Assembling Crankshaft

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NOTE: Dirt and contamination

Risk of damage to units or components

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

Information

Fit the connecting rods in such a way that the matching numbers are all facing the observer.

Information

The collar of the timing gear must point to bearing 7.

Information

The circlip must be inserted without play.

Clamp the crankshaft in a vice using retainer plate P209a -2- .

Fig 1: Identifying Crankshaft With Retainer Plate P209 A
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Lubricate the con-rod journals with grease (Optimol Optipit) and fit the connecting rods on the crankshaft.

Fig 2: Greasing Con-Rod Journals
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Tighten new connecting rod bolts according to specifications.
→ WM 1344IN MOUNTING SPECIFICATION FOR CONNECTING ROD BOLTS - GT3/GT3 RS .
1. 3.1. Initial tightening:
  → Initial tightening: 30 Nm (22 ftlb.)
2. 3.2. Final tightening torque angle:
  → Torque angle: 60°+/-2°
Insert and align new Woodruff key for timing gear.
Heat the timing gear to approx. 150 - 200 °C in the oil bath or on a heating plate and slide it as far as it will go onto the crankshaft journal.
Heat the intermediate ring in the same way and slide it on as far as it will go.

Fit the circlip.

7.1. The following circlips are available:

Part No.

Ref. No.

Thickness (mm)

Identifying feature

901.102.148.00

2.4

Blank

901.102.148.01⁽¹⁾

2.3

Tempered blue⁽¹⁾

901.102.148.02

2.2

Tempered yellow/brown

901.102.148.03

2.1

Black, gun-metal finish

⁽¹⁾	most frequently used circlip for first assembly

7.2. Choose the relevant circlip by performing an insertion test.

Fig 3: Locating Circlip On Crankshaft
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

The opening on the circlip must be opposite the Woodruff key groove -arrows- .
Tap the circlip into the retaining groove using a blunt chisel → Tapping in circlip .

Fig 4: Tapping Circlip
Courtesy of PORSCHE CARS NORTH AMERICA, INC.