Installing Crankshaft

→ Absolute cleanliness is essential when working on the engine.

→ Lay removed engine parts on a clean base and make sure to cover them.

→ Use the cover for dust protection when fitting the engine NR.165  on the engine assembly support.

1. Secure the engine support holder P201  and engine support 9667  to crankcase half 4-6.
2. Check the matching number of the crankcase halves. The number is located on the top of the head lug.
   Fig 1: Locating Mark On Crankcase Halves

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Allocation of the crankshaft gearwheel and intermediate shaft to the crankcase. The tolerance group number is imprinted on the crankcase -arrow-  and must match the number on the intermediate-shaft gearwheel and the crankshaft gearwheel.
   Fig 2: Locating Matching Number On Crankcase

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   Fig 3: Locating Matching Number On Crankshaft Gearwheel

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   Fig 4: Locating Matching Number On Intermediate-Shaft Gearwheel

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Clean the crankcase halves thoroughly. Check whether there are any foreign objects (e.g. residual sealant) in the take-up bores of the through bolts.
5. Insert new bearing shells for the intermediate shaft in crankcase half 4-6.
   Fig 5: Identifying Intermediate Shaft Bearing Shells (4-6)

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Oil bearing shells for intermediate shaft, insert intermediate shaft and check for true running.
   Fig 6: Checking Intermediate Shaft Visually For True Running

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. Insert new crankshaft bearing shells into the crankcase. Oil the bearings.
8. Check that dowel sleeves are seated correctly.
   Fig 7: Locating Dowel Sleeves On Crankcase

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
9. Insert crankshaft (without bearing 8) into crankcase half 4-6.

   Information 

   • If the wear dimension has been attained, replace the intermediate shaft and the paired drive wheel 
10. Check backlash on intermediate shaft. To do this, secure universal dial gauge bracket VW 387  to the crankcase joint. The sealing surface must not be damaged during this procedure. Align the dial gauge on a tooth profile and determine the amount of play. Then turn the intermediate shaft by 180° and repeat the measurement.
    Fig 8: Checking Backlash On Intermediate Shaft

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Designation	New measured value in mm	Wear dimension
    Backlash	0.035 - 0.084	0.10 mm

11. Remove intermediate shaft again.
12. Get another person to lift the crankshaft slightly and slide bearing no. 8  onto the crankshaft journal.
13. Lower the crankshaft slowly and insert crankshaft bearing no. 8 in the dowel pin.
    Fig 9: Fitting Crankshaft Bearing No. 8

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
14. Check installation position. If the position is correct, the center of the bearing notch should be level with the sealing surface.
    Fig 10: Identifying Crankshaft Installation Position

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
15. Fit shaft sealing ring on the crankshaft flange.
    Fig 11: Identifying Crankshaft Sealing Ring

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    Always replace gaskets and O-rings.

    Information 

    For all lubrication points, use Kluber Syntheso Glep (Part No. 000.043.204.68).

16. Grease new sealing ring (19.5 x 26) on both sides and insert it into crankcase half 4-6 close to the oil pump mount.
    Fig 12: Locating Sealing Ring On Oil Pump Mount

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
17. Insert oil pump with connecting shaft and intermediate shaft with both timing chains into the crankcase half.

    Information 

    • Always replace lock nuts. 
18. Fit and tighten three new M8 collar nuts. → Tightening torque: 23 Nm (17 ftlb.) 
    Fig 13: Locating Collar Nuts On Oil Pump

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
19. Check connecting shaft. The connecting shaft must move freely in axial direction. Loosen the oil pump with intermediate shaft again if necessary and shift the connecting shaft.
    Fig 14: Connecting Shaft Between Oil Pump And Intermediate Shaft

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
20. Prepare the through bolts for installation. The diagram shows through bolts already fitted on the designated thrust blocks.
    Fig 15: Identifying O-Rings And Inner Through Bolts

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    • Additional O-rings are inserted on four through bolts on the thrust block mount, thrust blocks 2, 3, 4 and 5. 
    • The four through bolts must be fitted before joining the crankcase halves. 

    Information 

    • Do not oil sealing rings until shortly before fitting. 
    • Do not store oiled sealing rings. 
21. Prepare four through bolts. Slide sealing washers onto the through bolts. Guide lightly oiled O-rings with conical sleeve from special tool assembly sleeve 9511  over the threaded area and push them onto the conical section towards the head of the bolt.
    Fig 16: Identifying Through Bolts (Assembly)

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
22. Observe the A and B side on the assembly sleeve 9511  .
    Fig 17: Identifying Special Tool Assembly Sleeve 9511

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
23. Insert the prepared through bolts as far as they will go into the right crankcase half from below and hold at this position.
    Fig 18: Locating Through Bolts

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
24. Fit conical sleeve on the end of the thread. Slide dry O-ring over the conical sleeve. Remove conical sleeve and push the O-ring with the cylinder sleeve as far as the chamfer in the thrust block. Remove cylinder sleeve.
    Fig 19: Locating Conical Sleeve For Assembling Through Bolts

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    Fig 20: Installing Conical Sleeve

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
25. Fit connecting rod of cylinder 4, 5 and 6 in a vertical position using special tool restraining straps P221  . Secure the timing chain with a restraining strap.
    Fig 21: Placing Connecting Rod In Vertical Position

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
26. Coat two new sealing rings on the oil pump and the new sealing ring on the crankcase half with Kluber grease and insert them.
    Fig 22: Locating Sealing Ring On Oil Pump

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
27. Prepare crankcase halves of cylinder bank 1-3. To do this, insert the bearing shells of the crankshaft and the intermediate shaft. Be careful with the dowel pin -arrow-  .
    Fig 23: Locating Dowel Pin

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
28. Remove any grease from the crankcase halves using acetone or solvent naphtha. Apply a uniform bead of sealant approximately 1.5 mm wide to the sealing face of crankcase half 1-3. Only use Drei Bond, type 2210  sealant.
    Fig 24: Locating Sealant Applying Area To Crankcase Halves

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
29. Check the relief groove close to main bearing no. 7 for foreign objects (e.g. silicone residue) and clean it if necessary.
    Fig 25: Locating Relief Groove On Main Bearing No. 7

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    • Cover the chain slot briefly when fitting so that parts do not fall into the crankcase. 
30. Insert the crankcase half carefully over the preassembled through bolts on thrust blocks 2, 3, 4 and 5, while at the same time getting another person to pull the chain upwards through the chain slot.
31. Remove restraining straps again.
32. Join the crankcase halves and secure them with six new lock nuts with washers. Distribute the lock nuts evenly all around the joint and tighten by hand.
    Fig 26: Locating Lock Nuts On Cross Bolt Connection

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
33. Insert the prepared through bolts for crankcase half 4-6 and hold them securely.
    Fig 27: Locating Through Bolts

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
34. Slide the conical sleeve of special tool assembly sleeve 9511  with an oiled O-ring to the end of the thread.
    Fig 28: Inserting Conical Sleeve With Oiled Sealing Ring

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
35. Slide the O-ring carefully over the conical sleeve with the -A-side-  of the cylinder sleeve (thin wall).
    Fig 29: Identifying Special Tool Assembly Sleeve 9511

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    Fig 30: Fitting O-Ring For Through Bolt

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
36. Remove conical sleeve and carefully slide the round sealing ring to its end position with the B side  of the cylinder sleeve (thick wall), while countering at the bolt head.
37. Fit dry sealing washers and press downwards slightly with the B side  of the cylinder sleeve.
38. Screw on outer multiple-tooth nuts (thread oiled) by hand.
39. Proceed in the same way with both studs on crankcase half 4-6 (bearing 1 area) on the flywheel side.
40. Screw M10 multiple-tooth nut onto stud (thread oiled) in the chain box.
    Fig 31: Locating Hexagon Nut In Chain Box

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    • When tightening the through bolts without a retaining device 9662, it is essential that a second person counters the bolts. 
    • The O-ring will be damaged when the through bolts are turned. 
    • Counter using a 14 mm multiple-tooth socket from Snap-on. 
41. Retaining device 9662  must be fitted on the corresponding through bolt and can then be positioned using an aluminum sleeve from the set of retaining nuts P140  .
    Fig 32: Identifying Retaining Device 9662

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
42. Bolt the crankcase halves.
    1. 42.1. Tighten through bolt on side 1-3 -1-11-  according to the specified tightening sequence and specifications (see table  below).
       Fig 33: Through Bolts Tightening Sequence

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 42.2. Tighten M10 multiple-tooth nut -12-  on the stud in the chain box on side 1-3.
       Fig 34: Locating Multiple-Tooth Nut M10 In Chain Box

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 42.3. Tighten through bolts on the flywheel side, side 4-6.
       Fig 35: Locating Through Bolts On Flywheel Side

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    4. 42.4. Tighten new self-locking hexagon nut and washer. → Tightening torque: 25 Nm (19 ftlb.) 
       Fig 36: Locating Lock Nut On Chain Box

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    CRANKCASE BOLTS TIGHTENING TORQUES SPECIFICATIONS
    
    

    Sequence	Designation	Bolts	Value
    Step 1	Initial tightening	Through bolts, long, No. 1-11 (side 1-3)	15 Nm (11 ftlb.)
    Step 2	Initial tightening	Multiple-tooth nut on chain box, side 1-3	15 Nm (11 ftlb.)
    Step 3	Initial tightening	Through bolts, short (side 4-6)	15 Nm (11 ftlb.)
    Step 4	Final tightening	Through bolts, long, No. 1-11 (side 1-3)	15 Nm (11 ftlb.) and 210° torque angle
    Step 5	Final tightening	Multiple-tooth nut on chain box, side 1-3	15 Nm (11 ftlb.) and 110° torque angle
    Step 6	Final tightening	Through bolts, short (side 4-6)	15 Nm (11 ftlb.) and 110° torque angle
    Step 7	Final tightening	Cross bolt connection	25 Nm (19 ftlb.)

43. Fit remaining M8 lock nuts on crankcase bolts. → Tightening torque: 25 Nm (19 ftlb.) 
    CAUTION: Removing/fitting the crankshaft pulley.

    • Danger of injury and damage.

    → The holding wrench must make contact with the pulley when tightening.

    → Get another person to help.

44. Fit the pulley.

    Please note: GT3 RS vehicles have an aluminum pulley as standard. 

    → 137619 REMOVING AND INSTALLING PULLEY .

    1. 44.1. Check the straight pin (5 x 18) for deformation before fitting and replace if necessary.
       Fig 37: Locating Pulley Straight Pin

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
45. Fit new straight pin so that it is flush.
    Fig 38: Locating Pulley Straight Pin Installation Position

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
46. Always replace fastening screw for pulley.

    When tightening the pulley, a second person must counter with the relevant holding wrench. 

    Turbo engine:  → Tightening torque: 170 Nm (126 ftlb.) 

    GT3 (steel pulley):  → Tightening torque: 250 Nm (185 ftlb.) 

    GT3 RS (aluminum pulley):  → Tightening torque: 170 Nm (126 ftlb.) 

    Fig 39: Loosening Pulley (View With Holding Wrench 9548)

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
47. Fit the flywheel.

    → 136019 REMOVING AND INSTALLING FLYWHEEL .

    → 136019 REMOVING AND INSTALLING SINGLE-MASS FLYWHEEL .