Engine: Specifications Porsche Boxster 986

TIGHTENING TORQUES

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

Scheme 1

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»(ref-199492-S29076881312005101900000) and «MAINTENANCE, CHECKING LID AND DOORS»(ref-199492-S09053515092005101900000).
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 6) 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 7); 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»(ref-199492-S29076881312005101900000).
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

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)

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

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SPECIAL TOOLS

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SPECIAL TOOLS

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

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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).

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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. see scheme 367
2. Coolant guide housing with 4-point screw connection and engine bracket with 4-point screw connection.

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TIGHTENING SEQUENCE

TIGHTENING SEQUENCE - BELT PULLEY

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SPECIAL TOOLS

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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 36)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 33

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

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Scheme 35

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

Observe running direction (color pen marking).

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1. Fit drive belt by hand, slightly pre-tensioned, in the following sequence: Coolant pump drive pulley (1) see scheme 466 Alternator drive pulley (2) see scheme 466 Deflection roller 1 (3) see scheme 466 Power steering pump drive pulley (4) see scheme 466 Air-conditioning compressor drive pulley (5) see scheme 466 Crankshaft pulley (6) see scheme 466 Tensioning roller (7) see scheme 466 Then turn the tensioning roller (7) in clockwise direction and simultaneously fit the drive belt on the deflection roller 2 (8). see 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.

TIGHTENING TORQUES - CAMSHAFTS, AS OF MY 2003

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SPECIAL TOOL DESIGNATION

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1. Disconnect battery.
2. Set up and secure convertible top compartment lid.
3. Remove top engine-compartment cover.
4. Remove left-hand seat.
5. Remove rear wall lining and rear wall cover. Put on floor protection cover.
6. In vehicles with air conditioning, the following additional operations must be performed: 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. Remove pulley of the hydraulic pump. Undo the front compressor fastening screws (2 ea.) and disconnect the electrical plug connection. Undo the compressor fastening screw between the intake pipes of cylinders 4 and 5. Undo the B+ connection (box) on the engine and put it aside. Suck out fluid from power steering reservoir until level is below the joint. Open bayonet lock and remove the reservoir. Close opening. Lift the air-conditioning compressor with the connected lines out of the engine compartment and place on a wooden surface on the Centre tunnel or console.
7. Remove the rear wheels.
8. Remove right and left diagonal braces.
9. Remove rear support sheet.
10. Detach and remove exhaust manifold of cylinder head 4-6.
11. Unclip oxygen-sensor plug from the brackets of the rear-axle support.
12. Detach cable between engine and rear-axle support at the rear-axle support.
13. Detach rear-axle support and remove to the side.
14. Drain engine oil.

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1. Move camshafts of cylinder bank 1-3 to basic position or removal position. Turn crankshaft clockwise until the bore 1 OT (top dead Centre) in the pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595. NOTE: The basic camshaft adjustment can be checked only after removal of the camshaft closure caps.
2. Remove camshaft closure caps above the cylinder-head oil pumps. The closure cap of cylinder bank 1-3 is located on the flywheel side and the closure cap of cylinder bank 4-6 is located on the pulley side. Drive awl into Centre of the closure cap and lever off the cap. Drawing shows closure cap of cylinder bank 4 - 6 (pulley side)
3. Check basic camshaft adjustment of cylinder bank 1 - 3. The groove in the camshaft must face outward toward the cylinder-head cover. View from the flywheel side If the position of the camshafts is incorrect, remove fixing pin at the pulley and rotate the crankshaft 360° clockwise. Then position or fix the fixing pin in the bore (1 OT) and in the fixing bore in the crankcase again.
4. Unscrew chain tensioner of cylinder bank 1 - 3. Installation position of chain tensioner on cylinder bank 1-3
5. Detach and remove oil extraction pump at cylinder head 1-3 on the flywheel side.
6. Separate plug connection of the tensioning element (VarioCam).
7. Unscrew two hexagon-head bolts (M6 x 20) and remove closure cap from the tensioning element (VarioCam).
8. Remove ignition coils, spark plugs and oil protection tubes. NOTE: As the available space is limited, the oil protection tubes must be removed before the cylinder-head cover can be removed. Refer to «REMOVING AND INSTALLING OIL PROTECTION TUBE»(ref-199829-S16317596292005102100000).
9. Remove the camshaft closure caps from the passenger compartment side. Drive awl into Centre of the closure cap and lever off the cap.
10. Fit special tool, holding-down device 9624, on the cylinder head. Fasten holding-down device with a hexagon-head bolt M8 x 30.
11. Remove cylinder-head cover. Loosen the hexagon-head bolts from the outside to the inside. Detach cylinder-head cover by tapping lightly with a plastic hammer.
12. Additionally fasten a holding-down device of special tool 9611 using M6 x 45 auxiliary screws.
13. Relieve camshaft tensioning element with special tool, tensioning screw 9632. Screw tensioning screw in only until the chain is slightly relieved.
14. Unscrew three fastening screws (M6 x 95) for tensioning element.
15. Affix auxiliary chain tensioner (screw in by approx. 3 turns). Undo four hexagon-head bolts (M6 x 15) on the chain sprocket. Remove auxiliary chain tensioner again.
16. Remove drive plate. Remove sprocket wheel and chain and connect with a tie wrap (installation position).
17. Detach bearing saddles and lever out of the guide sleeves.
18. Remove special tools, holding-down devices 9611 and 9624, and carefully lift the entire unit, consisting of camshafts with chain and tensioning element, out of the cylinder head. The chain must not jump over during this operation; reallocate if necessary.
19. Lift out valve tappets with a magnet.
20. Detach guide for valve tappets. Undo the pan-head screws (15 ea.) from the outside to the inside and remove the guide.

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1. Check guide for damage. Refer to «CHECKING GUIDE FOR VALVE TAPPETS»(ref-199829-S15374976572005102100000).
2. Fit guide. Tighten pan-head screws (M6 x 35) from the inside to the outside. Tightening torque: 10 Nm (7.5 ft.lb)
3. Lightly oil the valve tappets and fit in the guide.
4. Lay the complete unit, camshafts with chain and tensioning element, into the cylinder head. The groove or tab of the camshaft position sensor cover must face outward in installed position. If the allocation should be uncertain, e.g. chain jumped over, reallocation is necessary. Refer to «COMPLETING CAMSHAFTS»(ref-199829-S38141229872005102100000).
5. Fasten special tool, holding-down device 9611, with auxiliary screws M6 x 45.
6. Fit special tool, holding-down device 9624, on the cylinder head using a hexagon-head bolt M8 x 30.
7. Check dowel sleeves (4 ea.) of the bearing saddles to ensure that they are properly seated in the cylinder head. Oil bearing surface. Fit bearing saddles in the correct position and tighten evenly. Tightening torque: 10 Nm (7.5 ft.lb) E = Bearing saddle for inlet camshaft A = Bearing saddle for exhaust camshaft
8. Fit tensioning element (VarioCam). Tighten 3 M6 x 95 pan-head screws. Tightening torque: 10 Nm (7.5 ft.lb).
9. Unscrew tensioning screw, special tool 9632, from the tensioning element.
10. Remove tie wrap and fit sprocket wheel with chain on the flange of the exhaust camshaft.
11. Position drive plate or driver star on the sprocket wheel. Fit hexagon-head bolt M6 x 15 (10.9). Tighten hexagon-head bolt by hand only.
12. Unscrew chain tensioner (fitted on the crankcase half of cylinder bank 4-6) and fasten auxiliary chain tensioner (special tool 9599). Fit auxiliary chain tensioner without sealing ring and fasten on the crankcase only hand-tight. The mechanical auxiliary chain tensioners must be installed with the correct pre-tension when the valve timing is adjusted or checked. The necessary pre-tension force has been reached when the measuring pin is flush with the face surface of the thrust screw. Turn the screw if necessary.
13. Fit auxiliary chain tensioner on cylinder head 1-3 and adjust pre-tension force (refer to step 12 ).
14. Fit cylinder-head cover. Remove holding-down device 9611. Clean sealing surface of the cylinder head and cylinder-head cover very carefully. Apply bead of silicone on the cylinder-head cover. Refer to «SEALING COVER FOR CAMSHAFT HOUSING (CYLINDER HEAD COVER)»(ref-199829-S00979882172005102100000). Carefully place the cylinder-head cover in the correct position so that the sealing bead is not damaged. Screw two studs or centering pins into the corners of the cylinder head as centering aids. Tightening torque: 13 Nm (10.0 ft.lb) Immediately remove silicone material emerging in the area of the camshaft closure cap.
15. For the subsequent adjustment work on the camshaft, the pulley must be fixed at bore 1 OT (TDC) with the fixing pin (special tool 9595).
16. Fasten blocking device (special tool 9612) on the cylinder head. Fastening screw with star knob on the cylinder-head lug. Pull back centering piece (B) and sword bolt (C) when tightening. (Scheme 75) Centering piece in groove of the exhaust camshaft. Pull back sword bolt (C) when tightening. (Scheme 75) Sword bolt
17. Allocate camshafts; to do this, turn the pre-tensioned Centre piece accordingly until the sword bolt can be fixed in the bearing bore.
18. Fasten sprocket wheel. Tightening torque: 14 Nm (10.5 ft.lb)
19. Remove blocking device. NOTE: The auxiliary chain tensioners must remain fitted on cylinder bank 4 - 6 for the subsequent assembly work.
20. Fit oil extraction pump. NOTE: The oil extraction pumps on the cylinder heads are identical parts. Therefore, the installation position or direction of rotation must be correct. Installation position of oil extraction pump at cylinder head 1 - 3 (flywheel side): The arrow for the direction of rotation or the marking "1 - 3" must face the crankcase. Fit oil extraction pump. Use new sealing ring and new micro-encapsulated hexagon socket head screws. Tightening torque: 10 Nm (7.5 ft.lb).
21. Fit camshaft closure cap dry.
22. Fit closure cap on tensioning element (VarioCam). Tightening torque: 10 Nm (7.5 ft.lb).

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1. Remove fixing pin. Turn crankshaft 360° clockwise until the bore 1 OT (top dead Centre) in the pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595.
2. Check camshaft adjustment at cylinder bank 4-6: The groove in the camshaft must face inward toward the crankcase. View from the pulley side
3. Unscrew chain tensioner of cylinder bank 4 - 6.
4. Detach and remove oil extraction pump at cylinder head 4 - 6 (pulley side).
5. Separate plug connection of the tensioning element (VarioCam).
6. Unscrew two hexagon-head bolts (M6 x 20) and remove closure cap from the tensioning element (VarioCam).
7. Remove ignition coils, spark plugs and oil protection tubes. NOTE: As the available space is limited, the oil protection tubes must be removed before the cylinder-head cover can be removed. Refer to «REMOVING AND INSTALLING OIL PROTECTION TUBE - ENGINE INSTALLED»(ref-199829-S16317596292005102100000).
8. Remove the camshaft closure caps from the underside of the vehicle. Drive awl into Centre of the closure cap and lever off the cap.
9. Fit special tool, holding-down device 9624, on the cylinder head. Fasten holding-down device with a hexagon-head bolt M8 x 30.
10. Remove cylinder-head cover. Loosen the hexagon-head bolts from the outside to the inside. Detach cylinder-head cover by tapping lightly with a plastic hammer.
11. Additionally fasten a holding-down device of special tool 9611 using M6 x 45 auxiliary screws.
12. Relieve camshaft tensioning element with tensioning screw, special tool 9632. Screw tensioning screw in only until the chain is slightly relieved.
13. Unscrew three fastening screws (M6 x 95) for tensioning element.
14. Affix auxiliary chain tensioner (screw in by approx. 3 turns). Undo four hexagon-head bolts (M6 x 15) on the chain sprocket. Remove auxiliary chain tensioner again.
15. Remove drive plate. Remove sprocket wheel and chain and connect with a tie wrap for the subsequent installation position.
16. Detach bearing saddles and lever out of the guide sleeves.
17. Remove special tools, holding-down devices 9611 and 9624, and carefully lift the entire unit, consisting of camshafts with chain and tensioning element, out of the cylinder heads. The chain must not jump over during this operation; reallocate if necessary.
18. Lift out valve tappets with a magnet.
19. Detach guide for valve tappets. Undo the pan-head screws (15 ea.) from the outside to the inside and remove the guide.

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1. Check guide for damage. Refer to «CHECKING GUIDE FOR VALVE TAPPETS»(ref-199829-S15374976572005102100000).
2. Fit guide. Tighten pan-head screws (M6 x 35) from the inside to the outside. Tightening torque: 10 Nm (7.5 ft.lb)
3. Lightly oil the valve tappets and fit in the guide.
4. Lay the complete unit, camshafts with chain and tensioning element, into the cylinder head. The groove or tab of the camshaft position sensor cover must face outward in installed position. If the allocation should be uncertain, for example, chain jumped over, reallocation is necessary. Refer to «COMPLETING CAMSHAFTS»(ref-199829-S38141229872005102100000).
5. Fasten special tool, holding-down device 9611, with auxiliary screws M6 x 45.
6. Fit special tool, holding-down device 9624, on the cylinder head using a hexagon-head bolt M8 x 30.
7. Check dowel sleeves (4 ea.) of the bearing saddles to ensure that they are properly seated in the cylinder head. Oil bearing surface. Fit bearing saddles in the correct position and tighten evenly. Tightening torque: 10 Nm (7.5 ft.lb) E = Bearing saddle for inlet camshaft A = Bearing saddle for exhaust camshaft
8. Fit tensioning element (VarioCam). Tighten 3 M6 x 95 pan-head screws. Tightening torque: 10 Nm (7.5 ft.lb)
9. Unscrew tensioning screw, special tool 9632, from the tensioning element.
10. Remove tie wrap and fit sprocket wheel with chain on the flange of the exhaust camshaft.
11. Position drive plate or driver star on the sprocket wheel. Fit hexagon-head bolt M6 x 15 (10.9). Tighten hexagon-head bolt by hand only.
12. Fit auxiliary chain tensioner, special tool 9599, on cylinder head 4-6. Fit auxiliary chain tensioner without sealing ring and fasten on the crankcase only hand-tight. The mechanical auxiliary chain tensioners must be installed with the correct pre-tension when the valve timing is adjusted or checked. The necessary pre-tension force has been reached when the measuring pin is flush with the face surface of the thrust screw. Turn the screw if necessary.
13. Fit cylinder-head cover. Remove holding-down device 9611. Clean sealing surface of the cylinder head and cylinder-head cover very carefully. Apply bead of silicone on the cylinder-head cover. Refer to «SEALING COVER FOR CAMSHAFT HOUSING (CYLINDER HEAD COVER)»(ref-199829-S00979882172005102100000). Carefully place the cylinder-head cover in the correct position so that the sealing bead is not damaged. Screw two studs or centering pins into the corners of the cylinder head as centering aids. Tightening torque: 13 Nm (10.0 ft.lb.) Immediately remove silicone material emerging in the area of the camshaft closure caps.
14. For the subsequent adjustment work on the camshaft, the pulley must be fixed at bore 1 OT (TDC) with the fixing pin (special tool 9595). see scheme 679
15. Fasten blocking device (special tool 9612) on the cylinder head. Special-tool fitting sequence: Fastening screw with star knob on the cylinder-head lug. Pull back centering piece (B) and sword bolt (C) when tightening. see scheme 681 Centering piece in groove of the exhaust camshaft. Pull back sword bolt (C) when tightening. see scheme 681 Sword bolt
16. Allocate camshafts; to do this, turn the pre-tensioned Centre piece accordingly until the sword bolt can be fixed in the bearing bore.
17. Fasten sprocket wheel. Tightening torque: 14 Nm (10.5 ft.lb)
18. Remove blocking device.
19. . Fit oil extraction pump. NOTE: The oil extraction pumps on the cylinder heads are identical parts. Therefore, the installation position or direction of rotation must be correct. Installation position of oil extraction pump at cylinder head 4 - 6 (flywheel side): The arrow for the direction of rotation or the marking "4-6" must face the crankcase. Fit oil extraction pump. Use new sealing ring and new micro-encapsulated hexagon socket head screws. Tightening torque: 10 Nm (7.5 ft.lb)
20. Fit camshaft closure cap dry.
21. Fit closure cap on tensioning element (VarioCam). Tightening torque: 10 Nm (7.5 ft.lb.)

TIGHTENING TORQUES - HYDRAULIC VALVE FOR CAMSHAFT ADJUSTMENT, AS OF MY 2003

Engine type M 96/23 and M 96/24

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1. Disconnect the battery. Refer to «WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY»(/porsche/boxster/986-1996-2002/remont/cruise-control-systems/#starter-power-supply-cruise-control).
2. Remove respective rear wheel. To do this, use the socket wrench insert P 300 to avoid damaging the wheel.
3. Remove the rear underbody panel. Undo the torx screws, plastic nuts and the Centre M6 hexagon nut.
4. Drain engine oil. After a dripping time of about 20 minutes, refit oil drain plug (hexagon socket a/f 8) with a new sealing ring. Tightening torque 50 Nm (37 ft.lb)
5. Remove side plastic strut by undoing the M6 hexagon nut -arrow-. see scheme 791
6. Pull cable plug off oxygen sensor towards the front -arrow- expose the oxygen sensor cable. see scheme 791
7. Pull cable plug on cylinder head cover off oxygen sensor -1- and remove cable plug holder from cylinder head cover by undoing the M6 hexagon-head bolt -2-. see scheme 793
8. Unscrew exhaust manifold with catalytic converter. Remove flange with 2 M8 hexagon nuts and 1 M8 hexagon-head bolt as well as 6 exhaust manifold screws. Remove and replace metal seals.
9. Remove side plastic cover by undoing 2 M6 hexagon-head bolts -arrows- (cylinder bank 1 - 3). see scheme 794
10. Pull cable plugs off the ignition coils, oil pressure sensor (cylinder bank 1 - 3) and magnetic hydraulic valve. see scheme 794
11. Cylinder bank 4 - 6: Remove the holder for the servo line by undoing the M6 hexagon-head bolt-arrow-. see scheme 795
12. Remove 3 ignition coils. Unscrew 6 M6 x 25 pan-head screws (hexagon socket a/f 5), pull the ignition coils out of the spark-plug recess.
13. Remove holder and cover for magnetic hydraulic valve. Unscrew the two M6 x 20 pan-head screws (hexagon socket a/f 5), remove the connection cable for the hydraulic valve from the sheetmetal bracket and remove the holders. Remove cover with hydraulic valve. CAUTION: When levering off the cylinder head cover, the cast lugs may break!
14. Remove the cylinder head cover. To do this, unscrew 20 M6 x 30 hexagon-head bolts from the cylinder head cover. Unscrew the four M6 x 20 hexagon-head bolts on the sides of the oil extraction pump. To release the cylinder head cover, raise the cover carefully at the two protruding cast edges with a slotted screwdriver. If necessary, loosen the cover by carefully tapping it with a plastic hammer. Collect the dripping engine oil. NOTE: After removing the oil extraction pump, check the O-ring for damage and replace if necessary.
15. Remove oil extraction pump.
16. Disconnect the holder for the coolant lines and carefully push the coolant lines aside. Remove cylinder head cover (cylinder bank 1 - 3). see scheme 793
17. Remove the brown closure cap (45 mm) and 2 green closure caps.

Note. To work on cylinder bank 4 - 6, follow the steps described for cylinder bank 1 - 3 under see scheme 793.

TIGHTENING TORQUES - CYLINDER HEAD COVERS, AS OF MY 2003

Scheme 99

TIGHTENING TORQUES - BEARING COVER FOR INTERMEDIATE SHAFT, AS OF MY 2002

TIGHTENING TORQUES - OIL DRAIN PLUG

Refer to OVERVIEW OF APPROVED ENGINE OILS .

TIGHTENING TORQUES - OIL PUMP WITH COOLANT GUIDE HOUSING

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1. Place pan under the engine to collect any remaining engine oil which runs out.
2. Drain engine oil. Unscrew the oil drain plug (hexagon socket a/f 8) and drain emerging oil into an oil collection container. Insert plug with a new sealing ring and tighten. Tightening torque 50 Nm (37 ft.lb)
3. Remove engine carrier by undoing the four hexagon-head bolts M10 x 80 (a/f 15) -arrows-. see scheme 852 NOTE: Undo the pressure relief valve (hexagon a/f 17) before removing the oil pump cover since the cover must not be held in a clamping device to undo the valve if the oil pump is disassembled. see scheme 853
4. Remove oil pump cover by undoing the eight hexagon-head bolts: six M6 x 20 and two M6 x 80 -arrows-. see scheme 853
5. Carefully pull off oil pump cover. Do not use metal tools to lever off the cover as the sealing surface may be damaged. Remove moulded seal -arrow-. see scheme 854

TIGHTENING TORQUES - OIL PUMP COVER

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1. Remove oil pump cover. See «REMOVING AND INSTALLING OIL PUMP COVER - ENGINE REMOVED»(ref-199829-S35749926042005102100000).
2. Place the oil pump cover on a clean surface.
3. Disassemble oil pump. see scheme 859 REMOVAL AND INSTALLATION PROCEDURE FOR OIL PUMP No. Designation Qty. Removal Installation 1 (1) Oil-pump cover 1 Do not damage the sealing surfaces Clean sealing surfaces 2 (1) Gear wheel 1 Check for wear (pitting, cracks etc.) Replace if necessary and coat with new engine oil 3 (1) Drive gear 1 Check for wear (pitting, cracks etc.) Replace if necessary and coat with new engine oil 4 (1) Driver 1 Coat with new oil 5 (1) Pistons 1 Coat with new oil 6 (1) Spring 1 7 (1) Plug with guide pin 1 Loosen if cover installed Tightening torque 25 Nm (19 ft.lb). 8 (1) Sealing ring 1 Replace (1) For explanation see scheme 859
4. Assemble oil pump. To do this, clean with solvent and coat with fresh engine oil. When installed, fit pressure relief valve. Tightening torque pressure for relief valve 25 Nm (19 ft.lb)
5. Install oil pump cover. See «REMOVING AND INSTALLING OIL PUMP COVER - ENGINE REMOVED»(ref-199829-S35749926042005102100000)..

Scheme 106

See also:
• WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY