Service

Technical Information

27/12 ENU

WC21

1

WC21 Staking Plug on Crankcase (Workshop Campaign)

Revision 1:

September 14, 2012
This revision modifies the "Materials" section on page 2 to read: "Note: Please file a PTEC PAV (Parts
Availability) Request for release of required parts....."

Model Year:

As of 2011 up to 2012

Vehicle Type:

911 GT3 RS 4.0 (997)

Concerns:

Plug on crankcase for cylinders 1–3.

Information:

This is to inform you of a voluntary Workshop Campaign on the above-mentioned vehicles. There is the
possibility that a plug that was pressed into and sealed to the crankcase is not seated securely enough in
the opening on the affected vehicles. As a result, this can cause the plug to become loose and as a result,
oil can suddenly leak out of the crankcase, resulting in immediate engine damage.
Information
The affected plug is on the crankcase underneath cylinder 3 ⇒ Installation position of plug

Installation position of plug

2012© Porsche Cars North America, Inc.

AfterSales

Sep 13, 2012
Page 1 of 10

1

Service
WC21

Action
Required:

ENU

Technical Information

27/12

Stake the plug in the opening on the crankcase and also seal it with sealing compound.
Information
The applied sealing compound must harden for at least 12 hours at room temperature 64–72° F.
(18–22° C.) (leave the vehicle overnight).
Please bear this in mind when arranging an appointment with the customer and when planning
your workshop schedule.

Affected
Vehicles:

The VIN(s) can be checked by using PIWIS Vehicle Information link to verify if the campaign affects the
vehicle. This Campaign is scope specific to the VIN! Failure to verify in PIWIS may result in an improper
repair. This campaign affects 158 vehicles in North America.

Materials:

NOTE: PLEASE FILE A PTEC PAV (PARTS AVAILABILITY) REQUEST FOR RELEASE OF REQUIRED
PARTS AND/OR TOOLS. NEITHER PARTS NOR TOOLS REQUIRED FOR THIS CAMPAIGN WILL BE
AUTOMATICALLY ALLOCATED TO YOUR DEALERSHIP.
Sandpaper, 120 grit
Cleaning agent (isopropanol, acetone, Loctite 7063 or Interflon Metal Clean Aerosol)
Cardboard
Disposable gloves
000.043.204.35

⇒ Sealing compound

50 ml cartridge
(approx. 10-15 ml required
per vehicle)

Information
The sealing compound comes with a nozzle and a plunger for the cartridge. An additional metering gun is
not required.
Tools:

Wire brush
Steel hammer, 500 g
Metal or plastic spatula
000.043.207.87

Staking tool

1*

Information
* One staking tool is provided for each affected Porsche dealership.
Only one staking tool may be ordered for each affected Porsche dealership.

Sep 13, 2012
Page 2 of 10

AfterSales

2012© Porsche Cars North America, Inc.

Service

Technical Information

27/12 ENU

WC21

1

Overview of staking tool parts ⇒ Overview of staking tool
– Item 1: Guide pin
– Item 2: staking lugs
– Item 3: Stop
– Item 4: Lock nut
– Item 5: Grip handle

Overview of staking tool
NOTICE
Incorrect staking tool penetration depth setting
•

Risk of damage to bonding on plug

•

Oil leak

⇒

Check that the staking tool penetration depth is set correctly.

2012© Porsche Cars North America, Inc.

AfterSales

Sep 13, 2012
Page 3 of 10

1

Service
WC21

ENU

Technical Information

27/12

Information
The penetration depth of the staking tool is already preset correctly for the intended area of
application when the tool is delivered and must not be changed.
The correct setting for the tool in the as-delivered condition is marked by a green marking on the tool.
•

When the penetration depth of the staking tool is set correctly, the distance between the staking lugs
⇒ staking tool setting -1- and the stop ⇒ staking tool setting -2- is 1.0 mm ⇒ staking tool setting.

staking tool setting
•

This setting ensures that the staking tool will not press the plug deeper into the bore, thereby
damaging the bonding on the plug.

•

Once staking is complete, the distance between the staking marks ⇒ staking tool setting -4- and
the edge of the plug ⇒ staking tool setting -5- will be approx. 0.3 mm (⇒ staking tool setting
-arrow-).

Work
Procedure:

See Attachment “A”.

Claim
Submission:

See Attachment “B”.

Attachment "A": Work Procedure
Stake the plug in the bore on the crankcase and seal it.

Sep 13, 2012
Page 4 of 10

AfterSales

2012© Porsche Cars North America, Inc.

Service

Technical Information

27/12 ENU

WC21

1

CAUTION
Hot components
•

Risk of burns

⇒

Let hot components cool down.

⇒

Wear personal protective gear.
1

Raise the vehicle on a lifting platform ⇒ Workshop Manual ’4X00IN01 Lifting the vehicle’.

2

Clean the area around the bore on the crankcase using a wire brush.
Also sand down the chamfer of the bore if necessary using fine sandpaper (120 grit) to get a
smooth, even surface.

NOTICE
Plug installed at the wrong position
•

Risk of damage to bonding on plug

•

Oil leak

⇒

Before staking, check the installation position of the plug in the bore on the crankcase.
3

Check that the plug is seated at a sufficient depth in the bore.

Installation position of plug

2012© Porsche Cars North America, Inc.

AfterSales

Sep 13, 2012
Page 5 of 10

1

Service
WC21

ENU

4

Technical Information

27/12

•

Staking is only possible if the plug is seated far enough in the bore so that between the edge
of the plug ⇒ Installation position of plug -1- and the edge of the chamfer of the bore ⇒ Installation position of plug -2- there is a gap ⇒ Installation position of plug -A- of at least 0.5 mm.
If this is the case ⇒ continue with Step 4.

•

If the gap between the edge of the plug ⇒ Installation position of plug -1- and the edge of the
chamfer of the bore ⇒ Installation position of plug -2- is less than 0.5 mm or if the edge of the
plug is flush with the edge of the chamfer or projects out over the edge of the chamfer ⇒ Installation position of plug -bottom, inset-, the plug must not be staked in the bore. Otherwise,
the plug can be pressed deeper into the bore during staking. This will damage the bonding
on the plug, resulting in engine oil leaks. If staking is not possible because of the installation
position of the plug, please take relevant pictures of the installation situation of the plug and
contact Technical Support for advice on how to proceed.

Position the staking tool on the bore on the crankcase.
Information
If staking marks ⇒ Existing staking marks on
crankcase -arrows- are already visible at the bore on
the crankcase, the plug must still be re-staked.
In this case, position the staking lugs of the tool so
that they engage in the existing staking marks.

Information
There may be mold parting line burrs in the area
around the bore on the crankcase.
To prevent the stop on the staking tool from lying on
Existing staking marks on crankcase
the burr, there is a cut-out on the stop on the staking
tool.
When aligning the staking tool, always turn the cut-out on the tool towards the burr.
4.1

Guide the guide pin of the staking tool into the
bore on the crankcase.

4.2

Turn the tool until the cut-out ⇒ Aligning
staking tool -1- is facing the burr ⇒ Aligning
staking tool -arrows- so that the tool is not
lying on the burr.

4.3

Press the staking tool onto the crankcase
so that the six staking lugs are touching the
crankcase uniformly.
Aligning staking tool

Sep 13, 2012
Page 6 of 10

AfterSales

2012© Porsche Cars North America, Inc.

Service

Technical Information
5

27/12 ENU

WC21

1

Stake the plug in the bore.
To do this, tap the staking tool in as far as the stop
(metallic sound) by giving it up to three equally strong
taps using a steel hammer (500 g) ⇒ Staking plug
-top-.

6

Check staking.
The plug is staked correctly in the bore as soon
as the staking marks ⇒ Staking plug -bottom,
arrows- are visible at the chamfer of the bore and
material from the chamfer has been ejected towards
the plug so that the diameter of the bore at the
staking marks is narrower ⇒ Staking plug -bottom,