Engine Porsche Boxster S 986 рестайлинг

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TECHNICAL DATA ENGINE M96/20 (2.5L)

TECHNICAL DATA ENGINE M96/20 (2.5L)

ENGINE COOLING M96/20 (2.5L)

ENGINE LUBRICATION INTEGRATED DRY SUMP (2.5L)

ENGINE FUEL SYSTEM INJECTION (2.5L)

FUEL CONSUMPTION (2.5L)

ELECTRICAL SYSTEM ENGINE M96/20 (2.5L)

The following information describes the main engine differences which apply to the Boxster.

DIFFERENCES BETWEEN BOXSTER 2.5L, 2.7L AND BOXSTER S (3.2L) ENGINES

TIGHTENING TORQUES FOR ENGINE M96/20 (2.5L), M96/21 (3.2L), M96/22 (2.7L)

ENGINE DATA FOR ENGINES M 96/23 AND M 96/24 - AS OF MY 2003

ENGINE DESIGN FOR ENGINES M 96/23 AND M 96/24 - AS OF MY 2003

ENGINE COOLING DATA FOR ENGINES M 96/23 AND M 96/24 - AS OF MY 2003

TECHNICAL DATA FOR ENGINES M 96/23 AND M 96/24 - AS OF MY 2003

TIGHTENING TORQUES FOR ENGINE M96/23 (2.7L), M96/24 (3.2L) - AS OF MY 2003

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SPECIAL TOOLS

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

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

ADJUSTING TOOL

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 6) 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. Fasten the support for the manual transmission with 1 M8 x 25 bolt.
6. Fit complete retainer plate on the workshop jack.

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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. Detaching 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 them.
10. Remove left-hand seat. For better accessibility, remove the left-hand seat of the car. Unscrew the four internal-serration 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 -arrows-. (Scheme 13) CAUTION: Danger 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/986-2002-2004/remont/cruise-control-systems/#starter-power-supply-cruise-control). Remove the rear spoiler. «REMOVING AND INSTALLING REAR SPOILER»(/porsche/boxster-s/986-2002-2004/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/986-2002-2004/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 18)
17. Undo the fastening screw -C- and the collar nuts -D.- and remove the diagonal braces -B- together with the holder -E-. (Scheme 19)
18. Remove stabilizer.
19. To do so, unscrew the two fastening screws at each of the two bearing surfaces on the left and right.
20. Unscrew the stabilizer on the left and right of the links.
21. Detach rear cross member (aluminum V-member) on the body.
22. 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.
23. Undo halfshafts. To do so, undo the fastening screws of the halfshafts on the transmission. Fit protection on to the halfshafts.
24. 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.
25. 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.
26. Remove the front lining in the rear luggage compartment. Lever off plastic clips using a commercially available removal tool.
27. Remove the rear-axle support. Unscrew the four fastening screws and remove the rear-axle support to one side.
28. Drain coolant. To do so, remove the screw plug of the coolant circuit on the coolant guide housing. Collect coolant in a clean container.
29. 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.
30. 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.
31. Disconnect the steering lines. Remove the small undersealing on the left vehicle underside (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.
32. Disengage the retaining clips for the power-assisted steering lines and the brake vacuum hose and remove the lines.
33. Unscrew the heat shield on the transmission. To do so, unscrew the two fastening nuts and remove the plate.
34. Disengage shift cables on the transmission. Disengage the cables with the commercially available tool.
35. Detach the shift cables. Unclip the shift cables on the transmission mount. Then pull the shift cables upwards out of the engine compartment and set them aside. WARNING: Risk of damage! When the slave cylinder is removed, do not actuate the clutch again.
36. Uncouple clutch slave cylinder. To do so, unscrew the fastening screw and remove the clutch slave cylinder. Tie the cylinder with a wire.
37. Disengage the accelerator cable. Remove the cover on the deflector box and disengage the accelerator cable.
38. 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.
39. Press the spring band clamp on the oil filler hose apart and push it aside. Pull off the oil filler hose; heat, if necessary.
40. 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.
41. 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 40)
42. Disconnect B+ separator box. To do so, undo the hexagon nut in the separator box. Remove the cable and lay to one side.
43. Remove the 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, the points 45 to 48 must also be carried out. Never evacuate and open the air-conditioning circuit unless this is absolutely necessary.
44. Remove drive belt. Mark the running direction of the drive belt with a colored pen. Slacken belt by turning the tensioning pulley (wrench size 24 mm) clockwise, hold still and simultaneously take the belt off the drive pulleys.
45. 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.
46. Loosen air-conditioning compressor. To do so, undo the two front fastening screws -(arrows)-. (Scheme 45) Disconnect the electrical plug. NOTE: The air-conditioning compressor can be removed from the vehicle more easily if the engine has already been lowered.
47. 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.
48. Remove the rear luggage compartment lining. To do so, lever out the rear fastening clips and remove the lining from the luggage compartment.
49. 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.
50. Lock the ground point of the engine control module.
51. Unplug the 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.
52. 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.
53. Disconnect the plug connection at the guide tube of the oil dipstick. 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.
54. 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!
55. Remove the transmission support with the hydraulic mounts. Undo the two fastening nuts on the left and right.
56. Undo the front engine carrier. To do so, unscrew the four fastening nuts.
57. 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 TOOL AND EXPLANATION

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 62) 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. Fasten the support for the manual transmission with 1 M8 x 25 bolt.
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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1. Lift the engine-transmission unit carefully and in steps. Have a second person observe the engine-transmission clearance at the same time. When lifting, pay particular attention to the clearance between the rear-axle longitudinal support and the VarioCam cable. Place the air-conditioning compressor in its installation position at this stage.
2. Push the engine wiring harness through the bulkhead and into the luggage compartment before the final installation position is reached.
3. Tighten engine mount. Tighten the four engine mount fastening screws to 46 Nm (34 ft.lb). WARNING: Risk of damage! Do not turn the multiple-tooth nut -C-!
4. Install the transmission carrier and the hydraulic mount again. The M8 screws are tightened to 33 Nm (24 ft.lb).
5. Install engine carrier again. Tighten the four fastening screws to 65 Nm (48 ft.lb).
6. Remove the engine-transmission retainer plate. As soon as the engine has been fastened again, the car jack and the retainer plate can be removed.
7. Clip the guide tube of the oil dipstick into the socket.
8. Fit the rubber sleeve of the wiring harness again.
9. Re-connect engine control module. Start from the bottom and pay attention to the plug designations on the control module.
10. Connect the plug connections (X3/1, X3/2 and X59) of the engine wiring harness. To do so, insert the plug and lock the lateral slide.
11. Connect the ground point of the control module again and tighten the fastening nut.
12. Install the luggage compartment lining of the rear luggage compartment.
13. Screw air-conditioning compressor tight. Tighten the three fastening screws to 23 Nm (17 ft.lb).
14. Check the drive belt for damage and replace it if necessary. Fit the belt in its original running direction once more. The fitting sequence is shown in the following illustration. (Scheme 81)
15. Tighten the fuel line on the engine and the ground cable again. Make sure without fail to counter with a wrench when tightening the fuel line. The ground cable is tightened with 23 Nm (17 ft.lb).
16. Push the vacuum line for the brake booster in a straight line on to the flange, until the plug is heard to engage. Then install the grey snap ring again. Check that the line is seated properly by pulling on it gently.
17. Install the expansion tank of the power steering again. Check the sealing rings and replace, if necessary. Turn the lower adjusting ring to its original position and position the tank of the power steering. Press the tank downwards and at the same time turn the ring until the markings coincide. Then fill the tank with Pentosin according to the regulations.
18. Lay the B+ line of the alternator over the connecting bolt and tighten the fastening screw with 10 Nm (7.5 ft.lb). Close the protective cap of the B+ box.
19. Re-connect hot film mass air flow meter. Connect the connecting tube between the hot film mass air flow meter and the intake system and tighten the hose clamp.
20. Fit the oil filler line. Push the oil filler line back onto the flange and secure with a spring band clamp.
21. Engage the accelerator cable.
22. Refit clutch slave cylinder. Insert the cylinder back into the opening in the transmission. Tighten the fastening screw with 23 Nm (17 ft.lb).
23. Lay shift cables. Lay the shift cables in the engine compartment once more and clip them into the holder on the transmission. Then check once more that they are seated properly. Finally, press the shift cables back into the shift linkage. Check that the shift cables are installed correctly.
24. Screw heat shield tight. Fit the shield over the Tucker bolts and tighten the two sheetmetal nuts.
25. Screw the drive shafts on to the transmission again with new screws. The tightening torque is 39 Nm (29 ft.lb.) for the Boxster 2.7L and 81 Nm (60 ft.lb.) for the Boxster 3.2L. Subsequently remove the protective sheath.
26. Retighten cable. Fit the engine cable through the rear-axle support again and tighten the fastening nuts. Make sure to counter with a wrench when tightening. The tightening torque is 23 Nm (17 ft.lb).
27. Connect the power-assisted steering lines. To do so, tilt the holder on one side and pull out simultaneously.
28. Detach threaded part -A- by pulling it off the nipple. (Scheme 91)
29. Insert the holder -C- into the threaded part -A- and screw both into the plug-in coupling -B- and tighten. (Scheme 92) Make sure to counter with a wrench when tightening. The tightening torque for the steering pressure line is 30 Nm (22 ft.lb.) (wrench size 15). The tightening torque for the steering return line is 40 Nm (30 ft.lb.) (wrench size 19).
30. Insert the screwed plug into the plug-in coupling in a straight line. The plug must audibly engage in the holder. NOTE: The plug-in connection is designed so that the plug can be shifted in the plug-in coupling by approx. 1 mm in axial direction by slightly pulling or pressing.
31. The correct engagement of the plug-in couplings should be checked using the special tool 9623. To check this, insert the special tool 9623 between the plug-in coupling and the screwed plug and tilt the tool slightly. The plug must not slide out.
32. Install the servo lines, the return line and the vacuum hose for the brake booster again and insert the retaining clip. CAUTION: Risk of damage! The fuel lines must not be kinked.
33. Connect the fuel lines. Re-connect the fuel lines on the vehicle underbody. The plug must engage audibly. Check correct seating by pulling gently. CAUTION: Danger of slipping hoses. Never apply a lubricant to the coolant hoses to make fitting easier!
34. Fit all the coolant hoses again. To make fitting easier, the coolant hoses can be wetted with water in the fitting area.
35. Check the coolant drain plug. If the drain plug is removed, it should be equipped with a new seal and re-mounted. The tightening torque for the screw is from 10 to 15 Nm (7.5 to 11 ft.lb).
36. Fit vent line again.
37. Install rear-axle support again. The four fastening screws are tightened to 65 Nm (48 ft.lb).
38. Move the exhaust system to its installation position again. In the process, replace all the seals at opened points. Tighten the three hexagon-head bolts again. Then tighten the screws on the exhaust manifold/catalytic converter with 25 Nm (18 ft.lb).
39. Connect the oxygen sensor cables. Connect the plugs and engage the holder in the rear-axle support.
40. Install the rear V-member. The four fastening screws are tightened to 65 Nm (48 ft.lb).
41. Install stabilizer. To do so, insert the stabilizer on the left and right into the stabilizer mount and screw it tight to the two bearing surfaces. The fastening nuts on the mount are tightened with 46 Nm (34 ft.lb). The fastening screws on the bearing surfaces are tightened with 23 Nm (17 ft.lb).
42. Install the sheetmetal brace into the vehicle. Tighten the hexagon nuts with 65 Nm (48 ft.lb) and tighten the fastening screws with 46 Nm (34 ft.lb). Install the two diagonal braces into the vehicle. Tighten the fastening nuts to 65 Nm (48 ft.lb). NOTE: Vehicles with automatic headlight beam adjustment. Bear in mind that the angle sensor bracket (B) must be in contact at the bottom when the bolts on the rear-axle support (A) are tightened. Once installed, the control module must be calibrated with the PST 2. The headlights must then be reset. -A- Rear-axle support- -B - Angle sensor bracket- -C - Angle sensor- (Scheme 108)
43. Mount the underside panel.
44. Install the right and left wheel housing trims again.
45. Re-install the rear spoiler.
46. Install the rear spoiler again.
47. Re-position the trim of the rear luggage compartment and press in the fastening rivets. WARNING: Danger of short circuit! Pay attention to the correct seating of the rubber sleeve of the B+ lead!
48. Check the rubber sleeve. The rubber sleeve of the B+ lead must be fitted correctly and must not have slipped out of place.
49. Seal off the maintenance openings again. Seal off the upper and rear maintenance openings again. Tighten the seven fastening screws and the two fastening nuts of the rear maintenance opening with 10 Nm (7.5 ft.lb).
50. Re-install the left seat. Tighten the four fastening nuts to 65 Nm (48 ft.lb).
51. Top up operating fluids. Check that all operating fluids (engine oil, Pentosin, coolant) are at the correct level. Both the coolant circuit and the power steering must be bled according to regulations.
52. Connect battery. Connect the battery terminals again and tighten. Subsequently, the fault memories of the vehicle must be read out and the theft codes may possibly have to be entered again. Re-teach the power windows.
53. Carry out a test drive. After the test drive, check that all the operating fluids are at the correct level. Check all circuits for leaks.
54. Fit convertible top again. To do so, take the mandrel out of the fixing bore.
55. Move the convertible top towards the rear until the linkage can be pushed back onto the pin. Then push the retaining clip into place.
56. Close convertible top. To do so, pull the tension bow towards the rear again and engage the tension cables again on the left and right.
57. Engage the cloth covering of the convertible top on the left and right into the retaining lugs.

TIGHTENING TORQUES

TIGHTENING TORQUES - INSTALLING ENGINE, M96/20 (2.5L) WITH MANUAL TRANSMISSION

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Note. For environmental reasons, the engine may only be washed in car washes equipped with an oil separator.

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1. Remove engine lid in accordance with the instructions, retaining the maintenance cover to the interior in place; see «ENGINE MAINTENANCE: OPENING AND CLOSING ENGINE COMPARTMENT»(/porsche/boxster-s/986-2002-2004/remont/procedures/#maintenance) and «MAINTENANCE, CHECKING LID AND DOORS»(/porsche/boxster-s/986-2002-2004/remont/procedures/#maintenance).
2. Remove any maintenance labels affixed to the engine (e.g. oil change schedule tag) and replace after work is completed.
3. Protect components sensitive to moisture, possibly by covering them with plastic sheeting or bag. Oxygen sensor connectors must not get wet. NOTE: Engine cleaning agents must not attack plastic or rubber parts!
4. Spray engine top and bottom with an appropriate engine cleaning agent and allow it to work in. Observe the application time specified on the cleaning agent data sheet.
5. Pre-treat persistent dirt manually (e.g. with a sponge or brush). NOTE: Always make sure that no washing water enters the vehicle interior!
6. Fit special tool Engine lid with cut-out 9635 in the same way as for the engine compartment lid.
7. Protect vehicle interior against ingress of washing water with a cover film or the vehicle's own engine compartment lid. To do this, set the engine lid upright as a protective wall for the interior and prevent it falling down with an adhesive strip to the convertible top.
8. Guide the high-pressure lance through the wash opening provided for the purpose (Scheme 119) and clean the engine from the top. Ensure a minimum clearance of approx. 30 cm is maintained between the cleaning lance and engine components. The water temperature must not exceed 80 °C.
9. Raise the car and carry out the washing procedure from underneath (Scheme 120); the bottom engine cover does not need to be removed.
10. Dry sensitive components (e.g. electrical plug contacts) that become wet with a lint-free cloth or gentle jet of compressed-air.
11. Moving parts in the engine compartment, such as the catch hook for the bonnet, must be regreased.
12. Seal the engine surface with a special engine wax or corrosion inhibitor.
13. Re-affix the servicing labels.
14. Fit engine lid and close convertible top. Refer to «ENGINE MAINTENANCE: OPENING AND CLOSING ENGINE COMPARTMENT»(/porsche/boxster-s/986-2002-2004/remont/procedures/#maintenance).
15. After washing the engine, carry out a test drive, paying particular attention to rpm fluctuations or misfiring.

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Removal or installation of the compete bearing housing in the crankcase half, cylinders 1 - 3. As the bearing housing is heavy, it should be removed and installed using a workshop crane.

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ENGINE CRANKCASE SPECIFICATION

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ENGINE CRANKCASE DESIGNATION

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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Scheme 180

Scheme 181

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Scheme 197

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/986-2002-2004/remont/cruise-control-systems/#starter-power-supply-cruise-control). Remove the rear spoiler. «REMOVING AND INSTALLING REAR SPOILER»(/porsche/boxster-s/986-2002-2004/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/986-2002-2004/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.

Scheme 198

Scheme 199

SPECIAL TOOLS

Scheme 200

SPECIAL TOOLS

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

Scheme 201

Scheme 202

Scheme 203

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.

Scheme 204

Scheme 205

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.

Scheme 206

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Scheme 212

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Scheme 251

Scheme 252

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Scheme 255

1. Lift the engine-transmission unit carefully and in steps. Have a second person observe the engine-transmission clearance at the same time. When lifting, pay particular attention to the clearance between the rear-axle longitudinal support and the VarioCam cable. Place the air-conditioning compressor in its installation position at this stage.
2. Push the engine wiring harness through the bulkhead and into the luggage compartment before the final installation position is reached.
3. Install engine carrier again. Tighten the four fastening nuts to 65 Nm (48 ft.lb). WARNING: Risk of damage Do not turn the multiple-tooth nut -C-!
4. Install the transmission carrier and the hydraulic mount again. Tighten the M8 screws to 33 Nm (24 ft.lb) and the M10 screws to 65 Nm (48 ft.lb).
5. Remove the engine-transmission retainer plate. As soon as the engine has been fastened again, the car jack and the retainer plate can be removed.
6. Clip the guide tube of the oil dip stick into the socket.
7. Fit the rubber sleeve of the wiring harness again.
8. Re-connect engine control module. To do so, start at the bottom. Pay attention to the plug designations on the control module.
9. Re-connect and install the Tiptronic control module. Tighten the three fastening nuts.
10. Connect the plug connections (X3/1, X3/2 and X59) of the engine wiring harness. To do so, insert the plug and lock the lateral slide.
11. Connect the ground point of the control module again and tighten the fastening nut.
12. Install the luggage compartment lining of the rear luggage compartment.
13. Screw air-conditioning compressor tight. Tighten the three fastening screws to 23 Nm (17 ft.lb).
14. Check the drive belt for damage and replace it if necessary. Fit the belt in its original running direction once more. The fitting sequence is shown in the following illustration.
15. Tighten the fuel line on the engine and the ground cable again. Make sure without fail to counter with a wrench when tightening the fuel line. The ground cable is tightened to 23 Nm (17 ft.lb) and the fuel supply line to 30 Nm (22 ft.lb).
16. Push the vacuum line for the brake booster in a straight line onto the flange, until the plug is heard engaging. Then install the grey snap ring again. Check that the line is seated properly by pulling on it gently.
17. Install the expansion tank of the power steering again. Check the sealing rings and replace, if necessary. Turn the lower adjusting ring to its original position and position the tank of the power steering. Press the tank downwards and at the same time turn the ring until the markings coincide. Then fill the tank with Pentosin according to the regulations.
18. Lay the B+ line of the alternator over the connecting bolt and tighten the fastening screw to 10 Nm (7.5 ft.lb). Close the protective cap of the B+ box.
19. Re-connect hot film mass air flow meter. Connect the connecting tube between the hot film mass air flow meter and the intake system and tighten the hose clamp.
20. Attach oil filler neck. Push the oil filler neck back onto the flange and secure with a spring band clamp.
21. Engage the accelerator cable.
22. Engage selector lever cable at deflection lever and at the transmission support.
23. Position the plug at the transmission socket. Disconnect the plug and turn clockwise.
24. Re-connect the plug for the multifunction switch.
25. Screw the drive shafts to the transmission again. The tightening torque is 39 Nm (29 ft.lb). Then remove the protective sheaths.
26. Re-tighten cable. Fit the engine cables through the rear-axle support again and tighten the fastening nuts. Make sure to counter with a wrench when tightening. The tightening torque is 23 Nm (17 ft.lb).
27. Connect the power-assisted steering lines. To do so, tilt the holder on one side and pull out simultaneously.
28. Detach threaded part -A- by pulling it off the nipple. (Scheme 234)
29. Insert the holder -C- into the threaded part -A- and screw both into the plug-in coupling -B- and tighten. (Scheme 235) Make sure to counter with a wrench when tightening. The tightening torque for the steering pressure line is 30 Nm (22 ft.lb) (wrench size 15). The tightening torque for the steering return line is 40 Nm (30 ft.lb) (wrench size 19).
30. Insert the screwed plug into the plug-in coupling in a straight line. The plug must audibly engage in the holder. NOTE: The plug-in connection is designed so that the plug can be shifted in the plug-in coupling by approx. 1 mm in axial direction by slightly pulling or pressing.
31. The correct engagement of the plug-in couplings should be checked using the special tool 9623. To check this, insert the special tool 9623 between the plug-in coupling and the screwed plug and tilt the tool slightly. The plug must not slide out.
32. Install the servo lines, the return line and the vacuum hose for the brake booster again and insert the retaining clip. CAUTION: Risk of damage. The fuel lines must not be kinked.
33. Connect the fuel lines. Re-connect the fuel lines on the vehicle floor. The connector must engage audibly. Check correct seating by pulling gently. CAUTION: Danger of slipping hoses. Never apply a lubricant to the coolant hoses to make fitting easier!
34. Fit all the coolant hoses again. To make fitting easier, the coolant hoses can be wetted with water in the fitting area.
35. Check coolant drain plug. If the drain plug is removed, it should be equipped with a new seal and re-mounted. The tightening torque for the screw is from 10 to 15 Nm (7.5 to 11 ft.lb).
36. Fit vent line again.
37. Install rear-axle support again. The four fastening screws are tightened to 65 Nm (48 ft.lb).
38. Move the exhaust system to its installation position again. In the process, replace all the seals at opened points. Tighten the three hexagon-head bolts again. Then tighten the screws on the exhaust manifold/catalytic converter with 25 Nm (18 ft.lb).
39. Connect oxygen sensors. Connect the plugs and engage the holder in the rear-axle support.
40. Install the rear V-member. The four fastening screws are tightened to 65 Nm (48 ft.lb).
41. Install stabilizer. To do so, insert the stabilizer on the left and right into the stabilizer mount and screw it tight to the two bearing surfaces. The fastening nuts on the mount are tightened to 50 Nm (37 ft.lb). The fastening screws on the bearing surfaces are tightened to 23 Nm (17 ft.lb).
42. Install the sheetmetal brace into the vehicle. Tighten the hexagon nuts to 65 Nm (48 ft.lb) and tighten the fastening screws to 46 Nm (34 ft.lb). Install the diagonal braces into the vehicle. Tighten the fastening nuts to 65 Nm (48 ft.lb). NOTE: Vehicles with automatic headlight beam adjustment. Bear in mind that the angle sensor bracket (B) must be in contact at the bottom when the bolts on the rear-axle support (A) are tightened. Once installed, the control module must be calibrated with the System Tester PST 2. The headlights must then be reset. -A- Rear-axle support- -B - Angle sensor bracket- -C - Angle sensor- (Scheme 251)
43. Fit the underbody panel.
44. Install the right and left wheel housing trims again.
45. Re-install the rear spoiler.
46. Install the rear spoiler again.
47. Re-position the trim of the rear luggage compartment and press in the fastening rivets. WARNING: Risk of short circuit Pay attention to the correct seating of the rubber sleeve of the B+ lead!
48. Check the rubber sleeve. The rubber sleeve of the B+ lead must be fitted correctly and must not have slipped out of place.
49. Re-install the left seat. Tighten the four fastening screws to 65 Nm (48 ft.lb).
50. Top up operating fluids. Check that all operating fluids (engine oil, Pentosin, coolant) are at the correct level. Both the coolant circuit and the power steering must be bled according to regulations.
51. Connect battery. Connect the battery terminals again and tighten. Subsequently, the fault memories of the vehicle must be read out and the theft codes may possibly have to be entered again. Re-program the power windows.
52. Seal off the upper and rear maintenance openings again. Tighten the seven fastening screws and the two fastening nuts of the rear maintenance opening to 10 Nm (7.5 ft.lb).
53. Carry out a test drive. After the test drive, check that all the operating fluids are at the correct level. Check all circuits for leaks.
54. Fit convertible top again. To do so, take the mandrel out of the fixing bore.
55. Move the convertible top towards the rear until the linkage can be pushed back onto the pin. Then push the retaining clip into place.
56. Close convertible top. To do so, pull the tension bow towards the rear again and engage the tension cables again on the left and right.
57. Engage the cloth covering of the convertible top on the left and right into the retaining lugs.

TIGHTENING TORQUES - INSTALLING ENGINE, M96/20 (2.5L) WITH TIPTRONIC TRANSMISSION

Scheme 256

Scheme 257

SPECIAL TOOLS

Scheme 258

SPECIAL TOOLS

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

Scheme 259

Scheme 260

Scheme 261

Scheme 262

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 263) 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.

Scheme 263

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

Scheme 264

Scheme 265

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Scheme 274

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Scheme 306

Scheme 307

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 them.
10. Remove left-hand seat. For better accessibility, remove the left-hand seat of the car. Unscrew the four internal-serration 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. See -arrows- in (Scheme 269). CAUTION: Danger 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/986-2002-2004/remont/cruise-control-systems/#starter-power-supply-cruise-control). Remove the rear spoiler. «REMOVING AND INSTALLING REAR SPOILER»(/porsche/boxster-s/986-2002-2004/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/986-2002-2004/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 274)
17. Undo the fastening screw -C- and the collar nuts -D- and remove the diagonal braces -B- together with the holder -E-. (Scheme 275)
18. Remove stabilizer.
19. To do so, unscrew the two fastening screws at each of the two bearing surfaces on the left and right.
20. Unscrew the stabilizer on the left and right of the links.
21. Detach rear cross member (aluminum V-member) on the body.
22. 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.
23. Release drive shafts. To do so, loosen and protect the fastening nuts on the transmission.
24. 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.
25. 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.
26. Remove the front lining in the rear luggage compartment. Lever off plastic clips using a commercially available removal tool.
27. Remove the rear-axle support. Unscrew the four fastening screws and remove the rear-axle support to one side.
28. Drain coolant. To do so, remove the screw plug of the coolant circuit on the coolant guide housing. Collect coolant in a clean container.
29. 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.
30. 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.
31. Disconnect the steering lines. Remove the small undersealing on the left vehicle underside (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.
32. Disengage the retaining clips for the power-assisted steering lines and the brake vacuum hose and remove the lines.
33. Unscrew the heat shield on the transmission. To do so, unscrew the two fastening nuts and remove the plate.
34. Disengage shift cables on the transmission. Disengage the cables with the commercially available tool.
35. Detach the shift cables. Unclip the shift cables on the transmission mount. Then pull the shift cables upwards out of the engine compartment and set them aside. WARNING: Risk of damage When the clutch slave cylinder is removed, do not actuate the clutch again.
36. Uncouple clutch slave cylinder. To do so, unscrew the fastening screw and remove the clutch slave cylinder. Tie the cylinder with a wire.
37. 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.
38. Open the spring band clamp on the oil filler hose and push it aside. Pull off the oil filler hose; heat, if necessary.
39. 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.
40. 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.
41. Disconnect B+ separator box. To do so, undo the nut in the separator box. Remove the cable and lay to one side.
42. 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 44 to 47 must also be carried out. Never evacuate and open the air-conditioning circuit unless this is absolutely necessary.
43. 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.
44. 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.
45. Loosen air-conditioning compressor. To do so, undo the two front fastening screws -(arrows)-. (Scheme 299) Disconnect the electrical plug. NOTE: The air-conditioning compressor can be removed from the vehicle more easily if the engine has already been lowered.
46. 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.
47. Remove the rear luggage compartment lining. To do so, lever out the rear fastening clips and remove the lining from the luggage compartment.
48. 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.
49. Lock the ground point of the engine control module.
50. Unplug the 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.
51. 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.
52. 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.
53. 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!
54. Remove the transmission support with the hydraulic mounts. Undo the two fastening nuts on the left and right.
55. Undo the front engine carrier. To do so, unscrew the four fastening nuts.
56. 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.

Scheme 308

Scheme 309

SPECIAL TOOLS

Scheme 310

SPECIAL TOOLS

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

Scheme 311

Scheme 312

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Scheme 315

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. 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.

Scheme 316

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.

Scheme 317

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Scheme 361

1. Lift the engine-transmission unit carefully and in steps. Have a second person observe the engine-transmission clearance at the same time. When lifting, pay particular attention to the clearance between the rear-axle longitudinal support and the VarioCam cable. Place the air-conditioning compressor in its installation position at this stage.
2. Push the engine wiring harness through the bulkhead and into the luggage compartment before the final installation position is reached.
3. Install engine carrier again. Tighten the four fastening nuts to 65 Nm (48 ft.lb). WARNING: Risk of damage Do not turn the multiple-tooth nut -C-!
4. Install the transmission carrier and the hydraulic mount again. Tighten the M8 screws to 33 Nm (24 ft.lb) and the M10 screws to 65 Nm (48 ft.lb).
5. Remove the engine-transmission retainer plate. As soon as the engine has been fastened again, the car jack and the retainer plate can be removed.
6. Clip the guide tube of the oil dip stick into the socket.
7. Fit the rubber sleeve of the wiring harness again.
8. Re-connect engine control module. To do so, start at the bottom. Pay attention to the plug designations on the control module.
9. Connect the plug connections (X3/1, X3/2 and X59) of the engine wiring harness. To do so, insert the plug and lock the lateral slide.
10. Connect the ground point of the control module again and tighten the fastening nut.
11. Install the luggage compartment lining of the rear luggage compartment.
12. Screw air-conditioning compressor tight. Tighten the three fastening screws to 23 Nm (17 ft.lb).
13. Check the drive belt for damage and replace it if necessary. Fit the belt in its original running direction once more. The fitting sequence is shown in the following illustration.
14. Tighten the fuel line on the engine and the ground cable again. Make sure without fail to counter with a wrench when tightening the fuel line. The ground cable is tightened to 23 Nm (17 ft.lb) and the fuel supply line to 30 Nm (22 ft.lb).
15. Push the vacuum line for the brake booster in a straight line onto the flange, until the plug is heard engaging. Then install the grey snap ring again. Check that the line is seated properly by pulling on it gently.
16. Install the expansion tank of the power steering again. Check the sealing rings and replace, if necessary. Turn the lower adjusting ring to its original position and position the tank of the power steering. Press the tank downwards and at the same time turn the ring until the markings coincide. Then fill the tank with Pentosin according to the regulations.
17. Lay the B+ line of the alternator over the connecting bolt and tighten the fastening screw to 10 Nm (7.5 ft.lb). Close the protective cap of the B+ box.
18. Re-connect hot film mass air flow meter. Connect the connecting tube between the hot film mass air flow meter and the intake system and tighten the hose clamp.
19. Attach oil filler neck. Push the oil filler neck back onto the flange and secure with a spring band clamp.
20. Re-fit clutch slave cylinder. Insert the cylinder back into the opening in the transmission. Tighten the fastening screw with 23 Nm (17 ft.lb).
21. Lay shift cables. Lay the shift cables in the engine compartment once more and clip them into the holder on the transmission. Then check once more that they are seated properly. Finally, press the shift cables back into the shift linkage. Check that the shift cables are installed correctly.
22. Screw heat shield tight. Fit the shield over the Tucker bolts and tighten the two sheetmetal nuts.
23. Screw the drive shafts on to the transmission again with new screws. The tightening torque for the Boxster 2.7L is 39 Nm (29 ft.lb) and 81 Nm (60 ft.lb) for the Boxster 3.2L. If monobloc drive shafts are installed in the Boxster 2.7L, the tightening torque is 81 Nm (60 ft.lb). Remove protective sheath.
24. Re-tighten cable. Fit the engine cable through the rear-axle support again and tighten the fastening nuts. Make sure to counter with a wrench when tightening. The tightening torque is 23 Nm (17 ft.lb).
25. Connect the power-assisted steering lines. To do so, tilt the holder on one side and pull out simultaneously.
26. Detach threaded part -A- by pulling it off the nipple. (Scheme 341)
27. Insert the holder -C- into the threaded part -A- and screw both into the plug-in coupling -B- and tighten. (Scheme 342) Make sure to counter with a wrench when tightening. The tightening torque for the steering pressure line is 30 Nm (22 ft.lb) (wrench size 15). The tightening torque for the steering return line is 40 Nm (30 ft.lb) (wrench size 19).
28. Insert the screwed plug into the plug-in coupling in a straight line. The plug must audibly engage in the holder. NOTE: The plug-in connection is designed so that the plug can be shifted in the plug-in coupling by approx. 1 mm in axial direction by slightly pulling or pressing.
29. The correct engagement of the plug-in couplings should be checked using the special tool 9623. To check this, insert the special tool 9623 between the plug-in coupling and the screwed plug and tilt the tool slightly. The plug must not slide out.
30. Install the servo lines, the return line and the vacuum hose for the brake booster again and insert the retaining clip. CAUTION: Risk of damage The fuel lines must not be kinked.
31. Connect the fuel lines. Re-connect the fuel lines on the vehicle underbody. The connector must engage audibly. Check correct seating by pulling gently. CAUTION: Danger of slipping hoses. Never apply a lubricant to the coolant hoses to make fitting easier!
32. Fit all the coolant hoses again. To make fitting easier, the coolant hoses can be wetted with water in the fitting area.
33. Check coolant drain plug. If the drain plug is removed, it should be equipped with a new seal and re-mounted. The tightening torque for the screw is 10 Nm (7.5 ft.lb).
34. Fit vent line again.
35. Install rear-axle support again. The four fastening screws are tightened to 65 Nm (48 ft.lb).
36. Move the exhaust system to its installation position again. In the process, replace all the seals at opened points. Tighten the three hexagon-head bolts again. Then tighten the screws on the exhaust manifold/catalytic converter to 25 Nm (18 ft.lb).
37. Connect oxygen sensors. Connect the plugs and engage the holder in the rear-axle support.
38. Install the rear V-member. The four fastening screws are tightened to 65 Nm (48 ft.lb).
39. Install stabilizer. To do so, insert the stabilizer on the left and right into the stabilizer mount and screw it tight to the two bearing surfaces. The fastening nuts on the mount are tightened to 50 Nm (37 ft.lb). The fastening screws on the bearing surfaces are tightened to 23 Nm (17 ft.lb).
40. Install the sheetmetal brace into the vehicle. Tighten the hexagon nuts to 65 Nm (48 ft.lb.) and tighten the fastening screws to 46 Nm (34 ft.lb). Install the diagonal braces into the vehicle. Tighten the fastening nuts to 65 Nm (48 ft.lb). NOTE: Vehicles with automatic headlight beam adjustment. Bear in mind that the angle sensor bracket (B) must be in contact at the bottom when the bolts on the rear-axle support (A) are tightened. Once installed, the control module must be calibrated with the System Tester PST 2. The headlights must then be reset. -A- Rear-axle support- -B - Angle sensor bracket- -C - Angle sensor
41. Fit the underbody panel.
42. Install the right and left wheel housing trims again.
43. Re-install the rear spoiler.
44. Install the rear spoiler again.
45. Re-position the trim of the rear luggage compartment and press in the fastening rivets. WARNING: Risk of short circuit Pay attention to the correct seating of the rubber sleeve of the B+ lead!
46. Check the rubber sleeve. The rubber sleeve of the B+ lead must be fitted correctly and must not have slipped out of place.
47. Seal off the maintenance openings again. Seal off the upper and rear maintenance openings again. Tighten the seven fastening screws and the two fastening nuts of the rear maintenance opening to 10 Nm (7.5 ft.lb).
48. Re-install the left seat. Tighten the four fastening nuts to 65 Nm (48 ft.lb).
49. Top up operating fluids. Check that all operating fluids (engine oil, Pentosin, coolant) are at the correct level. Both the coolant circuit and the power steering must be bled according to regulations.
50. Connect battery. Connect the battery terminals again and tighten. Subsequently, the fault memories of the vehicle must be read out and the theft codes may possibly have to be entered again. Re-programme the power windows.
51. Carry out a test drive. After the test drive, check that all the operating fluids are at the correct level. Check all circuits for leaks.
52. Fit convertible top again. To do so, take the mandrel out of the fixing bore.
53. Move the convertible top towards the rear until the linkage can be pushed back onto the pin. Then push the retaining clip into place.
54. Close convertible top. To do so, pull the tension bow towards the rear again and engage the tension cables again on the left and right.
55. Engage the cloth covering of the convertible top on the left and right into the retaining lugs.

TIGHTENING TORQUES - INSTALLING ENGINE, M96/21 (3.2L) AND M96/22 (2.7L) WITH MANUAL TRANSMISSION

Scheme 362

ENGINE CARRIER COMPONENTS

Note. There are two model versions of engine brackets. Allocation occurs according to the number of screw connection points The 4-point engine bracket must not be installed with the 3-point coolant guide housing (from version 1).

Scheme 363

Scheme 364

1. Coolant guide housing with 4-point screw connection and engine bracket with 3-point screw connection. The additional bolting point at the upper right-hand side -arrow- on the coolant guide housing is fastened with a hexagon-head bolt M10 x 60. (Scheme 367)
2. Coolant guide housing with 4-point screw connection and engine bracket with 4-point screw connection.

Scheme 365

REMOVING DRIVE BELT

REMOVAL PROCEDURE FOR DRIVE BELT

INSTALLING DRIVE BELT

INSTALLATION PROCEDURE FOR DRIVE BELT

Scheme 366

REMOVAL AND INSTALLATION PROCEDURE OF DEFLECTION ROLLERS

Scheme 367

REMOVAL AND INSTALLATION PROCEDURE OF DEFLECTION ROLLERS

Scheme 368

SPECIAL TOOLS

Scheme 369

Scheme 370

Removing throttle body with intake distributor

Removing supply tank of power steering system

Separating steering pressure line and steering return line on underbod

Loosening steering return line in engine compartment

Separating steering return line from supply tank using tool

Loosening hydraulic pump and steering supply line in engine compartment

REMOVAL PROCEDURE OF BELT TENSIONER

Scheme 371

REMOVAL AND INSTALLATION PROCEDURE OF BELT TENSIONER

Scheme 372

DISASSEMBLY AND ASSEMBLY PROCEDURE OF BELT TENSIONER

Scheme 373

SPECIAL TOOL

The connecting-rod bearing caps must always remain allocated to the respective connecting rods and must never be interchanged.

Recommendation: After disassembly, immediately re-join the connecting-rod bearing cap and connecting rod or mark them on the sides with an electric scribing tool (e.g. with the cylinder designation). Never mark these parts with sharp objects such as pin punches or number embossing tools.

DISASSEMBLY AND ASSEMBLY PROCEDURE OF BEARING HOUSING WITH CRANKSHAFT (1 OF 2)

Scheme 374

DISASSEMBLY AND ASSEMBLY PROCEDURE OF BEARING HOUSING WITH CRANKSHAFT (2 OF 2)

ASSEMBLY INSTRUCTIONS

Tightening sequence for thrust-bearing screws

Scheme 375

TIGHTENING TORQUES - BEARING HOUSING WITH CRANKSHAFT

REMOVAL AND INSTALLATION OF THRUST-BEARING SCREWS

Scheme 376

CHECK PROCEDURE FOR BEARING HOUSING WITH CRANKSHAFT

Scheme 377

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Scheme 389

1. Detach thrust plate or flywheel. Fasten toothed segment (special tool 9538/1) on the crankcase half (cylinder bank 1 - 3) with hexagon-head bolt M12 x 50.
2. Detach thrust plate and remove with drive plate. Detach and remove the flywheel.
3. Clamp crankcase. Fasten engine holder, special tool 9589, to the crankcase half of cylinder bank 1 - 3.
4. Turn primary chain tensioner out of the crankcase (cylinder bank 4 - 6).
5. Loosen belt pulley. Undo hexagon-head bolt (M16 x 1.5 x 60) with special tool (socket wrench insert 9594); to do this, hold with holding device (special tool 9593).
6. Undo intermediate shaft flange. Unscrew the three fastening screws M6 x 20 on the intermediate-shaft flange. Undo the locknut using the socket wrench, special tool 9110. For this purpose, hold with a slotted screwdriver 7.0 x 1.1 at the slotted threaded pin.
7. Remove coolant guide housing.
8. Undo fastening screws between crankcase half of cylinder bank 1-3 and bearing housing.
9. Undo fastening screw between crankcase half of cylinder bank 4-6 and bearing housing.
10. Turn crankcase by 180°. Undo oil pan fastening screws (M6 x 16, 13 ea.). Detach oil pan by tapping it at the sides with a plastic hammer. Remove air-oil separator. See «REMOVING AND INSTALLING AIR/OIL SEPARATOR»(/porsche/boxster-s/986-2002-2004/remont/cooling-system-mechanical/#engine__removing-and-installing-airoil-separator) .
11. Turn crankcase 90° further. Crankcase half of cylinder bank 4 - 6 faces upward. Undo hexagon-head bolts (M6 x 35, 25 ea.) joining the crankcase halves.
12. Carefully lift the crankcase half up and off. Do not tilt - this might damage the pistons.
13. Mark pistons. Lever off front piston pin circlip. Push out piston pin.
14. Fasten assembly fixture (special tool 9607) on the bearing housing with two M10 x 20 hexagon-head bolts.

Scheme 390

SPECIAL TOOLS

FITTING PISTONS AND CONNECTING RODS

Prepare pistons and connecting rods for installation in the crankcase half of cylinders 1 - 3.

Scheme 391

Scheme 392

REMOVAL AND INSTALLATION PROCEDURE FOR PISTONS AND CONNECTING RODS

Scheme 393

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1. Fasten cylinder housing half, cyl. 1-3, in conjunction with mounting elements 9590 to engine holder 9589.
2. Clean bearing housing support surface, particularly in area of oil duct. Check dowel sleeves for correct seating.
3. Installation of the compete bearing housing in the crankcase half, cylinders 1-3. As the bearing housing is heavy, it should be installed using a workshop crane. Carefully and in stages, lower bearing housing with fitted holder 9607 and workshop crane towards the dowel sleeves (2 ea.), observing the following points: To aid in guiding, screw two pan head screws approx. 3 turns into the bearing housing from below. Just before reaching the final installation position, pull the loosened intermediate-shaft flange out of the housing area and rotate the flange so that the two flange lugs that are spaced closest together face upwards. After lowering, check whether there is sag in the upper chain area or sufficient lever travel exists. Lift the bearing housing and check the chain installation if necessary. Remove two cap head screws (guide aid).
4. For the following assembly procedure - piston installation, cylinders 1, 2 and 3 - the crankcase half and bearing housing unit must be held by at least two screwed connections. For this purpose, fasten two original cylinder head screws and plastic spacer sleeves, special tool 9613, from below. Tightening torque: 30 Nm (22 ft.lb) Use Torx screwdriver insert T50.
5. Turn crankcase by 90° on the assembly support. Cylinders 1, 2 and 3 face upwards.
6. Fit belt pulley. Screw in fastening screw by hand.
7. Turn crankshaft clockwise until the bore U4 on the pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595.
8. Remove preassembled connecting rod with piston of cylinder 1 from the assembly fixture.
9. Align the gaps of the piston rings offset by 120°.
10. Place piston with connecting rod in installation position.
11. Tighten piston ring clamp and fit piston with connecting rod. NOTE: Generously coat the piston and restraining strap with engine oil before fitting the piston.
12. Use the handle of a hammer to tap the piston into the cylinder while firmly pressing on the edge of the restraining strap. Use protective gloves. NOTE: The piston must be fitted in the cylinder carefully and with feeling. If the resistance increases, immediately interrupt the assembly process. Reposition the piston ring restraining strap and repeat the assembly operation.
13. Centre the piston in the cylinder bore and carefully push it down with the assembly aid (special tool 9598).
14. Turn crankcase by 90° to the left. Make sure the bearing shell is correctly seated in the connecting rod. The fixing lugs point to the oil pan.
15. Fit end caps. Lubricate bearing shells. The recesses of the connecting-rod bearing twist lock must face each other.
16. Tightening specification: Oil thread and contact surface. 1. Initial tightening 20 Nm (15 ft.lb) To facilitate subsequent checks it is recommended that, after initial tightening, the screw heads be marked with a colored pen. 2. Final tightening 1 x 90° turn Use 10 mm socket wrench insert (double hexagon).
17. Fitting piston and connecting rod in cylinder 2. Rotate crankshaft clockwise until bore U5 on the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595.
18. Prepare preassembled connecting rod of cylinder 2 for installation. Perform the following assembly steps as described from Steps 8 to 16 .
19. Fitting piston and connecting rod in cylinder 3 Rotate crankshaft clockwise until bore U6 on the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595.
20. Prepare preassembled connecting rod of cylinder 3 for installation. Perform the following assembly steps as described from Steps 8 to 16 . NOTE: Leave crankshaft at position U6 after fitting the piston and connecting rod in cylinder 3. This position is necessary for subsequent fitting of the piston of cylinder 6.
21. Remove belt pulley.

FITTING PISTONS ON CYLINDER BANK 4 - 6

Note. The crankcase half of cylinder bank 4 - 6 must be fitted before installation of the pistons.

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Scheme 449

1. Thoroughly clean sealing surface of the crankcase half of cylinder bank 1 - 3.
2. Ensure that the profile seals on the oil separator and the two seals on the coolant duct are seated correctly.
3. Apply a uniform bead of silicone approximately 1.5 mm wide to the cleaned sealing surface of the crankcase half of cylinder bank 4-6.
4. Place special tool 9645 on the receiving bore of the oil pump and turn the knob clockwise until the centering mandrel is braced in the crankcase half.
5. Before fitting the crankcase half, have a second person pull the drive chain out of the chain space using a wire.
6. Do not damage the sealing bead when setting the crankcase half in place.
7. Fasten crankcase half. Tightening torque: 13 Nm (10 ft.lb). Remove emerging silicone material.
8. Turn the centering mandrel anti-clockwise and remove. Remove silicone residue.
9. Remove special tool 9613.
10. Fit belt pulley. Screw in fastening screw by hand. Cylinder bank 4 - 6 faces upward. Bore U6 on the belt pulley must be aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595. NOTE: Fixing of the belt pulley is absolutely necessary in order to ensure precise fitting of the pistons.
11. Align connecting rod of cylinder 6. Insert centering mandrel, special tool 9608, in the assembly bore. NOTE: The centering mandrel remains in the eye of the connecting rod until the piston contacts the centering mandrel during fitting.
12. Install piston of cylinder 6. Check whether the piston pin circlip is present and was fitted correctly (flywheel side). The piston circlip opening must lie opposite the groove in the piston. Before installation, check whether the assembly tube (2) can be moved easily in the piston; remove burr if necessary.
13. Move piston to installation position, position the piston ring restraining strap and insert the piston. NOTE: Generously coat the piston, cylinder and restraining strap with engine oil before fitting the piston.
14. Use the handle of a hammer to tap the piston into the cylinder while firmly pressing on the edge of the restraining strap. Use protective gloves. NOTE: The piston must be fitted in the cylinder carefully and with feeling. If the resistance increases, immediately interrupt the assembly process. Reposition the piston ring restraining strap and repeat the assembly operation.
15. Centre the piston in the cylinder bore and carefully push it down with the assembly aid (special tool 9698) to the centering mandrel stop.
16. Carefully withdraw the centering mandrel and push the piston down to the stop.
17. Align piston and connecting rod again using the centering mandrel.
18. Push in piston pin as far as it will go using the pressure pin of special tool 9602.
19. Prepare piston pin circlip for fitting on the piston. It is important to pre-fit the circlip on a firm surface. The circlip must be pre-fitted only immediately prior to fitting on the piston pin eye. Manually insert the new circlip into the conical part of the assembly sleeve, special tool 9603. Place assembly sleeve 9603 onto the assembly tube of special tool 9602. Use assembly aid, special tool 9500/3, to slide the circlip from the conical sleeve into the assembly tube. Remove assembly sleeve 9500/3 and visually inspect the correct position of the circlip in the assembly tube. Carefully insert the pressure pin (1) of special tool 9602 into the assembly tube (2) until it contacts the piston pin circlip. The circlip can pop out of the assembly tube in the case of improper handling - danger of injury!
20. Carefully insert the complete unit, consisting of assembly tube with pressure pin, into the crankcase assembly bore. Press or position the assembly tube against the crankcase. Turn the assembly tube to move the piston pin circlip to the correct position. The piston circlip opening should lie opposite the groove in the piston for fitting. Mark the assembly tube. Move the piston pin circlip to the correct installation position by briefly and forcefully striking the palm against the handle of the pressure pin. Move the piston pin circlip to its installation position by briefly and forcefully striking the palm against the star knob of the pressure pin.
21. Visually inspect correct seating of the piston pin circlip, for example, with a shop-made electric torch with mirror. Drawing shows a torch with adjustable mirror.
22. Fitting piston in cylinder 5. Advance the crankshaft clockwise until bore U5 on the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin.
23. Perform the following assembly steps for piston installation in cylinder 5 as described from Steps 11 to 21 . Deviating assembly steps as from Step 24 .
24. A spacer sleeve (3) is additionally required when fitting the piston pin circlip in the piston of cylinder 5.
25. Fitting piston in cylinder 4. Advance the crankshaft clockwise until bore U4 on the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin.
26. Perform the following assembly steps for piston installation in cylinder 4 as described from Steps 11 to 21 . Deviating assembly steps as from Step 27 .
27. Two spacer sleeves (3 + 4) are additionally required when fitting the piston pin circlip in the piston of cylinder 4.
28. After fitting the pistons, fit a screw plug and new sealing ring in the assembly bore. Use a 12 mm hexagon socket wrench insert. Tightening torque: 80 Nm (59 ft.lb)
29. Fit guide rails of cylinder bank 1 - 3 (flywheel side); fit guide rails in correct position. View from the belt pulley side View from the flywheel side
30. Fit guide rails of cylinder bank 4-6 (pulley side); fit guide rails in correct position. View from the belt pulley side View from the belt pulley side
31. Fit oil pump with coolant guide housing. See «REMOVING AND INSTALLING OIL PUMP WITH COOLANT GUIDE HOUSING»(/porsche/boxster-s/986-2002-2004/remont/cooling-system-mechanical/#engine) .
32. Fit intermediate shaft flange. Grease sealing ring in area of intermediate shaft flange. Grease receiver bore in area of the crankcase. Carefully press in the intermediate flange. Screw in new micro-encapsulated hexagon-head bolts M6 x 20 (3 ea.). Tightening torque: 10 Nm (7.5 ft.lb) Tighten locknut with the socket wrench, special tool 9110. For this purpose, hold with a slotted screwdriver 7.0 x 1.1 at the slotted threaded pin. Tightening torque: 10 Nm (7.5 ft.lb). Further assembly instructions see «REMOVING AND INSTALLING SEALING RING FOR INTERMEDIATE SHAFT»(/porsche/boxster-s/986-2002-2004/remont/cooling-system-mechanical/#engine) .
33. Fit belt pulley.

Note. Check whether there are foreign objects in the drive belt grooves of the pulley and remove them if necessary.

Tighten hexagon-head bolt using the socket wrench insert 9594; simultaneously hold with retaining device 9593.

Tightening torque: 50 Nm (37 ft.lb)

Scheme 450

Scheme 451

TIGHTENING SEQUENCE

TIGHTENING SEQUENCE - BELT PULLEY

Scheme 452

SPECIAL TOOLS

Scheme 453

Scheme 454

Scheme 455

Scheme 456

Scheme 457

1. Disconnect battery.
2. Remove left-hand seat. Disconnect the electrical plug connection. Undo four Torx screws with socket TX 50 (3/8 inch). Put on floor protection cover.
3. Remove rear wall lining and rear wall cover
4. Remove drive belt. Mark the running direction of the belt with a colored pen. Relieve the belt tension. To do this, turn the tensioning roller (wrench size 24 mm) clockwise and simultaneously remove the belt from the drive pulleys.
5. Loosen belt pulley. Undo hexagon-head bolt (M16 x 1.5 x 60) with special tool 9594 (socket wrench insert); to do this, hold with special tool 9593 (retaining device).
6. Remove crankshaft sealing ring. The following tools and parts are required for removal of the crankshaft sealing ring: Angle drill Drill bit, $$ 3 mm Mounting lever, for example, special tool 9182 Sheetmetal screw with hexagon head (5.5 x 15) Washer Support, for example, wooden block 50 x 30 x 20 mm Removal procedure: Drill sealing ring on face side. (Scheme 461)Screw sheetmetal screw with washer approx. 5 mm into the bore. Position mounting lever on the sheetmetal screw; place support between the mounting lever and crankcase.
7. Lever crankshaft sealing ring out of the crankcase.

Scheme 458

1. Insert new sealing ring using special tool 9610 (insertion tool): Place assembly sleeve on crankshaft journal. Thoroughly lubricate the crankshaft journal, assembly sleeve and sealing lip. NOTE: Coat outer diameter of sealing ring with Loctite 574. Position sealing ring by hand and push off the assembly sleeve onto the crankshaft journal. Remove assembly sleeve. Position hexagon-head bolt (M16 x 1.5 x 60) and outer part of special tool and insert sealing ring as far as it will go.
2. Fit belt pulley. NOTE: Check whether there are foreign objects in the drive belt grooves of the pulley.
3. Tighten hexagon-head bolt using the socket wrench insert 9594; simultaneously hold with retaining device 9593.
4. Fit drive belt.

TIGHTENING SEQUENCE - BELT PULLEY

Scheme 459

Scheme 460

Note. Visually inspect the condition of the belt; remove foreign objects from the grooves if necessary.

Observe running direction (color pen marking).

Scheme 461

Scheme 462

1. Fit drive belt by hand, slightly pre-tensioned, in the following sequence: Coolant pump drive pulley (1) (Scheme 466) Alternator drive pulley (2) (Scheme 466) Deflection roller 1 (3) (Scheme 466) Power steering pump drive pulley (4) (Scheme 466) Air-conditioning compressor drive pulley (5) (Scheme 466) Crankshaft pulley (6) (Scheme 466) Tensioning roller (7) (Scheme 466) Then turn the tensioning roller (7) in clockwise direction and simultaneously fit the drive belt on the deflection roller 2 (8). (Scheme 466)
2. Slowly relieve the tensioning roller.
3. Visually check whether the belt is correctly positioned on all drive pulleys.
4. Fit rear wall trim, rear wall cover and seat again.
5. Connect the battery.
6. Perform tightness test.

REMOVING AND INSTALLING CRANKSHAFT SEALING RING - FLYWHEEL SIDE

Note. On vehicles with Tiptronic transmission, disconnect the battery, as the starter must be removed to separate the torque converter from the drive plate. Note the work instructions for disconnecting and reconnecting the battery. Disconnect the battery, see WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY . Remove Tiptronic transmission. Refer to REMOVING AND INSTALLING TIPTRONIC TRANSMISSION . Remove manual transmission. Refer to REMOVING AND INSTALLING TRANSMISSION G 86 . With the engine/transmission unit removed, uncouple the transmission.

Scheme 463

SPECIAL TOOLS

REMOVING CRANKSHAFT SEALING RING

Note. In order to avoid deforming the thrust plate housing, always loosen screws in several stages and in diametrically opposite sequence.

Scheme 464

Scheme 465

1. Remove the clutch pressure plate including clutch drive plate. Unscrew 6 M8 x 16 pan-head screws crossways in several stages. Remove the thrust plate, including the drive plate. Refer to «REMOVING AND INSTALLING THE CLUTCH PEDAL»(/porsche/boxster-s/986-2002-2004/remont/clutches-manual-hydraulic/#clutch-controls). NOTE: Make sure not to damage the crankshaft flange when installing and removing the double-mass flywheel (DMF) or Tiptronic drive plate!
2. Remove the double-mass flywheel (manual transmission) or the drive plate for the torque converter (Tiptronic). Unscrew 8 M10 x 1 x 50 pan-head screws for the DMF or M10 x 1 x 25 in the case of the drive plate, remove DMF or drive plate. To counter, fasten toothed segment 9538/1 to the crankcase using an M12 x 50 hexagon-head bolt (fine thread). (Scheme 469) NOTE: Never use an abrasive or polishing cloth or brushes with metal bristles on the sealing surface of the crankshaft flange!
3. Carefully remove small edges or burrs on the chamfer of the crankshaft flange with an oilstone. Then, carefully degrease the crankshaft journal and crankcase bore (e.g. using a clean, lint-free cloth that has been soaked in solvent naphtha or acetone). Blow dry using a low air pressure (0.5 bar) or ventilate. NOTE: The serial spindle sealing ring is pressed 11 mm in, measured from the end of the flange. The new sealing ring is pressed 13 mm in using the special tool insertion tool 9699 in order to generate a new running track. If the crankshaft flange is corroded, clean it as follows: Press the old crankshaft sealing ring in further with the special tool insertion tool 9699 in the same way as you would install a new sealing ring. Clean the crankshaft flange with a special metal-polishing pad (e.g. Never Dull, available in car and motor bike accessory stores). Then, carefully degrease the flange (e.g. using a clean, lint-free cloth that has been soaked in solvent naphtha or acetone). Replace the crankshaft sealing ring as described below.
4. Spot drill the crankshaft sealing ring on the front -arrow- with a 3 mm drill bit, grease the drill bit beforehand. (Scheme 470)
5. Screw sheetmetal screw (5 x 20) with washer approx. 5 mm into the bore.
6. Pull out the sealing ring with the puller 9237 -arrow-. If necessary, clean crankshaft flange again.

Scheme 466

INSTALLING THE CRANKSHAFT SEALING RING

Note. The tools should be thoroughly examined for any burred spots each time a sealing ring is fitted. Even minor damage to the tool can damage the micro sealing lips of the new sealing ring! The illustrations of the special tools below show their use with the engine removed and on the assembly support. Their use with the engine installed is identical.

Scheme 467

Scheme 468

Scheme 469

1. Small burred spots or damaged areas on the tools can be eliminated with a nail file, then pull off with a fine abrasive or polishing cloth. Remove residual dirt on the tools, e.g. using solvent naphtha or acetone.
2. Check crankshaft installation position. To do this, insert special tool measuring mandrel 9699/1 across the crankshaft flange into the fitting bore of the crankcase. (Scheme 472) The measuring mandrel must be placed with slight resistance in the bore. If the measuring mandrel cannot be positioned, the engine must be replaced. NOTE: The crankshaft sealing ring must not be oiled or greased. The micro sealing lips, in particular, are so sensitive that even the smallest contact can cause damage. Coat only the crankshaft case bore with new oil.
3. Coat the crankshaft case bore with new engine oil and slide the new crankshaft sealing ring over the crankshaft flange.
4. Fit insertion tool 9699 between the two internal M8 pan-head screws, (hexagon socket a/f 8) -with hexagon socket wrench insert- on the crankshaft flange and fasten it. The crankshaft flange's dowel pin must sit in the bore of the device.
5. To position the crankshaft sealing ring correctly on the crankshaft flange, turn an open-end/ring wrench in a clockwise direction as far as it will go on the hexagon (a/f 19) of the device. (Scheme 474) Then remove the tool by releasing the pan-head screws.
6. Install the DMF or drive plate. Make sure that the crankshaft flange is not damaged.
7. Install the clutch pressure plate and drive plate.
8. Refit or install the transmission.
9. Install the engine/transmission unit if necessary.

Scheme 470

Scheme 471

SPECIAL TOOLS

Prepare pistons and connecting rods for installation in the crankcase half of cylinders 1-3.

Scheme 472

Scheme 473

REMOVAL AND INSTALLATION PROCEDURE FOR PISTONS AND CONNECTING RODS

Scheme 474

Scheme 475

Scheme 476

Scheme 477