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Home >> Porsche >> 2016 >> 911 Turbo, 2D Convertible >> Repair and Diagnosis >> External Pages >> Different car >> Section 4 (Engine - 911 CARRERA (996)) >> Removing and installing bearing cover for intermediate shaft, as of MY 2002 >> Removing bearing cover

Removing 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.
  1. Remove air cleaner housing (engine installed) Refer to REPLACING AIR CLEANER ELEMENT .
  2. Lever out 2 green reservoir caps on the cylinder support 1 - 3 belt pulley side  . Refer to REMOVING AND INSTALLING CLOSURE CAP FOR CAMSHAFT BORE .
  3. Turn the engine at the hexagon-head bolt (a/f 24) of the crankshaft belt pulley clockwise to overlapping TDC cylinder support 1 - 3 and then fix it with special tool fixing pins 9595/1 (use short fixing pin).
    Fig 1: Turning Engine At Hexagon-Head Bolt Of Crankshaft Belt Pulley Clockwise To Overlapping TDC Cylinder Support 1 - 3
    G03100311Courtesy of PORSCHE OF NORTH AMERICA, INC.
    NOTE:
    • The timing setting must be correct to allow for controls with the adjustment gauge.
  4. Use the special tool adjustment gauge 9686 for camshafts in the camshaft slot (belt pulley side) to control the camshaft position (gauge markings point to cylinder head cover). See also INSTALLING CAMSHAFT - ENGINE REMOVED - INCLUDES ADJUSTING TIMING . If the gauge cannot be inserted, turn the crankshaft 360°.
    NOTE:
    • After removal of the chain tensioner, the crankshaft must not be turned under any circumstances, because otherwise the timing chain may jump over!
    • Drill the bore of the toothed segment 15 mm for countering on the starter ring.

    Tiptronic: 

  5. Remove the torque-converter drive plate. Fit special tool toothed segment 9538/1 for countering using an M12 x 50 screw. Unscrew 8 M10 x 25 x 1 Torx socket screws and remove drive plate.

    Manual transmission: 

    NOTE:
    • In order to avoid deforming the thrust plate housing, always loosen the pan-head screws on the clutch pressure plate in several stages and in diametrically opposite sequence.
  6. Remove thrust plate and drive plate. Release and unscrew 6 M8 pan-head screws gradually and in diametrically opposite sequence. Refer to REMOVING AND INSTALLING CLUTCH .
  7. Remove double-mass flywheel (DMF). Fit special tool toothed segment 9538/1 for countering using an M12 x 50 screw. Unscrew 8 M10 x 50 Torx socket screws and remove the DMF.
  8. Unscrew 2 M6 x 12 hexagon-head bolts on the coolant pipe (heating) cylinder side 4 - 6.
  9. Remove primary chain tensioner -arrow-  (hexagon socket a/f 32).
    Fig 2: Removing Primary Chain Tensioner
    G03100312Courtesy of PORSCHE OF NORTH AMERICA, INC.
  10. Remove chain tensioner, cylinder bank 1 - 3 (hexagon socket a/f 32).
    NOTE:
    • The sealing face can be sprayed with rust remover to make the bearing cover easier to remove.
  11. Unscrew M8 hexagon collar nut on the bearing cover of the intermediate shaft with special tool socket wrench 9110 , at the same time countering at the slotted threaded pin on the intermediate shaft with a suitable screwdriver.
    Fig 3: Unscrewing M8 Hexagon Collar Nut On Bearing Cover Of Intermediate Shaft
    G03100313Courtesy of PORSCHE OF NORTH AMERICA, INC.
  12. Unscrew the three M6 x 20 hexagon-head bolts (micro-encapsulated) on the intermediate-shaft flange. Replace screws during installation.
    NOTE:
    • Lever the bearing cover out carefully so as not to damage the sealing surfaces. The position of the bearing cover can be loosened by turning it left and right several times.
    • Do not press the threaded bolts on the intermediate shaft after removing the bearing cover.
  13. Lever the bearing cover out carefully using, for instance, two screwdrivers (or angle screwdrivers). Move the bearing cover frequently to the left and right to make the levering easier. Do not damage the sealing surfaces.
    Fig 4: Levering Out Bearing Cover
    G03100314Courtesy of PORSCHE OF NORTH AMERICA, INC.
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