Installing engine
Note. The engine/transmission unit is installed in reverse order to removal. The following work steps are specifically repeated here in order to avoid damage.
| CAUTION | Risk of damage when inserting the engine/transmission unit into the vehicle Material damage! |
> Enlist assistance of second and, if necessary, third person
1. Raise engine/transmission unit into the engine compartment and guide the engine wire harness through the assembly opening.
2. Pre-position right transmission bracket and guide when inserting the engine/transmission unit.
3. Guide air-conditioning compressor through the rear wall opening and place in installation position.
4. Clip in refrigerant hoses -1- and -2- between body and intake-air distributor. see scheme 48
5. Insert connector for air-conditioning compressor supply line and clip connector housing into the holder provided on the intake distributor.
6. Screw in front Torx screws for air-conditioning compressor (M8 x 90) -1- and -2-. (Scheme 139)
7. Screw in rear Torx screw for air-conditioning compressor (M8 x 120) -1- and tighten all three screws for air-conditioning compressor. --> Tightening torque: 23 (17 ftlb.) Nm. (Scheme 138)
8. Move engine/transmission unit into the final installation position.
9. Screw in collar nuts (M10) -arrows- on the engine carrier and tighten. --> Tightening torque: 65 (48 ftlb.) Nm. see scheme 51
10. Insert left transmission bracket -A-. Screw in and tighten the two collar nuts (M8) -arrows-. --> Tightening torque: 33 (24 ftlb.) Nm. see scheme 52
A - Transmission support
B - Hydraulic mount
C - Central nut (never loosen)
11. Position screws -arrows- on the left transmission support and tighten. --> Tightening torque: 65 (48 ftlb.) Nm. see scheme 53
12. Position screws -arrows- on the right transmission support and tighten. --> Tightening torque: 65 (48 ftlb.) Nm. see scheme 54
13. Lower elevating platform and move out of work area. Remove special tool retainer plate P 9592 from engine.
14. Insert hydraulic line for clutch control into the rapid-action coupling and clip in safety clip.
15. Join fuel lines at the underbody.
16. Join hydraulic lines for power-steering at the underbody.
17. Clip in safety clips -arrows- at the servo-line couplings. see scheme 55
Fit shift and selector cables
Scheme 142
18. Engage shift and selector cable in support and press onto ball pins.
Shift connection for 5-speed manual transmission
Shift connection for Tiptronic transmission
Scheme 143
19. Tiptronic: Push on multi-function connector and lock it.
20. Tiptronic: Push on cable plug.
21. Insert connectors for oxygen sensors -1- and clip into the brackets. Clip wires -2- into the brackets. see scheme 61
22. Connect small vacuum line with connecting piece of vacuum pump and connect to pump connection piece.
23. Fit drive shafts at transmission side. To do this, screw in and tighten the six hexagon socket head bolts (M10 x 50) joining each drive shaft and transmission flange. --> Tightening torque: 81 (60 ftlb.) Nm .
24. Position ground strap -2- and screw down collar nut (M8) -1-. --> Tightening torque: 23 (17 ftlb.) Nm see scheme 64
25. Install rear silencer. Refer to 26 33 19 Removing and installing rear silencer - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
26. Position cross member and screw in and tighten cross-member screws (M10 x 45) -arrows-. --> Tightening torque: 65 (48 ftlb.) Nm. see scheme 65
27. Insert connectors -1- for monitor sensors and clip into the brackets. Clip wire -2- into the bracket. see scheme 66
28. Guide the restraining cable holders through the bores and tighten nuts (M8). (The cable must be countered with a suitable wrench and must not be twisted!) --> Tightening torque: 23 (17 ftlb.) Nm
29. Engage suspension/stabilizer and tighten nuts (M10) to the specified tightening torque stage 1. The threaded pin must be countered with an internal Torx socket. --> Tightening torque stage 1: 50 (37 ftlb.) Nm . Loosen nuts by 90° and tighten to the specified tightening torque stage 2 (counter). --> Tightening torque stage 2: 65 (48 ftlb.) Nm
30. Screw in and tighten screws (M8 x 40) -arrows- of the anti-roll bar bearing shells. --> Tightening torque: 23 (17 ftlb.) Nm see scheme 69
31. Position V-brace and tighten screws (M10 x 70) -arrows-. --> Tightening torque: 65 (48 ftlb.) Nm. see scheme 70
32. Position support plate then screw in and tighten collar nuts (M10) and screws (M10). --> Tightening torque: 65 (48 ftlb.) Nm ; --> Tightening torque: 65 (48 ftlb.) Nm
33. Position diagonal braces and screw in collar nuts (M10) and screws (M10 x 45). --> Tightening torque: 65 (48 ftlb.) Nm ; --> Tightening torque: 65 (48 ftlb.) Nm .
34. Push on coolant hoses -2, 4, 6-. Position spring band clamps -1, 3, 5-. see scheme 71
35. Insert coolant hoses -3- into the rapid-action couplings and ensure secure seating. Clip in plastic holders -1-. Ensure that safety clips -2- are fitted correctly. see scheme 72
36. Tiptronic: Push on hoses and secure spring band clamps.
37. Pull in rubber sleeve -1-. Ensure that rubber sleeve is fitted correctly. see scheme 74
38. Insert connectors for engine wire harness -1- and -2- above the left wheel arch. see scheme 75
39. Position ground lead and tighten nut (M6) -1-. --> Tightening torque: 10 (7.5 ftlb.) Nm see scheme 76
40. Plug in connectors at the engine control module. Refer to 24 70 19 Removing and installing DME control module - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
41. Tiptronic: connect combination connector to transmission control module and lock.
42. Insert connectors for luggage compartment light.
43. Fit rear luggage-compartment lining and clip in fastening clips. Fit luggage-compartment lid seal and ensure a correct fit. Refer to 70 06 19 Removing and installing rear luggage-compartment trim panel - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
44. Clip mass air flow sensor (MAF) line -arrow- into the air-cleaner box. see scheme 77
45. Insert cooling system vent line into the rapid-action coupling.
46. Push in connector -1- for scavenging -air fan -2-. see scheme 78
47. Fit B+ box -1-. --> Tightening torque: 10 (7.5 ftlb.) Nm. (Scheme 98)
48. Position power-steering reservoir. Lock bayonet lock -arrow- on power-steering reservoir. (Scheme 98)
49. Replace the quantity of Pentosin removed during removal with new Pentosin and pour this into the power-steering reservoir.
50. Turn the tensioning roller clockwise using a ring wrench (a/f 24), position the drive belt and then tension it.