Installing Bearing Cover

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NOTE:

Replace bearing cover!

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.
NOTE:
- Replace hexagon collar nut M8 x 1 and micro-encapsulated screws for bearing cover!
Grease fitted bore and new bearing cover with special grease Optimoly MP3 (available from Porsche Parts Service) and place bearing cover in position.
Position 3 new M6 x 20 hexagon-head bolts (micro-encapsulated) on the crankcase and pull in the bearing cover by screwing in the screws uniformly. Tighten screws to the specified torque.
Tightening torque 10 Nm (7.5 ft.lb)
Position new M8 x 1 hexagon nut on the threaded pin of the intermediate shaft. Tighten the nut with special tool socket wrench 9110 to the correct tightening torque. At the same time, counter with a suitable screwdriver in the slotted threaded pin of the intermediate shaft.

Fig 1: Tightening Intermediate Shaft Nut With Special Tool
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Tightening torque 12 + 1 Nm (9 + 0.5 ft.lb).
Install both primary chain tensioner and chain tensioner cylinder bank 1 - 3 with a new aluminum sealing ring (hexagon a/f 32) and tighten to the correct tightening torque.
-A- Primary chain tensioner ; -B- chain tensioner, cylinder bank 1 - 3

Fig 2: Locating Primary Chain Tensioner And Chain Tensioner
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Tightening torque 80 Nm (59 ft.lb)
Fasten coolant pipe (heating), cylinder side 4 - 6, with 2 M6 x 12 hexagon-head bolts.
Tightening torque 10 Nm (7.5 ft.lb)
Pull fixing pin out of the fixing bore.
NOTE:
- Fastening screws for drive plate for the torque converter or the double-mass flywheel must be replaced!
- Drill open the bore of the toothed segment to 15 mm to counter against the toothed ring.
Install double-mass flywheel or drive plate for torque converter with new screws. Fit special tool toothed segment 9538/1 for countering using an M12 x 50 screw.

Fig 3: Installing Special Tool (9538) On Double-Mass Flywheel Or Drive Plate
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Tightening torque 25 Nm (19 ft.lb) + 120° torque angle
NOTE:
- 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.
Manual transmission: Install thrust plate and drive plate. Tighten 6 M8 pan-head screws to the prescribed torque.
Tightening torque: 23 Nm (17 ft.lb.)
Install Tiptronic transmission. Refer to REMOVING AND INSTALLING TIPTRONIC TRANSMISSION and REMOVING AND INSTALLING TRANSMISSION G 86 .
Fill engine oil. Refer to ENGINE MAINTENANCE: OIL CHANGE WITH FILTER CHANGE or CHANGING THE ENGINE OIL AND OIL FILTER -- AS 2003
Install the engine compartment lid and the maintenance cover in the passenger compartment. Refer to ENGINE MAINTENANCE: OPENING AND CLOSING ENGINE COMPARTMENT .

Fig 4: Removing Engine Compartment Lid
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig 5: Removing Maintenance Cover In Passenger Compartment
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Connect the battery. Refer to WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY .
Close convertible top, see REMOVING AND INSTALLING CONVERTIBLE TOP (Model year 2003).