Crankcase, Suspension Porsche Boxster S 987

Engine M96/25, M96/26 and M97/21

* including double-mass flywheel

Engine design

Engine control

Tools

Preliminary work

> Raise the vehicle at the prescribed jacking points --> 40 LIFTING THE VEHICLE - AS OF MY 2005 (ALL MODELS) .

Note. Take care to maintain access to the screws for the diagonal struts in the vicinity of the rear jacking points.

1. Raise the vehicle at the prescribed jacking points. --> 40 LIFTING THE VEHICLE - AS OF MY 2005 (ALL MODELS) .

2. Place protective covers on the vehicle to avoid damaging the body and passenger compartment.

3. Read out fault memory and print log. Refer to 03 35 00 On-board diagnosis (OBD) - as of MY 2005 (All Models) .

4. Move convertible top to service position. Refer to 61 01 IN Diagram of convertible top - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .

5. Remove linings (carpet for rear wall cover and engine cover).

Scheme 95

6. Remove engine compartment lid. Refer to 55 78 19 Removing and installing engine compartment lid - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .

Scheme 96

7. Remove rear wall cover. Refer to 55 59 19 Removing and installing rear wall cover - as of MY 2005 (All Models) .

8. Disconnect ground lead of battery. Refer to 27 06 IN External power connection, jump lead starting - as of MY 2005 (All Models) .

9. Remove throttle body with distributor pipe (do not disassemble!). Refer to 24 42 19 Removing and installing throttle body - as of MY 2005 (All Models) .

10. Unclip shift or selector cables on the engine.

11. Remove both rear wheels. Use the specified special tool socket wrench insert P 300 to avoid damaging the wheel rims. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .

Removing engine

> Do not work on the engine while it is hot.

Note. If the vehicle is placed on its wheels or moved in the workshop, the rear axle carrier must be refitted under all circumstances to maintain the structural strength.

Scheme 97

1. Slacken the drive belt. To do this, turn the tensioning roller clockwise using a ring wrench (a/f 24), remove the drive belt, check for damage and wear and replace if necessary.

> Wear protective gloves and goggles

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

> Collect escaping Pentosin

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

> Immediately clean hoses and wiring thoroughly

2. Remove Pentosin by suction out of the power-steering pump reservoir and dispose of according to the country-specific regulations for hazardous substances.

Scheme 98

3. Release bayonet lock -arrow- on the power-steering reservoir and remove power-steering reservoir. Collect dripping Pentosin with a cloth. (Scheme 98)

4. Loosen B+ box -1-. To do this, unscrew two M6 fastening screws. (Scheme 98)

Scheme 99

5. Release and pull off connector -1- on scavenging-air fan -2-. (Scheme 99)

6. Open cap on coolant expansion tank.

Scheme 100

> Wear protective gloves and goggles

> In case of contact with the skin or eyes, wash immediately with plenty of water!

7. Boxster: Disconnect vent line at the rapid-action coupling.

Scheme 101

8. Unclip mass air flow sensor (MAF) line -arrow- from the air-cleaner box. (Scheme 101)

Scheme 102

9. Remove rear luggage-compartment lining. To do this, remove the luggage compartment seal and lever off the rear fastening clips.

10. Pull connectors off the luggage compartment light.

11. Mark the position of the connectors at the engine control module so that it will be easier to arrange them during installation.

12. Release and remove 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) .

Scheme 103

13. Unscrew nut (M6) -1- and remove ground leads. (Scheme 103)

14. Tiptronic: release combination connector on transmission control module and pull off.

Scheme 104

15. Release and pull off connectors -1- and -2- above the left wheel arch. (Scheme 104)

Scheme 105

16. Press the rubber sleeve -1- on the luggage compartment rear wall inwards and guide the engine wire harness -2- towards the engine compartment, if the engine is to be lowered later. (Scheme 105)

17. Remove rear underbody cover. Refer to 51 94 19 Removing and installing cover for rear underbody - as of MY 2005 (All Models) .

18. Remove center underbody cover. Refer to 51 93 19 Removing and installing cover for center underbody - as of MY 2005 (All Models) .

19. Release plastic support for the coolant hoses -1- on the underbody. (Scheme 106)

Scheme 106

> Wear protective gloves and goggles

> In case of contact with the skin or eyes, wash immediately with plenty of water!

20. Disconnect coolant hoses -3- at the rapid-action couplings. To do this, release the safety clips -2- with a screwdriver and pull off coolant hoses. Collect coolant in a suitable container. Seal open lines with suitable plugs. Clip in safety clips again at their original positions. (Scheme 106)

Scheme 107

21. Loosen spring band clamps -1, 3, 5- and pull off coolant hoses -2, 4, 6-. see scheme 71

Scheme 108

22. Tiptronic: Disconnect coolant hoses from oil-water heat exchanger (transmission), loosen spring band clamps and pull off hoses.

Scheme 109

23. Unscrew collar nuts (M10) -D-, unscrew screw (M10 x 45) -C- and remove diagonal braces -B-. (Scheme 109)

Scheme 110

24. Unscrew collar nuts (M8) and screws (M8 x 40). Remove support plate -A-. (Scheme 110)

Scheme 111

25. Unscrew screws (M10 x 70) -arrows- and remove V-brace. (Scheme 111)

Scheme 112

26. Unscrew screws (M8 x 40) -arrows- for anti-roll-bar bearing shells. (Scheme 112)

Scheme 113

27. Unscrew nuts (M10) on suspension/anti-roll bar and disengage suspension/anti-roll bar. Counter threaded bolts with an internal Torx socket.

Scheme 114

28. Unscrew nuts (M8) on restraining-cable holder. (The cable must be countered with a suitable wrench and must not be twisted!)

Scheme 115

29. Unclip electric plug connections -1- for the oxygen sensors on the left and right transverse bar from the brackets. Unclip the lead -2- from the bracket. Release and disconnect plug connections. (Scheme 115)

30. Headlight beam adjustment: Pull off cable plug on sensor.

Scheme 116

31. Unscrew cross-member screws (M10 x 45) -arrows- and remove cross member. Pay attention to the bracket for the headlight beam adjustment (if present). (Scheme 116)

32. Remove rear silencer. Refer to 26 33 19 Removing and installing rear silencer - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .

Scheme 117

33. Unscrew nut (M8) -1- and remove ground strap -2- (right side of vehicle). (Scheme 117)

Scheme 118

Note. Protect drive shafts against mechanical damage (e. g. with a rubber hose which has been cut open).

34. Disconnect drive shafts at transmission side. To do this, unscrew the six hexagon socket head bolts (M10 x 50) joining each drive shaft and transmission flange. To prevent the brake disc turning, a second person in the vehicle must operate the brakes.

Scheme 119

35. Release vacuum line -2- on vacuum pump for brake booster and pull off. Then pull off the small vacuum line -1-. (Scheme 119)

Scheme 120

36. Unclip electric plug connections for oxygen sensors -1- at the left and right rear wall from the brackets. Unclip lines -2- from the brackets. (Scheme 120)

Scheme 121

Disassembly of shift and selector cables

Scheme 122

37. Lever out the shift and selector cables from the ball pins and disengage from the supports.

Scheme 123

Shift connection for 5-speed manual transmission

Scheme 124

Shift connection for Tiptronic

Scheme 125

38. Tiptronic: Release and disconnect multi-function connector.

Scheme 126

39. Tiptronic: Release and disconnect cable plug.

Scheme 127

40. Unclip safety clips -arrow- at the servo-line couplings. (Scheme 127)

> Wear protective gloves and goggles

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

> Collect escaping Pentosin

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

> Immediately clean hoses and wiring thoroughly

Note. If the holder on the servo line's plug-in coupling needs to be replaced, the special tool assembly aid P 9622 is already contained in the parts set.

41. Disconnect hydraulic lines for power-steering at the underbody. Unclip lines from the brackets. Collect Pentosin in a suitable container.

Scheme 128

Note. If the holder on the servo line's plug-in coupling needs to be replaced, the special tool assembly aid P 9622 is already contained in the parts set.

42. Tilt holder on one side -C, arrow- and simultaneously pull to disengage. Detach nipple from the pipe and remove the old O-ring. Close off line. (Scheme 128)

Scheme 129

43. Fit holder rosette -C- in threaded part -A- and, if necessary, fix using assembly aid P 9622. Screw threaded part with new O-ring into the screw coupling -B- and tighten. Counter the coupling when tightening. --> Tightening torque: 30 (22 ftlb.) Nm --> Tightening torque: 40 (30 ftlb.) Nm. (Scheme 129)

44. Seal open lines with suitable plugs.

Scheme 130

> Do not work on fuel system if engine is hot!

> Do not smoke, avoid fire and naked flames!

> Wear fuel-resistant protective gloves and goggles.

> Attach warning sign to vehicle in a clearly visible position.

45. Disconnect fuel lines -1- and -2- at underbody. Collect emerging fuel in a suitable container. Seal open lines with suitable plugs. (Scheme 130)

> Store brake fluid in suitable, labelled containers only

> Wear protective gloves and goggles

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

> In the event of contact with paint surfaces, wash off immediately with water, do not wipe off

46. Disconnect hydraulic line for clutch control. Collect emerging brake fluid in a suitable container. Seal open lines with suitable plugs. The rapid-action coupling is handled in the same way as the servo line. --> Tightening torque: 30 (22 ftlb.) Nm

47. Attach special tool retainer plate P 9592 to engine.

Scheme 131

48. Screw special tool support plate P 9592/1 to retainer plate in position -9592- using four M8x20 hexagon bolts. (Scheme 131)

48.1. Screw special tool mounting peg P 9163/2 to the support plate in the marked position -Boxster- using four M8x25 hexagon bolts. (Scheme 131)

49. To support the transmission, use special tool support plate P 9592/2 . Depending on transmission type, use the associated spacers.

Scheme 132

Retainer plate 9592 complete fitted to engine/transmission

Scheme 133

50. Prepare lifting table for the removal. Fasten mounting plate (Order No. 102 543) for sports cars using four screws and nuts -2- to the Master Gear unit lifting table. (Scheme 133)

Master Gear: Workshop Equipment Manual Gr. 3.0.13 Unit lifting table (+ sports car mounting accessory)

Scheme 134

51. Unscrew three M10 screws -arrows- on the left transmission support and remove these. (Scheme 134)

Scheme 135

52. Loosen the three M10 screws -arrows- on the right transmission support. (Scheme 135)

Scheme 136

Note. Do not loosen transmission support at the central nut as this will damage the hydraulic mount. Do not loosen transmission support at the central nut as this will damage the hydraulic mount.

53. Unscrew the two fastening nuts (M8) -arrows-. Remove left transmission bracket -A-. Remove the right transmission bracket by lowering the unit. (Scheme 136)

A - Transmission support

B - Hydraulic mount

C - Central nut (never loosen)

Scheme 137

54. Position lifting table under vehicle and support engine by raising the mounting plate on the mounting peg P 9163/2. Unscrew collar nuts (M10) -arrows- on the engine carrier. (Scheme 137)

55. Gently lower the engine/transmission unit with the lifting table.

Scheme 138

56. Unscrew rear Torx screw for air-conditioning compressor (M8 x 120) -1-. To do this, press the line for the charcoal canister load carefully to the side. (Scheme 138)

Scheme 139

57. Unscrew front Torx screws for air-conditioning compressor (M8 x 90) -1- and -2-. (Scheme 139)

58. Disconnect plug connection for air-conditioning compressor supply line to the intake distributor.

Scheme 140

59. Unclip refrigerant hoses -1- and -2- between body and intake-air distributor. (Scheme 140)

Scheme 141

Note. The air-conditioning lines on the compressor do not have to be disconnected in order to remove engine/transmission unit. After removal, place the air-conditioning compressor on a suitable protective support (e. g. foam, neoprene, etc.).

60. Guide refrigerant compressor through the rear wall opening and place on a suitable surface on the center tunnel.

> Enlist assistance of second and, if necessary, third person

61. Lower engine/transmission unit and guide the engine wire harness into the engine compartment.

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.

> 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.

Subsequent work for installing engine

1. Fit both rear wheels. Use the specified special tool socket wrench insert P 300 to avoid damaging the wheel rims. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .

2. Install throttle body with distributor pipe. Refer to 24 42 19 Removing and installing throttle body - as of MY 2005 (All Models) .

3. Connect ground lead of battery. Refer to 27 06 IN External power connection, jump lead starting - as of MY 2005 (All Models) .

4. Bleed the clutch hydraulic system. Refer to 30 01 07 Bleeding the clutch system - as of MY 2005 (All Models) .

5. Fill and bleed cooling system. Refer to 19 38 17 Draining and filling in coolant - as of MY 2005 (All Models) .

6. Check Pentosin level in power-steering reservoir. Refer to 48 02 01 Checking the fluid level for the power-assisted steering - as of MY 2005 (All Models) .

7. Start engine. Turn the steering wheel from stop to stop while the engine is running in order to bleed the steering system.

8. Check all fluid levels and seal tightness after the engine test run.

9. Install middle underbody cover. Refer to 51 93 19 Removing and installing cover for center underbody - as of MY 2005 (All Models) .

10. Install rear underbody cover. Refer to 51 94 19 Removing and installing cover for rear underbody - as of MY 2005 (All Models) .

11. Align the vehicle. Refer to 44 95 03 Suspension alignment, complete - as of MY 2005 (All Models) .

12. Install rear wall cover. Refer to 55 59 19 Removing and installing rear wall cover - as of MY 2005 (All Models) .

13. Install engine compartment lid. Refer to 55 78 19 Removing and installing engine compartment lid - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .

Scheme 144

14. Boxster: Close convertible top.

15. Install linings (carpet for rear wall cover and engine cover).

16. Read out fault memory and correct any faults that are present. Erase fault memory. Refer to 03 35 00 On-board diagnosis (OBD) - as of MY 2005 (All Models) .

17. Perform a test drive.

> Raise the vehicle at the prescribed jacking points --> 40 LIFTING THE VEHICLE - AS OF MY 2005 (ALL MODELS) .

Note. Take care to maintain access to the screws for the diagonal struts in the vicinity of the rear jacking points.

1. Raise the vehicle at the prescribed jacking points. --> 40 LIFTING THE VEHICLE - AS OF MY 2005 (ALL MODELS) .

2. Place protective covers on the vehicle to avoid damaging the body and passenger compartment.

3. Read out fault memory and print log. Refer to 03 35 00 On-board diagnosis (OBD) - as of MY 2005 (All Models) .

4. Remove the trim panel for engine compartment lid. Refer to 70 08 19 Removing and installing trim panel for convertible top rest/engine compartment lid - as of MY 2005 (Cayman S, Cayman S RHD) .

Scheme 145

5. Remove engine compartment lid. Refer to 55 78 19 Removing and installing engine compartment lid - as of MY 2005 (Cayman S, Cayman S RHD) .

6. Remove rear wall cover. Refer to 55 59 19 Removing and installing rear wall cover - as of MY 2005 (All Models) .

7. Disconnect ground lead of battery --> 27 06 IN WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY - AS OF MY 2005 (ALL MODELS) .

8. Remove throttle body with distributor pipe (do not disassemble!). Refer to 24 42 19 Removing and installing throttle body - as of MY 2005 (All Models) .

9. Unclip shift or selector cables on the engine.

10. Remove both rear wheels. Use the specified special tool socket wrench insert P 300 to avoid damaging the wheel rims. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .

> Do not work on the engine while it is hot.

Note. If the vehicle is placed on its wheels or moved in the workshop, the rear axle carrier must be refitted under all circumstances to maintain the structural strength.

1. Slacken the drive belt. To do this, turn the tensioning roller clockwise using a ring wrench (a/f 24), remove the drive belt, check for damage and wear and replace if necessary.

> Wear protective gloves and goggles

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

> Collect escaping Pentosin

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

> Immediately clean hoses and wiring thoroughly

2. Remove Pentosin by suction out of the power-steering pump reservoir and dispose of according to the country-specific regulations for hazardous substances.

3. Release bayonet lock -arrow- on the power-steering reservoir and remove power-steering reservoir. Collect dripping Pentosin with a cloth. see scheme 87

4. Loosen B+ box -1-. To do this, unscrew two M6 fastening screws. see scheme 87

5. Release and pull off connector -1- on scavenging-air fan -2-. see scheme 88

6. Open cap on coolant expansion tank.

> Wear protective gloves and goggles

> In case of contact with the skin or eyes, wash immediately with plenty of water!

7. Boxster: Disconnect vent line at the rapid-action coupling.

8. Unclip mass air flow sensor (MAF) line -arrow- from the air-cleaner box. see scheme 90

9. Remove rear luggage-compartment lining. To do this, remove the luggage compartment seal and lever off the rear fastening clips.

10. Pull connectors off the luggage compartment light.

11. Mark the position of the connectors at the engine control module so that it will be easier to arrange them during installation.

12. Release and remove connectors at the engine control module. Refer to 24 70 19 Removing and installing DME control module - as of MY 2006 (Cayman S, Cayman S RHD) .

13. Unscrew nut (M6) -1- and remove ground leads. see scheme 92

14. Tiptronic: release combination connector on transmission control module and pull off.

15. Release and pull off connectors -1- and -2- above the left wheel arch. see scheme 93

16. Press the rubber sleeve -1- on the luggage compartment rear wall inwards and guide the engine wire harness -2- towards the engine compartment, if the engine is to be lowered later. see scheme 94

17. Remove rear underbody cover. Refer to 51 94 19 Removing and installing cover for rear underbody - as of MY 2005 (All Models) .

18. Remove center underbody cover. Refer to 51 93 19 Removing and installing cover for center underbody - as of MY 2005 (All Models) .

19. Release plastic support for the coolant hoses -1- on the underbody. see scheme 95

> Wear protective gloves and goggles

> In case of contact with the skin or eyes, wash immediately with plenty of water!

20. Disconnect coolant hoses -3- at the rapid-action couplings. To do this, release the safety clips -2- with a screwdriver and pull off coolant hoses. Collect coolant in a suitable container. Seal open lines with suitable plugs. Clip in safety clips again at their original positions. see scheme 95

21. Loosen spring band clamps -1, 3, 5- and pull off coolant hoses -2, 4, 6-. see scheme 154

22. Tiptronic: Disconnect coolant hoses from oil-water heat exchanger (transmission), loosen spring band clamps and pull off hoses.

23. Unscrew collar nuts (M10) -D-, unscrew screw (M10 x 45) -C- and remove diagonal braces -B-. see scheme 98

24. Unscrew collar nuts (M8) and screws (M8 x 40). Remove support plate -A-. see scheme 99

25. Unscrew screws (M10 x 70) -arrows- and remove V-brace. see scheme 100

26. Unscrew screws (M8 x 40) -arrows- for anti-roll-bar bearing shells. see scheme 101

27. Unscrew nuts (M10) on suspension/anti-roll bar and disengage suspension/anti-roll bar. Counter threaded bolts with an internal Torx socket.

28. Unscrew nuts (M8) on restraining-cable holder. (The cable must be countered with a suitable wrench and must not be twisted!)

29. Unclip electric plug connections -1- for the oxygen sensors on the left and right transverse bar from the brackets. Unclip the lead -2- from the bracket. Release and disconnect plug connections. see scheme 104

30. Headlight beam adjustment: Pull off cable plug on sensor.

31. Unscrew cross-member screws (M10 x 45) -arrows- and remove cross member. Pay attention to the bracket for the headlight beam adjustment (if present). see scheme 105

32. Remove rear silencer. Refer to 26 33 19 Removing and installing rear silencer - as of MY 2005 (Cayman S, Cayman S RHD) .

33. Unscrew nut (M8) -1- and remove ground strap -2- (right side of vehicle). see scheme 106

Note. Protect drive shafts against mechanical damage (e. g. with a rubber hose which has been cut open).

34. Disconnect drive shafts at transmission side. To do this, unscrew the six hexagon socket head bolts (M10 x 50) joining each drive shaft and transmission flange. To prevent the brake disc turning, a second person in the vehicle must operate the brakes.

35. Release vacuum line -2- on vacuum pump for brake booster and pull off. Then pull off the small vacuum line -1-. see scheme 108

36. Unclip electric plug connections for oxygen sensors -1- at the left and right rear wall from the brackets. Unclip lines -2- from the brackets. see scheme 109

Disassembly of shift and selector cables

37. Lever out the shift and selector cables from the ball pins and disengage from the supports.

Shift connection for 5-speed manual transmission

Shift connection for Tiptronic

38. Tiptronic: Release and disconnect multi-function connector.

39. Tiptronic: Release and disconnect cable plug.

40. Unclip safety clips -arrow- at the servo-line couplings. see scheme 116

> Wear protective gloves and goggles

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

> Collect escaping Pentosin

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

> Immediately clean hoses and wiring thoroughly

Note. If the holder on the servo line's plug-in coupling needs to be replaced, the special tool assembly aid P 9622 is already contained in the parts set.

41. Disconnect hydraulic lines for power-steering at the underbody. Unclip lines from the brackets. Collect Pentosin in a suitable container.

Note. If the holder on the servo line's plug-in coupling needs to be replaced, the special tool Assembly aid P 9622 is already contained in the parts set.

42. Tilt holder on one side -C, arrow- and simultaneously pull to disengage. Detach nipple from the pipe and remove the old O-ring. Close off line. see scheme 117

43. Fit holder rosette -C- in threaded part -A- and, if necessary, fix using assembly aid P 9622. Screw threaded part with new O-ring into the screw coupling -B- and tighten. Counter the coupling when tightening. --> Tightening torque: 30 (22 ftlb.) Nm --> Tightening torque: 40 (30 ftlb.) Nm. see scheme 118

44. Seal open lines with suitable plugs.

> Do not work on fuel system if engine is hot!

> Do not smoke, avoid fire and naked flames!

> Wear fuel-resistant protective gloves and goggles.

> Attach warning sign to vehicle in a clearly visible position.

45. Disconnect fuel lines -1- and -2- at underbody. Collect emerging fuel in a suitable container. Seal open lines with suitable plugs. see scheme 119

> Store brake fluid in suitable, labelled containers only

> Wear protective gloves and goggles

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

> In the event of contact with paint surfaces, wash off immediately with water, do not wipe off

46. Disconnect hydraulic line for clutch control. Collect emerging brake fluid in a suitable container. Seal open lines with suitable plugs. The rapid-action coupling is handled in the same way as the servo line. --> Tightening torque: 30 (22 ftlb.) Nm

47. Attach special tool retainer plate P 9592 to engine.

48. Screw special tool support plate P 9592/1 to retainer plate in position -9592- using four M8x20 hexagon bolts. see scheme 120

48.1. Screw special tool mounting peg P 9163/2 to the support plate in the marked position -Boxster- using four M8x25 hexagon bolts. see scheme 120

49. To support the transmission, use special tool support plate P 9592/2 . Depending on transmission type, use the associated spacers.

Retainer plate 9592 complete fitted to engine/transmission

50. Prepare lifting table for the removal. Fasten mounting plate (Order No. 102 543) for sports cars using four screws and nuts -2- to the Master Gear unit lifting table. see scheme 122

Master Gear: Workshop Equipment Manual Gr. 3.0.13 Unit lifting table (+ sports car mounting accessory)

51. Unscrew three M10 screws -arrows- on the left transmission support and remove these. see scheme 123

52. Loosen the three M10 screws -arrows- on the right transmission support. see scheme 124

Note. Do not loosen transmission support at the central nut as this will damage the hydraulic mount. Do not loosen transmission support at the central nut as this will damage the hydraulic mount.

53. Unscrew the two fastening nuts (M8) -arrows-. Remove left transmission bracket -A-. Remove the right transmission bracket by lowering the unit. see scheme 125

A - Transmission support

B - Hydraulic mount

C - Central nut (never loosen)

54. Position lifting table under vehicle and support engine by raising the mounting plate on the mounting peg P 9163/2. Unscrew collar nuts (M10) -arrows- on the engine carrier. see scheme 126

55. Gently lower the engine/transmission unit with the lifting table.

56. Unscrew rear Torx screw for air-conditioning compressor (M8 x 120) -1-. To do this, press the line for the charcoal canister load carefully to the side. see scheme 127

57. Unscrew front Torx screws for air-conditioning compressor (M8 x 90) -1- and -2-. see scheme 128

58. Disconnect plug connection for air-conditioning compressor supply line to the intake distributor.

59. Unclip refrigerant hoses -1- and -2- between body and intake-air distributor. see scheme 129

Note. The air-conditioning lines on the compressor do not have to be disconnected in order to remove engine/transmission unit. After removal, place the air-conditioning compressor on a suitable protective support (e. g. foam, neoprene, etc.).

60. Guide refrigerant compressor through the rear wall opening and place on a suitable surface on the center tunnel.

> Enlist assistance of second and, if necessary, third person

61. Lower engine/transmission unit and guide the engine wire harness into the engine compartment.

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.

> 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 131

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-. see scheme 128

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. see scheme 127

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 134

10. Insert left transmission bracket -A-. Screw in and tighten the two collar nuts (M8) -arrows-. --> Tightening torque: 33 (24 ftlb.) Nm. see scheme 135

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 136

12. Position screws -arrows- on the right transmission support and tighten. --> Tightening torque: 65 (48 ftlb.) Nm. see scheme 137

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 138

Fit shift and selector cables

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

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 144

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 147

25. Install rear silencer. Refer to 26 33 19 Removing and installing rear silencer - as of MY 2005 (Cayman S, Cayman 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 148

27. Insert connectors -1- for monitor sensors and clip into the brackets. Clip wire -2- into the bracket. see scheme 149

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 152

31. Position V-brace and tighten screws (M10 x 70) -arrows-. --> Tightening torque: 65 (48 ftlb.) Nm. see scheme 153

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 154

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 155

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 157

38. Insert connectors for engine wire harness -1- and -2- above the left wheel arch. see scheme 158

39. Position ground lead and tighten nut (M6) -1-. --> Tightening torque: 10 (7.5 ftlb.) Nm see scheme 159

40. Plug in connectors at the engine control module. Refer to 24 70 19 Removing and installing DME control module - as of MY 2006 (Cayman S, Cayman 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 (carpet lining) - as of MY 2006 (Cayman S, Cayman S RHD) .

44. Clip mass air flow sensor (MAF) line -arrow- into the air-cleaner box. see scheme 160

45. Insert cooling system vent line into the rapid-action coupling.

46. Push in connector -1- for scavenging -air fan -2-. see scheme 161

47. Fit B+ box -1-. --> Tightening torque: 10 (7.5 ftlb.) Nm. see scheme 87

48. Position power-steering reservoir. Lock bayonet lock -arrow- on power-steering reservoir. see scheme 87

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.

1. Fit both rear wheels. Use the specified special tool socket wrench insert P 300 to avoid damaging the wheel rims. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .

2. Install throttle body with distributor pipe. Refer to 24 42 19 Removing and installing throttle body - as of MY 2005 (All Models) .

3. Connect ground lead of battery. Refer to 27 06 IN External power connection, jump lead starting - as of MY 2005 (All Models) .

4. Bleed the clutch hydraulic system. Refer to 30 01 07 Bleeding the clutch system - as of MY 2005 (All Models) .

5. Fill and bleed cooling system. Refer to 19 38 17 Draining and filling in coolant - as of MY 2005 (All Models) .

6. Check Pentosin level in power-steering reservoir. Refer to 48 02 01 Checking the fluid level for the power-assisted steering - as of MY 2005 (All Models) .

7. Start engine. Turn the steering wheel from stop to stop while the engine is running in order to bleed the steering system.

8. Check all fluid levels and seal tightness after the engine test run.

9. Install middle underbody cover. Refer to 51 93 19 Removing and installing cover for center underbody - as of MY 2005 (All Models) .

10. Install rear underbody cover. Refer to 51 94 19 Removing and installing cover for rear underbody - as of MY 2005 (All Models) .

11. Align the vehicle. Refer to 44 95 03 Suspension alignment, complete - as of MY 2005 (All Models) .

12. Install rear wall cover. Refer to 55 59 19 Removing and installing rear wall cover - as of MY 2005 (All Models) .

13. Install engine compartment lid. Refer to 55 78 19 Removing and installing engine compartment lid - as of MY 2005 (Cayman S, Cayman S RHD) .

14. Boxster: Close convertible top.

15. Install linings (carpet for rear wall cover and engine cover).

16. Read out fault memory and correct any faults that are present. Erase fault memory. Refer to 03 35 00 On-board diagnosis (OBD) - as of MY 2005 (All Models) .

17. Perform a test drive.

Preliminary work for disassembling engine

1. Remove engine > 100119 Removing and installing engine [987310 987311 987320 987321] > 100119 Removing and installing engine [987120 987121] .

2. Remove transmission. Refer to 34 35 27 Removing and refitting transmission - as of MY 2005 (Boxster, Boxster RHD) . Refer to 34 35 27 Removing and refitting transmission - as of MY 2005 (Boxster S, Boxster S RHD, Cayman S, Cayman S RHD) .

3. Remove exhaust manifold. Refer to 26 10 19 Removing and installing exhaust manifold (with primary catalytic converter) - as of MY 2005 (All Models) .

Tiptronic transmission

4. Remove drive plate for converter. Refer to 13 63 19 Removing and installing drive plate for converter - as of MY 2005 (All Models) .

Manual transmission

5. Remove clutch. Refer to 30 50 19 Removing and installing clutch - as of MY 2005 (All Models) .

6. Remove flywheel. Refer to 13 60 19 Removing and installing flywheel - as of MY 2005 (All Models) .

Component overview - engine

Note. The overview graphics are shown schematically and may be different to how the components actually look.

Intake system, belt drive

Scheme 146

1. 1 - Intake distributor
2. 2 - Belt drive
3. 3 - Belt guide and belt tensioner

Engine lubrication, engine cooling

Scheme 147

1. 4 - Oil pump, heat exchanger, water pump, coolant guide housing
2. 5 - Oil pan, oil separator

Cylinder head, crankcase

Scheme 148

1. 6 - Cylinder-head cover, camshafts, flat-base tappet housing, cylinder head
2. 7 - Cylinder head, flat-base tappets
3. 8 - Crankcase halves

Crank drive, pistons

Scheme 149

1. 9 - Pistons, connecting rods
2. 10 - Bearing housing with intermediate shaft
3. 11 - Bearing housing halves with crankshaft

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) .

Assembling engine

> 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.

Note. All O-rings and seals (shaft seals) and micro-encapsulated screws or lock nuts must be replaced.

Note. Replace all O-rings and grease shaft seals lightly with Optimol MP3 or Kluber Syntheso Glep.

Note. The O-rings for the spark-plug recesses must be replaced.

Note. Re-insert flat-base tappets in the fitted bores in which they were positioned before the disassembly. The flat-base tappets have been run in the fitting bores in the housing and therefore may not be switched.

The engine is assembled in reverse order to the disassembly. Components that are not replaced must be cleaned.

Markings on crankcase

Scheme 191

Engine number

Scheme 192

Cylinder arrangement

1. Fit 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) .

2. Fit air/oil separator (swirl pots) and oil suction tube.

3. Install oil pan. Apply a bead of sealant, Loctite 5900 , to the cleaned and greased oil pan and secure with 13 Torx screws from the inside out. --> Tightening torque: 10 (7.5 ftlb.) Nm

4. Install new oil filter using special tool oil filter spanner P 9204 .

5. Fit lower guide and tensioning rail screws.

6. Screw in aluminum screw plug (M27) for the assembly bore (piston pin).

7. Fit oil pump with housing.

Note. Cylinder-head gaskets are identical parts, lay them down with the TOP identification facing upwards.

8. Fit cylinder head 4-6. Refer to 15 70 19 Removing and installing cylinder head - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .

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

> Pay attention to cleanliness.

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

10. Install 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) .

11. Fit tandem pump.

12. Install 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) .

13. Fit cylinder head 1-3. Refer to 15 70 19 Removing and installing cylinder head - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .

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

> Pay attention to cleanliness.

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

15. Install 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) .

16. Install 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) .

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

18. Fit support for servo lines.

19. Fit transport eyebolt.

20. Fit all plastic components that have been removed (clips, support, etc.).

21. Fit brackets for oxygen sensor cable.

22. Fit coolant adapter.

23. Fit solenoid hydraulic valves 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) .

24. Install thermostat housing.

25. Fit coolant pump.

26. Fit coolant lines.

27. Fit crankshaft pulse sender.

28. Fit ignition coils.

29. Fit coolant guide housing.

30. Tiptronic only: Fit clip for guide belt.

31. Fit engine mounting.

32. Fit crankshaft belt pulley retaining device P 9593 .

33. Fit engine ground lead on cylinder 1-3.

34. Fit deflection roller.

35. Fit both hall senders.

36. Fit flange for positive crankcase ventilation.

37. Install oil pressure sender.

38. Coat spacer sleeve with acid-free grease at the base and insert it.

39. Install oil-level sensor.

40. Fit knock sensors.

41. Fit starter.

42. Fit secondary air pump.

43. Fit oil mist collector. Fix hose with spring band clamp.

44. Fit oil/water heat exchanger.

45. Fit engine wire harness.

46. Fit terminal 50 starter line.

47. Fit terminal 30 starter line.

48. Fit positive crankcase ventilation line.

49. Fit power-steering pump support.

50. Fit power-steering pump.

51. Tighten union nut for servo pressure line.

52. Fit oil filler neck.

53. Fit generator and deflection roller. 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) .

54. Fit B+ wire on generator.

55. Connect cable plug to generator.

56. Fit cover for drive belt.

57. Fit intake-air distributor.

58. Fit support for servo lines. Clip oxygen sensor line into support.

59. Connect cable plug for carbon canister solenoid valve.

60. Connect cable plug for all fuel injectors.

61. Push on cable plug for engine compartment temperature sensor.

62. Connect cable plug for the solenoid valves.

63. Fit pulley for power-steering pump.

Assembling engine, touching up

Manual transmission

1. Install flywheel. Refer to 13 60 19 Removing and installing flywheel - as of MY 2005 (All Models) .

2. Fit clutch. Refer to 30 50 19 Removing and installing clutch - as of MY 2005 (All Models) .

Tiptronic transmission

3. Install drive plate for converter. Refer to 13 63 19 Removing and installing drive plate for converter - as of MY 2005 (All Models) .

4. Remove exhaust manifold. Refer to 26 10 19 Removing and installing exhaust manifold (with primary catalytic converter) - as of MY 2005 (All Models) .

5. Fit transmission. Refer to 34 35 27 Removing and refitting transmission - as of MY 2005 (Boxster, Boxster RHD) . Refer to 34 35 27 Removing and refitting transmission - as of MY 2005 (Boxster S, Boxster S RHD, Cayman S, Cayman S RHD) .

6. Install engine > 100119 Removing and installing engine [987310 987311 987320 987321] > 100119 Removing and installing engine [987120 987121] .

7. Fill in engine oil. Unscrew 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) .

Preliminary work for removing crankcase vent line

1. Place protective covers on the vehicle to avoid damaging the body.

2. Remove intake-air distributor 1-3. Refer to 24 46 20 Removing and installing intake-air distributor - as of MY 2005 (All Models) .

Scheme 193

1. Remove holding clamp by unscrewing the Torx screw (M6 x 12) -arrow-. (Scheme 193)

Scheme 194

2. Release and disconnect rapid-action couplings on both cylinder heads -arrow-. (Scheme 194)

Scheme 195

3. Unclip all line clips.

4. Guide line out of the engine compartment.

Installing crankcase vent line

1. Replace the two O-rings on the rapid-action couplings. Apply a thin coat of Optimol MP3 grease to the O-rings.

2. Position line in the engine compartment.

3. Attach rapid-action couplings to the cylinder heads -arrow-. see scheme 217

4. Fit and tighten Torx screw (M6 x 12) to secure holding clamp on vent line -arrow-. --> Tightening torque: 7.5 ftlb. see scheme 219

5. Clip in all line clips.

Subsequent work for installing crankcase vent line

1. Install intake-air distributor 1-3. Refer to 24 46 20 Removing and installing intake-air distributor - as of MY 2005 (All Models) .

2. Remove protective covers on vehicle.

Preliminary work for removing oil separator

1. Move convertible top to service position. Refer to 61 01 IN Diagram of convertible top - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .

2. Place protective covers on the vehicle to avoid damaging the body.

3. Remove engine compartment lid. Refer to 55 78 19 Removing and installing engine compartment lid - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .

Removing oil separator

1. Disconnect oil filler pipe at the rapid-action coupling.

Scheme 196

2. Remove crankcase vent line at distributor pipe and oil separator. To do this, release and pull off rapid-action couplings -arrows-. (Scheme 196)

3. Release and pull off rapid-action coupling on crankcase vent line -1-. (Scheme 197)

Scheme 197

4. Unscrew two Torx screws (M6 x 20) -2-. (Scheme 197)

Scheme 198

5. Release spring band clamp -arrow- and loosen hose carefully to turning it using a water pump pliers if necessary. (Scheme 198)

6. Pull oil separator up and out. Cover openings with a cloth in order to catch any drops of oil.

Installing oil separator

Note. All O-rings, seals and micro-encapsulated screws or lock nuts must always be replaced.

Scheme 199

1. Replace O-ring on oil separator -arrow-. (Scheme 199)

2. Position oil separator, push hose onto connection piece and fit spring band clamp -arrow-. see scheme 224

3. Fit and tighten two new Torx screws (M6 x 20) -2-. --> Tightening torque: 7.5 ftlb.. see scheme 225

4. Fit rapid-action coupling on crankcase vent line -1-. see scheme 225

5. Fit crankcase vent line at distributor pipe and oil separator. To do this, fit rapid-action couplings -arrows-. see scheme 226

6. Insert oil filler pipe into the rapid-action coupling and secure with a plastic ring. Ensure that it is locked correctly.

Subsequent work for installing oil separator

1. Install engine compartment lid. Refer to 55 78 19 Removing and installing engine compartment lid - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .

2. Remove protective covers on vehicle.

Poses Online

See also:
• 40 LIFTING THE VEHICLE - AS OF MY 2005 (ALL MODELS)
• 03 35 00 On-board diagnosis (OBD) - as of MY 2005 (All Models)
• 61 01 IN Diagram of convertible top - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD)
• 55 78 19 Removing and installing engine compartment lid - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD)
• 27 06 IN External power connection, jump lead starting - as of MY 2005 (All Models)
• 24 42 19 Removing and installing throttle body - as of MY 2005 (All Models)
• 44 05 19 Removing and installing wheel - as of MY 2005 (All Models)
• 51 94 19 Removing and installing cover for rear underbody - as of MY 2005 (All Models)
• 26 33 19 Removing and installing rear silencer - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD)
• 70 06 19 Removing and installing rear luggage-compartment trim panel - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD)
• 30 01 07 Bleeding the clutch system - as of MY 2005 (All Models)
• 19 38 17 Draining and filling in coolant - as of MY 2005 (All Models)
• 48 02 01 Checking the fluid level for the power-assisted steering - as of MY 2005 (All Models)
• 34 35 27 Removing and refitting transmission - as of MY 2005 (Boxster, Boxster RHD)
• 13 63 19 Removing and installing drive plate for converter - as of MY 2005 (All Models)
• 17 01 55 Engine oil and oil filter change - as of MY 2005 (All Models)
• 15 37 19 Removing and installing solenoid hydraulic valve (camshaft timing) - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD)
• 28 70 20 Removing and fitting spark plugs - as of MY 2005 (All Models)
• socket wrench insert P 300