Subsequent work for installing engine Porsche Cayman S 987

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.