Assembling crankshaft

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2005 Porsche 911, 2004 Porsche 911, 2003 Porsche 911, 2002 Porsche 911, and 2001 Porsche 911. However, it is still accessible from the selected car via links, so may be relevant.

Clean crankshaft thoroughly.
Rinse out oil bores several times with a hand pump and solvent naphtha.
With a visual inspection, check whether the oil ducts are blocked at the bearing surfaces and on the front face (aluminum plugs).
Clamp crankshaft.
Lubricate the connecting-rod journals with grease (Optimal Optipit) and fit connecting rods on the crankshaft.

Fig 1: Lubricating Connecting-Rod Journals With Grease
Courtesy of PORSCHE OF NORTH AMERICA, INC.
NOTE:
- The matching numbers of the con-rods and the con-rod bearing caps must all point to the same side.
Fig 2: Matching Numbers Of Con-Rods And Con-Rod Bearing Caps
Courtesy of PORSCHE OF NORTH AMERICA, INC.
NOTE:
- Always coat con-rod bolts with special grease, Part No.: 000.043.300.12
NOTE: The con-rod bolts must not twist.
Tighten con-rod nuts.
After tightening, check whether the con-rod bolt has twisted.

Fig 3: Checking Whether Con-Rod Bolt Has Twisted
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Insert and align new Woodruff key for timing gear.
NOTE:
- The collar of the timing gear must point to bearing 7!
- As an assembly aid, remove the timing gear from the heat source, for example, with a piston restraining strap, and quickly mount or push it into place on the journal.
Fig 4: Inserting And Aligning New Woodruff Key For Timing Gear
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Warm the timing gear to approx. 150 - 200°C in an oil bath or on a heating plate and push it on to the crankshaft journal up to the stop.
Heat up the spacer ring in the same way and push it on up to the stop.

Mount snap ring.

NOTE: The snap ring must be inserted without play!

The following snap rings are available:

CRANKSHAFT SNAP RING SPECIFICATIONS

Part number

Thickness (mm)

Identification

901.102.148.00

2.4

bright

901.102.148.01

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 snap ring for first assembly

Select the corresponding snap ring using an insertion test.

Fig 5: Identifying Snap Ring Insertion Test
Courtesy of PORSCHE OF NORTH AMERICA, INC.
The opening of the snap ring should be opposite the Woodruff key groove.
Tap snap ring into the retaining groove using a blunt chisel.

Fig 6: Tapping Snap Ring Into Retaining Groove Using Blunt Chisel
Courtesy of PORSCHE OF NORTH AMERICA, INC.

TIGHTENING TORQUE - CON ROD NUT

Location	Thread	Tightening torque Nm (ftlb.)
Con-rod nut	M9 x1.25	Initial tightening: 30 (22); final tightening: 1x 90 ° torque angle