Installing Bearing Cover For Intermediate Shaft - Up To Engine Number 695 07 475

Information 

Always observe the following installation sequence when fitting the bearing cover for the intermediate shaft.

Do not click the collar nut for the intermediate shaft more than once (repeated application of torque) as to do so would exceed the yield strength on the intermediate shaft bearing pin, thereby damaging the intermediate shaft bearing pin.

Information 

• Clean working area of bore for bearing cover and crankcase thoroughly using acetone or solvent naphtha. 

1. Before installing the new bearing cover, check the fitting bore (axial sealing surface, bore chamfers) on the crankcase for sharp edges and burrs. These must be removed using an oilstone or polishing cloth. Remove any residues and clean the bore with a clean cloth soaked in solvent naphtha or acetone.

   Information 

   • Replace bearing cover or sealing ring for bearing cover →  REMOVING AND INSTALLING SEALING RING FOR INTERMEDIATE SHAFT  . 

     Information 

     Always observe specified engine number range. 

2. Grease fitting bore in the crankcase and new bearing cover (with new sealing ring) with special grease Optimoly MP3.
3. Fit bearing cover on the crankcase by hand and push it as far as possible into the crankcase.
4. First fit old fastening screws (M6 x 20) for the bearing cover and screw them in evenly in a clockwise direction by two turns until the bearing cover is completely fitted on the crankcase.

   Information 

   • Replace collar nut M8 x 1 and coated M6 screws for bearing cover. 
5. Fit new collar nut (M8 x 1) on the threaded bolt of the intermediate shaft and screw in evenly using special tool socket wrench 9110 until the collar nut is touching the bearing cover. At the same time, counter with a screwdriver at the slotted threaded bolt of the intermediate shaft.
   Fig 1: Identifying Collar Nut For Bearing Cover

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Unscrew and dispose of old fastening screws for the bearing cover.
7. Fit and tighten three new, coated fastening screws (M6 x 20) for the bearing cover on the crankcase.

   Tightening torque: 10 Nm (7.5 ft. lb.) 

8. Tighten collar nut (M8 x 1) on the threaded bolt of the intermediate shaft using special tool socket wrench 9110. At the same time, counter with a screwdriver at the slotted threaded bolt of the intermediate shaft.

   Do not "click" threaded connection more than once (repeated application of torque).

   Tightening torque: 12 Nm (9 ft. lb.) +1 Nm (+0.5 ft. lb.) 

   Fig 2: Identifying Collar Nut For Bearing Cover

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
9. Install primary chain tensioner with a new sealing ring (hexagon a/f 32) and tighten to the specified torque.

   Tightening torque: 80 Nm (59 ft. lb.) 

   Fig 3: Identifying Primary Chain Tensioner

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
10. Install chain tensioner for cylinders 1-3 with a new sealing ring (hexagon a/f 32) and tighten to the specified torque.

    Tightening torque: 80 Nm (59 ft. lb.) 

    Fig 4: Identifying Chain Tensioner (Cylinders 1-3)

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
11. Secure coolant pipe on cylinder bank 4-6 using two hexagon-head bolts (M6 x 12).

    Tightening torque: 10 Nm (7.5 ft. lb.) 

12. Fit new caps on the cylinder head cover
13. Pull locating pin out of the crankshaft pulley.