MOUNTING INSTRUCTIONS — Part 1 Porsche Boxster S 986

MOUNTING INSTRUCTIONS

Note. The black sealant Loctite 5900 or Drei Bond Type 1209 are used for sealing the crankcase halves. The separation of the crankcase halves is made rather more difficult if Loctite 5900 is used.

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1. Undo ring-edge bolt. Unscrew the 25 hexagon-head bolts for this purpose.
2. Undo the third fastening point -(arrow)- on the crankcase half cylinder bank 4 - 6 from the engine holder. (Scheme 132)
3. Use a slotted screwdriver with a tip which is 14 mm wide and 250 mm long to separate the crankcase halves.
4. Insert the screwdriver in the lugs of the crankcase halves and separate the crankcase halves by tapping gently. Alternate the sides during separation. NOTE: Clean the crankcase halves using a nylon brush.
5. Clean the crankcase halves and then remove any residual sealant with a nylon brush.

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SPECIAL TOOLS

Note. Only Drei Bond Silicon Type 1209 and Loctite 5900 should be used for surface sealing. After application of surface seals (silicone bead), screw together within five minutes. Observe the expiry date of the surface seal.

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1. At the processing nozzle, cut off the first metering step at an angle. NOTE: Do not process the sealant too generously. No sealant should be pressed into the crankcase when screwing.
2. Apply a uniform bead of silicone approximately 1.5 mm wide to the cleaned sealing surface of the crankcase half of cylinder bank 4 to 6. The silicone bead should be applied as shown in the following illustration.
3. Position the crankcase halves carefully and evenly. The sealant bead must not be damaged during this procedure.
4. Screw the crankcase into place. Mount the crankcase with new screws. The tightening torque is 13 Nm (9.5 ft.lb). Observe the tightening sequence.
5. After tightening the crankcase halves, fasten the third fastening point between the crankcase half (cylinders 4 - 6) and special tool engine holder 9589.

TIGHTENING TORQUES - CRANKCASE HALVES

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SPECIAL TOOLS - REMOVING/INSTALLING ENGINE, M96/20 (2.5L) WITH TIPTRONIC TRANSMISSION (1 OF 2)

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SPECIAL TOOLS - REMOVING/INSTALLING ENGINE, M96/20 (2.5L) WITH TIPTRONIC TRANSMISSION (2 OF 2)

Note. If the special tool 9592 is being used for the first time, (four) additional threaded holes must be applied.

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1. Lay the support plate 9592/1 on the rear of the retainer plate 9592 and fasten with four hexagon-head bolts M8 x 25.
2. Countersink the retainer plate at the designated bores -arrows- with a 9 mm drill bit. (Scheme 148) The support plate serves as the drilling template.
3. Drill through the countersunk bores on the retainer plate with a drill bit sized 6.8 mm and then cut an M8 thread.
4. Fasten the special tool adapter 9163/2 with a hexagon-head bolt M8 x 25 (bolt quality 10.9) and hexagon-head bolts M8 x 16 (bolt quality 10.9) at the designated position Boxster. The adapter and the support plate are fastened on the retainer plate with the M8 x 25 hexagon-head bolts. The M8 x 16 hexagon head bolts connect the adapter with the support plate.
5. Support for Tiptronic transmission with three M6 x 20 (2 ea.) and M8 x 25 (1 ea.) wood screws.
6. Fit complete retainer plate on the workshop jack. Drawing shows complete engine retainer plate fitted on the workshop jack.

Note. The engine is removed downwards complete with the manual transmission.

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1. Position the vehicle at the specified points on a lifting platform.
2. Open both the luggage compartment lids.
3. Cover the vehicle. Cover the vehicle with protective covers in such a way that the body can not be damaged.
4. Move convertible top or convertible-top compartment lid to service position. Open the convertible top until the convertible-top compartment lid is half open.
5. Detach cloth covering. Disengage the rear strip on the left and right sides of the cloth covering in downward direction.
6. Detach tension cables. Press the ball socket of the tension cable out of the ball head of the adjusting piece on the left and right.
7. Move convertible top to service position. To do so, press the tension bow of the convertible top towards the main bow, until it reaches its locking point.
8. Move the convertible-top compartment lid to service position and secure. Disengage the convertible-top compartment links at the extreme bottom. To do so, disengage the clips at the left and right and pull the links off the bolt.
9. Press the convertible-top compartment links forwards until the two bores coincide and a 5 mm mandrel can be pushed through.
10. Remove left-hand seat. For better accessibility, remove the left-hand seat of the car. Unscrew the four Torx screws, disconnect all the electrical plug connections and remove the seat.
11. Open the rear wall cover. To do so, remove the oddments tray behind the seats and remove the rear wall lining. Then undo the 6 fastening screws and the 2 fastening nuts. (Scheme 154) CAUTION: Risk of short circuit First remove the ground terminal. Cover the terminals. Never connect (short circuit) the terminals.
12. Disconnect battery. Before disconnecting, find out the relevant theft codes (e.g. radio) if necessary. At the battery, disconnect the ground terminal and remove the ground cable Refer to «WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY»(/porsche/boxster-s/986-1996-2002/remont/cruise-control-systems/#starter-power-supply-cruise-control). Remove the rear spoiler. «REMOVING AND INSTALLING REAR SPOILER»(/porsche/boxster-s/986-1996-2002/remont/mirrors/#exterior-equipment).
13. Remove rear bumper. While doing so, pay attention to the connection for the number plate lighting. Refer to «REMOVING AND INSTALLING REAR SPOILER»(/porsche/boxster-s/986-1996-2002/remont/mirrors/#exterior-equipment).
14. Remove left and right wheel housing trims.
15. Remove the rear part of the underbody cover.
16. Lift the vehicle. Before lifting, check that all fastening points of the diagonal braces are easily accessible. Pay particular attention to the threaded part -C-. (Scheme 159)
17. Undo the fastening screw -C- and the collar nuts -D- and remove the diagonal braces -B- together with the holder -E-. (Scheme 160)
18. Remove stabilizer. To do so, unscrew the two fastening screws on the left and right of the two bearing surfaces and unscrew the stabilizer on the left and right from the links.
19. Detach rear cross member (aluminum V-member) on the body.
20. Undo the cable. Undo the engine cable on the rear-axle support. The cable must be countered with a suitable wrench and must not be twisted.
21. Release drive shafts. To do so, loosen and protect the fastening nuts on the transmission.
22. Unclip and detach the oxygen sensor plug connection from the holders of the rear-axle support. On an OBD II vehicle, additionally disconnect the oxygen sensor plug connection in the rear wing area. Press the heat shield aside and disconnect the plugs.
23. Remove rear mufflers. To do so, secure the rear mufflers with a transmission jack. Then undo the flange connection between the catalytic converters and the exhaust manifold. Undo the three hexagon-head bolts on the exhaust bracket. NOTE: When lowering, do not damage the oxygen sensors, cables and plugs. Attach protective sleeves around the oxygen sensor plugs.
24. Remove the front lining in the rear luggage compartment. Lever off plastic clips using a commercially available removal tool..
25. Remove the rear-axle support. Unscrew the four fastening screws and remove the rear-axle support to one side.
26. Drain coolant. To do so, remove the screw plug of the coolant circuit on the coolant guide housing. Collect coolant in a clean container.
27. Disconnect coolant hoses. Open the supply and return lines for coolant on the engine and pull them off. Then close all openings. Collect emerging coolant in a clean container. CAUTION: Danger of fire! Collect emerging fuel. Avoid ignition sources and naked flames.
28. Detach the fuel return line. Disconnect the fuel return line under the vehicle floor by pressing gently on the button and pull apart. Collect emerging fuel. Close off the open ends of the line immediately. Then open the holder on the body and remove the line.
29. Disconnect the steering lines. Remove the small undersealing on the left vehicle side (six plastic nuts). Disconnect the two hydraulic lines of the power steering on the vehicle floor. To do so, undo the threaded part and disconnect. Any emerging Pentosin must be collected.
30. Disengage the retaining clips for the power-assisted steering lines and the brake vacuum hose and remove the lines.
31. Disconnect the plug connection of the multifunction switch.
32. Disconnect plug from transmission socket. The plug must be turned anti-clockwise. Then pull off the plug.
33. Detach selector lever cable at deflection linkage and at the transmission support.
34. Disengage the accelerator cable. Remove the cover on the deflector box and disengage the accelerator cable.
35. Disconnect the electric plug on the hot film mass air flow sensor. Then disconnect the connecting hose between the hot film mass air flow sensor and the throttle body. To do so, disconnect the hose clamp on the hot film mass air flow sensor.
36. Press the spring band clamp on the oil filler hose apart and push it aside. Pull off the oil filler hose; heat, if necessary.
37. Disconnect the fuel supply hose. Make sure without fail to counter with a suitable wrench when doing this. Collect emerging residual fuel. Then disconnect the ground cable of the secondary air pump.
38. Disconnect vacuum line for the brake booster. To do so, remove the grey snap ring. Then push the inner sleeve -1- against the outer sleeve -2- and pull off both sleeves together in the direction of the arrow. (Scheme 181)
39. Disconnect B+ separator box. To do so, undo the hexagon nut in the separator box. Remove the cable and lay to one side.
40. Remove supply tank of the power steering system. To do so, suck fluid out as much as possible. Then open the bayonet lock on the bottom of the expansion tank and remove the tank. Close the opening in the servo pump with a clean plug. NOTE: In vehicles with air conditioning, points 42 to 45 must also be carried out. Never evacuate and open the air-conditioning circuit unless this is absolutely necessary.
41. Remove drive belt. Mark the running direction of the drive belt with a colored pen. Slacken the belt. Slacken belt by turning the tensioning pulley (wrench size 24 mm) clockwise, hold still and simultaneously take the belt off the drive pulleys.
42. Undo the rear fastening screw of the air-conditioning compressor from above. The screw is positioned between the intake manifolds of the fifth and sixth cylinders.
43. Loosen air-conditioning compressor. To do so, undo the two front fastening screws -(arrows)-. (Scheme 186) Disconnect the electrical plug. NOTE: The air-conditioning compressor can be removed from the vehicle more easily if the engine has already been lowered.
44. Set the air-conditioning compressor with the hoses connected to one side or lift it out of the engine compartment and set it on a suitable base.
45. Remove the rear luggage compartment lining. To do so, lever out the rear fastening clips and remove the lining from the luggage compartment.
46. Disconnect the plug connections (X3/1, X3/2 and X59) of the engine wiring harness. To do so, raise the lock at the side and pull the plug out.
47. Remove the Tiptronic control module. Undo the three -fastening nuts- and pull off the control module plug.
48. Disconnect control module. Disconnect the plugs of the Tiptronic control module. At the same time, lock the ground point of the engine control module.
49. Disconnect engine control module. Open the topmost plug by actuating the side button and pull out. Remove the other plugs from the top down. To do so, press the locking button in and push the locking bar upwards.
50. Uncover the engine wiring harness. To do so, press the rubber sleeve on the luggage compartment rear wall inwards and guide the wiring harness towards the engine compartment, if the engine is to be lowered later.
51. Disconnect the plug connection at the guide tube of the oil dip stick. To do so, press the two tabs together and unclip the tube. NOTE: It is recommended to position the complete retainer plate using a transmission jack first. Only then should the workshop car jack be placed underneath. The support C1 should rest against the transmission oil pan under a slight pre-load. If necessary, fit the included spacer plate.
52. Place pre-assembled engine retainer plate with transmission support on the crankcase or transmission. CAUTION: Risk of damage When undoing the multi-tooth nut, the mount is destroyed!
53. Remove the transmission support with the hydraulic mounts. Undo the two fastening nuts on the left and right.
54. Undo engine carrier. Undo the front engine carrier. To do so, unscrew the four fastening nuts.
55. Lower the engine-transmission unit carefully. Ensure that there is sufficient clearance for the components. The engine wiring harness must be guided during the lowering procedure. WARNING: Risk of damage Only place the vehicle on its wheels or push it after the rear-axle support, the sheetmetal brace and both the diagonal braces have been installed.

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SPECIAL TOOLS

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SPECIAL TOOLS

Note. If the special tool 9592 is being used for the first time, (four) additional threaded holes must be applied.

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1. Lay the support plate 9592/1 on the rear of the retainer plate 9592 and fasten with four hexagon-head bolts M8 x 25.
2. Countersink the retainer plate at the designated bores -arrows- with a 9 mm drill bit. (Scheme 204) The support plate serves as the drilling template.
3. Drill through the countersunk bores on the retainer plate with a drill bit sized 6.8 mm and then cut an M8 thread.
4. Fasten the special tool adapter 9163/2 with a hexagon-head bolt M8 x 25 (bolt quality 10.9) and hexagon-head bolts M8 x 16 (bolt quality 10.9) at the designated positions Boxster. The adapter and the support plate are fastened on the retainer plate with the M8 x 25 hexagon-head bolts. The M8 x 16 hexagon head bolts connect the adapter with the support plate.
5. Support for Tiptronic transmission with three M6 x 20 (2 ea.) and M8 x 25 (1 ea.) wood screws.
6. Fasten complete retainer plate on the workshop jack.

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1. Check the fuel hose for correct routing. The fuel hose is routed behind the engine wiring harness.
2. When installing the rear-axle parts, it is essential to observe the correct sequence. The sheetmetal brace should be installed first, then the diagonal brace and finally the rear-axle support.
3. The V-brace must be fitted before the exhaust system is installed.
4. Finally, perform a suspension alignment.
5. Read out fault memory.

Note. In order to facilitate the fitting of the air-conditioning compressor, it should be moved back into its installation position during the running-in of the engine.

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