Installing bearing cover

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.

NOTE:

Replace bearing cover!

Before installing the new bearing cover, check the fitted bore on the crankcase for sharp edges and burrs. They should be removed with an oilstone or a polishing cloth. Remove any existing residue and clean the bore with a clean cloth soaked in solvent naphtha or acetone.
NOTE:
- Replace hexagon collar nut M8 x 1 and micro-encapsulated screws for bearing cover!
Grease fitted bore and new bearing cover with special grease Optimoly MP3 (available from Porsche Parts Service) and place bearing cover in position.
Place 3 new M6 x 20 hexagon-head bolts (micro-encapsulated) on the crankcase and insert the bearing cover by turning the screws equally. Tighten screws to the specified torque.
Tightening torque 10 Nm (7.5 ftlb.)
Position new M8 x 1 hexagon nut on the threaded pin of the intermediate shaft. Tighten the nut with special tool socket wrench 9110 with the correct tightening torque. At the same time, counter with a suitable screwdriver in the slotted threaded pin on the intermediate shaft.

Fig 1: Installing New M8 X 1 Hexagon Nut On Threaded Pin Of Intermediate Shaft
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Tightening torque 12 (+) 1 Nm (9 (+) 0.5 ftlb.).
Install both primary chain tensioner (-arrow- , Fig 2) and chain tensioner cylinder bank 1 - 3 with a new aluminum sealing ring (hexagon a/f 32) and tighten with the correct tightening torque (Fig 3 ).

Fig 2: Installing Primary Chain Tensioner
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Tighten chain tensioner cylinder bank 1 - 3 with torque wrench

Fig 3: Tightening Chain Tensioner For Cylinder Bank 1-3 With Torque Wrench
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Chain tensioner tightening torque 80 Nm
Fasten coolant pipe (heating), cylinder side 4 - 6, with 2 M6 x 12 hexagon-head bolts.
Tightening torque 10 Nm (7.5 ftlb.)
Pull fixing pin out of the crankshaft belt pulley.
NOTE:
- Fastening screws for drive plate for the torque converter or the double-mass flywheel must be replaced.
- Drill the bore of the toothed segment 15 mm for countering on the starter ring.
Install double-mass flywheel or drive plate for torque converter with new screws. Fit special tool toothed segment 9538/1 for countering using an M12 x 50 screw.

Fig 4: Identifying Special Tool Toothed Segment 9538/1
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Tightening torque 25 Nm (19 ftlb.) (+) 120° torque angle

Tiptronic vehicles:
Refit transmission Refer to REMOVING AND REFITTING THE TRANSMISSION (FROM MY 2002) .
Install the engine. Refer to REMOVING AND INSTALLING ENGINE AS FROM MY 02 (TIPTRONIC TRANSMISSION) . Then perform work steps 13 to 15.
Manual transmission vehicles:
NOTE:
- In order to avoid deforming the thrust plate housing, always tighten the pan-head screws on the clutch pressure plate in several stages and in diametrically opposite sequence.
Install the clutch pressure plate, including the drive plate. Refer to REMOVING AND INSTALLING CLUTCH .
Install transmission Refer to INSTALLING AND REMOVING TRANSMISSION G96/00 AND G96/01 .
Install air cleaner housing. Refer to REPLACING AIR CLEANER ELEMENT .
Fill in engine oil. Refer to ENGINE OIL AND OIL FILTER CHANGE or ENGINE OIL AND OIL FILTER CHANGE AS OF MY 02 .
Connect the battery. Refer to WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY .