Disassembling And Assembling Bearing Housing With Crankshaft: Tools: Notes

Fig 1: Identifying Assembly Fixture For Bearing Housing

Courtesy of PORSCHE OF NORTH AMERICA, INC.

SPECIAL TOOL

Item	Designation	Special tool
	Assembly fixture for bearing housing Fig 1	9607

WARNING: Danger to engine if connecting-rod bearing cap and connecting rod are mixed up!

The connecting-rod bearing caps must always remain allocated to the respective connecting rods and must never be interchanged.

Recommendation: After disassembly, immediately re-join the connecting-rod bearing cap and connecting rod or mark them on the sides with an electric scribing tool (e.g. with the cylinder designation). Never mark these parts with sharp objects such as pin punches or number embossing tools.

DISASSEMBLY AND ASSEMBLY PROCEDURE OF BEARING HOUSING WITH CRANKSHAFT (1 OF 2)

No.	Designation	Qty.	Removal	Installation
1	Connecting-rod bolt	6		Lightly oil thread and bearing surface
2	Connecting-rod bearing cap	1
3	Connecting rod, cyl. 4	1	Immediately join with the connecting-rod bearing cap after removal
4	Connecting-rod bearing cap	1
5	Connecting rod, cyl. 5	1	Immediately join with the connecting-rod bearing cap after removal
6	Connecting-rod bearing cap	1
7	Connecting rod, cyl. 6	1	Immediately join with the connecting-rod bearing cap after removal
8	Connecting-rod bearing shell half	6		Replace
9	Thrust-bearing screw M9 x 127	14		Lightly oil bearing surface and thread
10	Bearing housing half, cylinder bank 1 - 3	1
11	Crankshaft bearing shell half	7		Replace; insert in correct position, locating stud faces towards dowel-sleeve side
12	Spray nozzle for piston cooling in bearing housing half, cylinder bank 1 - 3	3	Drive out from rear side of bearing housing half using a plastic mandrel	Press in with plastic mandrel (4 mm)
13	Cylindrical pin A4.0 x 10	1
14	Roll pin 6.0 x 16	1
15	Crankshaft	1		Check axial play
16	Thrust plate	2		Replace; insert in correct position, oil groove faces the belt pulley or flywheel
17	Crankshaft bearing shell half	7		Insert in correct position, locating stud towards dowel-sleeve side
18	Spray nozzle for piston cooling in bearing housing half, cylinder bank 4 - 6	3		Press in with plastic mandrel (4 mm)
19	Dowel sleeve	3
20	Pin for tensioning rail	1		Press into bearing-housing half (cyl. 4 - 6)
21	Bearing housing half, cylinder bank 4 - 6	1	Do not damage sealing surfaces; fit on assembly fixture (special tool 9607)

CAUTION: Bearing housings without connecting-rod bearing twist locks should not be installed. As of engine number M962065W07047 with twist lock. See Figure.

Fig 2: Identifying Bearing Housing With Crankshaft

Courtesy of PORSCHE OF NORTH AMERICA, INC.

DISASSEMBLY AND ASSEMBLY PROCEDURE OF BEARING HOUSING WITH CRANKSHAFT (2 OF 2)

No.	Procedure	Instructions
1	Checking that sealing balls are present	Check that sealing balls (6 ea.) are present and correctly caulked. Rework if necessary.
2	Fitting dowel sleeves	Push dowel sleeves (3 ea.) into the main thrust bearings 7, 4 and 1 of the bearing-housing half, cyl. 4 - 6, as far as the stop.
3	Fitting spray nozzles for piston cooling	Press spray nozzles into the receiving bore with a plastic mandrel (4 mm).
4	Inserting crankshaft bearing shells	Lay crankshaft bearing shells in the main thrust bearings. Fit the locating stud on the dowel-sleeve side. Lightly oil sliding surfaces.
5	Inserting thrust plates	Insert the thrust plates in the recess of main thrust bearing 4 of the bearing-housing half of cyl. 4 - 6 with grease. The oil pockets must face pulley or flywheel side.
6	Checking thrust plates	After inserting the crankshaft, check the two thrust plates at main thrust bearing 4 for correct seating.
7	Tightening thrust-bearing screws	Oil thread and contact surface.
	Tightening specification	1. Initial tightening 20 Nm (15 ft.lb) To facilitate subsequent checks it is recommended that, after initial tightening, the screw heads be marked with a color line.
		2. Final tightening 1 x 90° turn Observe tightening sequence: see Assembly instructions.
8	Checking axial play of crankshaft	Screw gauge with gauge holder VW 387 to bearing housing and place against crankshaft flange. Press crankshaft by hand against the gauge and set gauge to zero. Press crankshaft away from gauge. Read off value: New installation 0.05 to 0.24 mm Wear limit 0.28 mm
9	Inserting connecting-rod bearing shells	Insert new connecting-rod bearing shells into connecting rod. Lubricate sliding surface liberally with grease, e.g. Optimol Optipit (00004320417).
9		Grease to facilitate assembly during subsequent piston pin installation of cylinder bank 4 - 6.
10	Completing connecting rod	Join connecting rod and connecting-rod bearing cap. The recesses of the connecting-rod bearing twist lock must face each other.
	Tightening specification	Oil thread and contact surface.
		Initial tightening 20 Nm (15 ft.lb.) To facilitate subsequent checks it is recommended that, after initial tightening, the screw heads be marked with a color line. Final tightening 1 x 90° turn.