Part 2
WM 100119 Removing and installing engineWARNING
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 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
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.
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 centre 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
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.).
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. -> 263319 Removing and installing rear silencer - section on "Removing" Service and Repair
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/stabiliser 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 -> 247019 Removing and installing DME control module Service and Repair.
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. -> 700619 Removing and installing rear luggage-compartment lining - section on "Installing" .
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 -> 440519 Removing and installing wheel 44051900 Removing and installing wheel.
2. Install throttle body with distributor pipe -> 244219 Removing and installing throttle body Service and Repair.
3. Connect ground lead of battery -> 2706IN Work instructions after disconnecting the battery 2706IN00 Work instructions after disconnecting the battery.
4. Bleed the clutch hydraulic system -> 300107 Bleeding the clutch system Service and Repair.
5. Fill and bleed cooling system -> 193817 Draining and topping up with coolant 193817 Draining and filling in coolant.
6. Check Pentosin level in power-steering reservoir -> 480201 Checking power-steering fluid level 48020150 Checking the fluid level for power steering.
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. -> 519319 Removing and installing middle cover 519319 Removing and installing Cover For Centre Underbody.
10. Install rear underbody cover -> 519419 Removing and installing rear cover 519419 Removing and Installing Cover for Rear Underbody.
11. Align the vehicle -> 449503 Suspension alignment, complete 44950300 Suspension alignment, complete.
12. Install rear wall cover -> 555919 Removing and installing rear wall cover 555919 Removing and Installing Rear Wall Cover.
Cover with grommet
13. Install engine compartment lid -> 557819 Removing and installing 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 -> 033500 On-board diagnosis (OBD) 033500 On-board diagnosis (OBD).
17. Perform a test drive.