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PORSCHE 911 ENGINE ASSEMBLY GUIDE INSTALL

Place two sealing O-rings (A) in oil pump. ' Porsche special tool P222 can be used to support the left timing chain during crankcase assembly.

Porsche special tool P221 can be used to support the left side connecting rods during crankcase assembly.

Slowly turn crankshaft back and forth to check for binding or interference.

Check that nose bearing (A) is correctly seated in case.

Make sure right side connecting rods for cylinders 4,5, and 6 are pointing down.

^ Place crankshaft assembly into right crankcase half.

PORSCHE 911 ENGINE ASSEMBLY GUIDE INSTALL

Lubricate nose bearing and install on crankshaft. Draw a line (B) on each side of bearing to use as a reference when installing crankshaft assembly. ^ Without nose bearing outer sealing O-ring in place, lay crankshaft nose bearing in crankcase so that it locks into locating pin (A). Install crankshaft nose bearing locating pin in crankcase half.

^ Lubricate crankshaft main bearing shells with engine oil and install in crankcase halves. Place new locking tabs (arrows) on oil pump mounting studs and install and torque nuts. Lower complete intermediate shaft assembly into right crankcase half, guiding front timing chain (arrow) through opening in case. The intermediate shaft is hollow and should be cleaned out whenever the engine is being reconditioned and in case of engine bearing failure.See 130 Crankcase and Crankshaft for checking and replacing. If the intermediate shaft gear is worn or damaged, the replacement gear must be matched to the crankcase and crankshaft drive gear. ' Check intermediate shaft gear for wear prior to installation. Install oil pump drive shaft with oil pump to intermediate shaft. ^ Place both timing chains on intermediate shaft sprockets. Lubricate oil pump gears with engine assembling lubricant. ^ Place oil pump sealing O-rings (arrows) in right crankcase half. ^ Install intermediate shaft bearing shells in crankcase halves.ĭue to the high loads the timing chains put on the intermediate shaft, it is recommended that the intermediate shaft bearings be replaced during engine overhaul. Install and tighten oil drain plug using new sealing ring. Mount right side crankcase half on engine stand. Install new connecting rod nuts on all rod bolts. Matching numbers on side of connecting rod and rod cap should all be facing same side of engine (i.e., all numbers face exhaust side of engine). ^ Install connecting rods on crankshaft in their original locations. With shoulder on gear facing in (arrow), slide drive gear fully onto crankshaft.Mount crankshaft to Porsche special tool P 209 or equivalent and clamp tool with crankshaft in shop vise. If gear is worn or damaged, replacement gear must be matched to crankcase and to gear on intermediate shaft. Install distributor drive gear with marks on face of gear facing pulley end of crankshaft.Ĭrankshaft reconditioning information is given in 130 Crank-case and Crankshaft.Ĭheck crankshaft drive gear for wear prior to installation. Use protective gloves or shop rag when handling the hot gear. Install connecting rod bearing shells in connecting rods. Install new connecting rod bolts in each connecting rod. Select circlip to best obtain near zero clearance.Circlip used to hold gears in place on crankshaft comes in different thicknesses.

Install gear retaining circlip to crankshaft. Drive gear (for distributor) mark 0 or 1) Install distributor drive gear to crankshaft.ģ. ♦ Camshaft cases, camshafts and camshaft timing chains, installing The assembly procedure is divided into subsections, as follows: Cylinder position will be referred to during the assembly process. See 130 Crankshaft and Crankcase.Ĭylinder numbering is shown in illustration. ♦ If either the crankcase, the crankshaft drive gear or the intermediate shaft drive gear are replaced, special installation instructions apply. Always check with an authorized Porsche parts department for the latest in parts information. ♦ Various head studs have been used on the Carrera 911 engines. Refer to 130 Crankcase and Crankshaft and 170 Engine Lubrication.

If the engine is disassembled because of bearing failure, a thorough flushing of the lubrication system must be carried out prior to reassembly.

If the engine failed mechanically, it is important to check the intake system for foreign objects.

Use suitable engine assembling lubricant during assembly. All machine work should be completed and all new replacement parts should be on hand. All parts must be clean and ready for reassembly at this point.