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INTRODUCTION

...................................................2

NOTES AND ADVICE

............................................6

PARTS LIST

.........................................................7

ASSEMBLING THE ENGINE

...............................15

Step 1. Pistons.....................................................15
Step 2. Crankshaft................................................15
Step 3. Crankshaft drive gear................................15
Step 4. Crankshaft assembly ................................16
Step 5. Cylinder barrels........................................16
Step 6. Crankcase rear .........................................17
Step 7. Crankcase assembly.................................17
Step 8. Valve guides ............................................18
Step 9. Valve assembly........................................18
Step 10. Oil cooler...............................................19
Step 11. Cylinder head – right side ......................19
Step 12. Camshaft tunnel – right rear ...................20
Step 13. Cam and rocker shafts – right side .........20
Step 14. Camshaft assembly – right side..............21
Step 15. Rocker shaft assembly – right side .........22
Step 16. Cylinder head – left side ........................23
Step 17. Timing pin .............................................24
Step 18. Crankshaft sprocket................................24
Step 19. Valve timing tool ....................................25
Step 20. Cam belt – left side................................25
Step 21. Cam belt cover – left side ......................26
Step 22. Distributor drive gears............................26

Step 23. Cam drive sprocket – right side..............27
Step 24. Cam belt – right side..............................27
Step 25. Cam belt cover – right side ....................28
Step 26. Distributor..............................................28
Step 27. Engine front ...........................................29
Step 28 Crankshaft pulley wheel...........................29
Step 29. Drive motor............................................30
Step 30. Cylinder head covers..............................30
Step 31. Exhaust manifolds ..................................31
Step 32. Exhaust pipes.........................................31
Step 33. Exhaust muffler ......................................32
Step 34. Base - battery installation.......................34
Step 35. Base label..............................................35
Step 36. Base ......................................................36
Step 37. Cooling fan assembly.............................34
Step 38. Cooling fan installation...........................34
Step 39. Spark plugs............................................35
Step 40. Carburettors ...........................................36
Step 41. Operation...............................................36

HOW AN ENGINE WORKS

.................................37

PE01 Porsche Flat-Six Boxer Engine

© Franzis

All rights reserved. No part of this 
publication may be reproduced, stored in a 
retrieval system or transmitted, in any form 
or by any means, electronic, mechanical, 
photocopying, recording 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 Rules. Operation is subject to 
the following two conditions:
(1)  this device may not cause harmful interference
(2)  this device must accept any interference received, 
 

including interference that may cause undesired operation.

Caution: Changes or modifications not expressly approved by the party responsible 
for compliance could void the user’s authority to operate the equipment.

Note: This equipment has been tested and found to comply with the limits for a Class 
B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to 
provide reasonable protection against harmful interference in a residential 
installation. This equipment generates, uses and can radiate radio frequency energy 
and, if not installed and used in accordance with the instructions, may cause harmful 
interference to radio communications. However, there is no guarantee that 
interference will not occur in a particular installation. If this equipment does cause 
harmful interference to radio or television reception, which can be determined by 
turning the equipment off and on, the user is encouraged to try to correct the 
interference by one or more of the following measures:
-   Reorient or relocate the receiving antenna.
-   Increase the separation between the equipment and receiver.
-   Connect the equipment into an outlet on a circuit different from that to which    
 

the receiver is connected.

-   Consult the dealer or an experienced radio/TV technician for help.

3

2

Flat-Six Boxer Engine

Build your own working, classic Porsche 911 flat-six engine model!

Contents

PORSCHE 911

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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