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Removing Sealing Ring For Intermediate Shaft

NOTE:
  • In order to avoid deforming the thrust plate housing, always loosen the pan-head screws on the clutch pressure plate in several stages and in diametrically opposite sequence.
  1. Remove the clutch pressure plate, including the drive plate. Refer to DISASSEMBLING AND ASSEMBLING CLUTCH .
  2. Remove drive plate for the torque converter or the double-mass flywheel (DMF). Fasten special tool toothed segment 9538/1 for countering on the right crankcase half (cylinder bank 1 - 3) with an M10 x 50 screw. Undo and remove drive plate or DMF.
  3. Drain engine oil. After a dripping time of 20 minutes, insert oil drain plug with new sealing ring and tighten.
    Fig 1: Draining Engine Oil
    G03092555Courtesy of PORSCHE OF NORTH AMERICA, INC.

    Tightening torque 50 Nm (37 ft.lb) 

  4. Turn the engine on the crankshaft belt pulley clockwise until the bore 1 TDC (top dead Centre) in the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with special tool fixing pins 9595/1. See Fig 2. Use short fixing pin.
    Fig 2: Installing Special Tool Into Belt Pulley
    G03092556Courtesy of PORSCHE OF NORTH AMERICA, INC.
  5. Remove camshaft closure caps from cylinder bank 1 - 3. The closure cap of cylinder bank 1 - 3 is located on the flywheel side. Drive small screwdriver into Centre of the closure cap and lever off the cap.
  6. Check basic camshaft adjustment -arrow-  . See Fig 3. If the position is not correct, remove the dowel pin and turn the crankshaft a further 360° in clockwise direction. Fix belt pulley again with fixing pin.
    Fig 3: Checking Basic Camshaft Adjustment - Cylinder Bank 1-3.
    G03092557Courtesy of PORSCHE OF NORTH AMERICA, INC.
  7. Turn primary chain tensioner out of the crankcase, cylinder bank 4 - 6.
  8. Turn secondary chain tensioner out of the cylinder head 1 - 3.
  9. Undo intermediate shaft flange. Unscrew the three fastening screws M6 x 20 on the intermediate-shaft flange. Undo the M8 x 1 lock nut with the socket wrench 9110. See Fig 4. At the same time, counter with a suitable screwdriver in the slotted threaded pin.
    Fig 4: Removing Intermediate Shaft Flange
    G03092558Courtesy of PORSCHE OF NORTH AMERICA, INC.
  10. Position and align special tool retaining device 9642. See Fig 5.
    Fig 5: Positioning And Aligning Special Tool Retaining Device (9642)
    G03092559Courtesy of PORSCHE OF NORTH AMERICA, INC.

    Tensioning the retaining device 

    Fig 6: Tensioning Retaining Device
    G03092560Courtesy of PORSCHE OF NORTH AMERICA, INC.
  11. Carefully press the intermediate shaft off, for instance with two angle screwdrivers. See Fig 7. Proceed carefully so as not to damage the sealing surfaces.
Fig 7: Pressing Intermediate Shaft Off With Two Angle Screwdrivers
G03092561Courtesy of PORSCHE OF NORTH AMERICA, INC.
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