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

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CAUTION: Danger of timing chain jumping out of position

Risk Of Engine Damage

→ Never turn the engine at the crankshaft without a chain tensioner.

→ Never turn the crankshaft against the direction of rotation.

→ Always counter the sprockets when performing assembly work on them.

→ Make sure that nobody starts the engine or pushes the vehicle while in gear when the chain tensioner is removed. To prevent this, stick a warning note on the steering wheel or ignition lock.

CAUTION: Ingress Of Dirt

Danger Of Material Damage Due To Blocked Oil Bores/Oil Ducts

→ 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.

Information

It is only possible to remove the bearing cover with the engine installed in vehicles with manual transmission
In Tiptronic vehicles, the complete engine/transmission unit must be removed.
Information

Always observe specified engine number range.

Bearing Cover up to Engine Number 695 07 475

Fig 1: Identifying Bearing Cover With Sealing Ring

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Lever out two green closure caps on pulley side of cylinder bank 1 - 3.
Turn the engine at the hexagon-head bolt (a/f 24) of the crankshaft belt pulley clockwise to overlapping TDC of cylinder bank 1 - 3 and fix it with special tool locating pins 9595/1.

Fig 2: Fixing Belt Pulley (Damper)
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Information
- For checking with the adjusting gauge, the timing adjustment must be correct.
To check the camshaft adjustment, insert adjusting gauge 9686 for camshaft into the camshaft slots (pulley side) (inscription on gauge pointing towards cylinder head cover). If the gauge cannot be inserted, rotate the crankshaft a further 360° and secure it again.
Unscrew two M6 x 12 hexagon-head bolts on the coolant pipe at cylinder side 4 - 6.
Remove primary chain tensioner (hexagon socket a/f 32).

Fig 3: Identifying Primary Chain Tensioner
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Remove chain tensioner, cylinder bank 1 - 3 (hexagon socket a/f 32).

Fig 4: Identifying Chain Tensioner (Cylinders 1-3)
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Information
- To make it easier to remove the bearing cover, spray the sealing surface with anti-rust agent.
Unscrew M8 hexagon collar nut on the bearing cover of the intermediate shaft with special tool socket wrench 9110, while at the same time countering the slotted threaded pin on the intermediate shaft with a screwdriver.

Fig 5: Identifying Collar Nut For Bearing Cover
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Unscrew the three M6 x 20 fastening screws (coated) on the intermediate-shaft flange. Replace screws during installation and clean thread in crankcase.
Information
- Remove bearing cover using special tool Puller 9673. If this is not available, lever the bearing cover out carefully with two screwdrivers so as not to damage the sealing surfaces. Turning several times to the left and right loosens the bearing cover.
- After removing the bearing cover, do not press the threaded bolts of the intermediate shaft.
Position special tool Puller 9673 at the bearing cover grooves and secure by turning the locking lever anti-clockwise.

Fig 6: Identifying Puller On Bearing Cover (View When Removed)
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Pull the slide hammer on the puller a number of times against the stop nuts while countering the tool at the same time with the other hand.

Fig 7: Removing Bearing Cover
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If the puller is not available, lever the bearing cover out carefully using two screwdrivers (or angle screwdrivers). Move the bearing cover a number of times to the left and right to make levering easier. Do not damage the sealing surfaces.

Fig 8: Levering Out Bearing Cover
Courtesy of PORSCHE CARS NORTH AMERICA, INC.