Auxiliary Shaft Cover: Service and Repair
Removing and installing bearing cover for intermediate shaft
Caution
^ After removal of the chain tensioner, the crankshaft must not be turned under any circumstances, because otherwise the timing chain may jump over!
^ Danger of engine damage!
Information
^ As from model year 2002, it will only be possible to remove the bearing cover with the engine installed in manual transmission vehicles!
^ In Tiptronic vehicles, the complete engine/transmission unit must be removed!
Preliminary work
Information
^ Note the work instructions for disconnecting and reconnecting the battery.
Disconnect the battery.
Drain engine oil (insert the oil drain plug again with a new aluminum sealing ring and tighten with a tightening torque of 50 Nm (37 ftlb.).
Tiptronic:
^ Remove and install the engine.
^ Remove transmission.
Manual transmission:
^ Remove transmission.
Removing bearing cover
1. Remove air cleaner housing (engine installed).
2. Lever out 2 green reservoir caps on the cylinder support 1 - 3 belt pulley side.
3. Turn the engine at the hexagon-head bolt (a/f 24) of the crankshaft belt pulley clockwise to overlapping TDC cylinder support 1 - 3 and then fix it with special tool fixing pins 9595/1 (use short fixing pin).
Information
^ The timing setting must be correct to allow for controls with the adjustment gauge.
4. Use the special tool adjustment gauge 9686 for camshafts in the camshaft slot (belt pulley side) to control the camshaft position (gauge markings point to cylinder head cover). If the gauge cannot be inserted, turn the crankshaft 360°.
Information
^ After removal of the chain tensioner, the crankshaft must not be turned under any circumstances, because otherwise the timing chain may jump over!
^ Drill the bore of the toothed segment 11 - 15 mm for countering on the starter ring.
Tiptronic:
5. Remove the torque-converter drive plate. Fit special tool toothed segment 9538/1 for countering using an M12 x 50 screw. Unscrew 8 M10 x 25 x 1 Torx socket screws and remove drive plate.
Manual transmission:
Information
^ 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.
6. Remove thrust plate and drive plate. Release and unscrew 6 M8 pan-head screws gradually and in diametrically opposite sequence.
7. Remove double-mass flywheel (DMF). Fit special tool toothed segment 9538/1 for countering using an M12 x 50 screw. Unscrew 8 M10 x 50 Torx socket screws and remove the DMF.
8. Unscrew 2 M6 x 12 hexagon-head bolts on the coolant pipe (heating) cylinder side 4 - 6.
9. Remove primary chain tensioner -arrow- (hexagon socket a/f 32).
10. Remove chain tensioner, cylinder bank 1 - 3 (hexagon socket a/f 32).
Information
^ The sealing face can be sprayed with rust remover to make the bearing cover easier to remove.
11. Unscrew M8 hexagon collar nut on the bearing cover of the intermediate shaft with special tool socket wrench 9110, at the same time countering at the slotted threaded pin on the intermediate shaft with a suitable screwdriver.
12. Unscrew the three M6 x 20 hexagon-head bolts (micro-encapsulated) on the intermediate-shaft flange. Replace screws during installation.
Information
^ Lever the bearing cover out carefully so as not to damage the sealing surfaces. The position of the bearing cover can be loosened by turning it left and right several times.
^ Do not press the threaded bolts on the intermediate shaft after removing the bearing cover.
13. Lever the bearing cover out carefully using, for instance, two screwdrivers (or angle screwdrivers). Move the bearing cover frequently to the left and right to make the levering easier. Do not damage the sealing surfaces.
Installing bearing cover
Information
^ Replace bearing cover!
1. Before installing the new bearing cover, check the fitted bore 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.
Information
^ Replace hexagon collar nut M8 x 1 and micro-encapsulated screws for bearing cover!
2. Grease fitted bore and new bearing cover with special grease Optimoly MP3 (available from Porsche Parts Service) and place bearing cover in position.
3. Place 3 new M6 x 20 hexagon-head bolts (micro-encapsulated) on the crankcase and insert the bearing cover by turning the screws equally. Tighten screws to the specified torque.
Tightening torque 10 Nm (7.5 ftlb.)
4. Position new M8 x 1 hexagon nut on the threaded pin of the intermediate shaft. Tighten the nut with special tool socket wrench 9110 with the correct tightening torque. At the same time, counter with a suitable screwdriver in the slotted threaded pin on the intermediate shaft.
Tightening torque 12 + 1 Nm (9 + 0.5 ftlb.).
5. Install both primary chain tensioner -arrow- and chain tensioner cylinder bank 1 - 3 -bottom picture- with a new aluminum sealing ring (hexagon a/f 32) and tighten with the correct tightening torque.
Tighten chain tensioner cylinder bank 1-3 with torque wrench
Chain tensioner tightening torque 80 Nm
6. Fasten coolant pipe (heating), cylinder side 4 - 6, with 2 M6 x 12 hexagon-head bolts.
Tightening torque 10 Nm (7.5 ftlb.)
7. Pull fixing pin out of the crankshaft belt pulley.
Information
^ Fastening screws for drive plate for the torque converter or the double-mass flywheel must be replaced.
^ Drill the bore of the toothed segment 11 - 15 mm for countering on the starter ring.
8. Install double-mass flywheel or drive plate for torque converter with new screws. Fit special tool toothed segment 9538/1 -Figure- for countering using an M12 x 50 screw.
Tightening torque 25 Nm (19 ftlb.) + 120° torque angle
Tiptronic vehicles:
9. Refit transmission.
10. Install the engine. Then perform work steps 13 to 15
Manual transmission vehicles:
Information
^ 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.
11. Install the clutch pressure plate, including the drive plate.
12. Install transmission.
13. Install air cleaner housing.
14. Fill in engine oil.
15. Connect the battery.
