Installing Lower Chain Housing Cover

IMPORTANT: Bevelling the dowel sleeve makes it easier to fit the lower chain housing cover when the cylinder head is installed.

IMPORTANT: The component must be installed and secured within five minutes of applying sealant.

IMPORTANT: Attach all tie-wraps at the same places during installation.

Pull upper right dowel sleeve out of cylinder block.
Bevel the dowel sleeve with a file as shown.

Dimension x = 6.5 mm

Dimension y = 8.0 mm

Fig 1: Dowel Sleeve On Lower Chain Housing Cover
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit the dowel sleeve on the cylinder block in such a way that the bevelled side is pointing upwards.
NOTE:
Residual sealant
- Oil bores blocked
Ensure that they are cleaned thoroughly and that any remaining sealant is removed completely.
Remove old sealant from the sealing faces.
WARNING:
Risk of damage or injury from foreign bodies flying around during grinding, drilling and milling
- Risk of eye injuries
Wear protective goggles.
1. Remove residual sealant from the lower chain housing cover, cylinder block and cylinder head using a rotating plastic brush.
2. Sealing faces must be free of oil and grease.
3. Before installing the transmission, clean any remaining particles from the threaded bores for the engine/transmission threaded joint in the cylinder block using a thread cutter.
  
  Fig 2: Cleaning Sealing Faces
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Remove old sealing compound from the bores -arrow- in the cylinder-head gaskets.

Fig 3: Cleaning Old Sealant From Holes In Cylinder Head Gaskets
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Bend the ends of the cylinder-head gaskets down slightly -arrows- , just far enough to allow you to clean the upper sealing face on the gasket and cylinder head.
Clean the top and bottom of the cylinder-head gaskets to remove any oil and grease.

Fig 4: Cleaning Cylinder-Head Gasket
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Cut off the nozzle on the tube at the front marking (nozzle diameter is approx. 2 mm).
Check use-by date of sealant.

Fig 5: Cutting Nozzle On Tube
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Apply a thin coat of sealant to the top and bottom sealing faces of the cylinder-head gaskets. Bend the cylinder-head gaskets down again slightly to do this -arrows- .
1. Use a flat object, e.g. a feeler gauge, to coat the surface between the cylinder head and gasket.
Fig 6: Cleaning Cylinder-Head Gasket
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fill the cleaned bores on the cylinder-head gaskets with sealant.

Fig 7: Cleaning Sealant On Cylinder-Head Gasket
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Apply beads of sealant.
1. Apply beads of sealant -1... 4- to the clean sealing faces of the lower chain housing cover as shown.
2. The groove on the sealing face must be completely filled with sealant.
3. The beads of sealant must project 1.5 2.0 mm over the sealing face.
4. Apply the bead of sealant -3- continuously as shown, even if the groove is interrupted.
5. Insert seals -arrows- into the grooves on the lower chain housing covers.
  
  Fig 8: Applying Beads Of Sealant
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit lower chain housing cover by guiding it towards the sealing face on the cylinder block and cylinder head at an angle from below.
Make sure not to damage the cylinder-head gaskets when fitting the cover.
Tighten the screws.
Further installation is performed in reverse order.