Work Procedure

1. Lift the vehicle.

2. Remove rear cover, part number, 986 504 129 00 of the underside panel.





3. Cut out a template (use copy of template pattern as shown).

4. Place the template (Figure 1, Item 7) against the air cleaner housing from below according to the housing contours.

Note:
In order to facilitate handling, coat the rear side of the template with grease, Vaseline or similar to temporarily "bond" it to the air cleaner housing. Insert the two hatched areas into the corresponding rib gaps up to the corner edge of the first seam of the air cleaner housing.

5. Make pilot holes for the three bores using the 2 mm drill bit. Then drill all bores with 6.5 mm drill bit.

6. Enlarge the center bore to 38 mm +/- 1 mm using a center bit.

7. Remove all drilling chips from the air cleaner housing (use a vacuum cleaner with small flexible suction nozzle if necessary). Remove the drilling template. Remove grease residues from the air cleaner housing.

8. Insert the holder (Item 3) through the 38 mm bore and fit it in the air cleaner housing.

9. Fit the water separator bowl (Item 5) and the gasket (Item 4) on the holder in the air cleaner housing using the two M6 nuts (Item 6). Tightening torque: 10 Nm (7.5 ftlb.)

10. Reinstall the rear cover of the underside panel.

11. Remove the left-hand air guide (refer to References: Boxster Technical Manual, Volume 6, Repair, 66 56 19 - Removing and installing the engine compartment vent).

12. The further procedure depends on the VIN:
As of 98 3VS 62 0061: Go to Step 14.

13. Remove the shield support, part number, 986 575 569 00 previously installed in the flow duct (no longer required). The riveted shield support is fastened on the flow duct with three rivets. The front support wall must be cut off with a saw blade so that the rivets can be removed. Grind off the rivet heads with a straight grinder. After removing the shield support, leave the rivet stumps in the flow duct and cover them with body sealant to protect against water leakage. Go to Step 16.

14. Remove the shield support, part number, 986 575 569 00 previously installed in the flow duct (no longer required). To do this, unscrew the upper fastening screw and disengage the shield support.

15. On the flow duct, remove the formerly used left-hand fastening hook of the shield support using a saw blade.

16. Fit deflector (Figure 1, item 1) with retaining clamp (Figure 2, item 2) on the air cleaner intake opening. The deflector is fixed on the air cleaner intake opening by means of a locking lug. Ensure the restraining clamp is fitted within the guide ribs. The deflector must be fitted horizontally; the open side must face up.

17. Tighten the restraining strap so that the deflector no longer can be rotated. The deflector must not touch the body after installation.

18. Clean rear side of the air guide and degrease using acetone or similar (Figure 2 as shown, dot-dash line A-B).

19. Starting from point A, stick on the gasket under slight tension up to point B on the air guide (dot-dash line).

Note:
Distance of the gasket from the outer edge: 1.5 mm (Figure 2 shown, detail Z). At start point A and end point B, stick on the gasket so that there is no space with respect to the locking rib (= hatched area) of the air guide (View Y). Cut off any part of the gasket that sticks out.

20. Before fitting the air inlet grill, place the air guide in the body aperture and check whether the gasket is visible from the outside. Correct position of the gasket it necessary.

21. Join air inlet grille and air guide. Reinstall engine compartment vent (refer to References: Boxster Technical Manual, Volume 6, Repair, 66 56 19 - Removing and installing the engine compartment vent).

22. Lower the vehicle.