Crankshaft
WM 134819 Removing and installing crankshaft
Preliminary work
Preliminary work
Caution:
Risk of damage due to particles of dirt.
- Danger of material damage due to blocked oil bores/oil ducts.
--> Absolute cleanliness is essential when working on the engine.
--> Lay removed engine parts on a clean base and make sure to cover them.
--> Use the cover for dust protection when fitting the engine NR.165 on the engine assembly support.
1. Disassemble engine to crankcase.
2. Remove piston.
3. Attach special tool retaining device 9607 to the gear carrier with two M10 x 25 hexagon-head bolts -Arrows-.
Retaining device, gear carrier
4. Unscrew cylinder-head screws with spacer sleeves 9613.
5. Screw in retaining eyes on retaining device, lift gear carrier out of the crankcase half using a workshop crane or engine lifter and secure in a vice.
Lifting gear carrier out of crankcase
6. Remove accessories on gear carrier.
Gear carrier components overview with intermediate shaft
Overview of gear carrier with intermediate shaft
7. Remove tensioning rail and guide rail. Unscrew three M6 x 40 hexagon-head bolts and remove tensioning rail -1-. Remove circlip and washer -2-, remove guide rail -3-.
Chain guide, intermediate shaft
8. Remove intermediate shaft with timing chains and place on a clean surface. Check timing chains and toothing on intermediate shaft for signs of damage, replace if necessary.
9. Remove oil guide on gear carrier. Unscrew six M6 x 16 Torx screws -1- and remove guide with seals.
Oil guide, intermediate shaft
Removing crankshaft
Removing crankshaft
Caution:
Incorrect allocation of connecting rod and connecting rod cap
- Risk of engine damage
--> Remove connecting rods one at a time.
--> When disassembling the connecting rod cap, connect it immediately to the related connecting rod.
--> Mark the installation position and related cylinder for each connecting rod and connecting rod cap.
--> Do not use prick punches or number embossing tools.
Gear carrier components overview with crankshaft
Overview of gear carrier
1. Fasten the special tool retaining device 9607 onto the workbench using two screw clamps.
2. Mark connecting rod 4-6 in the installation position.
3. Remove connecting rods on cylinder side 4-6 one after another. Loosen the two connecting rod bolts on each connecting rod, remove connecting rod cap. Using a plastic mandrel (possibly an in-house tool) push connecting rod down and out. Immediately after this, screw on loosely to associated connecting rod cap. Place on a clean surface.
Plastic mandrel
4. Loosen 14 M9 x 127 screws for the gear carrier in the opposite order to the tightening sequence, from the outside inwards, and unscrew them.
Gear carrier
Information: Watch out for bearing shells and oil spray jets that may fall out
5. Remove gear carrier half 1-3, possibly tapping it gently with a plastic hammer.
6. Place gear carrier half on a clean surface, remove seven crankshaft bearing shells and three oil spray jets for piston cooling.
Oil spray jets in gear carrier half 1-3
7. Lever out crankshaft with timing chain and place on a soft, clean surface.
8. Remove seven crankshaft bearing shells and oil spray jets for piston cooling from gearing carrier half 4-6. Unscrew gear carrier half from the retaining device and place on a clean surface.
Installing crankshaft
Installing crankshaft
Overview of connecting rod bearing position
Connecting rod bearing position in gear carrier
1. Fit gearing carrier half 4-6 on special tool retaining device 9607 using two M10 x 25 hexagon-head bolts.
Gear carrier half 4-6 on device
2. Ensure that the dowel sleeves are seated correctly in gear carrier half 4-6.
Dowel sleeves, gear carrier 4-6
3. Insert three oil spray jets in the take-up bores in each of the gear carrier halves, press in gently to the stop using a plastic mandrel (diameter 4 mm).
Oil spray jets for piston cooling
4. Insert two thrust washers onto the center thrust block (no. 4) of gear carrier half 4-6; when doing so, the oil pockets -Arrows- must always point outwards (to the belt pulley side or flywheel side).
Thrust washer, thrust block
5. Insert seven new bearing shells for the crankshaft and coat with new engine oil. Pay attention to the installation position: the fixing lugs of the bearing shells in gear carrier half 4-6 point towards the dowel sleeve side, the fixing lugs of the bearing shells in gear carrier half 1-3 face the opposite side.
Oil spray jets and bearing shells in gear carrier half 1-3
Twist lock of bearing shell
Twist lock of bearing shell in gear carrier half 4-6
6. Insert crankshaft. Check that the thrust washers are seated properly.
Seating of thrust washer with crankshaft
7. Carefully position gear carrier half 1-3 on the crankshaft and gear carrier half 4-6. Fix the gear carrier halves by tapping them carefully with a plastic hammer.
8. Position 14 M9 x 127 thrust-bearing screws manually. Pre-tighten screws to the required tightening torque in accordance with the tightening sequence. Then tighten to the required torque angle. --> Initial tightening: 15 Nm (11 ftlb.); --> Torque angle: 120°
Tightening sequence for gear carrier
9. Check axial play of crankshaft. Fit dial gauge and dial gauge holder on gear carrier (flywheel side) and place against crankshaft flange. Press crankshaft manually against probe of dial gauge and set dial gauge to '0'. Press crankshaft away from dial gauge. Repeat process several times and note measured value.
Dial gauge, crankshaft axial play
10. Insert connecting rod bearing in connecting rod and connecting rod cap. Coat sliding surface with Optimol Optipit (available from Porsche Parts Service: 000.043.204.17).
Information: Connecting rod bolts must always be replaced.
11. Fit each of the connecting rods of cylinder 4-6 with the allocated connecting rod cap at the bearing surfaces of cylinders 4, 5 and 6. Position new screws manually. Pay attention to the installation position of the connecting rods: The recesses of the connecting-rod bearing twist lock face the oil pan (when the gear carrier is installed in the crankcase).
12. First, screw in connecting rod bolts to the required torque and tighten to the specified torque angle. Then loosen the bolts again. The final tightening is performed again with an initial tightening per the torque and the final tightening is performed with the torque angle wrench. --> Initial tightening: 20 Nm (15 ftlb.); --> Torque angle: 110°
Connecting rod bolts
Subsequent work
Subsequent work
1. Fit oil guide with new seals. Tighten six new M6 x 16 (micro-encapsulated) Torx screws. --> Tightening torque: 10 Nm (7.5 ftlb.)
Information: Fix the intermediate shaft to the crankshaft using old O-rings, for example, to secure it.
2. Insert intermediate shaft with timing chains.
3. Install tensioning rail and guide rail. Tighten three M6 x 40 hexagon-head bolts for guide rail -1-. Fit tensioning rail -3- with new circlip and shim -2-. --> Tightening torque: 10 Nm (7.5 ftlb.)
Chain guide, intermediate shaft
4. Engine support 9589 must be secured to the engine assembly support.
5. Fit crankcase half 1-3 with two mounting parts 9590 to the engine support 9589. Check sealing face to gear carrier for damage. Carefully clean sealing face with a clean cloth soaked in solvent naphtha or acetone.
Use only dowel sleeves with dimension B = 26.5 mm for fixing the gear carrier.
Dowel sleeves for gear carrier in crankcase
6. Check dowel sleeves to ensure that they are seated correctly or insert two new dowel sleeves in crankcase -Arrows-.
Dowel sleeves, crankcase half 1-3
7. Replace seals for coolant ducts -Arrows-.
Seals for coolant ducts
Information: It is advisable to get a second person to assist in inserting the gear carrier into crankcase half 1-3.
8. Insert gear carrier in crankcase half 1-3 with retaining device.
Gear carrier in crankcase half 1-3
9. Screw in and tighten two additional screws for fastening the gear carrier to cylinder side 1-3, replace O-ring. -Arrows-. --> Tightening torque: 22 Nm (16 ftlb.)
Additional screws for gear carrier 1-3
10. Screw in and tighten another cylinder-head screw with spacer sleeve 9613 -Arrow- on the belt pulley side. --> Tightening torque: 20 Nm (15 ftlb.)
Auxiliary screw with spacer sleeve 9613
11. Unscrew special tool retaining device 9607 from gear carrier.
12. Install piston.