Installing Crankshaft

Overview of connecting rod bearing position

Fig 1: Identifying Connecting Rod Bearing Position In Gear Carrier

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1. Fit gearing carrier half 4-6 on special tool retaining device 9607  using two M10 x 25 hexagon-head bolts.
   Fig 2: Identifying Gear Carrier Half 4-6 On Device

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2. Ensure that the dowel sleeves are seated correctly in gear carrier half 4-6.
   Fig 3: Identifying Dowel Sleeves And Gear Carrier 4-6

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3. Insert three oil spray jets in the take-up bores in each of the gear carrier halves, press in gently to the stop using a plastic mandrel (ø 4 mm).
   Fig 4: Inserting Oil Spray Jets In Take-Up Bores

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4. Insert two thrust washers onto the center thrust block (no. 4) of gear carrier half 4-6; when doing so, the oil pockets -Arrows-  must always point outwards (to the belt pulley side or flywheel side).
   Fig 5: Locating Thrust Washer And Thrust Block

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5. Insert seven new bearing shells for the crankshaft and coat with new engine oil. Pay attention to the installation position:  the fixing lugs of the bearing shells in gear carrier half 4-6 point towards the dowel sleeve side, the fixing lugs of the bearing shells in gear carrier half 1-3 face the opposite side.
   Fig 6: Locating Oil Spray Jets And Bearing Shells In Gear Carrier Half 1-3

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   Twist lock of bearing shell

   Fig 7: Locating Twist Lock Of Bearing Shell In Gear Carrier Half 4-6

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6. Insert crankshaft. Check that the thrust washers are seated properly.
   Fig 8: Locating Seating Of Thrust Washer With Crankshaft

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7. Carefully position gear carrier half 1-3 on the crankshaft and gear carrier half 4-6. Fix the gear carrier halves by tapping them carefully with a plastic hammer.
8. Position 14 M9 x 127 thrust-bearing screws manually. Pre-tighten screws to the required tightening torque in accordance with the tightening sequence. Then tighten to the required torque angle. → Initial tightening: 15 Nm (11 ftlb.)  ; → Torque angle: 120° 
   Fig 9: Identifying Tightening Sequence For Gear Carrier

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9. Check axial play of crankshaft. Fit dial gauge and dial gauge holder on gear carrier (flywheel side) and place against crankshaft flange. Press crankshaft manually against probe of dial gauge and set dial gauge to '0'  . Press crankshaft away from dial gauge. Repeat process several times and note measured value.
   Fig 10: Checking Axial Play Of Crankshaft

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   Status	Tolerance range	Wear limit
   First fitting	0.05 - 0.24 mm	0.28 mm

10. Insert connecting rod bearing in connecting rod and connecting rod cap. Coat sliding surface with Optimol Optipit (available from Porsche Parts Service: 000.043.204.17).

    Information 

    Connecting rod bolts must always be replaced.

11. Fit each of the connecting rods of cylinder 4-6 with the allocated connecting rod cap at the bearing surfaces of cylinders 4, 5 and 6. Position new screws manually. Pay attention to the installation position of the connecting rods:  The recesses of the connecting-rod bearing twist lock face the oil pan (when the gear carrier is installed in the crankcase).
12. First, screw in connecting rod bolts to the required torque and tighten to the specified torque angle. Then loosen the bolts again. The final tightening is performed again with an initial tightening per the torque and the final tightening is performed with the torque angle wrench. → Initial tightening: 20 Nm (15 ftlb.)  ; → Torque angle: 110° 
    Fig 11: Identifying Connecting Rod Bolts

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