Replacing Joint Flange On Pulley Side With Crankshaft Sealing Ring

Unscrew screws for poly-V-belt pulley for coolant pump and counter using pin wrench 3212 .
Remove poly-V-belt pulley.

Fig 1: Removing Poly-V-Belt Pulley
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Remove screws -arrows- .
Information

The joint flange on the pulley side must always be replaced.

Carefully detach joint flange at the pulley side from the bonding.

Fig 2: Locating Joint Flange
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Remove sealant residue from the cylinder block and joint flange on the pulley using a rotating plastic brush for example.
WARNING:
Risk of damage or injury from foreign bodies flying around during grinding, drilling and milling
- Risk of eye injuries
→ Wear protective goggles.
NOTE:
Residual sealant
- Oil bores blocked
→ Ensure that they are cleaned thoroughly and that any remaining sealant is removed completely.

Clean sealing faces to remove any oil and grease.

Fig 3: Removing Sealant Residue
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut off the nozzle on the tube at the front marking (nozzle diameter is approx. 2 mm).

Fig 4: Cutting Off Nozzle On Tube
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

The joint flange must be fitted within 5 minutes of applying the sealant.
Apply a bead of sealant to the clean sealing face of the joint flange as shown.
1. 5.1. The groove -arrow- on the sealing face must be filled completely with sealant.
  NOTE:
  Residual sealant
  - Oil bores blocked
  → Ensure that they are cleaned thoroughly and that any remaining sealant is removed completely.
2. 5.2. The bead of sealant must project 1.5 to 2.0 mm over the sealing face.
  
  Fig 5: Locating Bead Of Sealant On Pulley Joint Flange
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Assembly tool T40048 must be fitted onto the fitting aid -T40048/2- . Then slide the joint flange -1- onto the fitting sleeve.
Remove assembly aid.

Fig 6: Installing Pulley Joint Flange
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
First fit the joint flange -1- (with fitting sleeve -T40048/2- inserted) on crankshaft.
Slide the joint flange onto the sealing face of the engine without tilting it.

Fig 7: Identifying Fitting Joint Flange
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

For tightening torques, tightening sequence and assembly overview, see → 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES, ASSEMBLY OVERVIEWS
Tighten fastening screws -arrows- crosswise and in several steps.

Fig 8: Locating Joint Flange Fastening Screws
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

For tightening torques, tightening sequence and assembly overview, see → 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES, ASSEMBLY OVERVIEWS
Further installation is performed in reverse order.