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Installing belt pulley

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NOTE:
  • Check friction plate and straight pin for signs of damage and replace if necessary.
  • Replace collar screw M14 x 1.5.
  • The parts to be screwed together must be clean, dry and free of grease; if necessary, clean with solvent naphtha or acetone.
  1. Position friction plate on straight pin of belt pulley (fitted bore for straight pin). Fit belt pulley to crankshaft journal using a new collar screw. Loosely pre-position drive belt on the belt pulley.
    Fig 1: View Of Belt Pulley And Friction Plate
    G03099852Courtesy of PORSCHE OF NORTH AMERICA, INC.
  2. Tighten M14 collar screw with torque wrench. To do this, fit holding wrench 9548 to the belt pulley and position against the left fastening nut of engine carrier to counter.

    Tightening torque 250 Nm (185 ftlb.) 

    NOTE:
    • Always replace the clamps at the joints with the rear mufflers.
    • Always replace the fastening nuts at the catalytic converter/exhaust manifold flange.
    • Always replace the flange seals between catalytic converter and exhaust manifold.
    • Before tightening screw connections of catalytic converters, first do up all nuts and bolts evenly to obtain a fastening that is as free of tension as possible.
    • When inserting catalytic converters, make sure that oxygen sensors, cables and plugs are not damaged.
  3. Install the two catalytic converters. Replace clamps between catalytic converter and rear muffler. Replace fastening nuts for flange connection to exhaust manifold and replace flange seal. Tighten screw connections to the specified tightening torque.
    Fig 2: Replacing Clamps Between Catalytic Converter & Rear Muffler
    G03099853Courtesy of PORSCHE OF NORTH AMERICA, INC.

    Tightening torques: 

    1. Fastening nuts for catalytic converter/exhaust manifold flange: 23 Nm (17 ftlb.)
    2. Clamp screws: 46 Nm (34 ftlb.)
    3. Clamp screw for holder on the engine carrier: 17 Nm (13 ftlb.)
  4. Route oxygen sensor cable with plug past engine carrier to the disconnection points in the engine compartment. To do this, gently press the engine carrier with a mounting lever towards the engine so that the plug can be led between the body and the engine carrier.
  5. Fit and tension the drive belt.
  6. Install air cleaner housing.
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