Removing belt pulley
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:
- When removing and refitting air cleaner housing, ensure that rubber plugs for fixing the housing do not fall out.
- Remove air cleaner housing. Undo screw-type hose clamp on throttle body and the M8 fastening screw. Pull off cable plug for the mass air flow sensor and remove air cleaner housing.
- Release drive belt. To do this, turn the tensioning roller clockwise at the hexagon of the tensioning lever and remove the drive belt at the deflection roller below the generator.NOTE:
- Wrap a cloth or similar around the mounting lever to avoid damaging the body paintwork.
- Observe precautionary measures when using oxygen sensors! Damage or soiling of the oxygen sensor cables or plug connections may cause a malfunction.
- Release oxygen sensor plug at the disconnection point in the engine compartment on the left and right and unclip. Release oxygen sensor cable from cable holders and, together with the plug, guide it past the engine carrier and down towards the catalytic converter. To do this, gently press the engine carrier with a mounting lever towards the belt pulley -arrows-
. On cylinder side 1-3, release the black oxygen sensor cable from the sheetmetal bracket.
Courtesy of PORSCHE OF NORTH AMERICA, INC.
NOTE:- To remove and install the catalytic converters the assistance of a second person is recommended!
- Before unscrewing, spray the screw connections of the exhaust system with penetrating oil. If the joints are severely corroded, the application of heat is helpful.
- When removing catalytic converters, make sure that oxygen sensors, cables and plugs are not damaged.
- Remove catalytic converters. Undo the clamp screws (-Item 2- ) at the joints to the rear muffler on the left and right. Unscrew each of the three fastening nuts for the exhaust manifold flange (-Item 1- ). Undo the clamp screws for the holder on the engine carrier (-Item 3- ) and push the clamps over the holder.
- Before removal, mark position of clamps at joint with rear muffler (for example, with a touch-up applicator). Then, gently tapping with an aluminum mandrel, move them towards the muffler (-arrow- ).
- Then press the flange of the catalytic converter at the exhaust manifold pipe out of the studs and simultaneously pull the two catalytic converters out and downwards -arrows- .
- Turn belt pulley clockwise until the two locating bores for the holding wrench 9548 are horizontal. In this position, the special tool can be used between the fastening nuts for the engine carrier. Refer to Fig 5. Making use of the nuts as a backstop for the tool reduces the effort required to undo and tighten the belt pulley screw.
NOTE:
- When undoing and tightening the belt pulley screw, the assistance of a second person to hold the special tool is recommended!
- Undo the collar screw on the belt pulley. To counter, position the special tool holding wrench 9548 against the right fastening nut of engine carrier and hold it there. As the torque required to release the screw is greater than to tighten it, a tool with a long lever arm should be used to release it. Now unscrew the collar screw and remove the belt pulley together with friction plate.