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ENGINE
13 ­ Engine ­ Crankgear, Pistons ­ 911 Carrera (991)

WM 131001 PISTON WEAR, WEIGHT GROUPS AND IDENTIFICATION

MARKINGS (EXCEPT CARRERA "EDITION", CARRERA CABRIOLET
"EDITION", CARRERA 4 "EDITION", CARRERA 4 CABRIOLET "EDITION",
GT3, GT3 RS)
INFORMATION
Weight Groups And Identification Markings

Information

Observe the different weight groups.

Identification markings:

1. Piston
2. Data matrix code on piston (intake side)
3. Porsche part number
4. Dimensional group (only dimensional group X available as replacement)
5. Manufacturer's logo
6. Weight group
7. Arrow marking for intake side (visible on new pistons)

Fig. 1: Identifying Piston Markings

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

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Weight groups:

Weight group Piston, complete, 997 3.8 l ­ Ø Piston, complete, 997 3.6 l ­ Ø
102 mm 97 mm
MA1.03 MA1.04
­ 565 ­ 571 g 497 ­ 503 g
+ 571 ­ 577 g 503 ­ 509 g

CHECKING PISTON WEAR

WARNING: Caustic fluids

Danger of chemical burns

→ Avoid contact with caustic fluid.

→ Wear personal protective gear.

→ Ensure that there is good ventilation.

→ If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if
necessary.

Information

When cleaning pistons, be careful of the hard layer on the first ring groove.
Be careful of the twist lock for the second ring groove.

1. Clean removed pistons with solvent naphtha or acetone first. To determine the dimensional group
(engraved on the piston crown), carbon deposits must be removed carefully.
1.1. To do this, we recommend that you clean the piston crown in an ultrasound bath or using a
brass brush.

Information

If the wear limit is exceeded, the piston must be replaced.

2. Check the piston diameter ­D­ at the prescribed measuring point on the piston shank using an outside
micrometer.

Measuring point from lower edge of shank dimension X = 15 mm .

3247 of 5326
 Fig. 2: Identifying Piston Shank Diameter
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

The maximum wear allowed at the specified measuring point is 100 μm (= 0.1 mm). If this
measurement is exceeded, the piston must be replaced. The reference measurements are listed in
the table below.

Dimensional groups:

Dimensional group (in MA1.03 engine MA1.04 engine Wear in mm

mm)
I 101.964 ­ 101.976 96.964 ­ 96.976 max. 0.1
X 101.974 ­ 101.986 96.974 ­ 96.986 max. 0.1
II 101.984 ­ 101.996 96.984 ­ 96.996 max. 0.1

Piston rings and piston ring groove:

Piston rings:

3. Check piston rings for signs of wear.

3.1. Piston­ring end clearance is measured in the cylinder.

Designation Ring end clearance in mm Explanation

1st piston ring < 0.4 mm Measurement in cylinder
2nd piston ring < 1.0 mm Measurement in cylinder, check
gap ends (twist lock)
3rd piston ring < 0.8 mm Measurement in cylinder

Piston rings:

Designation Dimension in mm
3248 of 5326
 Ring groove 1 1.2 + 0.15
Ring groove 2 1.5 + 0.15
Ring groove 3 2.0 + 0.15

Piston pins:

Check for signs of wear and tear.

MA1.03/MA1.04 engine: Dimensional check using outside micrometer: diameter = 22.0 ­
0.02 mm.

WM 131020 REMOVING AND INSTALLING PISTONS (EXCEPT CARRERA

"EDITION", CARRERA CABRIOLET "EDITION", CARRERA 4 "EDITION",
CARRERA 4 CABRIOLET "EDITION", GT3, GT3 RS)
TOOLS

Designation Type Number Description Â

locating pin Special tool 9595/1 Â

assembly aid Special tool 9598 Â

Disassembly tool Special tool 9764 Â

turning device Special tool 9773 Â

Assembly tool Special tool 9776 Â

Disassembly tool Special tool 9777 Â

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Retaining device Special tool 9778 Â

Piston receiving Special tool 9778/1 Â

element

holding bridge Special tool 9779 Â

Centering mandrel Special tool 9782 Â

Assembly aid Special tool 9783 Â

Funnel Special tool 9784 Â

funnel Special tool 9784/2 Â

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Piston assembly aid Special tool 9787 Â

piston assembly aid Special tool 9787/1 Â

assembly aid Special tool 9795 Â

TECHNICAL VALUES

Location Description Type Basic value Tolerance 1 Tolerance 2

Connecting rod M10 x 1.25 x 51 Initial tightening 20 Nm (15 Â Â
bolts ftlb.)
Connecting rod  Torque angle 80°  Â
bolts

TOOLS

Tools overview

3251 of 5326
Fig. 3: Identifying Special Tools For Engine Disassembly
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Retaining device 9778 with piston receiving element with a diameter of 97 mm.
2. Piston receiving element 9778/1 , diameter: 102 mm.
3. Funnel 9784 or funnel 9784/2 for piston assembly, diameter: 97 mm or 102 mm.
4. Piston assembly aid 9787 , diameter: 97 mm or piston assembly aid 9787/1 , diameter: 102 mm.
5. Handle for assembly aid 9598 .
6. Disassembly tool 9764 for piston­pin circlips.
7. Disassembly tool 9777 and assembly tool for piston pins.
8. Assembly tool 9776 for piston­pin circlips.
9. Centering mandrel 9782 for connecting rods and pistons.
10. Assembly aid 9783 for pressing out pistons (cylinders 1­3) and connecting rods with pistons (cylinders 4­
6).

Not shown ­ Rubber sleeves, assembly aid 9795 for protecting cylinder linings (fitted on connecting rods for
cylinders 1­3).

REMOVING PISTONS
Removing Pistons ­ Cylinders 1­3

Information

The specified positions relate to removing and installing components on the engine assembly support with
the engine in a vertical position.
Mark pistons in installation position using a water­resistant marker.

1. Unscrew screw plug (M30 x 1.5) ­1­ for removing piston pins.
1.1. Replace sealing ring.

3252 of 5326
 Fig. 4: Identifying Piston Pins Screw Plug
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

To remove a piston­pin circlip:

2. Turn the crankshaft and vibration damper to the bottom dead center position ­U 1/4 marking­ and lock at
this position using locating pin 9595/1 ­1­ .

3253 of 5326
 Fig. 5: Identifying Vibration Damper Marking
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

WARNING: Preloaded or pressurized components

Risk of eye injuries
Risk of bruising

→ Wear personal protective gear.

→ Secure components to prevent them from falling off suddenly.

Information

Special tool disassembly tool 9764 for removing piston­pin circlips must only be turned in a
clockwise direction.
Always hold the tool firmly with one hand when using it.
Replace removed piston­pin circlips.
3. Slide special tool disassembly tool 9764 through the assembly bore. The groove ­arrow­ for the hook on
the circlip must be at 9 o'clock position when the engine is positioned vertically.

3254 of 5326
 Fig. 6: Cutting Circlip Hook Groove
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Disassembly tool 9764 must now be pushed into the circlip.

4.1. Carefully turn the tool to the left and right. You should feel resistance from the hook.

3255 of 5326
 Fig. 7: Positioning (Tool 9764) Guide Groove
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Tighten circlip using tool 9764. To do this, turn the hexagonal handle clockwise ­arrow­ until you feel a
certain amount of resistance.

3256 of 5326
 Fig. 8: Tightening Circlip Using Tool (9764)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6. Keep the hexagonal handle ­1­ tight and turn the pipe ­3­ clockwise until you feel a certain amount of
resistance. The cheese head bolt ­2­ will move horizontally to the left from position A in the guide
groove.

3257 of 5326
Fig. 9: Turning Pipe Using Tool (9764) Position A
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6.1. Hold the tool firmly at the pipe and keep it pressed slightly against the piston in a clockwise
direction ­arrow 2­ . Slowly turn the hexagonal handle ­1­ until the cheese head bolt is at position
B.

3258 of 5326
Fig. 10: Turning Pipe Using Tool (9764) Position B
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6.2. Hold the hexagonal handle ­1­ firmly and turn the pipe clockwise ­arrow 2­ until you feel a
certain amount of resistance. The cheese head bolt will move horizontally to the left from position
B in the guide groove.

3259 of 5326
Fig. 11: Turning Pipe Using Tool (9764) Position C
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6.3. Hold the tool firmly at the pipe and press it slightly against the piston. Slowly turn the
hexagonal handle using spring force until the cheese head bolt is at position C . The circlip engages
in the tool with an audible click.

3260 of 5326
Fig. 12: Holding Tool (9764) Position C
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6.4. Slowly pull the tool with the circlip ­1­ out of the crankcase ­arrow­ . Dispose of old circlip.

3261 of 5326
Fig. 13: Pulling Tool 9764 Out Of Crankcase With Circlip
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

To remove a piston pin:

Disassembly tool 9777

3262 of 5326
Fig. 14: Identifying Piston Pins Tool 9777
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Interchangeable inserts for piston pins:

1. 53­mm insert for 2.7­litre engine

2. Roll pin (must be screwed in securely)
3. 56­mm insert for 3.4­litre and 3.8­litre engine

3263 of 5326
 Fig. 15: Identifying Tool 9777 With Inserts
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

7. Disassembly tool 9777 must be pushed as far as it will go into the piston pin.
7.1. Hold the tool firmly at the front hexagon ­1­ and turn the rear hexagon ­2­ anti­clockwise as far
as it will go ­arrow­ .

3264 of 5326
Fig. 16: Sliding Tool 9777 Into Piston Pin
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

7.2. Pull out the piston pin ­1­ using the correct interchangeable insert ­2­ . Inset shows the
tensioned piston pin.

3265 of 5326
 Fig. 17: Removing Piston Pin
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

7.3. To loosen the piston pin, turn the rear hexagonal handle clockwise until the pin can be
removed.

To remove a piston:

8. Assembly aid 9783 must be inserted into the cylinder bore from the oil pan side. Then press out the
piston (by tapping lightly on the handle with the ball of your hand).
8.1. Assign the correct piston pin to the piston immediately.
8.2. Fit assembly aid 9795 ­1­ (rubber sleeves) on the connecting rod to protect the cylinder liner.

3266 of 5326
 Fig. 18: Identifying Connecting Rods Protective Sleeves (9795)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

9. Turn the crankshaft to the bottom dead center position U 2/5 marking at the vibration damper and lock at
this position using a locating pin (tool 9595/1) ­1­ .

3267 of 5326
 Fig. 19: Identifying Vibration Damper Marking
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

9.1. Repeat steps 3 to 8 for removing piston 2.

10. Turn the crankshaft to the bottom dead center position U 3/6 marking at the vibration damper and lock at
this position using a locating pin (tool 9595/1) ­1­ .

3268 of 5326
 Fig. 20: Identifying Vibration Damper Marking
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

10.1. Repeat steps 3 to 8 for removing piston 3.

11. Check piston wear during re­installation.

→ WM 131001 PISTON WEAR, WEIGHT GROUPS AND IDENTIFICATION MARKINGS .

REMOVING PISTONS ­ CYLINDERS 4­6

Information

The parting surface between the connecting rod and connecting rod cap is broken during the
manufacturing process.
Assign connecting rod cap to the relevant connecting rod immediately after removal.
Also check the four­digit matching number.
Replace connecting rod bolts.
Replace connecting rod bearings.

1. Remove crankcase half.

→ 1001Z1 DISASSEMBLING ENGINE .

2. Secure the crankshaft to the main bearing in the middle using special tool holding bridge 9779 ­1­ .
2.1. Screw in and tighten two fastening screws ­2­ hand­tight.

3269 of 5326
 Fig. 21: Holding Crankshaft Using Holding Bridge 9779­1
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Mark pistons ­4, 5, 6­ in installation position using a water­resistant marker. ­E­ indicates intake side.

3270 of 5326
 Fig. 22: Locating Piston Marking
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Screw in three fastening screws ­2­ for the vibration damper at the crankshaft flange.
4.1. Turn the crankshaft using special tool turning device 9773 ­1­ so that the connecting rod bolts
can be reached.

3271 of 5326
 Fig. 23: Turning Crankshaft (Without Vibration Damper)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Remove pistons and connecting rods ­1­ on cylinder bank 4­6.

1. Connecting rod
2. Connecting rod bolts

3272 of 5326
Fig. 24: Identifying Connecting Rod Bolts
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5.1. Loosen and unscrew two M10 external serration screws ­1­ on the connecting rod cap ­2­ .

3273 of 5326
 Fig. 25: Identifying Connecting Rod Cap Screws
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5.2. Replace screws.

6. Remove pistons 4, 5 and 6 with connecting rods.
6.1. On assembly aid 9783 ­2­ , unscrew the grip handle and screw the bar into a threaded bore on
the connecting rod ­1­ . Press piston and connecting rod down out of the cylinder bore.
6.2. Repeat this step for pistons 5 and 6.

3274 of 5326
 Fig. 26: Pressing Pistons And Connecting Rods
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

7. Remove connecting rods 1­3 ­1­ on the crankshaft.

7.1. Unscrew connecting rod bolts ­2­ and remove connecting rod cap and connecting rod.
7.2. Replace screws.

3275 of 5326
 Fig. 27: Identifying Connecting Rods
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

8. Dispose of con­rod bearing shells.

WARNING: Preloaded or pressurized components

Risk of eye injuries
Risk of bruising

→ Wear personal protective gear.

→ Secure components to prevent them from falling off suddenly.

Procedure for replacing pistons or connecting rods:

9. For engine type MA.104 (3.4­litre): Insert connecting rod with piston in special tool retaining device
9778 .
9.1. For engine type MA.103 (3.8­litre): Pull off 3.4­litre piston receiving element and attach
piston receiving element 9778/1 .
9.2. Carefully remove piston­pin circlips with a small screwdriver.
9.3. Press out piston pin and set aside immediately with the relevant piston.
1. Connecting rod with piston
2. Retaining device

3276 of 5326
 Fig. 28: Holding Piston/Connecting Rod In Retaining Device 9778
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

10. Check piston wear during re­installation.

→ WM 131001 PISTON WEAR, WEIGHT GROUPS AND IDENTIFICATION MARKINGS .

PRE­ASSEMBLY OF PISTONS AND CONNECTING RODS

Information

Ensure even weight distribution when installing new pistons or connecting rods.
Only one weight group is permitted per engine.

Component overview

1. Connecting rod bolts → Initial tightening: 20 Nm (15 ftlb.) → Torque angle: 80°

3277 of 5326
 Fig. 29: Identifying Connecting Rod/Piston Components
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Tools:

1. Retaining device 9778

2. Inserts that can be used for the appropriate pistons: 9778 includes the insert for 3.4­litre pistons with a
diameter of 97 mm. 9778/1 is the insert for 3.8­litre pistons with a diameter of 102 mm.

3278 of 5326
 Fig. 30: Identifying Retaining Device 9778
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

The parting surface between the connecting rod and connecting rod cap is broken during the
manufacturing process.
Assign connecting rod cap to the relevant connecting rod immediately after removal.
Also check the four­digit matching number.
Replace connecting rod bolts.
Replace connecting rod bearings.

1. Allocate connecting rod bearings based on the marking on the crankshaft.

1.1. Read off the bearing shell color from the series of letters ­2­ . The con­rod marking indicates
the con­rod journal. This is read from left to right. The bearings are fitted from the belt side to the
flywheel side.
G ­ Yellow
B ­ Blue
R ­ Red

3279 of 5326
 Fig. 31: Identifying Crankshaft Bearing Shell Allocation Marking
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1.2. Fit new con­rod bearing shells in the connecting rod cap and connecting rod and grease with
Optimol Optipit grease (Part No. 000.043.204.17).
1.3. Check that the new con­rod bearing shells are seated correctly (check locking lugs) ­arrow­ .

3280 of 5326
 Fig. 32: Locating Connecting Rod Bearings Locking Lugs
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1.4. Secure connecting rod cap with relevant connecting rod and new M10 screws by hand.
2. Fit pistons and connecting rods for cylinders 4­6 (the positions of the above­mentioned markings also
apply for the pistons and connecting rods for cylinders 1­3).

3281 of 5326
 Fig. 33: Identifying Connecting Rod Matching Number
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2.1. The matching number ­2­ and data matrix code ­inset­ on the correctly installed connecting rod
must be facing the exhaust side.
2.2. In contrast, the cone­shaped neck and data matrix code ­1­ on the piston must be facing the
intake side.
2.3. The pistons for cylinders 1­3 are pre­fitted without connecting rods.
3. Insert connecting rod with piston ­1­ or only the piston into the retaining device 9778 (3.4­litre).
3.1. For 3.8­litre pistons, pull off the piston receiving element and then attach the piston receiving
element 9778/1 .

3282 of 5326
 Fig. 34: Holding Piston/Connecting Rod In Retaining Device 9778
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

WARNING: Preloaded or pressurized components

Risk of eye injuries
Risk of bruising

→ Wear personal protective gear.

→ Secure components to prevent them from falling off suddenly.

4. First, fit the piston­pin circlip, which must be facing the flywheel side later.
4.1. Fit the circlip on the side of the piston that does not have an assembly groove for the assembly
tool 9776 .
4.2. Fit the circlip ­1­ at the position shown. Use a small screwdriver to do this.
4.3. Press the circlip in with your thumbs and guide it to its final position with the screwdriver.

3283 of 5326
 Fig. 35: Identifying Circlip Facing Flywheel Side
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Pistons and connecting rods for cylinders 4­6:

5. Turn piston and connecting rod by 180° and fit the circlip, which must be facing the belt side later. Use
special tool assembly tool 9776 to do this.
5.1. Coat piston pin with new engine oil and press it into the relevant piston/connecting rod
assembly.
5.2. Turn the groove for the small hook on the tool ­2­ towards the observer.

3284 of 5326
Fig. 36: Pressing Piston­Pin Circlip Into Tool 9776
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5.3. Slide a new circlip ­1­ into the assembly tool and press the edges together.
5.4. Position small hook facing the groove ­arrow­ .

3285 of 5326
Fig. 37: Locating Hook Groove
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5.5. Turn the circlip ­1­ as required.

3286 of 5326
Fig. 38: Turning Piston­Pin Circlip In Tool
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5.6. Pull back and hold push rod in tool. Place the pipe ­1­ on a hard surface. Slowly guide the push
rod down and press the circlip into installation position. You should hear a distinct click.

3287 of 5326
 Fig. 39: Pressing Circlip Into Installation Position
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6. Assembly tool 9776 must be positioned on the piston in such a way that the small hook is lying in the
half­moon­shaped bore ­arrow­ .

3288 of 5326
Fig. 40: Locating Assembly Tool 9776
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

View of piston on the circlip ­1­ in the tool.

3289 of 5326
Fig. 41: Identifying Piston Circlip Position
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6.1. Hold on firmly to the tube of the tool ­1­ and tap the push rod slightly towards the piston with
the ball of your hand ­arrow­ . The circlip will lock with a clearly audible click.

3290 of 5326
Fig. 42: Installing Circlip On Piston
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6.2. The circlip ­1­ must be fitted as shown. The hook is at the 9 o'clock position ­2­ .

3291 of 5326
 Fig. 43: Identifying Piston Circlip (Viewed From Belt Side)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

7. Remove piston and connecting rod from the retaining device 9778 .
8. If piston rings will be replaced on the re­installed pistons, these can be removed and fitted by hand.

IMPORTANT: Check installation position and avoid breakage!

INSTALLING PISTONS
Installing Pistons For Cylinders 4­6

Preliminary work: Crankshaft is inserted in crankcase half 4­6; pistons and connecting rods are pre­
fitted.

1. Secure the crankshaft to the main bearing in the middle using holding bridge 9779 ­1­ .
1.1. Tighten two fastening screws ­2­ hand­tight.

3292 of 5326
 Fig. 44: Crankshaft Holding Bridge Tool 9779­1
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Tighten three M8 screws ­2­ securing the vibration damper to the crankshaft flange hand­tight.
2.1. Turn the crankshaft using turning device 9773 so that the conrod journal is at bottom dead
center position.

3293 of 5326
 Fig. 45: Turning Crankshaft (Without Vibration Damper)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

The parting surface between the connecting rod and connecting rod cap is broken during the
manufacturing process.
Assign connecting rod cap to the relevant connecting rod immediately after removal.
Also check the four­digit matching number.
Replace connecting rod bolts.
Replace connecting rod bearings.
3. Check that the new con­rod bearing shells are seated correctly (check locking lugs) ­arrow­ .

3294 of 5326
Fig. 46: Locating Connecting Rod Bearings Locking Lugs
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3.1. Check allocation of connecting rod to connecting rod cap (matching number ­1­ and data
matrix code).

3295 of 5326
 Fig. 47: Identifying Connecting Rod Matching Number
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

If pistons are to be replaced, only one weight group is permitted for all pistons.
4. Install piston and connecting rod.
4.1. For re­installation, fit the relevant piston into the related cylinder bore according to the
inscription. ­E­ indicates the intake side.

3296 of 5326
Fig. 48: Locating Pistons Marking (4­6)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4.2. Check installation position of pistons. The cone­shaped neck and data matrix code on the
piston must be facing the intake side. In contrast, the matching number and data matrix code on the
connecting rod must be facing the exhaust side.
1. Data matrix code on piston
2. Matching number and data matrix code on connecting rod

3297 of 5326
 Fig. 49: Identifying Connecting Rod Matching Number
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4.3. Align piston rings. Offset the ring gaps by 120°. Check the twist lock ­arrow­ at the second
ring groove.

3298 of 5326
Fig. 50: Locating Second Piston Ring Lock
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4.4. Coat pistons and tools with new engine oil.

4.5. Insert piston as far as required into the assembly funnel until the lower edge of the piston is
flush with the surface of the tool.
1. Piston
2. Funnel 9784 (3.4­litre) or funnel 9784/2 (3.8­litre)
3. Piston­pin circlip

3299 of 5326
 Fig. 51: Inserting Piston Into Assembly Funnel
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4.6. Guide connecting rod and piston ­1­ into the cylinder bore and position assembly funnel ­2­ on
the crankcase ­arrow­ .

3300 of 5326
Fig. 52: Inserting Piston Into Cylinder Bore
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4.7. Press the piston into the cylinder bore immediately using the handle of a hammer ­2­ and hold
assembly funnel ­1­ firmly while doing this.

3301 of 5326
 Fig. 53: Pressing Piston Into Cylinder Bore
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4.8. Remove assembly funnel.

4.9. Fit the correct connecting rod cap with new screws.
4.10. Repeat these steps for pistons 5 and 6.
5. Pre­fit connecting rods 1­3 with new bearings and the relevant connecting rod caps and new screws on
the crankshaft.
5.1. The matching number ­1­ and data matrix code are facing the exhaust side.

3302 of 5326
 Fig. 54: Identifying Connecting Rod Matching Number
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6. Tighten all connecting rod caps according to specifications.

3303 of 5326
 Fig. 55: Identifying Connecting Rod Cap And Screws
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

7. Fit rubber sleeves on connecting rods 1­3 to protect the cylinder lining (assembly aid 9795 ).
8. Remove vibration damper in order to install the crankcase half.

INSTALLING PISTONS FOR CYLINDERS 1­3

WARNING: Preloaded or pressurized components

Risk of eye injuries

Risk of bruising

→ Wear personal protective gear.

→ Secure components to prevent them from falling off suddenly.

Information

If pistons are to be replaced, only one weight group is permitted for all pistons.

1. Assemble the crankcase.

→ 1001Z2 ASSEMBLING ENGINE .

2. Secure the vibration damper to the crankshaft flange with two M8 screws.
3. Turn con­rod journal for cylinder 3 to installation position.
3.1. To do this, use turning device 9773 to turn the crankshaft to the bottom dead center position
U 3/6 at the vibration damper.
3304 of 5326
 Fig. 56: Identifying Vibration Damper Marking
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Pull off the boot on the connecting rod, set it in a vertical position and secure in place using centering
mandrel 9782 .
4.1. Guide centering mandrel with the correct diameter into the assembly bore.

3305 of 5326
Fig. 57: Installing Centering Mandrel Into Assembly Bore
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4.2. Center the connecting rod in the small connecting­rod eye ­1­ using the centering mandrel ­2­ .

3306 of 5326
 Fig. 58: Adjusting Connecting Rod Using Tool 9782
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Install pistons for cylinders 1­3.

5.1. For re­installation, fit the relevant piston into the related cylinder bore according to the
inscription. Start with piston 3.

3307 of 5326
Fig. 59: Identifying Pistons Marking
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5.2. Align piston rings. Offset the ring gaps by 120°. Check the twist lock ­arrow­ at the second
ring groove.

3308 of 5326
Fig. 60: Locating Second Piston Ring Lock
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5.3. Check installation position of pistons. Cone­shaped neck and data matrix code on the piston
must be facing the intake side.
1. Piston
2. Data matrix code on piston
3. Porsche part number
4. Dimensional group (only dimensional group X available as replacement)
5. Manufacturer's logo
6. Weight group

3309 of 5326
 Fig. 61: Locating Piston Markings
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5.4. Coat pistons and tools with new engine oil.

5.5. Insert the piston as far as required into the assembly sleeve until the lower edge of the piston is
flush with the surface of the sleeve.
1. Piston
2. Funnel 9784 (3.4­litre) or funnel 9784/2 (3.8­litre)
3. Piston­pin circlip

3310 of 5326
 Fig. 62: Inserting Piston Into Assembly Funnel
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5.6. Guide the piston into the cylinder bore and carefully position the funnel on the crankcase.

3311 of 5326
Fig. 63: Inserting Piston Into Cylinder Bore
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5.7. Press the piston into the cylinder bore immediately using the handle of a hammer ­2­ and hold
assembly funnel ­1­ firmly while doing this.

3312 of 5326
 Fig. 64: Pressing Piston Into Cylinder Bore
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5.8. Remove assembly funnel.

6. Position the piston.
6.1. Piston assembly aid 9787 or piston assembly aid 9787/1 must now be screwed to the handle
of the assembly aid 9598 .
6.2. Use the relevant assembly aid to press the piston into the cylinder bore as far as the contact
surface of the centering mandrel 9782 ­2­ .
6.3. Pull out the centering mandrel and press the piston down at the same time until the assembly
aid is positioned correctly.

3313 of 5326
 Fig. 65: Positioning Piston In Cylinder Using Assembly Aid
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

7. Fix piston and connecting rod in place using centering mandrel 9782 .

3314 of 5326
 Fig. 66: Adjusting Piston And Connecting Rod
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

8. Fit the piston pin.

8.1. Coat the piston pin with new engine oil and slide it onto the disassembly tool 9777 .
8.2. Secure the tool at the front hexagon ­1­ and turn it anti­clockwise as far as it will go at the rear
hexagon ­2­ (­arrow­ ).

3315 of 5326
Fig. 67: Fitting The Piston Pin
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

8.3. Slide the piston pin into the piston/connecting­rod eye. Guide the piston pin ­1­ using the tool
­2­ until it goes past the edge of the cylinder ­arrow­ to the piston.

3316 of 5326
Fig. 68: Installing Piston Pin
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

8.4. Tap the tool lightly with the ball of your hand, if necessary, while holding the tool firmly in
place ­1­ . Insert pin as far as it will go.

3317 of 5326
 Fig. 69: Tapping Piston Pin Using Tool
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

8.5. Turn the tool at the rear hexagon in clockwise direction until it pulls easily out of the piston
pin without resistance.

Information

Always replace piston­pin circlips following removal.

9. Insert new piston­pin circlip into assembly tool 9776 .
9.1. The large hook ­1­ on the circlip will have to be at approx. 9 o'clock position later (when
engine is vertical).

3318 of 5326
Fig. 70: Identifying Circlip Hook (Engine Vertical)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

9.2. Turn the groove for the small hook on the tool ­2­ towards the observer.

3319 of 5326
Fig. 71: Pressing Piston­Pin Circlip Into Tool 9776
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

9.3. Slide a new circlip into the assembly tool and press the edges together.
9.4. Position the small hook towards the groove ­arrow­ . Turn the circlip slightly if necessary.

3320 of 5326
Fig. 72: Locating Hook Groove
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Turn the circlip as required.

3321 of 5326
Fig. 73: Turning Piston­Pin Circlip In Tool
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

9.5. Pull back and hold push rod in tool. Place the pipe ­1­ on a hard surface. Slowly guide the push
rod down and press the circlip into installation position ­arrow­ . You should hear a distinct click.

3322 of 5326
 Fig. 74: Pressing Circlip Into Installation Position
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

10. Fit the piston­pin circlip on the piston.

10.1. Check the position of the piston­pin circlip ­1­ again.

3323 of 5326
Fig. 75: Identifying Piston­Pin Circlip
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

10.2. Assembly tool 9776 ­1­ must now be guided into the assembly bore ­arrow­ .

3324 of 5326
Fig. 76: Pressing Tool 9776 Into Assembly Bore
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

10.3. Position the tool with the small hook at approx. 11 o'clock position ­arrow­ and place it in
the assembly groove on the piston.

3325 of 5326
Fig. 77: Positioning Tool With Hook
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

10.4. Carefully turn the tube of the tool to the left and right ­arrows­ while pressing slightly against
the piston at the same time. You should feel a certain amount of resistance in the half­moon­shaped
bore on the piston at both sides.

3326 of 5326
Fig. 78: Turning Tool Tube (9776)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

10.5. Press the tube of the tool against the piston and hold it firmly in place. Then, tap the push rod
slightly towards the piston with the ball of your hand. The circlip will lock with a clearly audible
click.
10.6. Assembly tool 9776 must now be removed.
10.7. Check that the piston­pin circlip ­2­ is seated correctly over cylinder bore 2 using a mirror ­1­
and a torch. The correct assembly position is clearly visible.

3327 of 5326
 Fig. 79: Checking Position Of Piston­Pin Circlip Using Mirror
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

11. Turn con­rod journal for cylinder 2 to installation position.

11.1. To do this, use turning device 9773 to turn the crankshaft to the bottom dead center
position U 2/5 at the vibration damper.

3328 of 5326
 Fig. 80: Identifying Vibration Damper Marking
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

11.2. Repeat steps 4 ­ 10 for cylinder 2. Check the position of the circlip over cylinder bore 1.
12. Turn con­rod journal for cylinder 1 to installation position.
12.1. To do this, use turning device 9773 to turn the crankshaft to the bottom dead center
position U 1/4 at the vibration damper.

3329 of 5326
Fig. 81: Identifying Vibration Damper Marking
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

12.2. Repeat steps 4 ­ 10 for cylinder 1.

12.3. The position of the circlip can be checked on cylinder 1 through the assembly bore. The large
hook must be at 9 o'clock position when the engine is vertical.

3330 of 5326
 Fig. 82: Identifying Piston Circlip Installation Position
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

13. Fit screw plug (M30 x 1.5) for fitting piston pin with a new sealing ring.
14. Complete the engine.

→ 1001Z2 ASSEMBLING ENGINE .

WM 134837 DISASSEMBLING AND ASSEMBLING CRANKSHAFT (EXCEPT

CARRERA "EDITION", CARRERA CABRIOLET "EDITION", CARRERA 4
"EDITION", CARRERA 4 CABRIOLET "EDITION", GT3, GT3 RS)
TOOLS

Designation Type Number Description Â

retainer plate Special tool P209a Â

TECHNICAL VALUES

Location Description Type Basic value Tolerance 1 Tolerance 2

Connecting rod M10 x 1.25 x 51 Initial tightening 5 Nm (3.5 Â Â
bolt: Step 1 ftlb.)
3331 of 5326
 Connecting rod M10 x 1.25 x 51 Subsequent 20 Nm (15 Â Â
bolt: Step 2 tightening torque ftlb.)
Connecting rod M10 x 1.25 x 51 Torque angle 80°  Â
bolt: Step 3
Connecting rod M10 x 1.25 x 51 Initial tightening 5 Nm (3.5 Â Â
bolt: Step 5 ftlb.)
Connecting rod M10 x 1.25 x 51 Subsequent 20 Nm (15 Â Â
bolt: Step 6 tightening torque ftlb.)
Connecting rod M10 x 1.25 x 51 Final tightening 80°  Â
bolt: Step 7 torque angle

PRELIMINARY WORK

1. Disassemble the engine.

→ 1001Z1 DISASSEMBLING ENGINE .

DISASSEMBLING CRANKSHAFT

NOTE: Dirt and contamination

Risk of damage to units or components

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

Components:

Fig. 83: Identifying Crankshaft Components

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Crankshaft
2. Dowel pin for flywheel ­ replace if damaged
3. Dowel pin for vibration damper ­ replace if damaged
4. Crankshaft sealing ring on belt side
3332 of 5326
 5. Crankshaft sealing ring on flywheel side
6. Connecting rod
7. Connecting rod bush
8. Connecting rod bolt ­ replace
9. Connecting­rod bearing
10. Main bearing ­ smooth bearing
11. Main bearing ­ partial­groove bearing
12. Supporting mount

1. Fit special tool retainer plate P209a on the crankshaft flange (flywheel side) using two flywheel screws.

CAUTION: fine thread!

1.1. Clamp crankshaft ­1­ with retainer plate ­2­ in a vice.

Fig. 84: Identifying Crankshaft With Retainer Plate In Vise

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Loosen and unscrew connecting rod bolts for connecting rods for cylinders 1­3 using a multiple­tooth
socket­wrench insert.
2.1. Remove connecting rod cap and connecting rod, remove bearing shells and store the parts
together.
2.2. Replace connecting rod bolts.
3. Clean the crankshaft and connecting rods.

ASSEMBLING CRANKSHAFT

NOTE: 3333 of 5326

NOTE: Dirt and contamination

Risk of damage to units or components

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

1. Assemble new connecting­rod bearing shells on the crankshaft according to the marking ­2­ .

Fig. 85: Identifying Crankshaft Bearing Shell Marking

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Fit connecting rods.

2.1. The data matrix code marking ­1­ must be facing the outlet side for all connecting rods.
2.2. The markings ­2­ must be on one side.
2.3. Screw in new connecting rod bolts and tighten according to specifications.

Step 1: Initial tightening 5 Nm (3.5 ftlb.)

Step 2: Subsequent tightening torque 20 Nm (15 ftlb.)

Step 3: Torque angle 80°

Step 4: Loosen bolts

Step 5: Initial tightening 5 Nm (3.5 ftlb.)

Step 6: Subsequent tightening torque 20 Nm (15 ftlb.)

Step 7: Final tightening torque angle3334
80°of 5326
 Step 7: Final tightening torque angle 80°

Fig. 86: Identifying Connecting Rod Markings

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Assemble and fit new bearing shells for both crankcase halves on the crankshaft and crankcase half 1­3
according to the markings.
3.1. Coat bearing shells with new engine oil.
4. Insert crankshaft into crankcase half.

SUBSEQUENT WORK

1. Assemble the engine.

→ 1001Z2 ASSEMBLING ENGINE .

WM 135955 REPLACING CRANKSHAFT SEALING RING (TRANSMISSION

SIDE) (EXCEPT CARRERA "EDITION", CARRERA CABRIOLET "EDITION",
CARRERA 4 "EDITION", CARRERA 4 CABRIOLET "EDITION", GT3, GT3
RS)
TOOLS

Designation Type Number Description Â

insertion tool Special tool 9699 Â

3335 of 5326
 Assembly aid Special tool 9699/3 Â

slide hammer kit Commercially Nr.168 Â

available tool

Mod. G puller for Commercially Nr.168­1 Â

sealing rings available tool

TECHNICAL VALUES

Location Description Type Basic value Tolerance 1 Tolerance 2

Installation Crankshaft flange Measured value 7 mm +/­0.3 mm Â
dimension of surface to sealing
crankshaft ring
sealing ring

PRELIMINARY WORK

NOTE: Removing and installing flywheel

Leaks
Risk of damage to the flywheel and adjacent components

→ Be very careful during removal and installation.

→ Get another person to help because of the weight.

Information

Loosen and tighten screws on the component according to specifications.

1. Remove transmission.

3336 of 5326
 → 343519 REMOVING AND INSTALLING TRANSMISSION .

→ 373419 REMOVING AND INSTALLING PORSCHE DOPPELKUPPLUNG (PDK) .

Manual transmission:

2. Remove the clutch.

→ 305019 REMOVING AND INSTALLING CLUTCH .

3. Remove dual­mass flywheel.

→ 136019 REMOVING AND INSTALLING FLYWHEEL.

Porsche Doppelkupplung (PDK):

4. Remove the flywheel.

→ 136019 REMOVING AND INSTALLING FLYWHEEL ­ PORSCHE DOPPELKUPPLUNG

(PDK).

REMOVING CRANKSHAFT SEALING RING

Information

Work on delicate engine parts must be carried out conscientiously and precisely.
Use a suitable tray.
Absolute cleanliness is essential.

Crankshaft flange sealing ring ­1­:

3337 of 5326
Fig. 87: Identifying Crankshaft Sealing Ring
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

WARNING: Caustic fluids

Danger of chemical burns

→ Avoid contact with caustic fluid.

→ Wear personal protective gear.

→ Ensure that there is good ventilation.

→ If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if
necessary.

1. Carefully remove small edges or burrs on the chamfer of the crankshaft flange with an oilstone.
1.1. Then, carefully remove metal chips and residual dirt from the crankshaft journal and the
crankcase bore using a clean, lint­free cloth soaked in solvent naphtha or acetone.

CAUTION: The crankshaft flange can be damaged if not cleaned correctly.

Leaks

→ Never use an abrasive or polishing cloth or brushes with metal bristles.

→ Follow cleaning instructions.

2. If there are corroded areas on the crankshaft flange, only use a metal­polishing pad to remove these.
2.1. Then, carefully clean the flange using a clean, lint­free cloth that has been soaked in solvent
naphtha or acetone.

NOTE: Drilling work on crankshaft sealing ring

Risk of engine damage caused by drilling chips
Risk of damage to the crankcase
Do not apply pressure while drilling

→ Carefully remove drill chips

→ Drill carefully

3. Drill the crankshaft sealing ring ­1­ at two opposite positions ­arrows­ using a greased drill bit (ø 2 mm)
­2­ and carefully remove chips.

3338 of 5326
 Fig. 88: Drilling Sealing Ring For Removal
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Screw extractor tip of tool Mod. G puller for sealing rings Nr.168­1 ­1­ into the bores alternately and
pull the sealing ring out evenly.

3339 of 5326
Fig. 89: Pulling Sealing Ring Using Puller No. 168­1
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4.1. Alternatively, screw two tapping screws into the bores ­arrows­ .

3340 of 5326
 Fig. 90: Tapping Screw Using Hammer Kit No. 168
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4.2. Pull sealing ring off alternately using slide hammer kit Nr.168 at the tapping screws.

Information

Visually inspect the crankshaft flange and crankcase bore for damage.

5. Check crankshaft flange and crankcase bore for damage.

6. Clean the crankshaft flange again using the metal­polishing pad if necessary.
6.1. Then, carefully remove grease from the flange and crankcase bore using a clean, lint­free cloth
soaked in solvent naphtha or acetone.
6.2. Leave to dry off for at least three minutes to ensure that the vapors of the cleaning agent do not
attack the new sealing ring (sealing lip).

INSTALLING CRANKSHAFT SEALING RING

NOTE: Incorrect tool

Risk of damage to components

→ Use prescribed tool.

Component overview of insertion tool

1. Screw for pulling in sealing ring

2. Sleeve of insertion tool 9699
3. Guide pin for guiding assembly aid 9699/3
4. Fastening screws for securing insertion tool
5. Assembly aid 9699/3

3341 of 5326
 Fig. 91: Identifying Insertion Tool 9699
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Fit the assembly aid 9699/3 into the insertion tool 9699 .
1.1. To do this, unscrew the hexagon­head bolt and replace the inserts.
2. Small burred spots or damaged areas on the tools can be removed with a nail file.
2.1. Then pull off the tool using an oil stone or polishing cloth.
2.2. Remove residual dirt on the tools using solvent naphtha or acetone.
3. Adjust insertion tool for fitting the supporting sleeve of the sealing ring.
3.1. Unscrew the screw until the groove ­arrow­ of the assembly aid ­1­ is flush with the contact
surface of the sleeve.

3342 of 5326
 Fig. 92: Locating Insertion Tool
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

CAUTION: Damage to the sealing lip.

Leaks

→ The crankshaft flange and tools must be perfectly clean and free of grease.

→ The sealing ring must be fitted dry, i.e. no oil, grease or other lubricants can be used.

→ The crankcase bore must not be oiled.

→ The sealing ring can only be positioned on the assembly tool using the supporting sleeve.

→ The new crankshaft sealing ring (PTFE) is supplied on a supporting sleeve as a spare part.

→ Do not remove the sealing ring from the supporting sleeve.

4. Slide new crankshaft sealing ring ­1­ with supporting sleeve ­2­ onto the assembly aid 9699/3 .
4.1. The collar of the sleeve must be facing away from the tool ­inset­ .
4.2. Make sure the sealing ring is dry.

3343 of 5326
 Fig. 93: Identifying Crankshaft Sealing Ring And Supporting Sleeve
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Insertion tool 9699 is then fitted.

Check the position of the dowel pin!

5.1. Secure the insertion tool to the crankshaft flange using cheese head bolts ­arrows­ .

3344 of 5326
 Fig. 94: Installing Insertion Tool On Crankshaft Flange
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

Insertion tool 9699 must be left in place for two to three minutes after fitting the sealing ring
so that the sealing lip can settle into position on the crankshaft flange.
6. Turn the hexagon­head bolt clockwise as far as it will go.
6.1. Leave the tool in place for two minutes.

3345 of 5326
 Fig. 95: Turning Hexagon­Head Bolt Of Insertion Tool 9699
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

7. Remove insertion tool.

7.1. Turn hexagon­head bolt anti­clockwise until the guide screws are still just visible.
7.2. Loosen the two cheese head bolts and remove the tool.
8. Check that the sealing ring is seated correctly.
8.1. To check this, take measurements at four different places, offset by 90°, from the crankshaft
flange surface to the sealing ring (level surface).

→ Measured value: 7 mm+/­0.3 mm

9. Leave supporting sleeve ­1­ on the tool after fitting to protect the edges of the tool.
9.1. Using a small screwdriver, carefully lever off the supporting sleeve at the ventilation bore ­
arrow­ and remove it.

3346 of 5326
 Fig. 96: Locating Insertion Tool Supporting Sleeve
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

SUBSEQUENT WORK

NOTE: Removing and installing flywheel

Leaks
Risk of damage to the flywheel and adjacent components

→ Be very careful during removal and installation.

→ Get another person to help because of the weight.

Manual transmission:

1. Install dual­mass flywheel.

→ INSTALLING FLYWHEEL .

Information

Loosen and tighten screws on the component according to specifications.

2. Install the clutch.

→ INSTALLING CLUTCH .

3. Install manual transmission.

→ INSTALLING TRANSMISSION .
3347 of 5326
 Porsche Doppelkupplung (PDK):

4. Install the flywheel.

→ INSTALLING FLYWHEEL .

5. Install transmission.

→ INSTALLING PORSCHE DOPPELKUPPLUNG (PDK) .

WM 136019 REMOVING AND INSTALLING FLYWHEEL (EXCEPT CARRERA

"EDITION", CARRERA CABRIOLET "EDITION", TURBO, TURBO S,
CARRERA 4 "EDITION", TURBO CABRIO, TURBO S CABRIO, CARRERA 4
CABRIOLET "EDITION", GT3, GT3 RS)
TOOLS

Designation Type Number Description Â

Torque/torque angle Workshop WE 1440 Â
screw tool equipment

Counter­hold tool Workshop WE 1487 Â Â

equipment
Centering pins Special tool 9321 Â

PRELIMINARY WORK

1. Remove manual transmission.

→ 343519 REMOVING AND INSTALLING TRANSMISSION .

Information

Loosen and tighten screws on the component according to specifications.

2. Remove the clutch.

→ 305019 REMOVING AND INSTALLING CLUTCH .

REMOVING FLYWHEEL
Component Overview

3348 of 5326
Fig. 97: Overview Of Flywheel And Clutch
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Dual­mass flywheel (DMF)

2. Multiple­tooth screw, M10 x 29 (micro­self­locking) ­ always replace screws
3. Clutch plate
4. Clutch pressure plate
5. External Torx screw, M8

1. Counter­hold tool WE 1487 ­1­ must be screwed to the engine flange in order to counter it.
1.1. To do this, secure the tool through the lower left bore in the flange using a screw and M10 nut
­2­ .

3349 of 5326
 Fig. 98: Identifying Flywheel Counter­Hold Tool
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

NOTE: Removing and installing flywheel

Leaks
Risk of damage to the flywheel and adjacent components

→ Be very careful during removal and installation.

→ Get another person to help because of the weight.

2. Loosen and unscrew ten (multiple­tooth, micro­self­locking) fastening screws (M10 x 29) on the
flywheel. Carefully remove the flywheel.
2.1. Replace fastening screws.

Information

Check the friction surface of the flywheel. The flywheel must be replaced if it is damaged or
discolored.

3. Visually inspect the friction surface on the flywheel.

INSTALLING FLYWHEEL

NOTE: Removing and installing flywheel

Leaks
Risk of damage to the flywheel and adjacent components

3350 of 5326
→ Be very careful during removal and installation.

→ Get another person to help because of the weight.

WARNING: Caustic fluids

Danger of chemical burns

→ Avoid contact with caustic fluid.

→ Wear personal protective gear.

→ Ensure that there is good ventilation.

→ If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if
necessary.

1. Remove protective wax on new parts with acetone or solvent naphtha.

2. Fit two centering pins 9321 ­1­ with M10 thread on the crankshaft flange by screwing them in by one to
two turns only (caution: fine thread!).

Recommendation: Screw in one centering pin next to the dowel pin.

Fig. 99: Identifying Crankshaft Flange Centering Pins

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

Before re­installing the flywheel, clean the friction surface of the flywheel using a clean, lint­free cloth
soaked in acetone or solvent naphtha).

3351 of 5326
3. Fit flywheel ­1­ over the centering pins ­2­ at the dowel pin on the crankshaft and push it onto the
crankshaft flange.
3.1. Fit ten new M10 x 29 (internal serration) fastening screws and tighten them uniformly and in
diagonally opposite sequence.

Fig. 100: Identifying Flywheel On Crankshaft Flange

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

The flywheel screws are micro­self­locking and must be replaced.

4. Tighten screws uniformly and in diagonally opposite sequence to the prescribed tightening torque.

Tool recommendation: Torque/torque angle screw tool WE 1440 .

3352 of 5326
 Fig. 101: Display ­ Adjusting Special Tool Screen
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

SUBSEQUENT WORK

1. Install the clutch.

→ INSTALLING CLUTCH .

2. Install transmission.

→ INSTALLING TRANSMISSION .

WM 136019 REMOVING AND INSTALLING FLYWHEEL ­ PORSCHE

DOPPELKUPPLUNG (PDK) (EXCEPT CARRERA "EDITION", CARRERA
CABRIOLET "EDITION", CARRERA 4 "EDITION", CARRERA 4
CABRIOLET "EDITION", GT3, GT3 RS)
TOOLS

Designation Type Number Description Â

Torque/torque angle Workshop WE 1440 Â
screw tool equipment

Counter­hold tool Workshop WE 1487 Â Â

equipment
3353 of 5326
 Centering pins Special tool 9321 Â

TECHNICAL VALUES

Location Description Type Basic value Tolerance 1 Tolerance 2

Flywheel to Internal serration Initial tightening 25 Nm (19 Â Â
crankshaft screw, M10 x 1 x ftlb.)
29, micro­self­
locking ­ replace
screws
Flywheel to Internal serration Torque angle 120°  Â
crankshaft screw, M10 x 1 x
29, micro­self­
locking ­ replace
screws

PRELIMINARY WORK

1. Remove transmission.

→ 373419 REMOVING AND INSTALLING PORSCHE DOPPELKUPPLUNG (PDK) .

REMOVING FLYWHEEL

NOTE: Removing and installing flywheel

Leaks
Risk of damage to the flywheel and adjacent components

→ Be very careful during removal and installation.

→ Get another person to help because of the weight.

Installation position of flywheel for PDK transmission ­1­ with ten fastening screws ­2­ :

3354 of 5326
Fig. 102: Identifying Flywheel Threaded Joint For Porsche Doppelkupplung (PDK)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Counter­hold tool WE 1487 ­1­ must be screwed to the ring gear on the engine flange.
1.1. To do this, secure the tool through the lower left bore in the flange using a screw and M10 nut
­2­ .

3355 of 5326
 Fig. 103: Identifying Flywheel Counter­Hold Tool
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

Check that the through­bores on the hub of the flywheel are flush with the screw heads.
Screw heads can damage the flywheel when unscrewing them if the bores are not flush.
A damaged flywheel must not be installed!
2. Loosen and unscrew ten screws (multiple­tooth, a/f 12, M10 x 29) on the flywheel. Carefully remove the
flywheel (it is quite heavy ­ so be careful).
2.1. The screws are micro­self­locking and must be replaced!
2.2. Remove adhesive residues from the threaded bores and clean with brake cleaner.

Allow a drying time of at least 10 minutes!

1. Socket­wrench insert for internal serration screws, a/f 12

Fig. 104: Loosening Flywheel Screws

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

Check the diaphragm spring on the flywheel for mechanical damage before installing it.
A damaged flywheel must not be installed!
3. Check diaphragm spring ­1­ on the flywheel for damage.

There must be no dents or damage!

3.1. The flywheel must be replaced if the diaphragm spring is damaged ­arrow­ .

3356 of 5326
 Fig. 105: Locating Flywheel Diaphragm Spring
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

INSTALLING FLYWHEEL

1. Check that the through­bores on the hub of the flywheel are flush with the screw heads.

WARNING: Caustic fluids

Danger of chemical burns

→ Avoid contact with caustic fluid.

→ Wear personal protective gear.

→ Ensure that there is good ventilation.

→ If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if
necessary.

2. Remove protective wax on new parts with acetone or solvent naphtha.

3. Fit two centering pins 9321 ­1­ with M10 thread on the crankshaft flange by screwing them in by one to
two turns only (caution: fine thread!).

Recommendation: Screw in one centering pin next to the dowel pin.

3357 of 5326
 Fig. 106: Identifying Crankshaft Flange Centering Pins
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

Before re­installing the flywheel, clean the friction surface of the flywheel using a clean, lint­free cloth
soaked in acetone or solvent naphtha).

Information

Check the diaphragm spring on the flywheel for mechanical damage before installing it.
A damaged flywheel must not be installed!
4. Fit flywheel ­1­ over the centering pins ­2­ at the dowel pin on the crankshaft and push it onto the
crankshaft flange.
4.1. Fit ten new screws and tighten uniformly in diagonally opposite sequence.

3358 of 5326
 Fig. 107: Identifying Crankshaft Flange Flywheel
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Tighten screws uniformly and in diagonally opposite sequence to the prescribed tightening torque.

Tool recommendation: Torque/torque angle screw tool WE 1440 .

Initial tightening 25 Nm (19 ftlb.)

Torque angle 120°

1. Initial tightening to the specified toque

2. Final tightening torque angle

3359 of 5326
 Fig. 108: Display ­ Adjusting Special Tool Screen
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

SUBSEQUENT WORK

1. Install transmission.

→ INSTALLING PORSCHE DOPPELKUPPLUNG (PDK) .

WM 137319 REMOVING AND INSTALLING BELT TENSIONER (EXCEPT

CARRERA "EDITION", CARRERA CABRIOLET "EDITION", CARRERA 4
"EDITION", CARRERA 4 CABRIOLET "EDITION", GT3, GT3 RS)
TECHNICAL VALUES

Location Description Type Basic value Tolerance 1 Tolerance 2

Belt tensioner to Internal Torx, M8 Tightening 28 Nm (21 +/­3 Nm (+/­2 Â
coolant pump x 60 torque ftlb.) ftlb.)
bracket, top
Belt tensioner to Internal Torx, M8 Tightening 28 Nm (21 +/­3 Nm (+/­2 Â
coolant pump x 26 torque ftlb.) ftlb.)
bracket, bottom
Tensioner to Internal Torx, M8 Tightening 23 Nm (17 Â Â
tensioning roller x 33 torque ftlb.)
carrier

PRELIMINARY WORK

1. Loosen drive belt.

→ 137801 CHECKING DRIVE BELT.

3360 of 5326
REMOVING BELT TENSIONER

Installation position of drive belt and belt tensioner:

Fig. 109: Identifying Belt Tensioner Position

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Unscrew fastening screw at the bottom ­arrow­ of the tensioner.

3361 of 5326
 Fig. 110: Locating Belt Tensioner Lower Screw
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Unscrew fastening screw at the top ­arrow­ of the belt tensioner.

Fig. 111: Locating Belt Tensioner Upper Screw

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Lift the belt tensioner up and off.

INSTALLING BELT TENSIONER

Replacing Tensioner/Damper Element

1. Clamp belt tensioner in a vice at the hexagon.

Use protective jaws!

2. Unscrew fastening screw ­arrow­ on the lever.

3362 of 5326
 Fig. 112: Locating Damper/Tensioner
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

When fitting the damper element/tensioner, make sure that the lettering can be read from outside.
The bellows must be facing upwards.
3. Fit new tensioner on the holder with the deflection roller and check installation position.
3.1. Tighten M8 screw.

Tightening torque 23 Nm (17 ftlb.)

Installing Belt Tensioner

1. Position the belt tensioner from above and secure with the fastening screw ­arrow­ .

Tightening torque 28 Nm (21 ftlb.) +/­3 Nm (+/­2 ftlb.)

3363 of 5326
 Fig. 113: Locating Belt Tensioner Upper Screw
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Tighten fastening screw at the bottom ­arrow­ of the tensioner.

Tightening torque 28 Nm (21 ftlb.) +/­3 Nm (+/­2 ftlb.)

3364 of 5326
 Fig. 114: Locating Belt Tensioner Lower Screw
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

SUBSEQUENT WORK

1. Secure the drive belt.

→ 137801 CHECKING DRIVE BELT.

WM 137455 REPLACING CRANKSHAFT SEALING RING (ON BELT SIDE)

(EXCEPT CARRERA "EDITION", CARRERA CABRIOLET "EDITION",
CARRERA 4 "EDITION", CARRERA 4 CABRIOLET "EDITION", GT3, GT3
RS)
TOOLS

Designation Type Number Description Â

assembly aid Special tool 9774 Â

slide hammer kit Commercially Nr.168 Â

available tool

3365 of 5326
 impact puller Commercially Nr.168­1 Â
available tool

TECHNICAL VALUES

Location Description Type Basic value Tolerance 1 Tolerance 2

Crankshaft Installation Dimension 2.7 mm +/­0.3 mm Â
flange sealing position of
ring on belt side sealing ring to
flange surface

PRELIMINARY WORK

1. Remove front silencer. → 262519 REMOVING AND INSTALLING FRONT SILENCER .

2. Remove vibration damper. → 137519 REMOVING AND INSTALLING VIBRATION DAMPER.

REMOVAL
Removing Crankshaft Sealing Ring

NOTE: Drilling work on crankshaft sealing ring

Risk of engine damage caused by drilling chips

Risk of damage to the crankcase
Do not apply pressure while drilling

→ Carefully remove drill chips

→ Drill carefully

1. Spot­drill the crankshaft sealing ring ­1­ at two opposite positions ­arrows­ using a greased drill bit (ø 2
­ 2.5 mm) and carefully remove chips.
1.1. An electric screwdriver ­2­ or a small drill can be used to drill the holes.

3366 of 5326
 Fig. 115: Drilling Sealing Ring
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Pull out sealing ring.

2.1. Screw the extractor tip of the tool impact puller Nr.168­1 ­1­ into the bore holes alternately
and pull the sealing ring out evenly.

3367 of 5326
 Fig. 116: Pulling Out Sealing Ring
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2.2. Alternatively, screw two tapping screws into the bore holes.
2.3. Pull out sealing ring alternately using slide hammer kit Nr.168 at the tapping screw.

CAUTION: The crankshaft flange can be damaged if not cleaned correctly.

Leaks

→ Never use an abrasive or polishing cloth or brushes with metal bristles.

→ Follow cleaning instructions.

WARNING: Caustic fluids

Danger of chemical burns

→ Avoid contact with caustic fluid.

→ Wear personal protective gear.

→ Ensure that there is good ventilation.

→ If you do come into contact, wash off immediately with plenty of warm water and contact a
doctor if necessary.

3. Clean the flange.

3.1. Carefully clean the flange ­1­ and crankcase bore using a clean, lint­free cloth soaked in
solvent naphtha or acetone.

3368 of 5326
 Fig. 117: Identifying Crankshaft Flange
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

CAUTION: The crankshaft flange can be damaged if not cleaned correctly.

Leaks

→ Never use an abrasive or polishing cloth or brushes with metal bristles.

→ Follow cleaning instructions.

4. Check crankshaft flange and crankcase bore for damage.

4.1. Remove traces of corrosion on the flange with a metal­polishing pad (Nevr Dull has been
approved, available in car and motor bike accessory stores).
4.2. Then, carefully clean the flange using a clean, lint­free cloth that has been soaked in solvent
naphtha or acetone.
4.3. Leave to dry off for at least three minutes to ensure that the vapors of the cleaning agent do not
attack the new sealing ring (sealing lip).

INSTALLATION
Installing Crankshaft Sealing Ring

NOTE: Incorrect tool

Risk of damage to components

→ Use prescribed tool.

Tool overview:

3369 of 5326
 1. Assembly sleeve of special tool assembly aid 9774
2. Insertion part of special tool assembly aid 9774
3. PTFE sealing ring with support ring for crankshaft flange on belt side

Fig. 118: Overview Of Special Tool

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

WARNING: Caustic fluids

Danger of chemical burns

→ Avoid contact with caustic fluid.

→ Wear personal protective gear.

→ Ensure that there is good ventilation.

→ If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if
necessary.

1. Small burred spots or damaged areas on the tools can be removed with a nail file; then whet with an
oilstone, fine abrasive or polishing cloth.
1.1. Remove residual dirt on the tools using solvent naphtha or acetone.

CAUTION: Damage to the sealing lip.

Leaks

→ The crankshaft flange and tools must be perfectly clean and free of grease.

→ The sealing ring must be fitted dry, i.e. no oil, grease or other lubricants can be used.
3370 of 5326
 → The crankcase bore must not be oiled.

→ The sealing ring can only be positioned on the assembly tool using the supporting sleeve.

→ The new crankshaft sealing ring (PTFE) is supplied on a supporting sleeve as a spare part.

→ Do not remove the sealing ring from the supporting sleeve.

2. Position sealing ring ­2­ dry on the insertion part ­1­ . When doing so, only press on the support ring ­3­ .
2.1. Do not use lubricants.

Fig. 119: Identifying Sealing Ring

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Fit sealing ring ­1­ with insertion part ­3­ on crankshaft flange.
3.1. Screw tool onto the crankshaft flange by hand with the two cheese head bolts ­2­ .

3371 of 5326
 Fig. 120: Identifying Crankshaft Flange Sealing Ring With Insertion Part
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Assembly aid 9774 ­1­ with sealing ring must be fitted on the insertion part.
4.1. To do this, place the hexagon­head bolt for the assembly sleeve onto the thread of the insertion
part.

3372 of 5326
 Fig. 121: Identifying Crankshaft Flange Assembly Aid 9774
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Pull in sealing ring.

5.1. Assembly aid 9774 must then be turned slowly clockwise as far as it will go using the ratchet
­1­ .
5.2. Leave the tool fitted for two minutes to allow the sealing lip to settle into position.

3373 of 5326
 Fig. 122: Pulling Sealing Ring
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

6. Remove assembly aid.

6.1. Undo the hexagon­head bolt and take off the assembly sleeve.
6.2. Unscrew two cheese head bolts on the insertion part and remove the component with the
support ring.
6.3. Leave supporting sleeve on the tool after installing to protect the edges of the tool.
7. Check that the sealing ring is seated correctly and straight using calliper gauge.
7.1. To do this, measure at four points 90° apart from the crankshaft flange surface to the sealing
ring (flat surface).

→ Dimension: 2.7 mm+/­0.3 mm

SUBSEQUENT WORK

1. Install vibration damper. → INSTALLING VIBRATION DAMPER .

2. Install front silencer. → INSTALLING FRONT SILENCER .

WM 137519 REMOVING AND INSTALLING VIBRATION DAMPER (EXCEPT

CARRERA "EDITION", CARRERA CABRIOLET "EDITION", CARRERA 4
"EDITION", CARRERA 4 CABRIOLET "EDITION", GT3, GT3 RS)
TOOLS

Designation Type Number Description Â

locating pins Special tool 9595/1 Â

3374 of 5326
 electronic torque Special tool 9768 Â
wrench, 2­100
Nm/1.5­74 ftlb.

turning device Special tool 9773 Â

TECHNICAL VALUES

Location Description Type Basic value Tolerance 1 Tolerance 2

Heat shield to Hexagon­head Tightening 10 Nm (7.5 Â Â
engine carrier bolt, M6 x 16 torque ftlb.)
Engine carrier to M10 x 135 Tightening 60 Nm (44 Â Â
crankcase ­ bolt torque ftlb.)

PRELIMINARY WORK

1. Remove rear spoiler. → 665819 REMOVING AND INSTALLING REAR SPOILER .

2. Remove air cleaner. → 242519 REMOVING AND INSTALLING AIR CLEANER HOUSING .
3. Slacken the drive belt. → 137819 REMOVING AND INSTALLING DRIVE BELT.
4. Remove front silencer. → 262519 REMOVING AND INSTALLING FRONT SILENCER .

REMOVAL
Removing Vibration Damper

1. Remove heat shield on the engine carrier.

1.1. Unscrew three external Torx screws (M6 x 12) and remove heat shield.
2. Position vibration damper ­1­ for removal.
2.1. Turn the vibration damper clockwise using special tool turning device 9773 ­3­ until one
staking bore is flush with the bore in the crankcase.
2.2. Stake the vibration damper using one of the locating pins 9595/1 ­4­ .

3375 of 5326
 Fig. 123: Turning Vibration Damper
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Unscrew fastening screw ­10­ and remove dowel sleeve ­11­ .

3376 of 5326
 Fig. 124: Overview Of Engine Carrier
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Remove vibration damper.

4.1. Unscrew six external Torx screws (M8 x 1 x 25) ­2­ and carefully guide the vibration damper
out through the engine carrier.
4.2. Check the vibration damper and dowel pin for damage (e.g. cracks, deformation) and replace
components if necessary.
4.3. Replace screws.

INSTALLATION
Installing Vibration Damper

Information

Replace screws for vibration damper.

The screw thread and crankshaft flange thread must not be greased.
Clean the thread on the crankshaft flange to remove grease.

1. Position vibration damper on the crankshaft flange. Check the position of the dowel pin.
2. Fit six new external Torx screws (M8 x 1 x 25) and tighten uniformly in diagonally opposite sequence.
3. Fix vibration damper ­1­ in place with locating pin 9595/1 ­4­ .

3377 of 5326
 3.1. Pre­tighten screws uniformly in diagonally opposite sequence according to tightening
specifications.
3.2. Final tightening using special tool electronic torque wrench, 2­100 Nm/1.5­74 ftlb. 9768 .

Fig. 125: Installing Vibration Damper

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Position dowel sleeve ­11­ and tighten fastening screw ­10 ­ . Tightening torque 60 Nm (44 ftlb.)

3378 of 5326
 Fig. 126: Overview Of Engine Carrier
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Install heat shield on the engine carrier.

5.1. Position heat shield and screw in and tighten three external Torx screws (M6 x 12).

Tightening torque 10 Nm (7.5 ftlb.)

SUBSEQUENT WORK

1. Install front silencer. → INSTALLING FRONT SILENCER .

2. Fit drive belt. → INSTALLING DRIVE BELT .
3. Install air cleaner. → INSTALLING AIR CLEANER HOUSING .
4. Install rear spoiler. → INSTALLING REAR SPOILER .

1. Install rear silencer. → INSTALLING REAR SILENCER .

2. Install pressure pipe. → INSTALLING PRESSURE PIPE .
3. Fit drive belt. → INSTALLING DRIVE BELT .
4. Install air cleaner. → INSTALLING AIR CLEANER HOUSING .
5. Install rear spoiler. → INSTALLING REAR SPOILER .

WM 137619 REMOVING AND INSTALLING PULLEY (GT3, GT3 RS)

TOOLS
3379 of 5326
 Designation Type Number Description Â
locating pins Special tool 9595/1 Â

Electronic torque Special tool 9768 Â

wrench, 2 ­ 100 Nm
(1.5 ­ 74 ftlb.)

turning device Special tool 9773 Â

TECHNICAL VALUES

Location Description Type Basic value Tolerance 1 Tolerance 2

Pulley to Fastening screws Initial tightening 10 Nm (7.5 Â Â
crankshaft ftlb.)
Pulley to Fastening screws Final tightening 90°  Â
crankshaft

PRELIMINARY WORK

1. Remove air cleaner. → 242519 REMOVING AND INSTALLING AIR CLEANER HOUSING .
2. Relieve drive belt. → 137819 REMOVING AND INSTALLING DRIVE BELT.

REMOVING PULLEY

1. Position pulley ­1­ for removal.

1.1. Turn the pulley clockwise using special tool turning device 9773 ­3­ until one staking bore is
flush with the bore in the crankcase.
1.2. Stake the pulley using one of the locating pins 9595/1 ­4­ .

3380 of 5326
 Fig. 127: Positioning Pulley For Removal
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Remove pulley ­1­ .

2.1. Unscrew fastening screws ­2­ .
2.2. Guide the pulley ­2­ out through the engine carrier.
2.3. Check the pulley ­1­ and dowel pin for damage and replace them if necessary.
2.4. Replace fastening screws ­2­ .

3381 of 5326
 Fig. 128: Removing Pulley
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

INSTALLING PULLEY

Information

Replace fastening screws for pulley.

The screw thread and crankshaft flange thread must not be greased.
Clean the thread on the crankshaft flange to remove grease.

1. Fit pulley on the crankshaft flange.

1.1. Check the position of the dowel pin.
2. Install pulley ­1­ .
2.1. Fit new fastening screws ­2­ in diagonally opposite sequence.
2.2. Fix pulley ­1­ in place with locating pin 9595/1 ­4­ .
2.3. Pre­tighten fastening screws ­2­ to the specified tightening torque in diagonally opposite
sequence. → Initial tightening: 10 Nm (7.5 ftlb.)
2.4. Perform final tightening using special tool Electronic torque wrench, 2 ­ 100 Nm (1.5 ­ 74
ftlb.) 9768 → Final tightening: 90°

3382 of 5326
 Fig. 129: Installing Pulley
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Locating pin 9595/1 can now be removed.

SUBSEQUENT WORK

1. Fit drive belt. → INSTALLING DRIVE BELT .

2. Install air cleaner. → INSTALLING AIR CLEANER HOUSING .

WM 137719 REMOVING AND INSTALLING CONSOLE WITH DEFLECTION

ROLLER (EXCEPT CARRERA "EDITION", CARRERA CABRIOLET
"EDITION", TURBO S, CARRERA 4 "EDITION", TURBO CABRIO, TURBO S
CABRIO, CARRERA 4 CABRIOLET "EDITION")
PRELIMINARY WORK

1. Release drive belt.

→ 137819 REMOVING AND INSTALLING DRIVE BELT.

REMOVING CONSOLE
Console With Deflection Roller

Console with deflection roller:

3383 of 5326
Fig. 130: Overview Of Console Parts
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Deflection roller console

2. Deflection roller
3. External Torx screws on unit carrier (M8)
4. External Torx screw on crankcase (M6)

1. Remove ­1­ console.

1.1. Unscrew three fastening screws ­2 and 3­ .
1.2. Remove console.

3384 of 5326
 Fig. 131: Locating Deflection Roller Console And Fasteners
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

INSTALLING CONSOLE
Installing Console With Deflection Roller

1. Install ­1­ console.

1.1. Fit two fastening screws (M8) ­2­ .
1.2. Fit and tighten one M6 fastening screw ­3­ .
1.3. Tighten M8 fastening screws.

3385 of 5326
 Fig. 132: Identifying Deflection Roller Console Installation Position
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

SUBSEQUENT WORK

1. Fit and tension the drive belt.

→ INSTALLING DRIVE BELT .

WM 137801 CHECKING DRIVE BELT (EXCEPT CARRERA "EDITION",

CARRERA CABRIOLET "EDITION", CARRERA 4 "EDITION", CARRERA 4
CABRIOLET "EDITION", GT3, GT3 RS)
PRELIMINARY WORK

1. Remove rear spoiler. → 665819 REMOVING AND INSTALLING REAR SPOILER

2. Remove air cleaner. → 242519 REMOVING AND INSTALLING AIR CLEANER HOUSING

CHECKING DRIVE BELT

Information

Mark running direction of drive belt with a colored pen.

Even minor damage means that the drive belt must be replaced (even if the maintenance interval has not
expired).
If the drive belt has to be replaced (change interval), it can be cut to facilitate removal.

Drive belt routing:

3386 of 5326
Fig. 133: Drive Belt Routing Diagram (Engine Removed)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Drive belt
2. Generator pulley
3. PDCC pump pulley/deflection roller
4. Air­conditioning compressor pulley
5. Crankshaft vibration balancer
6. Coolant pump pulley
7. Belt tensioner tensioning roller

WARNING: Do not remove the drive belt when it is warm!

Risk of damage or deformation!

→ Only remove the drive belt when it is cold.

1. Slacken the drive belt.

3387 of 5326
 Fig. 134: Slackening Drive Belt Tension
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1.1. Fit a ring wrench (a/f 30) ­2­ on the hexagon on the tensioner ­3­ , turn it clockwise as far as it
will go and hold it at that position.
1.2. Remove the drive belt ­1­ from the pulley on the generator.
1.3. Carefully allow the tensioning roller to slide back to its original position.

Information

The drive belt can be checked when installed (slackened).

Always check the running surface carefully on both sides.
Check the belt by pulling it through slowly.
2. Pull the drive belt through slowly and check the running tracks carefully on both sides.
2.1. If you find the slightest damage, the belt must be replaced.

→ 137819 REMOVING AND INSTALLING DRIVE BELT.

Information

Check for foreign objects in the grooves of the pulley.

3. Check the pulleys for damage and foreign bodies in the running grooves.
3.1. Replace damaged components if necessary.

3388 of 5326
 4. If no damage is found, place the drive belt on the pulleys in the marked running direction.
4.1. Turn the tensioning roller clockwise as far as it will go, fit the belt and let the tensioning roller
slide back into tensioning position.
4.2. Check that the belt is fitted correctly.

SUBSEQUENT WORK

1. Install air cleaner. → INSTALLING AIR CLEANER HOUSING .

2. Install rear spoiler. → INSTALLING REAR SPOILER .

WM 137819 REMOVING AND INSTALLING DRIVE BELT (EXCEPT

CARRERA "EDITION", CARRERA CABRIOLET "EDITION", CARRERA 4
"EDITION", CARRERA 4 CABRIOLET "EDITION", GT3, GT3 RS)
PRELIMINARY WORK

1. Remove rear spoiler. → 665819 REMOVING AND INSTALLING REAR SPOILER

2. Remove air cleaner. → 242519 REMOVING AND INSTALLING AIR CLEANER HOUSING

REMOVING DRIVE BELT

Drive belt routing:

3389 of 5326
Fig. 135: Drive Belt Routing Diagram (Engine Removed)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Drive belt
2. Generator pulley
3. PDCC pump pulley/deflection roller
4. Air­conditioning compressor pulley
5. Crankshaft vibration balancer
6. Coolant pump pulley
7. Belt tensioner tensioning roller

1. Slacken the drive belt.

WARNING: Do not remove the drive belt when it is warm!

Risk of damage or deformation!

→ Only remove the drive belt when it is cold.

Information

Mark running direction of drive belt with a colored pen.

Even minor damage means that the drive belt must be replaced (even if the maintenance interval
has not expired).
If the drive belt has to be replaced (change interval), it can be cut to facilitate removal.
1.1. Fit a ring wrench (a/f 30) ­2­ on the hexagon on the tensioner ­3­ , turn it clockwise as far as it
will go and hold it at that position.
1.2. Remove the drive belt ­1­ from the pulley on the generator.
1.3. Carefully allow the tensioning roller to slide back to its original position.

3390 of 5326
 Fig. 136: Removing Tension From Drive Belt
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Remove special screw (M10 x 130) ­1­ through the bore on the rear­end carrier.

3391 of 5326
 Fig. 137: Identifying Engine Carrier And Spacer Sleeve Screw
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2.1. Pull spacer sleeve ­2­ up to the right and remove it. Press the engine carrier back slightly if
necessary.
3. Slide the drive belt (flat side) up past the coolant pump pulley ­arrow­ .

3392 of 5326
 Fig. 138: Locating Drive Belt On Coolant Pump Pulley
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Turn the drive belt ­1­ 90 degrees, guide the flat side past the vibration balancer and remove it.

Fig. 139: Identifying Vibration Balancer Drive Belt

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Check pulleys for damage.

Information

Check for foreign objects in the grooves of the pulley.

INSTALLING DRIVE BELT

1. Guide the drive belt with the flat side ­1­ first past the vibration balancer ­2­ .

If you intend to reuse the old belt, make sure to observe the running direction marked earlier.

3393 of 5326
 Fig. 140: Identifying Vibration Balancer And Drive Belt
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1.1. Position the belt on the running track on the vibration balancer.

Fig. 141: Identifying Drive Belt

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Guide the drive belt ­1­ to the left past the coolant pump pulley.
3394 of 5326
 2.1. Then guide the flat side of the belt through between the pulley and engine carrier ­arrow­ .

Fig. 142: Locating Coolant Pump Pulley And Drive Belt

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. Fit the drive belt on the pulleys for the air­conditioning compressor ­4­ , PDCC pump (or deflection
roller) ­3­ and generator ­2­ .
3.1. Then, pre­position it on the tensioning roller.

Drive belt routing:

3395 of 5326
 Fig. 143: Drive Belt Routing Diagram (Engine Removed)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Drive belt
2. Generator pulley
3. PDCC pump pulley/deflection roller
4. Air­conditioning compressor pulley
5. Crankshaft vibration balancer
6. Coolant pump pulley
7. Belt tensioner tensioning roller
4. Relieve the tensioner and slide the drive belt over the tensioning roller ­1­ .
4.1. Fit an open­ended wrench (a/f 30) ­2­ on the hexagon on the tensioner ­3­ and turn it clockwise
as far as it will go.
4.2. Fit drive belt on the tensioning roller and let the tensioner slide slowly back into tensioning
position (anti­clockwise).

3396 of 5326
 Fig. 144: Installing Drive Belt
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

5. Check that the drive belt is fitted correctly.

SUBSEQUENT WORK

1. → 242519 REMOVING AND INSTALLING AIR CLEANER HOUSING

2. → 665819 REMOVING AND INSTALLING REAR SPOILER

WM 138219 REMOVING AND INSTALLING TENSIONING ROLLER FOR

DRIVE BELT (EXCEPT CARRERA "EDITION", CARRERA CABRIOLET
"EDITION", CARRERA 4 "EDITION", CARRERA 4 CABRIOLET "EDITION",
GT3, GT3 RS)
TOOLS

Designation Type Number Description Â

Insert for torque Special tool 9792 Â
wrench

3397 of 5326
 Torque wrench Commercially Nr.90 Pos.3 Â
available tool

TECHNICAL VALUES

Location Description Type Basic value Tolerance 1 Tolerance 2

Tensioning roller Internal Torx Tightening 23 Nm (17 Â Â
to tensioning screw M8 x 25 torque ftlb.)
lever

PRELIMINARY WORK

1. Remove rear spoiler.

→ 665819 REMOVING AND INSTALLING REAR SPOILER .

2. Remove tail lights.

→ 943119 REMOVING AND INSTALLING TAIL LIGHT .

3. Remove air cleaner housing.

→ 242519 REMOVING AND INSTALLING AIR CLEANER HOUSING .

REMOVING TENSIONING ROLLER

1. Release drive belt.

→ 137819 REMOVING AND INSTALLING DRIVE BELT.

2. Loosen protection cap ­1­ using a small screwdriver ­2­ and remove it ­arrow­ .

3398 of 5326
 Fig. 145: Pulling Protection Cap On Tensioning Roller
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

3. The following tools are recommended for removal and installation.

Tensioning roller tools:

1. Torque wrench Nr.90 Pos.3

2. Ratchet head from tool box Insert for torque wrench 9792
3. Internal Torx bit T50 with width across flats 8 mm

3399 of 5326
 Fig. 146: Identifying Tensioning Roller Tools
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

4. Remove tensioning roller ­2­ .

4.1. Loosen internal Torx screw ­1­ using the specified tool, unscrew screw and remove tensioning
roller.

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 Fig. 147: Identifying Tensioning Roller Screw
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

INSTALLING TENSIONING ROLLER

1. Fit tensioning roller with screw.

1.1. Tighten the screw using the specified tool.

→ Tightening torque: 23 Nm (17 ftlb.)

2. Fit protection cap.

3. Fit and tension the drive belt.

→ INSTALLING DRIVE BELT .

SUBSEQUENT WORK

1. Install air cleaner housing.

→ INSTALLING AIR CLEANER HOUSING .

2. Install tail lights.

→ INSTALLING TAIL LIGHT .

3. Install rear spoiler

→ INSTALLING REAR SPOILER .

WM 138419 REMOVING AND INSTALLING COVER FOR DRIVE BELT

(EXCEPT CARRERA "EDITION", CARRERA CABRIOLET "EDITION",

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CARRERA 4 "EDITION", CARRERA 4 CABRIOLET "EDITION", GT3, GT3
RS)
TECHNICAL VALUES

Location Description Type Basic value Tolerance 1 Tolerance 2

Cover on drive External Torx Tightening 10 Nm (7.5 Â Â
belt screw, M6 x 16 torque ftlb.)
(5x)

PRELIMINARY WORK

1. Remove air cleaner housing.

→ 242519 REMOVING AND INSTALLING AIR CLEANER HOUSING .

REMOVING COVER FOR DRIVE BELT

1. Unscrew screws ­3­ on both covers ­1 and 2­ and remove the covers.

Fig. 148: Identifying Drive Belt Covers And Fasteners

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

INSTALLING COVER FOR DRIVE BELT

1. Fit covers ­1 and 2­ and secure with the screws.

Tightening torque 10 Nm (7.5 ftlb.)

3402 of 5326
 Fig. 149: Identifying Drive Belt Covers And Fasteners
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

SUBSEQUENT WORK

1. Install air cleaner housing.

→ INSTALLING AIR CLEANER HOUSING .

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Article GUID: A00704546

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