Disassembling engine down to crankcase Porsche Boxster S 987

Disassembling engine down to crankcase

> When working on the engine, absolute cleanliness is essential.

> Lay removed engine parts on a clean base and cover them without fail.

> Use the cover for dust protection when fitting the engine NR.165 on the engine assembly support.

> Wear protective gloves and goggles.

> If you come into contact with coolant, wash off immediately with plenty of warm water.

> Wear protective gloves and goggles.

> If the eyes or skin come into contact with the fluid, wash immediately with water.

> Collect emerging Pentosin. Clean hoses which come into contact with Pentosin thoroughly.

> Use caps to protect the wiring against soiling and damage.

> Allow the engine to cool

> Wear specified protective gear.

Note. The central screws of the camshaft adjustment elements must be undone before removing the cylinder head cover.

Note. The bearing housing remains screwed to the retaining device when the bearing housing and intermediate shaft are disassembled.

Scheme 150

1. Engine support P 9589 must be secured to the crankcase using special tool mounting elements P 9590 . Refit engine with support on the engine assembly support.

Scheme 151

2. Drain engine oil. Unscrew the oil drain plug (hexagon socket a/f 8). Refer to 17 01 55 Engine oil and oil filter change - as of MY 2005 (All Models) .

Scheme 152

3. Remove pulley -2- of power-steering pump; to do this, counter the pulley -2- as shown using a screwdriver, then remove three Torx screws (M8 x 12) -1-. (Scheme 152)

4. Disconnect cable plug -2- of solenoid valves -3-. (Scheme 153)

5. Disconnect cable plug -4- of engine-temperature sensor -5-. (Scheme 153)

Scheme 153

6. Disconnect cable plug -1- of all fuel injector valves. (Scheme 153)

Scheme 154

7. Disconnect cable plug -Arrow- for carbon canister solenoid valve. (Scheme 154)

Scheme 155

8. Loosen support for servo lines -2- by unclipping the oxygen sensor line from the support -3- and unscrewing two Torx screws (M6 x 12) -1-. (Scheme 155)

9. Unscrew six fastening screws (M6 x 35) for each intake-air distributor.

10. Completely remove the intake bridge. Replace gaskets during installation.

Scheme 156

11. Remove drive belt cover by unscrewing three Torx screws (M6 x 12) -Arrows-. (Scheme 156)

12. Disconnect cable plug -1- on generator. (Scheme 157)

Scheme 157

13. Unscrew collar nut (M8) -2- and remove ground B+ line -3-. (Scheme 157)

Scheme 158

14. Remove generator -3- by unscrewing the Torx screws (M10 x 35) -1- and (M10 x 145) -2-. The deflection roller is removed together with the generator ( -3- ). Refer to 27 22 19 Removing and installing three-phase generator - as of MY 2006 (Cayman S, Cayman S RHD). Refer to 27 22 19 Removing and installing three-phase generator - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD). (Scheme 158)

Scheme 159

15. Remove oil filler neck -2- by unscrewing two Torx screws (M6 x 11) -1-. Replace O-ring and screws during installation. (Scheme 159)

16. Unscrew union nut of servo pressure line (a/f 16) -1-. (Scheme 160)

Scheme 160

17. Remove power-steering pump with the lines by unscrewing three Torx screws (M8 x 30) -3- and the Torx screw (M8 x 12) -2-. (Scheme 160)

Scheme 161

18. Remove power-steering pump support -2- by unscrewing four Torx screws (M8 x 35) -1-. The power-steering pump support -2- is also fixed with roll pins; if necessary use a rubber hammer for the removal. (Scheme 161)

Scheme 162

19. Remove the positive crankcase ventilation line -1- by releasing and disconnecting the rapid-action couplings -Arrows-. Replace O-rings during installation. (Scheme 162)

20. Unscrew collar nut (M8) -1- and remove terminal 30 line -2-. (Scheme 163)

Scheme 163

21. Unscrew collar nut (M6) -3- and remove terminal 50 line -4-. (Scheme 163)

Scheme 164

22. Remove engine wire harness; to do this, remove all remaining cable plugs, unscrew Torx screws (M6 x12) -1- of the ground straps -2- and unscrew two Torx screws (M6 x 12) and (M8 x 20) for each of the plastic cable wire harness guides. (Scheme 164)

Scheme 165

Scheme 166

23. Remove oil-water heat exchanger -1- by unscrewing four Torx screws (M6 x 16) -2-. Replace all O-rings during installation. (Scheme 166)

Scheme 167

24. Remove oil mist separator -3- by unscrewing two Torx screws (M6 x 20) -1- and loosening the spring band clamp -2-. Pull oil mist separator -3- from the cylinder head and pull off the hose. Replace O-ring during installation. (Scheme 167)

Scheme 168

25. Unscrew three Torx screws (M6 x 20) -1- on the bracket for the secondary air pump. (Scheme 168)

Scheme 169

26. Unscrew two Torx screws (M6 x 20) -1- on the flange of the secondary air pump -2-. Remove secondary air pump. Replace both metal seals during installation. (Scheme 169)

Scheme 170

27. Remove starter -2- by unscrewing two Torx screws (M10 x 35) -1-. Refer to 27 60 19 Removing and installing starter - as of MY 2005 (All Models). (Scheme 170)

28. Remove knock sensors -2- by unscrewing one Torx screw (M8 x 35) on each -1-. Mark the position of the electric connection for re-installation. (Scheme 171)

29. Unscrew oil level sensor with a ring wrench (a/f 19) -3-. Replace copper sealing ring during installation. (Scheme 171)

Scheme 171

30. Remove spacer sleeve -4-. (Scheme 171)

Scheme 172

31. Unscrew oil pressure sender with a ring wrench (a/f 24) -1-. Replace aluminum sealing ring during installation. (Scheme 172)

Scheme 173

32. Remove connection piece for positive crankcase ventilation -2- by unscrewing two Torx screws (M6 x 11) -1-. Replace O-ring during installation. (Scheme 173)

Scheme 174

33. Remove both hall senders -2- by unscrewing one Torx screw (M6 x 11) on each -1-. Replace O-rings during installation. (Scheme 174)

34. Remove deflection roller by unscrewing the Torx screw (M8 x 60). Check deflection roller for damage, wear and smooth operation.

35. Remove engine ground strap on cylinder 1-3 by unscrewing the Torx screw (M8 x 30).

Scheme 175

36. Remove crankshaft belt pulley by countering the belt pulley with special tool retaining device P 9593 and screwing out central screw (M16 x 60).

37. Remove engine mounting by unscrewing the three hexagon-head bolts (M10 x 120) and the hexagon-head bolt (M10 x 80). Only loosen the left upper hexagon-head bolt (M10 x 120); the hexagon-head bolt can be unscrewed after the engine mounting has been removed.

38. Tiptronic only: Remove clip for belt routing by unscrewing two Torx screws (M6 x 12).

39. Remove coolant guide housing by unscrewing five external Torx screws (M6 x 35) and three internal Torx screws (M6 x 20). Replace O-rings during installation.

Scheme 176

40. Remove ignition coils -1- by unscrewing two Torx screws (M6 x 25) -2-. (Scheme 176)

Scheme 177

41. Remove crankshaft pulse sender -1- by unscrewing the Torx screw (M6 x 15) -2-. (Scheme 177)

Scheme 178

42. Remove coolant lines -1- and -2- by unscrewing two Torx screws (M6 x 16) -3-. (Scheme 178)

Scheme 179

43. Remove coolant pump by unscrewing six hexagon-head bolts (M6 x 25, M6 x 30) -Arrows-. Replace metal seal during installation. (Scheme 179)

44. Remove thermostat housing. Unscrew four Torx screws (M6 x 20) and remove housing complete with thermostat. Replace seal during installation.

Scheme 180

45. Remove tandem pump by unscrewing four Torx screws (micro-self-locking, M6 x 30) -Arrows-. During installation, note the position of the pump drive with respect to the groove on the camshaft sprocket. Both parts must be in line in installation position. Otherwise the pump drive must be rotated. Replace O-ring and screws during installation. (Scheme 180)

Scheme 181

46. Remove solenoid hydraulic valve for camshaft adjustment. Refer to 15 37 19 Removing and installing solenoid hydraulic valve (camshaft timing) - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .

Scheme 182

47. Remove coolant adapter by unscrewing six Torx screws (M6 x 20) -Arrows-. Replace metal seal during installation. (Scheme 182)

Scheme 183

48. Remove brackets for oxygen sensor cables by unscrewing five Torx screws (M6 x 12) -Arrows-. (Scheme 183)

Scheme 184

49. Remove all remaining plastic accessories (clips, supports etc.).

50. Remove transport eyebolt -1- by unscrewing two Torx screws (M6 x 16) -2-. (Scheme 185)

Scheme 185

51. Remove supports -3- by unscrewing one Torx screw (M6 x 12) -4-. (Scheme 185)

52. Remove spark plugs. Refer to 28 70 20 Removing and fitting spark plugs - as of MY 2005 (All Models) .

53. Remove cylinder head cover 1 - 3. Refer to 15 82 20 Removing and installing cylinder head cover - engine removed - as of MY 2005 (Cayman S, Cayman S RHD) . Refer to 15 82 20 Removing and installing cylinder head cover - engine removed - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .

54. Remove camshaft 1 - 3. Refer to 15 05 20 Removing and installing camshaft - as of MY 2005 (Boxster S, Boxster S RHD) . Refer to 15 05 20 Removing and installing camshaft - as of MY 2005 (Boxster, Boxster RHD) .

Scheme 186

> The components have been run in the fitting bores in the housing, therefore do not interchange them.

> Pay attention to cleanliness.

55. Remove flat-base tappet 1 - 3. Refer to 15 70 19 Removing and installing cylinder head - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .

56. Remove cylinder head 1-3. Loosen and unscrew 12 Torx screws M10 x 230 from outside to inside on each cylinder head. Lift cylinder head and seal from crankcase. Refer to 15 70 19 Removing and installing cylinder head - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .

57. Remove cylinder head cover 4 - 6. Refer to 15 82 20 Removing and installing cylinder head cover - engine removed - as of MY 2005 (Cayman S, Cayman S RHD) . Refer to 15 82 20 Removing and installing cylinder head cover - engine removed - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .

58. Remove camshaft 4 - 6. Refer to 15 05 20 Removing and installing camshaft - as of MY 2005 (Boxster S, Boxster S RHD) . Refer to 15 05 20 Removing and installing camshaft - as of MY 2005 (Boxster, Boxster RHD) .

> The components have been run in the fitting bores in the housing, therefore do not interchange them.

> Pay attention to cleanliness.

59. Remove flat-base tappet 4 - 6. Refer to 15 70 19 Removing and installing cylinder head - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .

60. Remove cylinder head 4 - 6. Loosen and unscrew 12 Torx screws (M10 x 230) from outside to inside on each cylinder head. Lift cylinder head and seal from crankcase. Refer to 15 70 19 Removing and installing cylinder head - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .

Scheme 187

61. Remove oil pump with housing -1- by unscrewing two hexagon-head bolts (M6 x 80) -2-, two Torx screws (M6 x 20) -3- and (M10 x 100) -4-. Remove housing and ensure that the flange projection of the oil pump drive is not tilted. Replace the two O-rings during installation. (Scheme 187)

Scheme 188

62. Remove all carbon deposits and other residues on all six pistons with a brass brush, which will make the engraved markings -Arrow- visible. In addition, number and mark the pistons in installation position before removal. (Scheme 188)

63. Unscrew aluminum screw plug (M27) for the assembly bore (piston pin).

64. Remove lower M6 guide and tensioning rail screws (hexagon socket a/f 5), remove the guide and tensioning rails from the chain spaces.

65. Remove oil filter with special tool release key P 9204 .

Scheme 189

66. Unscrew 13 Torx screws M6 x 20 on the oil pan cover. Tap cover gently on the sides using a plastic hammer, then carefully lift it at the leverage bar --> Lifting the oil pan cover using a plastic-coated mounting lever and remove the oil pan. (Scheme 189)

Scheme 190

67. Remove air/oil separator (swirl pots) and oil suction pipe. To remove each separator, unscrew two M6 x 20 Torx screws and pull out the separator. Unscrew two M6 x 20 Torx screws on the oil suction pipe and remove the oil suction pipe. Replace O-rings during installation.

68. Remove bearing cover for intermediate shaft. Refer to 15 21 19 Removing and installing bearing cover for intermediate shaft - M96/26 - as of MY 2005 (Boxster S, Boxster S RHD) . Refer to 15 21 19 Removing and installing bearing cover for intermediate shaft - M96/25 - as of MY 2005 (Boxster, Boxster RHD) .