Cylinder Head - Seal Plug Oil Leak

Boxster

5/98

1586

Binder - Engine, Part 2

Date: 9-4-98

Cylinder Head - Seal Plug Oil Leak

Vehicle Type:
Boxster

Model Year:
Gas of 1997 (V)

Concern:
Cylinder head oil leak at seal plug.

Information:

It is possible that oil leakage can occur at the 10 mm sheet metal seal plug on the Boxster cylinder head. If this should occur, the plug must be replaced with a new plug made of aluminum.

Work Procedure:





1. Drain engine oil into a clean container. (For reuse)

2. Remove the following parts, as required:

^ Rear underbody cover (for lower and/or lateral plug in the area of cylinder 4).

^ Rear-axle support and diagonal brace (for lateral plug in the area of cylinder 3).

3. Remove the seal plug by tilting the edge of the plug with a hammer and drift. Then remove it from the bore using a pair of pointed-nose pliers. (A cotter-pin removal tool can also be used)

4. Coat the sealing surface of the seal plug with Optimoly HT. Drive the plug into the bore up to the collar.

Parts Info.:

Part Number Description

996 104 411 00 New Plug (10 mm aluminum)
000 043 004 00 Optimoly HT (copper mounting paste)

Warranty Info:

Labor Operation Time Units Description

15 86 55 00 80 T.U. Replacing one seal plug,
bank 1-3. Includes: Draining and filling
in engine oil. Without: Removing and
installing rear underbody cover and
rear-axle support.

15 86 55 03 90 T.U. Replacing one seal plug,
bank 4-6 Includes: Draining and filling
in engine oil, removing and installing
rear underbody cover.

Literature:

Boxster Technical Manual, Binder-Group 1, Section 17 19 19 - Removing and installing oil extraction pumps (rear-axle support)

Boxster Technical Manual, Binder-Group 4, Section 42 13 19 - Removing and installing diagonal brace