Part 1
WM 100119 Removing and installing engine
Preliminary work
Preliminary work
Danger
Vehicle raised incorrectly.
^ Danger of fatal injury or material damage should the vehicle fall down.
--> Raise the vehicle at the prescribed jacking points.
Information
^ 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.
2. Place protective covers on the vehicle to avoid damaging the body and passenger compartment.
3. Read out fault memory and print log.
4. Remove the trim panel for engine compartment lid.
5. Remove engine compartment lid.
Removing engine compartment lid
6. Remove rear wall cover.
Cover with grommet
7. Disconnect ground lead of battery.
8. Remove throttle body with distributor pipe (do not disassemble!).
9. Unclip shift or selector cables on the engine.
10. Remove both rear wheels. Use the specified special tool socket wrench insert 300 to avoid damaging the wheel rims.
Removing engine
Removing engine
Warning
Risk of injury from hot engine and hot engine fluids.
^ Danger of burns, scalding, damage to skin, injury to the eyes.
--> Do not carry out work on the engine while it is hot.
Information
^ 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.
Tensioning pulley for drive belt
Warning
Danger of injury and material damage when using Pentosin.
^ Risk of skin irritation and damage to skin.
^ Damage to hoses and wiring.
--> Wear protective gloves and goggles.
--> In the event of contact (eyes or skin), wash immediately with water.
--> Collect emerging Pentosin.
--> Use caps to protect the wiring against soiling and damage.
--> Clean hoses and wiring immediately.
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.
Servo-tank
4. Loosen B+ box -1-. To do this, unscrew two M6 fastening screws.
5. Release and pull off connector -1- on scavenging-air fan -2-.
Connector on scavenging-air fan
6. Open cap on coolant expansion tank.
Warning
Coolant is hazardous to health.
^ ^ Risk of skin irritation.
--> Wear protective gloves and goggles.
--> In the event of contact with the skin or eyes, wash immediately with plenty of water.
7. Boxster: Disconnect vent line at the rapid-action coupling.
Vent line
8. Unclip mass air flow sensor (MAF) line -arrow- from the air-cleaner box.
MAF line
9. Remove rear luggage-compartment lining. To do this, remove the luggage compartment seal and lever off the rear fastening clips.
Levering off clip
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.
13. Unscrew nut (M6) -1- and remove ground leads.
Engine control module
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.
Connectors for engine wire harness
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.
Removing rubber sleeve
17. Remove rear underbody cover.
18. Remove center underbody cover.
19. Release plastic support for the coolant hoses -1- on the underbody.
Warning
Coolant is hazardous to health.
^ Risk of skin irritation.
--> Wear protective gloves and goggles.
--> In the event 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.
Coolant hoses
21. Loosen spring band clamps -1, 3, 5- and pull off coolant hoses -2, 4, 6-.
Coolant hoses for engine and heating
22. Tiptronic: Disconnect coolant hoses from oil-water heat exchanger (transmission), loosen spring band clamps and pull off hoses.
Tiptronic coolant hoses
23. Unscrew collar nuts (M10) -D- , unscrew screw (M10 x 45) -C- and remove diagonal braces -B-.
Diagonal braces
24. Unscrew collar nuts (M8) and screws (M8 x 40). Remove support plate -A-.
Support plate
25. Unscrew screws (M10 x 70) -arrows- and remove V-brace.
V-brace
26. Unscrew screws (M8 x 40) -arrows- for anti-roll-bar bearing shells.
Anti-roll-bar bearing shells
27. Unscrew nuts (M10) on suspension/anti-roll bar and disengage suspension/anti-roll bar. Counter threaded bolts with an internal Torx socket.
Connecting link for anti-roll bar
28. Unscrew nuts (M8) on restraining-cable holder. (The cable must be countered with a suitable wrench and must not be twisted!)
Restraining cable
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.
Oxygen sensor connector
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).
Cross member
32. Remove rear silencer.
33. Unscrew nut (M8) -1- and remove ground strap -2- (right side of vehicle).
Ground strap to engine
Information
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.
Drive shaft
35. Release vacuum line -2- on vacuum pump for brake booster and pull off. Then pull off the small vacuum line -1-.
Vacuum line on vacuum pump
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.
Connector for left oxygen sensor
Connector for right oxygen sensor
Disassembly of shift and selector cables:
37. Lever out the shift and selector cables from the ball pins and disengage from the supports.
Shift and selector cables, 6-speed
Shift connection for 5-speed manual transmission
Shift and selector cables, 5-speed
Shift connection for Tiptronic
Tiptronic selector cable
38. Tiptronic: Release and disconnect multi-function connector.
Releasing electric connector
39. Tiptronic: Release and disconnect cable plug.
Plug
40. Unclip safety clips -arrow- at the servo-line couplings.
Servo-line coupling
Warning
Danger of injury and material damage when using Pentosin.
^ Risk of skin irritation and damage to skin.
^ Damage to hoses and wiring.
--> Wear protective gloves and goggles.
--> In the event of contact (eyes or skin), wash immediately with water.
--> Collect emerging Pentosin.
--> Use caps to protect the wiring against soiling and damage.
--> Clean hoses and wiring immediately.
Information
^ If the holder on the servo line's plug-in coupling needs to be replaced, the special tool assembly aid 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.
Information
^ If the holder on the servo line's plug-in coupling needs to be replaced, the special tool assembly aid 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.
Removing pressure pipe holder
43. Fit holder rosette -C- in threaded part -A- and, if necessary, fix using assembly aid 9622. Screw threaded part with new O-ring into the screw coupling -B- and tighten. Counter the coupling when tightening. --> Tightening torque: 30 Nm (22 ftlb.) --> Tightening torque: 40 Nm (30 ftlb.).
Servo line plug-in coupling
44. Seal open lines with suitable plugs.
Danger
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.
Fuel lines
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, labeled 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 Nm (22 ftlb.)
47. Attach special tool retainer plate 9592 to engine.
48. Screw special tool support plate 9592/1 to retainer plate in position -9592- using four M8x20 hexagon bolts.
48.1. Screw special tool mounting peg 9163/2 to the support plate in the marked position -Boxster- using four M8x25 hexagon bolts.
Position of mounting peg for lifting table
49. To support the transmission, use special tool support plate 9592/2. Depending on transmission type, use the associated spacers.
Retainer plate 9592 complete fitted to engine/transmission
Engine retainer complete