Installing oil pump

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NOTE:

The O-rings on the oil pump flange and the metal seals must be replaced!

Clean and degrease sealing surfaces on oil pump housing and on crankcase (e.g. with acetone or solvent naphtha). Refer to Fig 1. Replace both O-rings on oil pump drive flange (-Arrow- ). Grease oil pump flange and the bore on the crankcase with Optimoly MP 3 special grease (available from Porsche parts service).

Fig 1: Identifying Oil Pump Drive Flange O-Rings (As Of MY 2002)
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Separate new metal seal (combination seal for coolant pump and oil pump housing) at the connecting webs (-see arrows- ) and position seals for oil pump and coolant guide housing. Refer to bottom of Fig 2.

Fig 2: Separating New Metal Seal At Connecting Webs (As Of MY 2002)
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig 3: Identifying Metal Seals For Oil Pump/Coolant Guide Housing (As Of MY 2002)
Courtesy of PORSCHE OF NORTH AMERICA, INC.
NOTE:
- Do not use force when positioning oil pump (otherwise the housing could break or the oil pump drive could be damaged). Carefully remove any burrs on the crankcase bore or drive flange of the oil pump using an oilstone!
Fit the oil pump. To do this, fix the oil pump onto the studs of the engine carrier. Insert the oil pump driver (outer hexagon) into the oil pump drive flange and turn manually until it fits into the hexagon socket of the intermediate shaft. At the same time, gently push the oil pump onto the crankcase. When doing this, the drive flange must slide into the crankcase bore of the intermediate shaft (do not tilt).
Push on cable plug of the coolant temperature sensor (-Arrow- ). Then position eight M6 x 20 and two M6 x 80 hexagon-head bolts -see Fig 4- evenly for the oil pump and coolant guide housing and tighten.

Fig 4: Pushing On Cable Plug Of Coolant Temperature Sensor (As Of MY 2002)
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Tightening torque 10 Nm (7.5 ftlb.)
Install primary chain tensioner with new sealing ring and tighten with torque (hexagon a/f 32).
Tightening torque 80 Nm (59 ftlb.)
Position chain tensioner, cylinder bank 1 - 3 with new sealing ring and tighten with torque (-Arrow- ) (hexagon a/f 32).

Fig 5: Installing Chain Tensioner, Cylinder Bank 1-3 (As Of MY 2002)
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Tightening torque 80 Nm (59 ftlb.)
Position chain tensioner, cylinder bank 4 - 6 with new sealing ring using socket wrench insert (outer hexagon a/f 14) -Arrow- and tighten with torque.

Fig 6: Installing Chain Tensioner, Cylinder Bank 4-6 (As Of MY 2002)
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Tightening torque 80 Nm (59 ftlb.)
Fill engine oil. Refer to ENGINE OIL AND OIL FILTER CHANGE or ENGINE OIL AND OIL FILTER CHANGE AS OF MY 2002 .
Install engine carrier. To so this, position four new M10 hexagon-head collar nuts (self-locking, a/f 15) and one M6 hexagon-head bolt -Arrows- and tighten.

Fig 7: Installing Engine Carrier Nuts & Bolt (As Of MY 2002)
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Tightening torque M6 bolt 10 Nm (7.5 ftlb.)

Tightening torque M10 collar nuts 45 Nm (33 ftlb.)
Pull fixing pin off crankshaft belt pulley.
Install catalytic converters.. Refer to REMOVING AND INSTALLING REAR MUFFLERS .