Dismantling and assembling intermediate shaft

Hunger Thrust Bearings

330/13

NO.

Designation

Removal

Installation

1

Connecting shaft

1

check for smooth running

2

Snap ring 13x1

2

3

Snap ring 36 x 1.75

2

4

Chain sprocket

2

press off, check teeth. Chain sprockets available as spare parts

heat on heater plate, press on to stop, observe installation position

5

Woodruff key

2

6

Intermediate shaft

1

matched with crankshaft gear, fit both parts as a unit

7

Snap ring 16x1

1

8

Plug, aluminium

1

remove in case of bearing damage

9

Thrust bearing

2

10

Bearing

2

911 Carrera 4 Engine, Crankshaft, Pistons

Measuring and repairing the crankcase Tools

No.

Description

Special Tools

Remarks

1

Guide rod for reamer 35 x 1500 mm

comm. avail, (supplied by Hunger)

2

Tap wrench size 4

comm. avail, (supplied by Hunger)

3

Main bearing reamers

comm. avail, (supplied by Hunger)

4

End bearing bushings EL 35

comm. avail, (supplied by Hunger)

5

Internal measuring device with measuring ring dia. 65.000 mm

commercially available

6

Wrench, 58 A/F

comm. avail, (supplied by Hunger)

7

Guide for support of guide rod

comm. avail, (supplied by Hunger)

Measuring and repairing the crankcase General

Whenever the crankcase is dismantled in the course of rebuilding the engine, measure the main bearing bores.

Measuring

1. Attach crankcase to engine support P 201 using mounting hardware P 201 b and assemble both housing sections.

Lightly tighten all through bolts and four M 8 fastening nuts at bearing 1 (flywheel side) and at bearing 8 (pulley side).

2. Applying light blows with a plastic mallet, align both crankcase sections. The gap at bearing bore 8 must not show any offset whatsoever.

Use an internal measuring device to measure bearing bore 8 diagonally and align to max. 0.02 mm.

931-13

4. Measure all 8 main bearing bores using an internal measuring device.

If the bearing bores are too narrow, use a standard reamer to ream bores to standard dia. 65.00.

Specified size for bearing bores 1 to 8 is 65.000 mm to 65.019 mm.

5. If the bearing bores are too large, use a roughing or finishing reamer, respectively, to ream to 65.25 mm oversize dia.

The checking dimension for B bearings is 65.25 mm dia. to 65.269 mm dia.

Reworking and reaming General

Reaming of the light-alloy Silumin crankcase for B bearings is done in two steps. When reaming the bearings, always grease the reamer using white spirits.

1 st step = roughing reamer 65.20 mm dia. 2nd step = finishing reamer 65.25 mm dia.

931-13

3. Tighten all through bolts and 4 additional hexagon nuts (M 8) at bearing 1 and bearing 8 to specified torque.

911 Carrera 4 Engine, Crankshaft, Pistons

Reaming

1. Fit shop-made tool to crankcase and tighten in a vise.

932-13

2. Place end bearing bushing EL 35 in bearing bore 1.

3. Place end bearing bushing EL 35 in bearing bore 8 and align using the guide rod.

4. Now attach and align both guides for support of the guide rod.

Note

When tightening the guides, make sure the guide rod does not bind, i.e. the guide rod must be checked for free rotation during the whole tightening process.

932-13

2. Place end bearing bushing EL 35 in bearing bore 1.

3. Place end bearing bushing EL 35 in bearing bore 8 and align using the guide rod.

933-13

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5. Remove end bearing bushings after tightening and aligning, respectively.

6. Insert guide rod complete with reamer into bearing 8 and ream all bearing bores slowly and steadily.

Note

Have an assistant apply liberal amounts of white spirits for greasing while the bearing bores are reamed to the correct size.

936-13
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