Part 2
WM 100119 Removing and installing engine (Continued)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.
Mounting plate on Master Gear
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.
Left transmission support
52. Loosen the three M10 screws -arrows- on the right transmission support.
Right transmission support
Information
Do not loosen transmission support at the central nut as this will damage the hydraulic mount.
Information
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.
A - Transmission support
B - Hydraulic mount
C - Central nut (never loosen)
Transmission bracket
54. Position lifting table under vehicle and support engine by raising the mounting plate on the mounting peg 9163/2. Unscrew collar nuts (M10) -arrows- on the engine carrier.
Transmission mount
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.
Rear screw for air-conditioning compressor
57. Unscrew front Torx screws for air-conditioning compressor (M8 x 90) -1- and -2-.
Front screws for air-conditioning compressor
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.
Refrigerant hoses
Information
The air-conditioning lines on the compressor do not have to be disconnected in order to remove engine/transmission unit.
Information
^ 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.
Air-conditioning compressor
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.
Installing engine
Installing engine
Information
^ The engine/transmission unit is installed in reverse order to removal. The following work steps are specifically repeated here in order to avoid damage.
Caution
Risk of damage when inserting the engine/transmission unit into the vehicle
^ Material 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.
Refrigerant hoses
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-.
Front screws for air-conditioning compressor
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 Nm (17 ftlb.).
Rear screw for air-conditioning compressor
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 Nm (48 ftlb.).
Engine mount
10. Insert left transmission bracket -A-. Screw in and tighten the two collar nuts (M8) -arrows-. --> Tightening torque: 33 Nm (24 ftlb.).
A - Transmission support
B - Hydraulic mount
C - Central nut (never loosen)
Transmission bracket
11. Position screws -arrows- on the left transmission support and tighten. --> Tightening torque: 65 Nm (48 ftlb.).
Left transmission support
12. Position screws -arrows- on the right transmission support and tighten. --> Tightening torque: 65 Nm (48 ftlb.).
Right transmission support
13. Lower elevating platform and move out of work area. Remove special tool retainer plate 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.
Servo-line coupling
Fit shift and selector cables:
18. Engage shift and selector cable in support and press onto ball pins.
Shift and selector cables, 6-speed
Shift connection for 5-speed manual transmission
Shift and selector cables, 5-speed
Shift connection for Tiptronic transmission
Tiptronic selector cable
19. Tiptronic: Push on multi-function connector and lock it.
Locking plug
20. Tiptronic: Push on cable plug.
Tiptronic connector
21. Insert connectors for oxygen sensors -1- and clip into the brackets. Clip wires -2- into the brackets.
Connector for left oxygen sensor
Connector for right oxygen sensor
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 Nm (60 ftlb.).
Drive shaft
24. Position ground strap -2- and screw down collar nut (M8) -1-. --> Tightening torque: 23 Nm (17 ftlb.)
Engine ground strap
25. Install rear silencer.
26. Position cross member and screw in and tighten cross-member screws (M10 x 45) -arrows-. --> Tightening torque: 65 Nm (48 ftlb.).
Cross member
27. Insert connectors -1- for monitor sensors and clip into the brackets. Clip wire -2- into the bracket.
Connectors for monitor sensor
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 Nm (17 ftlb.)
Restraining cable
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 Nm (37 ftlb.). Loosen nuts by 90° and tighten to the specified tightening torque stage 2 (counter). --> Tightening torque stage 2: 65 Nm (48 ftlb.)
Connecting link to anti-roll bar
30. Screw in and tighten screws (M8 x 40) -arrows- of the anti-roll bar bearing shells. --> Tightening torque: 23 Nm (17 ftlb.)
Anti-roll bar bearing shells
31. Position V-brace and tighten screws (M10 x 70) -arrows-. --> Tightening torque: 65 Nm (48 ftlb.).
V-brace
32. Position support plate then screw in and tighten collar nuts (M10) and screws (M10). --> Tightening torque: 65 Nm (48 ftlb.); --> Tightening torque: 65 Nm (48 ftlb.)
33. Position diagonal braces and screw in collar nuts (M10) and screws (M10 x 45). --> Tightening torque: 65 Nm (48 ftlb.); --> Tightening torque: 65 Nm (48 ftlb.).
34. Push on coolant hoses -2, 4, 6-. Position spring band clamps -1, 3, 5-.
Coolant hoses for engine and heating
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.
Coolant hoses
36. Tiptronic: Push on hoses and secure spring band clamps.
Tiptronic coolant hoses
37. Pull in rubber sleeve -1-. Ensure that rubber sleeve is fitted correctly.
Removing rubber sleeve
38. Insert connectors for engine wire harness -1- and -2- above the left wheel arch.
Connectors for engine wire harness
39. Position ground lead and tighten nut (M6) -1-. --> Tightening torque: 10 Nm (7.5 ftlb.)
40. Plug in connectors at the engine control module.
Engine control module
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.
44. Clip mass air flow sensor (MAF) line -arrow- into the air-cleaner box.
MAF line
45. Insert cooling system vent line into the rapid-action coupling.
46. Push in connector -1- for scavenging -air fan -2-.
Connector on scavenging-air fan
47. Fit B+ box -1-. --> Tightening torque: 10 Nm (7.5 ftlb.).
48. Position power-steering reservoir. Lock bayonet lock -arrow- on power-steering reservoir.
Servo-tank
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.
Belt tensioner for drive belt
Subsequent work
Subsequent work for installing engine
1. Fit both rear wheels. Use the specified special tool socket wrench insert 300 to avoid damaging the wheel rims.
2. Install throttle body with distributor pipe.
3. Connect ground lead of battery.
4. Bleed the clutch hydraulic system.
5. Fill and bleed cooling system.
6. Check Pentosin level in power-steering reservoir.
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.
10. Install rear underbody cover.
11. Align the vehicle.
12. Install rear wall cover.
Cover with grommet
13. Install engine compartment lid.
Boxster engine compartment lid
Cayman engine compartment lid
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.
17. Perform a test drive.