Engine: Removal & Installation Porsche Boxster 986 рестайлинг

REMOVAL

REMOVING AND INSTALLING CYLINDER HEAD

Note. For removal the cylinder-head cover must be heated in the area of the oil protection tube. Two different methods can be used for this: see REMOVING AND INSTALLING OIL PROTECTION TUBE - ENGINE REMOVED .

REMOVAL METHOD OF OIL PROTECTION TUBE

The second method is preferable if no further assembly work has to be performed, e.g. sealing cylinder-head cover, replacing tensioning element (VarioCam) or replacing the flat-base tappets, etc.

Scheme 163

REMOVAL PROCEDURE OF OIL PROTECTION TUBE

INSTALLATION

INSTALLING PROCEDURE OF OIL PROTECTION TUBE

Remove the cylinder-head cover, heat upper area with a hot-air gun and press the oil protection tube out.

Scheme 164

Scheme 165

1. Coat sealing rings with tire mounting paste. Push tube onto pressure piece, special tool 9605. Place hand pressure piece, special tool 9604, onto the pressure piece.
2. Manually press the oil protection tube as far as it will go into the fitted cylinder-head cover.

Scheme 166

SPECIAL TOOLS - VALVE TAPPETS

Scheme 167

Scheme 168

Scheme 169

1. Turn crankshaft clockwise until the bore 1 OT (top dead Centre) in the belt 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 setting can be checked only after removal of the camshaft closure caps.
2. Remove camshaft closure caps above the cylinder head oil extraction 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.

Basic camshaft adjustment of cylinder bank 1 - 3

For adjustment, the groove in the camshaft must face outward toward the cylinder head cover.

Scheme 170

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.

Basic camshaft adjustment of cylinder bank 4 - 6

For adjustment, the groove in the camshaft must face inward toward the crankcase.

Scheme 171

View from the belt pulley side

If the position of the camshafts is incorrect, remove fixing pin at the pulley and rotate the crankshaft 360° clockwise.

Scheme 172

Scheme 173

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Scheme 179

1. Move camshafts to basic position The groove in the camshaft must face outward toward the cylinder head cover. View from the flywheel side
2. Turn engine on assembly support until cylinder bank 1 - 3 faces upwards.
3. Unscrew chain tensioner of cylinder bank 1 - 3.
4. Detach and remove oil extraction pump at cylinder head 1 - 3 on flywheel side.
5. Unscrew hexagon-head bolts M6 x 20 (2 ea.). Remove closure cap from tensioning element (VarioCam).
6. Remove cylinder head cover. Loosen hexagon-head bolts from the outside to the inside.
7. Fasten special tool 9611, holding-down device for camshafts, with auxiliary screws M6 x 45.
8. Relieve camshaft tensioning element with special tool, tensioning screw 9632. NOTE: Screw in tensioning screw only so far as to slightly relieve the chain.
9. Unscrew three fastening screws (M6 x 95) for tensioning element.
10. 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.
11. Remove drive plate. Connect sprocket wheel and chain with a tie wrap (installation position). With a second tie wrap suspend the sprocket wheel and chain to the side under slight tension.
12. Detach two bearing saddles. Lever bearing saddles out of the guide sleeves.
13. Remove holding-down device (special tool 9611) from the camshafts.
14. Carefully lift the complete unit, camshafts with chain and tensioning element out of the cylinder head. The chain must not jump over.
15. Lift out valve tappets with a magnet.
16. Detach guide for valve tappets. Undo the pan-head screws (15 ea.) from the outside to the inside, and remove the guide.

Scheme 180

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Scheme 191

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 tappet and fit it 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 upward If the allocation should be uncertain, for example, chain jumped over, reallocation is necessary. Refer to «COMPLETING CAMSHAFTS»(ref-199829-S38141229872005102100000).
5. Special tool 9611; fit holding-down device for camshafts. Fit auxiliary screws M6 x 45 with washers and tighten to 10 Nm (7.5 ft.lb).
6. 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
7. Fit tensioning element (VarioCam). Tighten 3 M6 x 95 pan-head screws. Tightening torque 10 Nm (7.5 ft.lb)
8. Unscrew tensioning screw (special tool 9632) from the tensioning element.
9. Remove tie wrap and fit sprocket wheel with chain on the flange of the exhaust camshaft.
10. Position drive plate or driver star on the sprocket wheel. Fit hexagon-head bolts M6 x 15 (10.9). Tighten hexagon-head bolts by hand only.
11. Unscrew chain tensioner (fitted on the crankcase half of cylinder bank 4 - 6) and fasten auxiliary chain tensioner (special tool 9599).
12. 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 achieved when the measuring pin is flush with the face surface of the pressure 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 a silicone bead to 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. 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. Special tool fitting sequence: Fastening screw with star knob on cylinder head lug. Pull back B and C when tightening. (Scheme 197) Centering piece in groove of the exhaust camshaft. Pull sword bolt (C) back when tightening. (Scheme 197). 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 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 and 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.)

Scheme 192

Scheme 193

Scheme 194

Scheme 195

Scheme 196

Scheme 197

Scheme 198

1. Remove fixing pin. Turn crankshaft clockwise until the bore 1 OT (top dead Centre) in the belt pulley is aligned with the fixing bore on the crankcase. (Scheme 200) 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 belt pulley side
3. Turn engine by 90° on assembly support until cylinder bank 4-6 faces upwards.
4. Unscrew chain tensioner of cylinder bank 4 - 6.
5. Remove closure cap from tensioning element (VarioCam). Hexagon-head bolts M6 x 20 (2 ea.).
6. Remove cylinder head cover. Loosen hexagon-head bolts from the outside to the inside.
7. Fit holding-down device for camshafts, special tool 9611. Use auxiliary screws M6 x 45.
8. Detach and remove oil extraction pump at cylinder head 4 - 6 (pulley side).
9. Relieve camshaft tensioning element with tensioning screw, special tool 9632. NOTE: Screw in tensioning screw only so far as to slightly relieve the chain.
10. Unscrew three fastening screws (M6 x 95) for tensioning element.
11. 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.
12. Remove drive plate. Connect sprocket wheel and chain with a tie wrap (installation position). With a second tie wrap suspend the sprocket wheel and chain to the side under slight tension.
13. Detach two bearing saddles. Lever bearing saddles out of the guide sleeves.
14. Remove holding-down device (special tool 9611) from the camshafts.
15. Carefully lift the complete unit, camshafts with chain and tensioning element out of the cylinder head. The chain must not jump over. The groove or tab of the camshaft position sensor cover must face downward. If the allocation should be uncertain, e.g. chain jumped over, reallocation is necessary. Refer to «COMPLETING CAMSHAFTS»(ref-199829-S38141229872005102100000).
16. Lift out valve tappets with a magnet.
17. Detach guide for valve tappets. Undo the pan-head screws (15 ea.) from the outside to the inside, and remove the guide.

Scheme 199

Scheme 200

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Scheme 210

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 tappet and fit it 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 downward.
5. Special tool 9611; fit holding-down device for camshafts. Fit auxiliary screws M6 x 45 with washers and tighten to 10 Nm (7.5 ft.lb).
6. Check dowel sleeves (4 ea.) of the bearing saddles to ensure that they are properly seated in the cylinder head. Grease bearing surface, fit bearing saddles in 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
7. Fit tensioning element (VarioCam). Tighten 3 M6 x 95 pan-head screws. Tightening torque 10 Nm (7.5 ft.lb.)
8. Unscrew tensioning screw, special tool 9632, from the tensioning element.
9. Remove tie wrap and fit sprocket wheel with chain on the flange of the exhaust camshaft.
10. Position drive plate or driver star on the sprocket wheel. Fit hexagon-head bolts M6 x 15 (10.9). Tighten hexagon-head bolts by hand only.
11. 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 achieved when the measuring pin is flush with the face surface of the pressure screw. Turn the screw if necessary.
12. Check whether the auxiliary chain tensioners of cylinder bank 1-3 and the auxiliary chain tensioner are fitted on the crankcase half. Chain tensioner on the crankcase Chain tensioner on cylinder head 1 - 3
13. Remove holding-down device 9611.
14. Prepare cylinder head cover for installation: Clean sealing surface of the cylinder head and cylinder head cover very carefully. Apply a silicone bead to 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. Immediately remove silicone material emerging in the area of the camshaft closure cap.
15. Fasten blocking device (special tool 9612) on the cylinder head. BFastening screw with star knob on cylinder head lug. Pull back B and C when tightening. (Scheme 216) Centering piece in groove of exhaust camshaft. Pull sword bolt (C) back when tightening. (Scheme 216) 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 ft.lb)
18. Remove blocking device.
19. Fit camshaft closure caps (3 ea.) dry.
20. Fit closure cap on tensioning element (VarioCam). Tightening torque 10 Nm (7.5 ft.lb.)
21. Fit oil supply pump. NOTE: The oil extraction pumps on the cylinder heads are identical parts. Therefore, the installation position and direction of rotation must be correct. Installation position of oil extraction pump at cylinder head 4 - 6 (belt pulley 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)
22. Unscrew auxiliary chain tensioner, put new sealing ring on the original chain tensioner and install. Tightening torque 80 Nm (59 ft.lb)

1. Chain tensioner, cylinder bank 4 - 6 Identification "Without". see scheme 753
2. Chain tensioner on crankcase Identification "1 ring"
3. Chain tensioner, cylinder bank 1 - 3 Identification "2 rings"

Scheme 211

Installation position of the chain tensioners (engine in installed position)

Scheme 212

Chain tensioner on the crankcase

Chain tensioner on cylinder bank 1 - 3

Scheme 213

Chain tensioner on cylinder bank 4 - 6

Scheme 214

Scheme 215

1. Remove rear wall lining and rear wall cover. To do this, unscrew the hexagon nuts and screws. Refer to «ENGINE MAINTENANCE: OPENING AND CLOSING ENGINE COMPARTMENT»(ref-199492-S29076881312005101900000).
2. Carefully push a suitable screwdriver in the Centre of the closure caps and lever them off -arrows-. see scheme 758

Scheme 216

Installing closure caps at pulley side of cylinder head 1 - 3

1. Clean receiving bore. Fit new caps dry and press in as far as they will go.
2. Install rear wall lining and rear wall cover.

Tightening torque 10 Nm (7.5 ft.lb)

Scheme 217

Scheme 218

1. Remove rear wall lining and rear wall cover. To do this, unscrew the hexagon nuts and screws. Refer to «ENGINE MAINTENANCE: OPENING AND CLOSING ENGINE COMPARTMENT»(ref-199492-S29076881312005101900000) .
2. Carefully push a suitable screwdriver in the Centre of the closure cap and lever it off.

1. Remove solenoid hydraulic valve. NOTE: Install the solenoid valve only if the VarioCam tensioning element is vertical. Correct seating of the compression spring (No. 4) is no longer ensured if the solenoid hydraulic valve is installed horizontally (installation position of engine).
2. Undo self-tapping screws (Torx T 20) No. 1. NOTE: Mark a threaded screw and threaded bore for reinstallation
3. Remove solenoid valve. Leave valve plunger and compression spring in installation position.

1. Fit new solenoid valve. Screw in threaded screws by hand. The thread cut when the screw was screwed in for the first time must be found again. Tightening torque 3.7 + 0.15 Nm (2.7 + 0.10 ft.lb)

Scheme 219

At each cylinder head, undo 4 hexagon-head bolts fastening the oil extraction pump.

Note. After removing the oil extraction pumps, do not lay them on the drivers.

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.

Scheme 220

Installation position of oil extraction pump at cylinder head 4 - 6 (pulley side): The arrow for the direction of rotation or the marking "4 - 6" must face the crankcase or the coolant temperature sensor.

Scheme 221

Scheme 222

At each cylinder head, undo 4 hexagon-head bolts fastening the oil extraction pump.

Note. After removing the oil extraction pumps, do not lay them on the drivers.

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.

Scheme 223

Installation position of oil extraction pump at cylinder head 4 - 6 (pulley side): The arrow for the direction of rotation or the marking "4 - 6" must face the crankcase or the coolant temperature sensor.

Scheme 224

Scheme 225

Scheme 226

1. Remove cap on coolant expansion tank.
2. Undo drain plug on the coolant guide housing and drain the coolant.
3. Equip drain plug with a new sealing ring and fit in the coolant guide housing. Tightening torque: 10+5 Nm (7.5+3.5 ft.lb)
4. Raise convertible top compartment lid.
5. Remove engine-compartment cover.
6. Remove throttle body with intake distributor intermediate piece.
7. Remove oil-water heat exchanger.

Scheme 227

Scheme 228

1. Insert new sealing rings and fit oil-water heat exchanger. Tightening torque: 10 Nm (7.5 ft.lb)
2. Fit throttle body with intake distributor intermediate piece. Align rubber sleeves with the markings (arrows) and tighten inner hose clamps. Shift or align the distributor pipe between the intake distributors so that dimension X is identical on the right and left sides. Tighten outer hose clamps. Fasten support between the throttle body and crankcase.
3. Check whether the vacuum control line is seated properly. The vacuum control line must be securely seated in the left rubber sleeve.
4. Fit engine compartment cover.
5. Fill in coolant and bleed the system; refer to «DRAINING AND FILLING IN COOLANT (INCLUDES: BLEEDING)»(ref-199829-S41714753422005102100000) .

Scheme 229

SPECIAL TOOLS - CHECKING OIL PRESSURE

Scheme 230

1. Move convertible top to service position. On vehicles with hardtop, additionally remove the hardtop.
2. Remove upper engine compartment lid.
3. Unscrew plug (M14 x 1.5) on the cylinder head of cylinder bank 1 - 3. Use a 6 mm Allen key.
4. Screw oil pressure tester into the cylinder head in combination with the M 14 x 1.5/ M10 x 1 adapter. Engine removed for the sake of clarity (cylinder bank 1 - 3)
5. Warm up engine to operating temperature (80 - 90°C oil temperature). The oil temperature can be read out with the Porsche System Tester 2 under the "Actual values" menu.
6. The oil pressure should be approx. 1.5 bar at idle.
7. Have a second person increase the engine speed to 4000 rpm. Read off the oil pressure on the oil pressure tester. The oil pressure should be approx. 5.5 bar.
8. Remove oil pressure tester with adapter. Fit plug with a new sealing ring (A14 x 18). Tightening torque: 20 +/- 5 Nm (15 +/- 3.5 ft.lb).

Scheme 231

Scheme 232

SPECIAL TOOLS

Scheme 233

1. Check sealing ring and use a KD (service) sealing ring if necessary. NOTE: As standard, the temperature sensor has a captive sealing ring. Tightening torque 25 +/- 5 Nm (18 +/- 3.5 ft.lb)

Scheme 234

SPECIAL TOOLS - DRAINING AND FILLING COOLANT

Scheme 235

SPECIAL TOOLS - DRAINING AND FILLING COOLANT

Scheme 236

RADIATOR, VACUUM, FILLER DEVICE COMPONENTS