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Install sealing ring for intermediate shaft

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  1. Check crankcase bore for sharp edges. Break off (deburr) any sharp edges on the crankcase bore (intermediate shaft flange) with polishing cloth or an oilstone.
  2. Grease the new sealing ring slightly with Optimoly MP3 (available from Porsche Parts Service) and insert in the groove of the intermediate shaft flange.
    NOTE:
    • The sealing ring must not be twisted and must not be pulled over sharp edges of the flange.
  3. Position intermediate shaft flange on the bore and affix with new micro-encapsulated hexagon-head bolts.
    NOTE:
    • Do not exert any pressure on the threaded pin when pushing in the intermediate shaft flange, as the threaded pin might otherwise be pressed inward into the intermediate shaft.
    • As soon as the threaded pin projects at the intermediate shaft flange, screw the new lock nut into position.
  4. Position and align special tool retaining device 9642. Refer to Figure. Centre intermediate shaft and intermediate shaft flange by turning the crankshaft to and fro a little (max. 2° to 3°, remove dowel pin from the belt pulley first).
    Fig 1: Aligning Special Tool Retaining Device 9642
    G03100107Courtesy of PORSCHE OF NORTH AMERICA, INC.
    NOTE:
    • It must be possible to insert the intermediate shaft flange almost completely into the intermediate shaft bore by hand.
  5. Tighten the three micro-encapsulated M6 x 20 hexagon-head bolts evenly. Refer to Fig 2.
    Fig 2: Tightening Three Micro-Encapsulated M6 X 20 Hexagon-Head Bolts
    G03100108Courtesy of PORSCHE OF NORTH AMERICA, INC.

    Tightening torque 10 Nm (7.5 ftlb.) 

  6. Tighten lock nut M8 x 1 with the socket wrench 9110. At the same time, have a second person counter with a suitable screwdriver in the slotted threaded pin. Refer to Fig 3.
    Fig 3: Tightening Lock Nut M8 X 1
    G03100109Courtesy of PORSCHE OF NORTH AMERICA, INC.

    Tightening torque 11 Nm (8 ftlb.) 

  7. Equip both chain tensioners with new sealing rings, screw in and tighten.

    Tightening torque 80 Nm (59 ftlb.) 

  8. Fill in engine oil. Refer to ENGINE OIL AND OIL FILTER CHANGE .
    NOTE:
    • Replace screws for the double-mass flywheel and drive plate for the torque converter.
  9. Fit double-mass flywheel or drive plate for the torque converter.
    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.
  10. Fit the clutch pressure plate with drive plate.
  11. Install manual transmission or Tiptronic transmission.
    TIGHTENING TORQUES - SEALING RING FOR INTERMEDIATE SHAFT

    Location Thread Tightening torque [Nm] (ftlb.)
    Oil drainage plug M18 x 1.5 50 (37)
    Hexagon-head bolts, intermediate shaft flange M6 x 20 10 (7.5)
    Lock nut, intermediate shaft M8 x 1 12 (9)
    Chain tensioner M27 x 2 80 (59)
    Pan-head screw, clutch pressure plate M8 x 16 23 (17)
    Screw for DMF M10 x 50 x 1 25 (19) + 120° torque angle; observe TI 3/02 Serv. No. 1363!
    Screw for torque converter drive plate M10 x 25 x 1 25 (19) + 90° or 120° torque angle; observe TI 3/02 Serv. No. 1363!
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