Attachment B - Work Procedure

Check whether the engine crankcase was milled incorrectly by measuring the depth of the thread bore on the oil filter flange.

1. Check the dimension on the threaded flange for securing the oil filter housing.

1.1 Raise vehicle on platform lift according to Workshop Manual, Group 4.

1.2 Remove oil filter according to Workshop Manual, Group 1, Chapter 17 01 55.





1.3 Measure the dimension from the face of the oil filter flange to the base of the threaded bore using a caliper gauge (Figure 1, arrow A). Figure 1 is enlarged to improved clarity.

Measured dimension = 35 mm +/- 0.2 mm - Crankcase milled incorrectly, install oil filter housing according to Step 1.4 and then continue with Step 2.

Measured dimension = 36 mm +/- 0.2 mm - Crankcase OK, install oil filter housing according to Step 1.4 and then continue with Step 6.

1.4 Install oil filter housing according to Workshop Manual, Group 1, Chapter 17 01 55 with a new sealing ring and a new oil filter element.

2. Additional test with transmission removed.

2.1 Remove transmission according to Workshop Manual.

2.1.1 Remove Tiptronic transmission - engine and transmission - according to Workshop Manual, Group 3, Chapter 37 35 19.

2.1.2 Remove manual transmission according to Workshop Manual, Group 3, Chapter 34 35 19.





2.2 Incorrect crankcases were only milled on one machine. The crankcases that were milled on this machine can be identified by the position of the two markings on the crankcase transmission flange close to the oil/water heat exchanger (Figure 2, pos. B).

2.3 To identify these crankcases, screw in the fastening screw as shown in Figure 2 and measure the distance between the outside of the fastening screw and the two markings (Figure 2, pos. B) on the crankcase using a caliper gauge (Figure 2, arrow A).

Measured distance = approx. 36 mm - Crankcase incorrect, continue with Step 3.

Measured distance = 26/46/56/66/76/86 mm - Crankcase OK, continue with Step 5.

3. Retrofit a spacer plate on the intermediate shaft bearing cover.

3.1 Loosen intermediate shaft bearing cover according to Workshop Manual, Group 1, Chapter 15 21 19.

Note:
The bearing cover must not be removed fully.





3.1.1 Loosen hexagon collar nut (Figure 3, pos. B) using special tool (socket wrench 9110) and screw out by approx. 4 mm until it is flush with the end of the threaded bolt on the intermediate shaft.

Note:
Do not unscrew or remove the hexagon collar nut fully.

3.1.2 Unscrew three hexagon-head bolts (Figure 3, pos. A).





3.2 Attach puller for intermediate shaft bearing cover according to Workshop Manual, Chapter 15 21 19 (Figure 4, pos. A) and using the special tool, pull the intermediate shaft bearing cover out by approx. 4 mm until it touches the hexagon collar nut.

3.3 Remove puller for intermediate shaft bearing cover.

Note:
The spacer plate (part number, 996.105.924.00) is not symmetrical and has a specific installation position. It is therefore important to determine the preset installation position based on the bores for the fastening screws before installing the spacer plate.





3.4 Starting at the left (left cylinder bank), insert the spacer plate (Figure 5, pos. A) behind the intermediate shaft bearing cover.

3.5 Secure intermediate shaft bearing cover according to Workshop Manual, Group 1, Chapter 15 21 19. Use three new hexagon head bolts for this (part number, 900.385.093.09).

3.6 Unscrew hexagon collar nut. Then install new hexagon collar nut (part number, 900.380.019.02) and tighten according to Workshop Manual, Group 1, Chapter 15 21 19.

4. Write down crankcase matching number and send it to PCNA.





4.1 Read the crankcase matching number (Figure 6, inset) on bottom of crankcase and write it down.

4.1.1 Send the crankcase matching number of the repaired engine to Porsche Cars North America, Inc., attention:

Recall Administrator
E-mail: recalladministrator@porschecars.com or by fax to: (770) 290-6509.

5. Concluding work:

5.1 Install transmission according to Workshop Manual.

5.1.1 Install Tiptronic transmission according to Workshop Manual, Group 3, Chapter 37 35 19.

5.1.2 Install manual transmission according to Workshop Manual, Group 3, Chapter 34 35 19.

6. Lower the platform lift.

7. Check engine oil level according to Workshop Manual, Group 1, Chapter 17 01 01.

8. Enter the service action into the Warranty & Maintenance booklet.





Time Allowance

Labor Operation:
Will automatically be inserted along with the part number when the damage code is entered.





Parts Required





Tools





Reference