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ASSEMBLING THE ENGINE

ASSEMBLING THE ENGINE

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Step 19. Valve timing tool

Fit the valve timing tool (6) to 

the left hand side of the engine. 

There are two pins at one end 

that fit into the holes in the 

sprocket beneath the 

crankshaft, and three at the 

other end that fit into holes in 

the camshaft sprocket.

Step 20. Cam belt – left side

Remove the timing alignment 

pin as shown (but do not 

remove the one in the lower 

sprocket). Place one of the 

cam timing belts in position 

over the cam and drive 

sprockets. Install the idler 

pulley (37), making sure the 

cam belt goes up and 

over this.

Step 17. Timing pin

In order to accurately set the valve and ignition 

timing, the crankshaft must be locked into 

position. Note that the pistons in cylinders 

1 and 4 must be at Top Dead 

Centre (TDC). Insert a timing 

alignment pin (77) through the 

holes in the crankcase and 

crankshaft counterweight.

Insert the metal shaft for the 

cam chain sprocket into the 

crankcase.

Step 18. Crankshaft sprocket

Slide the crankshaft gear B (75) on to the end 

of the crankshaft. Note that there is a slot in the 

inside surface of the sprocket that engages 

with a rib on the crankshaft.

Fit the crankshaft sprocket A 

(10) to the metal shaft. Note 

that the shaft has a flat surface 

on one side that matches a flat 

surface on the inside of the 

sprocket. IMPORTANT! There 

is a hole on one side of the 

sprocket through which the 

second timing alignment pin 

(77) must be inserted to fit into 

a hole in the crankcase. This 

ensures that the sprocket is 

correctly aligned. You may 

need to reposition the sprocket 

to allow the pin to be inserted.

Содержание PE01

Страница 1: ...classic Porsche 911 flat six engine model Mehr Franzis Produkte im Internet www franzis de Designed by John Anson for FRANZIS Verlag GmbH D 85540 Haar bei Munchen Germany Item number PE01 Trends UK L...

Страница 2: ...or otherwise without prior permission in writing from the publisher Printed in China Please retain the information in this manual for future reference This device complies with Part 15 of the FCC Rule...

Страница 3: ...mber with a small smooth and heat absorbing surface Initial versions of the engine used Solex overflow type carburettors and although these had the benefit of being relatively insensitive to forces ca...

Страница 4: ...unnel right outer 1 63 Cam belt tunnel middle 1 67 Drive gear 1 68 Crankshaft gear 1 69 Distributor gear 1 Cam timing belt 2 72 Spark plug lead mounting clip 1 74 Distributor bushing 1 75 Crankshaft g...

Страница 5: ...PARTS LIST PARTS LIST 8 9...

Страница 6: ...PARTS LIST PARTS LIST 10 11...

Страница 7: ...25 Crankshaft pulley 34 Fan housing 42 Cooling fan 47 Crankcase upper 48 Crankcase lower 49 Cylinder barrels 37 Idler pulley 37 mm shaft 41 Crankshaft 26 Fan pulley 27 Oil return pipes 50 51 Cylinder...

Страница 8: ...pin 13 through the small end of a connecting rod 1 Push two halves of a piston 2 together over the pin and press together firmly Repeat for the other five piston rod assemblies Step 2 Crankshaft The...

Страница 9: ...ankcase 48 to the upper crankcase and secure with seven screws Step 4 Crankshaft assembly Place the upper crankcase 47 upside down on a table Hold the piston crankshaft assembly and lower it on to the...

Страница 10: ...ft cylinder head 50 Step 8 Valve guides Fit two valve guide plates to each of the lower cylinder heads Note that each head uses one narrow plate 55 and one wide plate 54 Each plate has three round stu...

Страница 11: ...tep 12 Camshaft tunnel right rear Attach the rear part of the right hand camshaft tunnel 60 to the crankcase and secure with two screws Step 13 Cam and rocker shafts right side Assemble the camshaft f...

Страница 12: ...cker shaft assemblies for the inlet and exhaust valves on to the cylinder head refer to the inset picture for guidance Use your fingers to separate the rockers so that each sits between the bearings t...

Страница 13: ...position Note that the pistons in cylinders 1 and 4 must be at Top Dead Centre TDC Insert a timing alignment pin 77 through the holes in the crankcase and crankshaft counterweight Insert the metal sha...

Страница 14: ...sprocket Fit the cam belt tunnel cover 61 and secure with three screws Step 22 Distributor drive gears Install the distributor drive bevel gears Fit the smaller crankshaft gear C 76 first it has a slo...

Страница 15: ...ight hand cam belt cover in position and secure with three screws Step 26 Distributor Fit the distributor bush 74 to the end of the shaft and secure with a screw One end of the bush has a recess for t...

Страница 16: ...o parts Assemble the upper 23 and lower 24 halves of the right exhaust and secure with one screw Fit the assembled exhaust to the manifold and secure with three screws Repeat for the left hand side us...

Страница 17: ...e the battery cover Step 33 Exhaust muffler Assemble the two halves of the exhaust muffler 19 20 and secure with four screws Slide the muffler over the ends of the exhaust pipes The muffler is secured...

Страница 18: ...5 and 6 so they are routed neatly over the cooling fan Step 37 Cooling fan assembly Assemble the cooling fan components as shown Attach the rear cover 78 to the fan housing 34 first and secure with t...

Страница 19: ...includes various different components connected together whose job it is to drive the car s wheels making the car move Now let s look at how the engine works in more detail We ll look at just one cyli...

Страница 20: ...of the compression stroke 4 stroke cycle Inlet valve open Valves closed Piston rises compressing fuel air mixture Exhaust valve closed Inlet port Piston moves down sucking in fuel air mixture Connect...

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