Engine - Oil Leak by Crankshaft Seal
Boxster2/04
Binder - 1, Engine Part 1
This bulletin replace bulletin Group 1, Part 1, # 2/04, dated 6-25-04.
Engine Oil Leak By Crankshaft Seal (Flywheel Side)
Vehicle Type:
Boxster/Boxster S
Model Year:
As of '97 (V)
Concerns:
Engine oil leaks in area of crankshaft sealing ring on flywheel side may be coming from the crankcase and intermediate-shaft flange bolts.
Filing:
Replace Technical Bulletin Group 1, Part 1, # 2/04 dated 6-25-04 that is filed in the Technical Manual with this one.
Information
Examination of engines that were the subject of complaints revealed other oil leaks in addition to those found in the crankshaft sealing ring on the flywheel side. These engine oil leak areas included:
> crankcase bolt threads
> intermediate-shaft flange area.
Since March 10, 2004, bolts with a sealant coating on the thread and head have been used during assembly to fasten the crankcase halves in the area of the flywheel.
On vehicles manufactured prior to the above-mentioned date (See Introduction), the four crankcase bolts and the three intermediate shaft flange bolts must be replaced in addition to the crankshaft sealing ring in the event of an oil leak in the area.
Engines replaced for this reason under warranty will be subject to a charge back and the engine returned to the dealer.
The work procedure for replacing the affected fastening bolts is described.
Introduction:
Introduction of the coated fastening bolts on the crankcase: March 10, 2004, from the Engine # S shown.
Parts Information
Work Procedure:
1. Replace crankshaft sealing ring (Figure 1, Item C), see Technical Manual, Group 1, Repair, 13 59 19 - Removing and installing crankshaft sealing ring - flywheel side.
2. Replace four bolts on the crankcase (Figure 2, Item A).
2.1 Unscrew and remove the four bolts (Figure 2, Item A) and clean oil residues out of the threaded holes using a suitable cleaning agent (e.g., brake cleaner).
2.2 Screw the new bolts, Part No. 999 385 004 09, completely into the threaded holes. Tightening torque: 13 Nm (9.5 ft lb.)
3. Replace fastening bolts on the intermediate shaft flange (Figure 3, Item B). Since the intermediate shaft flange is loaded by the chain tensioners, the fastening bolts must be replaced only one at a time.
3.1 Unscrew and remove one fastening bolt and clean oil residues out of the threaded hole using a suitable cleaning agent (e.g., brake cleaner).
3.2 Fully screw the new bolt, Part No. 900 385 275 09, into the threaded holes. Tightening torque: 10 Nm (7.5 ft lb.)
3.3 Repeat steps 3.1 to 3.2 for the second and third fastening bolts.
Working Time
Reference:
Boxster Technical Manual, Group 1:
> Repairs: 13 59 19 - Removing and installing crankshaft sealing ring - flywheel side.
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