Removal
Removing and installing engineTools
Preliminary work
DANGER
Incorrect raising of the vehicle
^ Damage to person or property caused by the car falling down
^ Raise the vehicle at the prescribed jacking points.
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..
2. Place protective covers on the vehicle to avoid damaging the body and passenger compartment.
3. Read out fault memory and print log.
4. Move convertible top to service position.
5. Remove linings (carpet for rear wall cover and engine cover).
6. Remove engine compartment lid.
7. Remove rear wall cover.
8. Disconnect ground lead of battery.
9. Remove throttle body with distributor pipe (do not disassemble!)
10. Unclip shift or selector cables on the engine.
11. Remove both rear wheels. Use the specified special tool socket wrench insert 300 to avoid damaging the wheel rims.
Preliminary work
DANGER
Incorrect raising of the vehicle
^ Damage to person or property caused by the car falling down
^ Raise the vehicle at the prescribed jacking points.
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.
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.
6. Remove rear wall cover.
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
WARNING
Danger of injury from hot engine parts.
^ Risk of burns, damage to skin, injury to the eyes.
^ o 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.
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.
3. Release bayonet lock -arrow- on the power-steering reservoir and remove power-steering reservoir. Collect dripping Pentosin with a cloth.
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-.
6. Open cap on coolant expansion tank.
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.
8. Unclip mass air flow sensor (MAF) line -arrow- from the air-cleaner box.
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.
13. Unscrew nut (M6) -1- and remove ground leads.
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.
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.
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
^ Irritation 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.
21. Loosen spring band clamps -1, 3, 5- and pull off coolant hoses -2, 4, 6-.
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-.
24. Unscrew collar nuts (M8) and screws (M8 x 40). Remove support plate -A-.
25. Unscrew screws (M10 x 70) -arrows- and remove V-brace.
26. Unscrew screws (M8 x 40) -arrows- for 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.
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.
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).
32. Remove rear silencer.
33. Unscrew nut (M8) -1- and remove ground strap -2- (right side of vehicle).
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-.
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.
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.
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 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 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.
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 (22 ft lb.) Nm Tightening torque: 40 (30 ft lb.) Nm.
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.
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 ft lb.) Nm
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.
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
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.
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.
52. Loosen the three M10 screws -arrows- on the right transmission support.
Note: Do not loosen transmission support at the central nut as this will damage the hydraulic mount.
Note: 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)
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.
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.
57. Unscrew front Torx screws for air-conditioning compressor (M8 x 90) -1- and -2-.
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.
Note: The air-conditioning lines on the compressor do not have to be disconnected in order to remove engine/transmission unit.
Note:
^ 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.
ATTENTION
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.