Engine - Flywheel Side Sealing Ring Removal/Installation
911 (997)6/05
September 12, 2005
New Crankshaft Sealing Ring On Flywheel Side
Vehicle Type:
911 Carrera (997)/911 Carrera S (997)
Model Year:
As of 2005
Concerns:
New crankshaft sealing ring on flywheel side.
Situation:
Crankshaft sealing ring on flywheel side leaking.
Because of possible leaks at the crankshaft sealing ring, a new crankshaft sealing ring has been installed in the engines of the vehicles mentioned above since May 17, 2005.
The new crankshaft sealing ring is made from a different material (PTFE). The modified sealing lip design is the same as that of the crankshaft sealing ring used in Cayenne engines.
In the event of a complaint or when carrying out engine repair work that involves replacing the crankshaft sealing ring, the new crankshaft sealing ring must always be fitted.
Note
^ For information on the assembly tools to be used, refer to the Workshop Manual.
Note
^ The new crankshaft sealing ring (sports cars) can be identified not only by it's part No. but also by it's green assembly sleeve.
^ The crankshaft sealing ring with a white assembly sleeve is only designed for Cayenne engines and must not be installed in the engines of sports cars.
Date of Introduction
May 17, 2005, from the Engine Nos.
M96/05 69 5 09405
M97/01 68 5 13598
Part Numbers
References:
--> Workshop Manual '135919 Removing and installing crankshaft sealing ring - flywheel side'
Enclosure:
Removing and installing crankshaft sealing ring - flywheel side
Preliminary work for crankshaft sealing ring on flywheel side
Note
^ In Tiptronic vehicles, the complete engine/transmission unit must be removed.
^ In vehicles with manual transmission, the sealing ring can be changed on the engine, irrespective of whether it is installed or removed.
Manual transmission:
1. Remove manual transmission --> Workshop Manual '343519 Removing and installing transmission - chapter on "removing".
2. Remove clutch --> Workshop Manual '305019 Removing and installing clutch - chapter on "removing"
3. Remove double-mass flywheel --> Workshop Manual '136019 Removing and installing double-mass flywheel- chapter on "removing".
Tiptronic transmission
4. Remove engine --> Workshop Manual '100119 Removing and installing engine - chapter on "removing".
5. Remove Tiptronic transmission --> Workshop Manual '373527 Removing and refitting automatic transmission - chapter on "removing".
6. Remove drive plate for converter --> Workshop Manual '136319 Removing and installing drive plate for converter- chapter on "removing".
Removing crankshaft sealing ring on flywheel side
Note
Perform a visual inspection of the crankshaft flange and crankshaft bore for damage.
ATTENTION
Ingress of dirt
^ Risk of engine damage.
--> When working on the engine, absolute cleanliness is essential.
7. Carefully remove small edges or burrs on the chamfer of the crankshaft flange with an oilstone. Then, carefully remove the metal filings and any dirt remaining on the crankshaft journal and crankcase bore (using a clean, lint-free cloth that has been soaked in solvent naphtha or acetone).
ATTENTION
The crankshaft flange can be damaged if not cleaned correctly.
^ Leaks
--> Never use an abrasive or polishing cloth or brushes with metal bristles.
--> Follow cleaning instructions.
8. If there are corroded spots on the crankshaft flange. clean them off using a metal-polishing pad (e.g. Never Dull, available in car and motorcycle accessory stores). Then, carefully rub off the flange (using a clean, lint-free cloth that has been soaked in solvent naphtha or acetone).
9. Punch the installed sealing ring at a depression (round window in the ring) with a drift punch (1 mm tip) NR.167.
10. Drill crankshaft sealing ring at the punched position with a greased drill bit (diameter 3 mm) and carefully remove the swarf (e.g. with compressed air).
11. Screw extractor tip of the tool puller, model G for sealing rings NR.168-1 into the bore on the sealing ring and pull out the sealing ring.
12. Alternatively, screw a sheetmetal screw with washer approx. 5 mm into the bore.
13. Pull out sealing ring using puller 9237 alternative tool to puller Mod. G (No. 168-1) at the tapping screw.
14. Check crankshaft flange and crankcase bore for damage.
15. If necessary, clean the crankshaft flange again using the metal-polishing pad. Then, carefully degrease the flange and crankcase bore using a clean, lint-free cloth that has been soaked in solvent naphtha or acetone.Ventilate this for at least three minuets to prevent the acetone vapors from destroying the new sealing ring.
Installing crankshaft sealing ring (PTFE) on flywheel side
New insert part assembly aid P 9699/2 Assembly of PTFE sealing ring for special tool insertion tool P 9699.
Component overview of insertion tool
16. Fit assembly aid P 9699/2 into the insertion tool P 9699. To do so, unscrew the hexagon-heed bolt and replace the insert parts.
ATTENTION
Sharp tool edges and burrs.
^ Damage to the sealing lip.
--> Always examine tools for signs of burrs and sharp edges.
17. Small burred spots or damaged areas on the tools can be eliminated with a nail file, then polished with an oilstone, fine abrasive or polishing cloth. Remove residual dirt on the tools, e.g. using solvent naphiha or acetone.
18. Check crankshaft installation position. To do this, insert special tool measuring mandrel 9699/1 across the crankshaft flange into the fitted bore of the crankcase -->figure-. The measuring mandrel must be placed with slight resistance in the bore. If the measuring mandrel cannot be positioned, the engine must be replaced.
19. Adjust insertion tool in order to position the supporting sleeve of the sealing ring. Unscrew the hexagon-head bolt until the groove of the assembly aid P 9699/2 is flush with the contact surface of the Sleeve --> Adjusting insertion part for positioning Sealing ring -arrow-.
ATTENTION
Damage to the sealing lip.
^ Leaks
--> The crankshaft flange and tools must be perfectly clean and free of grease.
--> The sealing ring must be fitted dry, i.e. no oil, grease or other lubricants can be used.
--> The crankcase bore must not be oiled.
--> The sealing ring can only be positioned on the assembly tool using the supporting sleeve.
--> The new crankshaft sealing ring (PTFE) is supplied on a supporting sleeve as a spare part.
--> Do not remove the sealing ring from the supporting sleeve.
20. Slide new crankshaft sealing ring --> Sliding PTFE sealing ring with supporting sleeve onto tool -1- with supporting sleeve onto the assembly aid P 9699/2 by pushing only on the sleeve --> Sliding PTFE sealing ring with supporting sleeve onto tool -2-. The collar of the sleeve must be pointed away from tool --> Sliding PTFE sealing ring with supporting sleeve onto tool -inset-. Make sure sealing ring is dry.
21. Fit insertion tool 9699 between the two internal M8 pan-head screws, (hexagon socket a/f 8) on the crankshaft flange and fasten it. The crankshaft flange's dowel pin must sit in the bore of the device.
Note
After pulling in the sealing ring, leave assembly tool 9699 in place for about one minuet so that the sealing lip can settle into position on the crankshaft flange.
22. To position the crankshaft sealing ring correctly on the crankshaft flange, turn at the hexagon (a/f 19) of the device in a clockwise direction as far as it will go --> figure-. Let the tool in place for about one minuet.
23. Remove tool, loosen the large hexagon-head bolt and the two inner hexagon-head bolts alternately on the crankshaft flange until the tool can be removed.
24. Check whether the sealing ring is properly seated and aligned. To do this, measure at four points, offset by 90° from the flywheel attachment surface on the crankshaft flange to the sealing ring (outer radias). Dimension 13 mm.
25. Leave supporting sleeve on the the tool following assembly to protect the edges of the tool. Carefully lift off the sleeve at the bore with a small screwdriver to remove it.
Subsequent work for crankshaft sealing ring on flywheel side
Manual transmission:
26. Install double mass flywheel --> Workshop Manual '136019 Removing and installing double mass flywheel. Chapter on 'installing"'.
27. Install clutch --> Workshop Manual '305019 Removing and installing clutch - chapter on 'installing"'.
28. Install manual transmission --> Workshop Manual '343519 Removing and installing transmission - chapter on "Installing".
Tiptronic transmission
29. Install drive plate for converter --> Workshop Manual '136319 Removing and installing drive plate for converter - Chapter on "installing".
30. Refit Tiptronic transmission --> Workshop Manual '373527 Removing and refitting automatic transmission - Chapter on "refitting".
31. Install engine --> Workshop Manual '100119 Removing and installing engine - chapter on "installing",
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