Removing engine
| WARNING | Danger of injury from hot engine parts. Risk of burns, damage to skin, injury to the eyes. |
> 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 144
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.
| WARNING | Danger of injury and damage to material through Pentosin Irritation and damage to skin Damage to hoses and wiring |
> 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 145
3. Release bayonet lock -arrow- on the power-steering reservoir and remove power-steering reservoir. Collect dripping Pentosin with a cloth. (Scheme 145)
4. Loosen B+ box -1-. To do this, unscrew two M6 fastening screws. (Scheme 145)
Scheme 146
5. Release and pull off connector -1- on scavenging-air fan -2-. (Scheme 146)
6. Open cap on coolant expansion tank.
Scheme 147
| WARNING | Coolant is hazardous to health Irritation of skin |
> 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 148
8. Unclip mass air flow sensor (MAF) line -arrow- from the air-cleaner box. (Scheme 148)
Scheme 149
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 150
13. Unscrew nut (M6) -1- and remove ground leads. (Scheme 150)
14. Tiptronic: release combination connector on transmission control module and pull off.
Scheme 151
15. Release and pull off connectors -1- and -2- above the left wheel arch. (Scheme 151)
Scheme 152
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 152)
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 153)
Scheme 153
| WARNING | Coolant is hazardous to health Irration of skin |
> 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 153)
Scheme 154
21. Loosen spring band clamps -1, 3, 5- and pull off coolant hoses -2, 4, 6-. see scheme 71
Scheme 155
22. Tiptronic: Disconnect coolant hoses from oil-water heat exchanger (transmission), loosen spring band clamps and pull off hoses.
Scheme 156
23. Unscrew collar nuts (M10) -D-, unscrew screw (M10 x 45) -C- and remove diagonal braces -B-. (Scheme 156)
Scheme 157
24. Unscrew collar nuts (M8) and screws (M8 x 40). Remove support plate -A-. (Scheme 157)
Scheme 158
25. Unscrew screws (M10 x 70) -arrows- and remove V-brace. (Scheme 158)
Scheme 159
26. Unscrew screws (M8 x 40) -arrows- for anti-roll-bar bearing shells. (Scheme 159)
Scheme 160
27. Unscrew nuts (M10) on suspension/anti-roll bar and disengage suspension/anti-roll bar. Counter threaded bolts with an internal Torx socket.
Scheme 161
28. Unscrew nuts (M8) on restraining-cable holder. (The cable must be countered with a suitable wrench and must not be twisted!)
Scheme 162
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 162)
30. Headlight beam adjustment: Pull off cable plug on sensor.
Scheme 163
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 163)
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 164
33. Unscrew nut (M8) -1- and remove ground strap -2- (right side of vehicle). (Scheme 164)
Scheme 165
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 166
35. Release vacuum line -2- on vacuum pump for brake booster and pull off. Then pull off the small vacuum line -1-. (Scheme 166)
Scheme 167
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 167)
Scheme 168
Disassembly of shift and selector cables
Scheme 169
37. Lever out the shift and selector cables from the ball pins and disengage from the supports.
Scheme 170
Shift connection for 5-speed manual transmission
Scheme 171
Shift connection for Tiptronic
Scheme 172
38. Tiptronic: Release and disconnect multi-function connector.
Scheme 173
39. Tiptronic: Release and disconnect cable plug.
Scheme 174
40. Unclip safety clips -arrow- at the servo-line couplings. (Scheme 174)
| WARNING | Danger of injury and damage to material through Pentosin Irritation and damage to skin Damage to hoses and wiring |
> 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 175
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 175)
Scheme 176
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 176)
44. Seal open lines with suitable plugs.
Scheme 177
| WARNING | Fuel can escape when fuel line is disconnected. Risk of fatal injury! Damage to skin |
> 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 177)
| WARNING | Danger of injury and damage from brake fluid! Poisonous if swallowed! Irritation and damage to skin Avoid contact with paint surfaces |
> 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 178
48. Screw special tool support plate P 9592/1 to retainer plate in position -9592- using four M8x20 hexagon bolts. (Scheme 178)
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 178)
49. To support the transmission, use special tool support plate P 9592/2 . Depending on transmission type, use the associated spacers.
Scheme 179
Retainer plate 9592 complete fitted to engine/transmission
Scheme 180
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 180)
Master Gear: Workshop Equipment Manual Gr. 3.0.13 Unit lifting table (+ sports car mounting accessory)
Scheme 181
51. Unscrew three M10 screws -arrows- on the left transmission support and remove these. (Scheme 181)
Scheme 182
52. Loosen the three M10 screws -arrows- on the right transmission support. (Scheme 182)
Scheme 183
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 183)
A - Transmission support
B - Hydraulic mount
C - Central nut (never loosen)
Scheme 184
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 184)
55. Gently lower the engine/transmission unit with the lifting table.
Scheme 185
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 185)
Scheme 186
57. Unscrew front Torx screws for air-conditioning compressor (M8 x 90) -1- and -2-. (Scheme 186)
58. Disconnect plug connection for air-conditioning compressor supply line to the intake distributor.
Scheme 187
59. Unclip refrigerant hoses -1- and -2- between body and intake-air distributor. (Scheme 187)
Scheme 188
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.
| CAUTION | Material damage when lowering engine |
> Enlist assistance of second and, if necessary, third person
61. Lower engine/transmission unit and guide the engine wire harness into the engine compartment.