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Home >> Porsche >> 2003 >> 911 Carrera 4S, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 38 (Engine) >> Removing And Installing Bearing Cover For Intermediate Shaft - As Of My 2002 >> Removing Bearing Cover

Removing Bearing Cover

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NOTE:
  • The air conditioning circuit must not be opened to release the air conditioning compressor!
  1. Lever out 2 green closure caps on the cylinder bank 1 - 3 pulley side. See REMOVING AND INSTALLING CLOSURE CAP FOR CAMSHAFT BORE - ENGINE INSTALLED .
  2. Turn the engine at the hexagon-head bolt (a/f 24) of the crankshaft belt pulley clockwise to overlapping TDC of cylinder bank 1 - 3 and fix it with special tool fixing pins 9595/1 (use short fixing pin).
    Fig 1: Installing Special Tool Into Belt Pulley
    G03092597Courtesy of PORSCHE OF NORTH AMERICA, INC.
    NOTE:
    • For checking with the adjusting gauge, the timing adjustment must be correct.
  3. In order to check the camshaft adjustment of special tool, insert adjusting gauge 9686 for camshaft into the camshaft slots (pulley side) (Inscription on gauge points towards the cylinder head cover), see also INSTALLING CAMSHAFT - ENGINE REMOVED - INCLUDES ADJUSTING TIMING, - AS OF MY 2003 . If the gauge can't be inserted, rotate the crankshaft a further 360°.
    NOTE:
    • After removal of the chain tensioner, the crankshaft must not be turned under any circumstances, because otherwise the timing chain may jump over!
    • Drill open the bore of the toothed segment to 15 mm to counter against the toothed ring.
  4. 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.
    NOTE:
    • 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.
  5. Remove thrust plate and drive plate. Release and unscrew 6 M8 pan-head screws gradually and in diametrically opposite sequence.
  6. 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.
  7. Unscrew 2 M6 x 12 hexagon-head bolts on the coolant pipe (heating) cylinder side 4 - 6.
  8. Remove primary chain tensioner and chain tensioner, cylinder bank 1 - 3 (hexagon socket a/f 32).

    -A- Primary chain tensioner ; -B- chain tensioner, cylinder bank 1 - 3 

    Fig 2: Locating Primary Chain Tensioner And Chain Tensioner - Cylinder Bank 1-3
    G03092598Courtesy of PORSCHE OF NORTH AMERICA, INC.
    NOTE:
    • In order to make it easier to remove the bearing cover, the sealing surface can be sprayed with anti-rust agent.
  9. 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.
    Fig 3: Removing Hexagon Collar Nut On Bearing Cover Of Intermediate Shaft
    G03092599Courtesy of PORSCHE OF NORTH AMERICA, INC.
  10. Unscrew the three M6 x 20 hexagon-head bolts (micro-encapsulated) on the intermediate-shaft flange. Replace screws during installation.
    NOTE:
    • Lever the bearing cover out carefully so as not to damage the sealing surfaces. Turning several times to the left and right loosens the bearing cover.
    • After removing the bearing cover, do not press the threaded bolts of the intermediate shaft.
  11. 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 levering out easier. Do not damage the sealing surfaces.
    Fig 4: Removing Intermediate Shaft Bearing Cover
    G03092600Courtesy of PORSCHE OF NORTH AMERICA, INC.
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