PET. Illustration Pos Part Number Description Remark Qty Model jack operating rod tool bag 1

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1 Model : tool and accessories tool jack operating rod tool bag spark plug wrench - 0 A ring wrench 36 MM - - tyre pressure gauge L rim wrench crank narrow v-belt tool bag contents tool and accessories A tool bag contents comprising: tool bag spark plug wrench rim wrench double-end spanner X double-end spanner 0 X double-end spanner X double-end spanner 7 X ring wrench screwdriver et_text.frm Page: 00 KAT 7

2 Model : phillips screwdriver B universal pliers 70 MM long narrow v-belt tyre pressure gauge - MESKO - bag - N 00 ball seat nut ball seat nut A bag 5 fuse tool and accessories CARRERA tool bag contents comprising: tool bag rim wrench double-end spanner X double-end spanner 0 X double-end spanner X double-end spanner 7 X screwdriver phillips screwdriver B universal pliers narrow v-belt et_text.frm Page: 00 KAT 7

3 Model : tyre pressure gauge - MESKO - bag - N 00 ball seat nut ball seat nut A ring wrench allen key retaining bracket v-belt socket wrench socket wrench spark plug wrench comprising: ratchet spanner 3/" extension " ball joint articulated piece double socket wrench bag 5 fuse jack socket wrench 7 et_text.frm Page: 003 KAT 7

4 Model : accessories box bulbs 6 VOLT luggage rack belt belt luggage rack belt suitcase mount - PCG vehicle cover porsche crest X, A Coupe et_text.frm Page: 00 KAT 7

5 : badge sticker PCG badge X PCG badge X 3 PCG badge X PCG badge X 5 PCG badge X 6 PCG badge X decal label X PCG sticker X 9 PCG sticker X 0 PCG sticker X PCG sticker X PCG badge X 3 PCG badge X PCG badge X 5 PCG badge X 6 PCG sticker X 7 PCG sticker X et_bt.frm Page: 00 KAT 7

6 : crankcase M >> 0 99 M >> 70 M >> M >> 999 M >> M >> crankcase VW 0 0 cylinder 0 MM crankcase cylinder 7,5 MM S 300 A S crankcase crankcase 500 S hexagon-head bolt tensioning device /S magnet stud cylinder head nut cylinder head nut washer 6 copper cap nut 6 (9) gasket cylinder $ 73,5 MM ABIL gasket cylinder $ 0 MM copper gasket /S et_bt.frm Page: 00 KAT 7

7 : crankcase M 00 >> M 50 0 >> M >> M 00 >> M >> M 0 00 >> crankcase housing cover bearing and studs M 00 >> 9 M 50 0 >> 50 6 M >> M 00 >> 5 M >> M 0 00 >> crankcase housing cover bearing and studs M >> 6 97 M 0 >> crankcase housing cover bearing and studs M 6 9 >> M 70 >> crankcase housing cover bearing and studs M >> M 3 5 >> S S S S S S S S S et_bt.frm Page: 00 KAT 7

8 : stud BM X 5 cover camshaft hexagon-head bolt M X cover camshaft stud hexagon-head bolt tensioning device crankcase hexagon-head bolt tensioning device crankcase o-ring washer $ 0 copper cap nut stud mount transmission 0 N hexagon-head bolt M X spring washer 0 B hexagon nut 0 M drain plug () sealing ring oil duct crankcase rubber seal oil duct crankcase rubber seal oil duct (6) guide tube 7 MM crankcase (6) guide tube oil level dipstick 5 MM crankcase sealing ring guide tube crankcase guide tube oil level dipstick 5 MM crankcase straight pin stud stud stud crankcase screw socket LL 6 M radial shaft seal DG 60 X 0 X 0/ dowel sleeve straight pin oil tube oil tube stud et_bt.frm Page: 00 KAT 7

9 : N washer 0 6, spring washer 0 B 6 - N washer 0 6, hexagon nut 0 M oil drain lid oil drain lid filter element rivet 5 X gasket oil strainer (36) 66 0 gasket crankcase gasket crankcase oil tube crankcase stopper crankcase lid not available when required order also: crankcase (39) lid spring washer B hexagon nut M stud shaft seal DG X 65 X 0/ gasket crankcase cover crankcase gasket spring washer B hexagon-head bolt M X bracket screw bearing spring washer B (5) stud fuel pump crankcase stud fuel pump crankcase stud distributor crankcase (53) stud distributor crankcase stud BM X spring washer B hexagon nut M et_bt.frm Page: 003 KAT 7

10 : crankcase M >> crankcase stud sealing ring 6 A 0 X 6 X copper cap nut hexagon-head bolt M X hexagon-head bolt 6 M X 60 7 N hexagon-head bolt M X hexagon-head bolt M X stud M X straight pin N 0 spring washer 3 B hexagon nut stud M X straight pin 3 3 H X housing straight pin 3 H X tab washer stud M X stud M X stud M X 0 CARRERA 500 GS/GT et_bt.frm Page: 00 KAT 7

11 : stud stud 57 0 stud threaded bush stopper stopper stopper straight pin nozzle I nozzle II nipple oil pressure switch (30) screw plug M X,5 3 N 03 9 sealing ring A X copper sealing ring sealing ring aluminium A X X, drain plug oil strainer strainer /L strainer /R 3 N hexagon-head bolt 3 M 6 X washer 3 6, X X, lock ring 3 B hexagon nut M piston relief valve spring relief valve screw plug relief valve bush o-ring bleeder hexagon-head bolt M 6 X 5 9 N washer 6, lock ring B hexagon nut M cap et_bt.frm Page: 00 KAT 7

12 : crankcase crankcase picture NR. NR.+6,+, crankcase picture NR. NR.+6,+,5-7 () crankcase picture NR.-5 () crankcase picture NR stud sealing ring A 0 X 6 copper cap nut hexagon-head bolt M X hexagon-head bolt 6 M X 60 7 N hexagon-head bolt M X stud M X stud M X 50 housing cover stud M X straight pin spring washer B CARRERA 600 GS/GT 69/0 69///3 69/0 69///3 et_bt.frm Page: 00 KAT 7

13 : hexagon nut stud M X straight pin 3 3 H X housing straight pin 3 H X tab washer stud M X stud M X stud M X stud 69///3 M X stud stud 57 0 stud threaded bush stud M X 5 housing distributor driving mechanism straight pin 6 H X 0 oil pump stopper X stopper stopper stopper 69/ stopper 69/// straight pin X nozzle I nozzle II screw plug M X,5 3 N 03 9 sealing ring A X copper sealing ring sealing ring A X X,5 aluminium drain plug oil strainer oil drain lid crankcase gasket oil drain lid and oil strainer stud M 6 X oil drain lid strainer /L strainer /R 3 N hexagon-head bolt 3 M 6 X washer 3 6, lock ring 3 B hexagon nut M 6 3 et_bt.frm Page: 00 KAT 7

14 : piston relief valve spring relief valve $ X spring relief valve $, X spring relief valve $,5 X 6,5 69/0 69///3 69/// screw plug relief valve bush o-ring bleeder 69/ bleeder 69// filler tube 69/// bleeder 69/0// pot retaining bracket bleeder 69/0// cap bleeder bore stud BM 6 X 55 cap cap nut M 6 cap sealing ring A 6 X 0 cap nut 69//3 69//3 69//3 69// breather pipe 69// lock ring A 5 breather pipe - - hexagon nut M 5 breather pipe hexagon-head bolt M 6 X 9 N washer 6, spring washer B hexagon nut M cap cover plate bleeding 3 69//3 3 69//3 et_bt.frm Page: 003 KAT 7

15 : crankshaft M >> 0 99 M >> 70 M >> M >> 999 M >> M >> () crankshaft flywheel ready installation crankshaft flywheel () crankshaft flywheel ready installation () crankshaft flywheel > flywheel roller 6 X gasket connecting rod bush thrust washer crankshaft X drive wheel distributor circlip crankshaft pulley $ 6 MM (6) 0 0 pulley $70,5 MM banjo bolt bush S 300 A S 369/ /506 57/5 57/ /56/ banjo bolt 56 et_bt.frm Page: 00 KAT 7

16 : (9) banjo bolt sealing ring () crankshaft flywheel () crankshaft ready installation connecting rod bearing shell tab washer connecting rod nut connecting rod bush 56 et_bt.frm Page: 00 KAT 7

17 : crankshaft M 00 >> M 50 0 >> M >> M 00 >> M >> M 0 00 >> crankshaft flywheel and connecting rod ready installation crankshaft roller 6 X radial sealing ring crankshaft thrust washer 0,0 MM () thrust washer 0,5 MM () thrust washer 0,90 MM () thrust washer 0,95 MM () thrust washer,00 MM () thrust washer,05 MM sealing ring crankshaft gasket 6 > flywheel banjo bolt banjo bolt sealing ring banjo bolt S S S et_bt.frm Page: 00 KAT 7

18 : lock washer woodruff key timing gear 3 N spring pulley timing gear intermediate ring drive pinion circlip sealing washer X pulley spring washer fastening screw bearing shell () bearing shell undersize inner 0,5 MM X () bearing shell undersize inner 0,50 MM () bearing shell undersize inner 0,75 MM connecting rod out bearing shell connecting rod bush connecting rod nut pinion thrust washer spring X X set of crankshaft bearings comprising: bearing sleeve I bearing shell II bearing sleeve III bearing sleeve IV (9) set of crankshaft bearings undersize inner 0,5 MM comprising: (30) bearing sleeve I undersize 0,5 MM (3) bearing shell II undersize 0,5 MM (3) bearing sleeve III undersize 0,5 MM (33) bearing sleeve IV undersize 0,5 MM (9) set of crankshaft bearings oversize outer 0,5 MM comprising: (30) bearing sleeve I oversize 0,5 MM (3) bearing shell II oversize 0,5 MM et_bt.frm Page: 00 KAT 7

19 : (3) bearing sleeve III oversize 0,5 MM (33) bearing sleeve IV (9) set of crankshaft bearings oversize outer 0,5 MM undersize inner 0,5 MM comprising: (30) bearing sleeve I (3) bearing shell II (3) bearing sleeve III (33) bearing sleeve undersize inner 0,5 MM outer standard dimension (9) set of crankshaft bearings oversize 0,5 MM undersize inner 0,50 MM comprising: (30) bearing sleeve I (3) bearing shell II (3) bearing sleeve III (33) bearing sleeve IV undersize inner 0,50 MM outer standard dimension et_bt.frm Page: 003 KAT 7

20 : crankshaft M >> crankshaft flywheel flywheel banjo bolt banjo bolt banjo bolt sealing ring cover plate feather key A X 5 X feather key A X 5 X connecting rod bush radial shaft seal -S spacer X,00 MM spacer X,05 MM spacer X,0 MM spacer X,5 MM spacer X,0 MM spacer X,5 MM spacer X,30 MM deep-groove ball bearing intermediate ring CARRERA 500 GS/GT et_bt.frm Page: 00 KAT 7

21 : intermediate ring - timing gear see group /03/5 * lock washer hexagon-head bolt 5 PCG radial sealing ring v-belt pulley washer spring washer fastening screw et_bt.frm Page: 00 KAT 7

22 : crankshaft crankshaft connecting rod and flywheel crankshaft connecting rod and flywheel crankshaft flywheel and stopper crankshaft out flywheel stopper CARRERA 600 GS/GT 69/0 69///3 69///3 69/// flywheel 69/ flywheel 69/// connecting rod 69/// connecting rod bolt 69/// connecting-rod bearing 69/// tensioner 3 69/// bush 69/// banjo bolt 69/ banjo bolt 69/// banjo bolt 69/ banjo bolt 69/ bearing sleeve I 69///3 et_bt.frm Page: 00 KAT 7

23 : bearing sleeve II bearing sleeve III woodruff key X sealing ring banjo bolt 69///3 69///3 69///3 69/ cover plate 69/ feather key 69/0 A X 5 X feather key A X 5 X connecting rod bush 69/ connecting rod bush 69///3 7 PCG radial sealing ring 69/0 "S" radial shaft seal 69///3 "S" spacer X 69/0,00 MM spacer X 69/0,05 MM spacer X 69/0,0 MM spacer X 69/0,5 MM spacer X 69/0,0 MM spacer X 69/0,5 MM spacer X 69/0,30 MM deep-groove ball bearing 69/ intermediate ring 69/ spring washer 69/0 - timing gear see group /03/ lock washer 69/ lock washer 69/// hexagon-head bolt 5 PCG radial sealing ring "K" v-belt pulley fastening screw 69/ fastening screw v-belt pulley 69/// spring washer B pan-head screw hexagon socket head bolt M 6 X 0 et_bt.frm Page: 00 KAT 7

24 : cylinder head cylinder piston M >> 0 99 M >> 70 M >> M >> 999 M >> M >> cylinder head valves ready installation 73,5 MM mount 3 pin cylinder head valves ready installation 73,5 MM mount pin cylinder head valves ready installation 0 MM cylinder head valves ready installation cylinder head valves ready installation intake exhaust 0 MM cylinder head valves ready installation intake exhaust 0 MM cylinder head out valves 73,5 MM mount 3 pin S 300 A S /56/ /56 57/5 369 et_bt.frm Page: 00 KAT 7

25 : cylinder head out valves 73,5MM mount pin cylinder head out valves 0 MM cylinder head 0 MM cylinder head intake exhaust 0 MM cylinder head intake exhaust 0 MM /56/ /56 57/ clamp lid gasket valve cap X MM valve cap X 0 MM valve cap X collet 6 divided concave washer concave washer reincement.0 I valve spring inner valve spring inner reincement 0.75 I valve spring outer valve spring outer reincement.5 I shim guide washer X valve spring intake valve $ MMX 7,5 MM intake valve $ MM X 9, intake valve $ 0 MM X 30,6MM exhaust valve $ MM X,6 MM exhaust valve $ MM X 30,6 MM exhaust valve $ 0 MM X 30,6 MM exhaust valve sticker valve clearance aluminium 5 : 0 X sticker valve clearance steel 0 : sticker valve clearance 0,0 + 0, valve guide exhaust X st oversize old version X X et_bt.frm Page: 00 KAT 7

26 : valve guide intake X st oversize valve guide exhaust X st oversize valve guide exhaust and intake 0 X st oversize piston $ 73,5 MM piston $ 73,5 MM 6 - oil scraper ring A 73,5 X 5AC 7 - piston rings A 73,5 X 3AC piston rings upper B 0 X 3AC piston pin 0 X cylinder $ 0 MM aluminium piston $ 0 MM piston $ 0 MM 30 - oil scraper ring A 0 X 5AC 3 - piston rings B 0 X 3AC 3 - piston rings upper B 0 X 3AC piston pin X circlip - piston rings upper B 73,5 X 3AC piston pin 0 X cylinder $ 73, piston $ piston $ oil scraper ring A 0 X 5AC piston rings B 0 X 3AC et_bt.frm Page: 003 KAT 7

27 : cylinder head cylinder piston M 00 >> M 50 0 >> M >> M 00 >> M >> M 0 00 >> X cylinder head exchange valves ready installation cylinder head out valves valve seat ring intake oversize valve seat ring X valve seat ring exhaust nd oversize X valve guide st oversize intake and exhaust (5+6) valve guide nd oversize intake and exhaust stud BM X exhaust manifold (7) stud intake manifold threaded insert M X,5 X,75 spark plug gasket intake valve S S S 600 /S X X X et_bt.frm Page: 00 KAT 7

28 : exhaust valve collet 6 divided concave washer valve spring shim washer gasket (9) cylinder head nut see classic technical inmation 3/9 (0) cylinder head nut see classic technical inmation 3/9 () cylinder head nut see classic technical inmation 3/ lid cylinder head cover strainer cotter pin ball gasket cork clamp cylinder base gasket copper cylinder piston aluminium $ 7,5 MM cylinder piston aluminium $ 7,5 MM 300 S piston ring upper $ 7,5 MM 300 /S oil scraper ring 300 /S $ 7,5 MM oil scraper ring 300 /S $ 7,5 MM piston pin 300 /S circlip C cylinder piston 600 (37) cylinder piston when required order also: cylinder base gasket X 600 S cylinder $,5 MM piston $,5 MM (39) piston $ 3 MM repair material (39) cylinder piston $,5 MM when required order also: cylinder base gasket (39) piston $ 3 MM (39) piston $ 3,5 MM piston ring groove groove groove 3 $,5 MM 600 /S X 600 S 600 S 600 S 600 et_bt.frm Page: 00 KAT 7

29 : (0) piston ring groove groove groove 3 $ 3 MM (0) piston ring groove groove groove 3 $ 3,5 MM oil scraper ring $,5 MM () oil scraper ring $ 3 MM () oil scraper ring $ 3,5 MM piston pin identification black () piston pin identification white () piston pin oversize identification blue 600 /S 600 S /S 600 S X 600 /S X 600 /S X 600 /S et_bt.frm Page: 003 KAT 7

30 : cylinder head cylinder piston M >> CARRERA 500 GS/GT cylinder head valves cylinder head out valves stud housing M X 57 0 stud housing and valve cover housing camshaft housing camshaft lock housing tab washer housing hexagon nut threaded bush spark plug straight pin 3H X threaded bush threaded bush old version valve seat ring intake oversize valve seat ring exhaust oversize valve guide intake oversize et_bt.frm Page: 00 KAT 7

31 : valve guide exhaust oversize circlip valve guide intake circlip 6 valve guide exhaust stud M X stud M 6 X stud M 6 X stud M X stud M X stud M X 0 old version stud M X 30 S stud M X valve cover intake valve cover exhaust sealing ring A X copper tab washer cap nut 6 M intake valve,5 MM M >> (3) intake valve 9,9 MM M 90 0 >> exhaust valve 7, MM M >> (3) exhaust valve,9 MM M >> washer valve spring outer valve spring inner concave washer valve collet cap,0 MM mounting length 3 MM valid intake valve exhaust valve X (3) cap,5 MM mounting length 3 MM valid intake valve exhaust valve (3) cap 3,0 MM mounting length 3 MM valid intake valve exhaust valve X X et_bt.frm Page: 00 KAT 7

32 : (3) cap 3,5 MM mounting length 3 MM valid intake valve exhaust valve (3) cap,5 MM mounting length 3 MM valid intake valve exhaust valve (3) cap,0 MM mounting length MM valid intake valve exhaust valve (3) cap,5 MM mounting length MM valid intake valve exhaust valve (3) cap 3,0 MM mounting length MM valid intake valve exhaust valve X X X X X (3) cap 3,5 MM mounting length MM valid intake valve exhaust valve (3) cap,5 MM mounting length MM valid intake valve exhaust valve o-ring catch 57 0 sealing rubber stopper 6 rubber gasket I gasket II gasket oval cylinder head nut washer cylinder piston $ 5 MM piston ring I piston ring II oil scraper ring III piston ring IV X X et_bt.frm Page: 003 KAT 7

33 : piston pin circlip cylinder head gasket cylinder head gasket 0, MM crankcase cylinder head gasket 0,5 MM crankcase cylinder head gasket,0 MM crankcase X X X et_bt.frm Page: 00 KAT 7

34 : cylinder head cylinder piston cylinder head out valves picture NR.3-6,9+0,-0, cylinder head out valves picture NR cylinder head valves picture NR stud M X 0 housing 57 0 stud housing and valve cover housing camshaft housing camshaft lock housing tab washer 6 housing hexagon nut threaded bush spark plug straight pin 6 3H X threaded bush CARRERA 600 GS/GT et_bt.frm Page: 00 KAT 7

35 : valve seat ring intake oversize valve seat ring exhaust oversize valve guide intake oversize valve guide exhaust oversize circlip valve guide intake circlip 6 valve guide exhaust stud M X stud M 6 X stud M 6 X stud M X stud M X stud M X 30 new design stud M X valve cover intake valve cover exhaust sealing ring A X copper tab washer cap nut 6 M intake valve 9,9 MM exhaust valve,9 MM washer valve spring outer valve spring inner concave washer valve collet cap,0 MM alternative parts: X cap X,5 MM o-ring catch 57 0 sealing rubber stopper 6 rubber gasket I gasket II gasket oval cylinder head nut washer cylinder piston $ 5 MM 69/0/ et_bt.frm Page: 00 KAT 7

36 : cylinder piston $ 7,5 MM piston ring $ 5 MM piston ring $ 7,5 MM piston ring $ 5 MM bracket ring $ 7,5 MM oil scraper ring $ 5 MM oil scraper ring $ 7,5 MM 69//3 69/0/ 69//3 69/0/ 69// oil slot ring $ 5 MM oil slot ring $ 7,5 MM piston pin circlip 5 PCG cylinder head gasket cylinder head gasket copper crankcase 0, MM X cylinder head gasket aluminium crankcase 0,5 MM cylinder head gasket aluminium crankcase,0 MM 69/0/ 69//3 X X et_bt.frm Page: 003 KAT 7

37 : camshaft M >> 0 99 M >> 70 M >> M >> 999 M >> M >> camshaft - VW camshaft gear wheel wheel wheel aluminium wheel X plastic material valve pushrod M >> 79 M >> X valve pushrod cam follower cam follower ball socket circlip protective tube valve pushrod M 0 >> M >> rocker arm mounting M >> 79 M >> washer rocker shaft M >> 79 M >> S 300 A S et_bt.frm Page: 00 KAT 7

38 : adjusting screw M >> 79 M >> hexagon nut M X rocker arm mounting M 0 >> M >> rocker shaft M 0 >> M >> rocker arm M 0 >> M >> adjusting screw M 0 >> M >> spring rocker arm M 0 >> M >> et_bt.frm Page: 00 KAT 7

39 : camshaft M 00 >> M 50 0 >> M >> M 00 >> M >> M 0 00 >> - camshaft alternative parts: camshaft gear wheel size camshaft gear wheel camshaft gear wheel camshaft gear wheel camshaft gear wheel + () - camshaft alternative parts: camshaft gear wheel camshaft gear wheel S S S X 300/ / / / / /600 X 300 S 600 S 300 S 600 S 300 S 600 S et_bt.frm Page: 00 KAT 7

40 : camshaft gear wheel camshaft gear wheel camshaft gear wheel + - gear wheel alternative parts: gear wheel 0 aluminium gear wheel - aluminium gear wheel - aluminium gear wheel + aluminium gear wheel gear wheel + aluminium 300 S 600 S 300 S S 600 S tab washer hexagon-head bolt 3 M X hexagon-head bolt 3 M X 6 5 N straight pin 3 6 X cam follower 300/600 X (6) cam follower 300 S 600 S valve pushrod cylinder grey cast iron 600/600 S (7) valve pushrod cylinder aluminium PCG protective tube gasket rocker arm bridge rocker shaft long rocker shaft short rocker arm rocker arm long rocker arm short spring thrust washer X 0,50 MM (7) thrust washer X 0,0 MM (7) thrust washer X 0,60 MM N 0 6 circlip 6 X nut M X adjusting screw hexagon-head bolt M 0 X spring washer et_bt.frm Page: 00 KAT 7

41 : driving mechanism valve control M >> CARRERA 500 GS/GT intermediate shaft timing gear filler rod stopper circlip 0 X 5 N 0 73 woodruff key 5 X 6,5 repair kit valve control see group /9/ set comprising: picture 6, set comprising: picture, A bevel pinion A spiral right only together picture A pinion A spiral left only together picture 6 et_bt.frm Page: 00 KAT 7

42 : D bevel pinion D spiral left only together picture D pinion D spiral right only together picture thrust washer gear wheel oil pump washer castle nut N 0 53 cotter pin 3 X bearing sleeve shim X 0,05 MM (6) shim X 0,0 MM (6) shim X 0,0 MM (6) shim X 0,35 MM bearing shell set o-ring bearing shell set stopper flange N spring 3 X 6, shim X 0,05 MM (3) shim X 0,0 MM (3) shim X 0,0 MM (3) exhaust socket X 0,35 MM tab washer hexagon nut 6 - see group /03/30 * et_bt.frm Page: 00 KAT 7

43 : driving mechanism valve control intermediate shaft timing gear CARRERA 600 GS/GT 69/ timing gear 69/ intermediate shaft timing gear /// timing gear 69///3 - PCG 0 00 timing gear 69/// straight pin timing gear 5 M 6 X filler rod wood 69/// stopper circlip 0 X 5 N 0 73 woodruff key 5 X 6, set comprising: picture set comprising: picture thrust washer gear wheel oil pump washer castle nut N 0 53 cotter pin 3 X 5 et_bt.frm Page: 00 KAT 7

44 : bearing sleeve shim 0,05 MM shim 0,0 MM shim 0,0 MM shim 0,35 MM bearing shell set bearing shell set X X X X o-ring bearing shell set bearing shell set stopper flange N spring 3 X 6, shim 0,05 MM shim 0,0 MM shim 0,0 MM exhaust socket 0,35 MM X X X X tab washer hexagon nut 6 - see group /03/3 * et_bt.frm Page: 00 KAT 7

45 : set B comprising: picture,, 3 cylinder and cylinder valve control M >> repair kit valve control see group /9/ set E comprising: picture (), (), (3) cylinder 3 and cylinlder set C comprising: picture 5, 6 cylinder and cylinder set F comprising: picture (5), (6) cylinder 3 and cylinlder B vertical shaft long B spiral left cylinder and cylinder only together picture, 3 CARRERA 500 GS/GT et_bt.frm Page: 00 KAT 7

46 : () E vertical shaft long E spiral right cylinder 3 and cylinlder only together picture (), (3) B bevel pinion B spiral right cylinder and cylinder only together picture, 3 () E bevel pinion E spiral left cylinder 3 and cylinlder only together picture (), (3) B pinion B spiral left cylinder and cylinder only together picture, (3) E pinion E spiral right cylinder 3 and cylinlder only together picture (), () o-ring C vertical shaft short C spiral right cylinder and cylinder only together picture 6 (5) F vertical shaft short F spiral left cylinder 3 and cylinlder only together picture (6) C bevel pinion C spiral left cylinder and cylinder only together picture 5 (6) F bevel pinion F spiral right cylinder 3 and cylinlder only together picture (5) shim 0,05 MM (7) shim 0,0 MM (7) shim 0,0 MM (7) shim 0,35 MM X X X X et_bt.frm Page: 00 KAT 7

47 : flange 6 9 N spring bearing shell bearing shell tab washer hexagon nut o-ring protective tube short protective tube long stopper camshaft exhaust camshaft intake feather key A 6 X X 0 camshaft intake exhaust cylinder and cylinder (0) feather key A 6 X X 6 camshaft intake exhaust cylinder 3 and cylinlder feather key short camshaft intake exhaust cylinder and cylinder () feather key long camshaft intake exhaust cylinder 3 and cylinlder stopper shim X 0,05 MM (3) shim X 0,0 MM (3) shim X 0,0 MM (3) shim X 0,35 MM bearing sleeve spacer filler rod bearing sleeve control cams driver stud driver roll pin,5 X 6 (3) adjusting screw old version adjusting screw valve lever valve lever spring spring washer B hexagon nut M 6 et_bt.frm Page: 003 KAT 7

48 : retaining bar et_bt.frm Page: 00 KAT 7

49 : valve control vertical shaft long set B comprising: picture -3 cylinder and cylinder () vertical shaft long set E comprising: picture -3 cylinder 3 and cylinlder o-ring vertical shaft short set C comprising: picture 5+6 cylinder and cylinder (5) vertical shaft short set F comprising: picture 5+6 cylinder 3 and cylinlder shim 0,05 MM shim 0,0 MM shim 0,0 MM X X X CARRERA 600 GS/GT et_bt.frm Page: 00 KAT 7

50 : shim X 0,35 MM flange 6 9 N spring 6 3 X 6, bearing shell bearing shell bearing shell bearing shell tab washer hexagon nut o-ring protective tube short protective tube long stopper camshaft exhaust camshaft intake feather key A 6 X X 0 camshaft intake exhaust cylinder and cylinder (0) feather key long camshaft intake exhaust cylinder 3 and cylinlder feather key short camshaft intake exhaust cylinder and cylinder () feather key long camshaft intake exhaust cylinder 3 and cylinlder stopper shim X 0,05 MM shim X 0,0 MM shim X 0,0 MM shim X 0,35 MM bearing sleeve spacer filler rod bearing sleeve control cams driver stud driver roll pin,5 X adjusting screw valve lever et_bt.frm Page: 00 KAT 7

51 : valve lever spring spring washer B hexagon nut M bracket bracket et_bt.frm Page: 003 KAT 7

52 : engine lubrication M >> M >> oil cooler sealing ring spring washer A hexagon nut oil filter gasket insert - sealing ring 9 - hexagon-head bolt restraining strap hexagon-head bolt M X support oil filter hexagon-head bolt M 6 X N spring washer B washer hexagon nut M screw socket LL hose distributing piece 0 N sealing ring 3 A 0 X banjo bolt screw socket LL 6 M 300 /S S et_bt.frm Page: 00 KAT 7

53 : sealing ring X LL union nut X ALL hose piston relief valve spring relief valve sealing ring C 6 X screw plug sealing ring A X 0 X, sender oil temperature electric oil pump housing roller housing roller drive shaft oil pump gear gasket gasket lid lid sealing ring thrust washer X 0, MM () thrust washer 0,6 MM X () thrust washer X 0,5 MM pinion sealing ring A 0 X CU pressure screw hexagon-head bolt M spring washer B guide tube oil level dipstick 5 MM () guide tube oil level dipstick 75 MM sealing ring oil level dipstick 35 MM (50) oil level dipstick 5 MM bleeder bleeder 5 connection piece tab spring sealing ring bleeder connection piece sealing ring sealing ring hexagon-head bolt M 6 X 5 55 N washer 6, 5 et_bt.frm Page: 00 KAT 7

54 : hexagon nut M washer et_bt.frm Page: 003 KAT 7

55 : engine lubrication M >> M 0 >> oil cooler A sealing ring sealing ring spring washer 3 B6 - N washer 6, hexagon nut 3 M piston relief valve spring relief valve spring relief valve sealing ring 3 C X () sealing ring C X M >> 6 97 M 0 >> screw plug (9) screw plug M 6 9 >> M 70 >> bleeder sealing ring sealing ring hexagon-head bolt M 6 X spring washer B S S S et_bt.frm Page: 00 KAT 7

56 : hexagon nut M guide tube oil level dipstick oil filter gasket insert sealing ring A X CU - FRAM - () sealing ring A 6 X CU - HENGST support oil filter hexagon-head bolt M 6 X washer spring washer B hexagon nut M restraining strap hexagon-head bolt M X screw socket LL 6 M union nut 3 ALL sealing ring 3 LL screw socket LL 6 M hose hose screw socket sealing ring A X CU 37 N sealing ring A 0 X 6 CU M >> 6 97 M 0 >> 707 (37) N sealing ring A 0 X 6 CU M 6 9 >> M 70 >> washer M 6 9 >> M 70 >> distributing piece intermediate piece banjo bolt M >> 6 97 M 0 >> 707 () banjo bolt M 6 9 >> M 70 >> N 03 9 sealing ring A X 0 CU sender oil temperature electric oil pressure switch roller drive shaft oil pump gear lid 9 N pin 3 M 6 X pinion thrust washer 0, MM X S S S S S et_bt.frm Page: 00 KAT 7

57 : (5) thrust washer 0,6 MM (5) thrust washer 0,5 MM sealing ring A 0 X CU X X pressure screw sealing ring washer gasket spring washer B hexagon nut M deleted lid sealing ring lid retaining bracket spring washer B hexagon nut oil pipe screw plug et_bt.frm Page: 003 KAT 7

58 : engine lubrication oil cooler oil cooler plate oil cooler union A 3 plate tab washer sealing ring hexagon nut M lock ring B bearing oil cooler /L bearing oil cooler rubber ply oil cooler - N hexagon-head bolt M 6 X - N washer 6, lock ring B hexagon nut M air duct upper front air duct upper front /R /L /R CARRERA 600 GS/GT 69///3 et_bt.frm Page: 00 KAT 7

59 : air duct upper rear air duct upper rear /L /R hexagon nut M lock ring B hexagon-head bolt 6 M 6 X lock ring 6 B 6 - N washer 6 6, air duct /L lower air duct /R lower - N hexagon-head bolt M 6 X lock ring B rubber sleeve bracket 55 MM oil cooler long and round hole - N hexagon-head bolt M 6 X hexagon-head bolt M 6 X lock ring B 6 - N washer 6, spacer sleeve $ 5 X 0 MM hexagon-head bolt M 6 X hexagon nut M 6 - N washer 6, lock ring B 6 - N hexagon-head bolt M 6 X 35 - N washer 6, lock ring B cover plate oil cooler hexagon nut threaded joint EL oil hose pipeline I pipeline II retaining bar hexagon-head bolt 3 M X lock ring 3 B hexagon nut 3 M washer, et_bt.frm Page: 00 KAT 7

60 : hose piece X X 30 MM rubber sleeve X 3 X t-connecting socket QL 5 6 et_bt.frm Page: 003 KAT 7

61 : oil tank M >> oil tank F >> F >> 6 3 F 0 7 >> 030 () oil tank F 55 6 >> F 6 3 >> F 03 >> filler neck oil tank oil tank F >> F >> 6 3 F 0 7 >> 030 () filler neck oil tank F 55 6 >> F 6 3 >> F 03 >> hose piece oil tank F >> F >> 6 3 F 0 7 >> 030 (3) hose piece oil tank F 55 6 >> F 6 3 >> F 03 >> hose clamp * 5 PCG fuel tank cap strainer sealing ring A 30 X screw plug CM X,5 CARRERA 500 GS/GT et_bt.frm Page: 00 KAT 7

62 : sender sealing ring A X oil level dipstick hexagon-head bolt 3 M X lock ring 3 B hexagon nut M breather hose I breather hose II oil hose M >> (7) oil hose M 90 6 >> 07 0 oil hose M >> () oil hose M 90 6 >> F >> F >> 6 73 F >> 3 () oil hose F >> F >> F 3 5 >> oil hose F >> F >> 6 73 F >> 3 (9) oil hose F >> F >> F 3 5 >> cap nut M X, lid sealing ring A X sealing ring A X hose clamp 3 5 PCG oil filter cork gasket oil filter double socket sealing ring A X lock ring B hexagon nut M support hexagon-head bolt M 6 X lock ring B clip filler neck (33) clip filler neck hexagon nut M pan-head screw M 6 X hexagon-head bolt M 6 X angled pipe et_bt.frm Page: 00 KAT 7

63 : hexagon nut M X, angled pipe hexagon nut M X, union A union A insulating piece F >> F >> 6 3 F 0 7 >> 030 (3) insulating piece F 55 6 >> F 6 3 >> F 03 >> insulating piece not available * protective plate pan-head screw 3 M 6 X hexagon-head bolt M 6 X 5 50 N washer 5 6, lock ring B 6 et_bt.frm Page: 003 KAT 7

64 : oil tank oil filter oil tank protective plate oil tank filler neck hose piece clip pan-head screw M 6 X hose clamp X catch covering plate filler neck covering plate pressure line screw plug sealing ring A X strainer sealing ring A 30 X 3 strainer CARRERA 600 GS/GT 69/// sender 69/ remote temperature sensor 69// oil level dipstick PCG oil filter double socket sealing ring A X 9 3 et_bt.frm Page: 00 KAT 7

65 : screw socket ring fitting support oil filter hexagon-head bolt M 6 X lock ring spacer sleeve $ X oil hose oil hose 0 X hose 0 X hose 0 X hose housing and bleeder container tube hose 0 X hose clamp X oil hose connection piece A 6/ sealing ring oil hose union engine housing sealing ring A X banjo bolt A sealing ring A X oil thermostat union sealing ring 3 A X oil hose oil hose pipeline VII hose piece pipeline bracket threaded joint KL seat pipeline V pipeline bracket threaded joint UL pipeline pipeline pipe clamp hexagon-head bolt M X lock ring B hexagon nut M et_bt.frm Page: 00 KAT 7

66 : oil pump CARRERA 600 GS/GT oil pump 69/ oil pump 69/// gasket spring washer B hexagon-head bolt M 6 X sealing ring A 6 X cap nut 69/0 M 6 (6) cap nut M 6 69///3 et_bt.frm Page: 00 KAT 7

67 : air cooling () air guide housing M >> 79 M >> () air guide housing A 300 /S air guide housing 600 black () air guide housing 600 S silver stopper stopper compensating line bearing bracket 3 air guide housing rubber sleeve rubber sleeve nut impeller impeller cover disc washer X drive plate hub flange lid N hexagon-head bolt 6 M 6 X spring washer B hexagon nut M thermostat hexagon-head bolt M X 5 et_bt.frm Page: 00 KAT 7

68 : spring washer B connecting rod upper connecting rod lower ball socket clamping piece and hexagon nut hexagon nut M ball socket A hexagon-head bolt M 6 X spring washer B hexagon nut M flap connection piece ventilation tube /L (9) ventilation tube /R (30) air duct /L air duct /L A (30) air duct /R (30) air duct /R A spring tension spring (33) connecting rod /L (33) connecting rod /R connecting rod A cover plate engine tread 30 MM rubber sleeve cover plate fuel pump cover plate engine cover plate cover plate () cover plate engine PCG cover plate engine it is necessary to rework A rubber moulding cover plate /V/L upper (3) cover plate /V/R upper cover plate /H/L upper () cover plate /H/R upper support cover plate 6 N hexagon-head bolt M 6 X spring washer B 6 () cover plate lateral cover plate lateral cast elbow /03 : / /S et_bt.frm Page: 00 KAT 7

69 : () cover plate lateral sheet metal elbow /03 5/600 S deleted * 5 N hexagon-head bolt M 6 X spring washer B pan-head screw M 6 X 5 N washer A 6, washer 6, X X, cover plate lateral (55) cover plate lateral 6 6 /L /R tread rubber moulding baffle plate /L (57) baffle plate /R clamp et_bt.frm Page: 003 KAT 7

70 : air cooling engine cover /V engine cover /L () engine cover /R engine cover /H strut /L strut /R hexagon-head bolt 6 M 6 X hexagon-head bolt M 6 X lock ring B hexagon nut M gasket upper rubber moulding 95 MM long sealing rubber rubber sleeve rubber cap lower part /L air duct () lower part /R air duct cover plate connecting piece /L () cover plate connecting piece /R cover plate /H/L (3) cover plate /H/R CARRERA 500 GS/GT et_bt.frm Page: 00 KAT 7

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