Installing Oil Pump

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NOTE:

Replace O-rings on oil pump flange and metal gaskets!

Clean and degrease the sealing surfaces on the oil pump housing and on crankcase (for example, with acetone or solvent naphtha). Replace O-rings on the oil pump flange -arrow- . See Fig 1. Grease oil pump flange and bore on crankcase with special grease Optimoly MP 3 (obtainable from Porsche Parts Service).

Fig 1: Locating O-Ring On The Oil Pump Flange
Courtesy of PORSCHE OF NORTH AMERICA, INC.
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. See Fig 1.

Fig 2: Cutting New Metal Seal At The Connecting Webs
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig 3: Identifying Metal Seals For Oil Pump And Coolant Guide Housing
Courtesy of PORSCHE OF NORTH AMERICA, INC.
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.
Fit the oil pump. To do this, fix the oil pump on the stud bolts of the 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).
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 for the oil pump and coolant guide housing and tighten. See Fig 4.

Fig 4: Pushing Cable Plug Of Coolant Temperature Sensor
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Tightening torque 10 Nm (7.5 ft.lb)
Insert primary chain tensioner with new sealing ring and tighten to the specified torque (hexagon a/f 32).
Tightening torque 80 Nm (59 ft.lb)
Insert chain tensioner, cylinder bank 1 - 3, with new sealing ring and tighten to the specified torque (hexagon a/f 32). See Fig 5.

Fig 5: Locating Chain Tensioner - Cylinder Bank 1-3
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Tightening torque 80 Nm (59 ft.lb)
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. See Fig 6.

Fig 6: Locating Chain Tensioner - Cylinder Bank 4-6
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Tightening torque 80 Nm (59 ft.lb)
Fill in engine oil. Refer to ENGINE MAINTENANCE: OIL CHANGE WITH FILTER CHANGE or CHANGING THE ENGINE OIL AND OIL FILTER -- AS 2003 .
Install engine carrier by screwing in four new hexagon-head bolts M10 (self-locking, a/f 15) -arrows- and tightening. See Fig 7.

Fig 7: Installing Engine Carrier
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Tightening torque for M10 hexagon-head bolts 45 Nm (33 ft.lb)
Pull fixing pin off crankshaft belt pulley.