -arrow- (hexagon a/f 32).
Tightening torque 80 Nm (59 ftlb.)
7. Insert chain tensioner, cylinder bank 4-6, with new sealing ring using socket wrench insert (hexagon a/f 14) -arrow- and tighten to the specified torque.
Tightening torque 80 Nm (59 ftlb.)
8. Fill in engine oil.
9. Install engine carrier by screwing in four new hexagon-head bolts M10 (self-locking, a/f 15) -arrows- and tightening.
Tightening torque for M10 hexagon-head bolts 45 Nm (33 ftlb.)
10. Pull fixing pin off crankshaft belt pulley.
Tightening Torques
