Carrera 4Engine Crankcase Suspension

Location

Thread

Tightening torque Nm (ftlb)

Blower

Restraining strap

8(6)

Alternator pulley (Carrera RS)

50 + 5 (37 ± 3) 40 (29.5)

Pulley half / impeller

M 6

9.7 (7)

Fan wheel for alternator cooling

14 ± 1 (10)

Exhaust system

Heat exchanger cylinder head

23(17)

Heat exchanger - primary muffler or catalytic converter

23(17)

Primary muffler / catalytic converter - intermediate muffler (spherical clip)

25- 30(18 -22)

Intermediate muffler -final muffler (spherical clip)

25 - 30 (18 - 22)

Restraining strap to intermediate muffler

14(10)

Lambda probe to catalytic converter

M 18 x 1.5

50 - 60 (37 - 44)

Screw plug on catalytic converter

M 8 x 1

15(11)

Belt monitor

Bracket to crankcase

M 6

15-20(11 -15)

Belt monitor bracket

M 6

9.7 (7)

Fuel system

Cap nut on the fuel distribution line

M 12 x 1.5

12(9)

Tank sensor

30

Location

Thread

Tightening Torque Nm (ftlb)

Clutch -

two-mass-flywheel

Two-mass flywheel to crankshaft

M 10 x 1.25x70

85 (62)

Primary flywheel to cover plate

M 7x34

22 (16)

Primary flywheel to secondary flywheel

M 8x21

35 (26)

Pressure plate

M 8x40

23 (17)

911 Carrera 4 Enginge, Crankcase, Suspension

No.

Description

Special Tool

Order number

Remarks

1

Engine mounting plate

9111/3

000.721.911.13

2

Adapter for engine mounting plate

9111/1

000.721.911.11

3

Support plate

9111/2

000.721.911.12

Crow's foot wrench

9501

000.721.950.10

36 mm A/F

Carrera Transmission Install

88/502

88-500

Removing and installing the engine

The engine/transmission assembly is removed complete from below.

Removing

1. Raise the vehicle at the jacking points.

Note:

Adjust the right-hand rear jacking point in such a way that the transmission guard can be removed later.

2. Disconnect the battery ground cable.

3. Disconnect the plug for the differential lock control/pump assembly (in the area of the luggage compartment lock panel).

4. Disconnect the plugs (5) from the intake distributor and remove the cable clip from the air-flow sensor.

88/502

5. Remove the hot-air blower

Illustration shows engine removed 88/288

6. Disconnect the following plug connections/ lines on the left-hand side of the engine department

88-500

1 - To the carbon canister

2 - To the reference mark sensor

3 - To the knock sensor

4 - To temperature sensor II (cylinder 3)

5 - Fuel return line*

6 - Plug connection - cruise control

7 - Plug connection - Lambda probe

* To prevent fuel running out if the fuel tank is full, join the disconnected line to Special Tool 9507 connection line, order No. 000 721 950 70 and pinch the connection line with a standard hose clamp.

7. Remove the cover from the engine electrics board. Pull off both multiple connectors.

8. Pull off both ignition cables 4 and the plugs from the dual ignition distributor.

9. Pull off the plug from the pulley control unit.

10. Disconnect the vent line.

88/503

11. For vehicles with air-conditioner, disassemble the compressor from the console and, with lines still connected, laid it on the adequately protected left-hand rear fender.

12. Remove the air filter cover with filter insert.

13. Disconnect the fuel supply line to the fuel filter, while bracing. Catch the escaping fuel.

14. Empty the reservoir for the power steering pump. Draw-off fluid.

a. Undo the hose clip and pull off the upper line, catch any oil.

b. Release the lower line and remove with bracket, catch any oil.

88/462

15. Remove the rear wheel.

88/503

Note

The cover can also be pushed out from below.

Illustration shows section without console.

122-03

88/511

Carrera 4 Table Of Contents Carrera 2 Addendum Main Menu

10 Engine, Crankcase, Suspension 911 Carrera 4

16. Undo the upper fastening screw for the central pipe - transmission; for this, remove the rear tray from the transmission tunnel console. Remove the layer of PVC and take off the cover.

Note

The cover can also be pushed out from below.

Illustration shows section without console.

Note

If an engine is being overhauled, also drain the engine oil from the crankcase.

122-03

88/511

17. Disconnect the throttle operating cable from the reverse-transfer lever of the foot controls, and remove the spherical head.

18. Remove engine, transmission and central pipe guard.

19. Drain engine oil from the thermostat housing.

911 Carrera 4 Engine, Crankcase, Suspension

20. Undo the oil line in the rear right-hand wheel house with Special Tool 9501, bracing under all circumstances. Remove the retaining clip for the line from the wheel house. Block the line.

Engine Block Head Crankcase
88/501

21. Disconnect the drive shaft at the flange from the differential. Left-hand side: remove the profiled sheet beforehand.

22. Detach the heater lines from the heat exchanger.

23. Disconnect the ground strap between body and starter from the lower starter fastening point.

24. Disconnect cable terminal 30 from the starter.

25. Detach the clutch slave cylinder and, with line still attached, lay aside.

26. Remove stabilizer.

88/458

27. Pull the rubber sleeve forwards over the shift rod coupling and undo the body-fit screw.

28. Undo both Allen screws for the clamping sleeve and slide the sleeve forwards along the central shaft.

88/535

29. Pull the throttle operating cable out of the guide tube in the floor group.

Cable Side Pull Both Hands Exercise

Sketch of the self-made tool

88/514

148-10

Carrera 4 Table Of Contents Carrera 2 Addendum Main Menu

10 Engine, Crankcase, Suspension 911 Carrera 4

Sketch of the self-made tool

88/514

32. Undo the Allen screw from the slave cylinder for the interaxle differential lock and pull out the lock. Do not undo the line.

148-10

33. Unclip the connecting line at the transmission and suspend both cylinders on one side with the lines still connected.

34. Undo the oil hose from the oil line in the rear right-hand wheel house and block the oil line.

30. Mount a self-made flat steel tool. (To support the central tube when disconnecting the flange).

156-10

31. Undo the fastening nuts from the slave cylinder for the wheel-to-wheel differential lock. Do not undo the line.

146/03

911 Carrera 4 Engine, Crankcase, Suspension

35. Undo the bracket for the engine guard, remove it and retighten the hexagon nuts or hexagon screws. (Contact surface for the engine mounting plate)

147-10

37. Undo the lower fastening screws from the central transmission pipe flange.

38. Undo the transmission cross members (6 screws).

39. Remove the cap from the engine mount assembly hole in the rear engine cover panel and undo the hexagon nuts from the engine bearings from below.

88/509

40. Lower the engine/transmission assembly until the central tube makes contact with the self-made flat steel tool.

Pull off the multiple connector from the airflow sensor.

41. Pull the engine/transmission assembly slightly to the rear and lower carefully.

Note:

Pay attention to the drive shafts and slave cylinder.

147-10

36. Position the jack with engine mounting plate under the vehicle with a certain amount of preload. Make sure that the adapter is in the right position. (Engine/transmission horizontal)

88/533

Carrera 4 Table Of Contents Carrera 2 Addendum

10 Engine, Crankcase, Suspension

Engine/transmission assembly, separating and joining

Separating:

1. Disconnect the cable from the starter and the cable from the switch for the backup lamp.

2. Undo the hexagon head screw. Remove the bracket and cap. Pull out the clutch release shaft with hexagon head screw M 6 x 40.

3. Undo 4 fastening nuts and separate the transmission from the engine. Undo the upper fastening nut on the starter with Special Tool P119.

Olista Longtime
88-513

Joining Note:

Lubricate all sliding surfaces of the clutch release mechanism and the gear teeth of the drive shaft with Olista Longtime 3 EP.

1. Guide the clutch release fork in the release bearing and fix in the installation position provisionally with suitable adhesive tape.

Olista LongtimeOlista Longtime

911 Carrera 4 Engine, Crankcase, Suspension

2. Flange-mount the transmission to the engine.

3. Guide the clutch release shaft with sealing rings into the release fork.

4. Remove the adhesive tape through the assembly hole.

5. Install needle bearing, cap and bracket and secure with fastening screw (M 6 x 16).

Note:

Pack the cap with grease. Also refer to notes on installation in Volume 3, Group 30,

Tightening torques: removing and installing the engine/transmission assembly

Location

Thread

Tightening torque Nm (ftlb)

Engine mount to engine bearing

M

12

85

(62)

Transmission mount to body

M

12

46

(34)

Central tube to transmission

M

12

85

(52)

Twin clamping sleeve to the central shaft

75

(65)

Shift rod (body-fit screw)

23

(17)

Drive shaft to transmission flange

42

(31)

Stabilizer to stabilizer mount

M

10

46

(34)

Oil drain plug in thermostat housing

60

(44)

Oil drain plug in crankcase

70

(51)

Oil line to oil filter housing

80

The following points must be observed during installation.

1. Do not pinch the heating lines, slide on to the heat exchanger shortly before the engine/transmission assembly has reached the correct Installation position.

2. Make sure that the inner rubber seal of the connector is seated correctly.

911 Carrera 4 Engine, Crankshaft, Pistons

Disassembling and Assembling Crankcase Engine Holder

Engine Crank Disassembly

No.

Description

Special Tool

Order Number

Remarks

1

Engine holder

P 201

000.721.201.00

Old version with three or

four arms should no

longer be used in the in

terest of safety. Mount

engine holder on right

crankcase section (cyl.

4 ... 6). Use spacers.

2

Toothed element and

P 201 b

000.721.201.20

mounting parts

0 0

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