Installing Engine
Installing Engine M96/21 (3.2 l) and M96/22 (2.7 l) With Manual Transmission
Engine, M96/21 (3.2 l) and M96/22 (2.7 l)
Special Tools
Adjusting Tool
NOTE: If the special tool 9592 is being used for the first time, (four) additional threaded holes must be applied.
1. Lay the support plate 9592/1 on the rear of the retainer plate 9592 and fasten with four hexagon-head bolts M8 x 25.
2. Countersink the retainer plate at the designated bores -arrows- with a 9 mm drill bit. The support plate serves as the drilling template.
3. Drill through the countersunk bores on the retainer plate with a drill bit sized 6.8 mm and then cut an M8 thread.
4. Fasten the special tool adapter 9163/2 with a hexagon-head bolt M8 x 25 (bolt quality 10.9) and hexagon-head bolts M8 x 16 (bolt quality 10.9) at the designated positions "Boxster". The adapter and the support plate are fastened on the retainer plate with the M8 x 25 hexagon-head bolts. The M8 x 16 hexagon head bolts connect the adapter with the support plate.
5. Support for Tiptronic transmission with three M6 x 20 (2 ea.) and M8 x 25 (1 ea.) wood screws.
Drawing shows complete engine retainer plate fitted on the workshop jack.
6. Fasten complete retainer plate on the workshop jack.
Special Notes
- Check the fuel hose for correct routing. The fuel hose is routed behind the engine wiring harness.
- When installing the rear-axle parts, it is essential to observe the correct sequence. The sheetmetal brace should be installed first, then the diagonal brace and finally the rear-axle support.
- The V-brace must be fitted before the exhaust system is installed.
- Finally, perform a suspension alignment.
- Read out fault memory.
Installing Engine
NOTE: In order to facilitate the fitting of the air-conditioning compressor, it should be moved back into its installation position during the running-in of the engine.
1. Lift the engine-transmission unit carefully and in steps. Have a second person observe the engine-transmission clearance at the same time. When lifting, pay particular attention to the clearance between the rear-axle longitudinal support and the VarioCam cable. Place the air-conditioning compressor in its installation position at this stage.
2. Push the engine wiring harness through the bulkhead and into the luggage compartment before the final installation position is reached.
3. Tighten engine mount. Tighten the four engine mount fastening screws to 46 Nm (34 ftlb.).
WARNING:
Risk of damage!
- Do not turn the multiple-tooth nut -C-!
4. Install the transmission carrier and the hydraulic mount again. The M8 screws are tightened to 33 Nm (24 ftlb.).
5. Install engine carrier again. Tighten the four fastening screws to 65 Nm (48 ftlb.).
6. Remove the engine-transmission retainer plate. As soon as the engine has been fastened again, the car jack and the retainer plate can be removed.
7. Clip the guide tube of the oil dipstick into the socket.
8. Fit the rubber sleeve of the wiring harness again.
9. Re-connect engine control module. To do so, start at the bottom. Pay attention to the plug designations on the control module.
10. Connect the plug connections (X3/1, X3/2 and X59) of the engine wiring harness. To do so, insert the plug and lock the lateral slide.
11. Connect the ground point of the control module again and tighten the fastening nut.
12. Install the luggage compartment lining of the rear luggage compartment.
13. Screw air-conditioning compressor tight. Tighten the three fastening screws to 23 Nm (17 ftlb.).
14. Check the drive belt for damage and replace it if necessary. Fit the belt in its original running direction once more. The fitting sequence is shown in the illustration.
15. Tighten the fuel line on the engine and the ground cable again. Make sure without fail to counter with a wrench when tightening the fuel line. The ground cable is tightened with 23 Nm (17 ftlb.).
16. Push the vacuum line for the brake booster in a straight line on to the flange, until the plug is heard to engage. Then install the grey snap ring again. Check that the line is seated properly by pulling on it gently.
17. Install the expansion tank of the power steering again. Check the sealing rings and replace, if necessary. Turn the lower adjusting ring to its original position and position the tank of the power steering. Press the tank downwards and at the same time turn the ring until the markings coincide. Then fill the tank with Pentosin according to the regulations.
18. Lay the B+ line of the alternator over the connecting bolt and tighten the fastening screw with 10 Nm (7.5 ftlb.). Close the protective cap of the B+ box.
19. Re-connect hot film mass air flow meter. Connect the connecting tube between the hot film mass air flow meter and the intake system and tighten the hose clamp.
20. Fit the oil filler line. Push the oil filler line back onto the flange and secure with a spring band clamp.
21. Re-fit clutch slave cylinder. Insert the cylinder back into the opening in the transmission. Tighten the fastening screw with 23 Nm (17 ftlb.).
22. Lay shift cables. Lay the shift cables in the engine compartment once more and clip them into the holder on the transmission. Then check once more that they are seated properly. Finally, press the shift cables back into the shift linkage. Check that the shift cables are Installed correctly.
23. Screw heat shield tight. Fit the shield over the Tucker bolts and tighten the two sheetmetal nuts.
24. Screw the drive shafts on to the transmission again with new screws. The tightening torque is 39 Nm (29 ftlb.) for the Boxster 2.7 l and 81 Nm (60 ftlb.) for the Boxster 3.2 l. Subsequently remove the protective sheath.
25. Re-tighten cable. Fit the engine cable through the rear-axle support again and tighten the fastening nuts. Make sure to counter with a wrench when tightening. The tightening torque is 23 Nm (17 ftlb.).
26. Connect the power-assisted steering lines. To do so, tilt the holder on one side and pull out simultaneously.
27. Detach threaded part -A- by pulling it off the nipple.
28. Insert the holder -C- into the threaded part -A- and screw both into the plug-in coupling -B- and tighten. Make sure to counter with a wrench when tightening. The tightening torque for the steering pressure line is 30 Nm (22 ftlb.) (wrench size 15). The tightening torque for the steering return line is 40 Nm (30 ftlb.) (wrench size 19).
29. Insert the screwed plug into the plug-in coupling in a straight line. The plug must audibly engage in the holder.
NOTE: The plug-in connection is designed so that the plug can be shifted in the plug-in coupling by approx. 1 mm in axial direction by slightly pulling or pressing.
30. The correct engagement of the plug-in couplings should be checked using the special tool 9623. To check this, insert the special tool 9623 between the plug-in coupling and the screwed plug and tilt the tool slightly. The plug must not slide out.
31. Install the servo lines, the return line and the vacuum hose for the brake booster again and insert the retaining clip.
CAUTION:
Risk of damage!
The fuel lines must not be kinked.
32. Connect the fuel lines. Re-connect the fuel lines on the vehicle underbody. The plug must engage audibly. Check correct seating by pulling gently.
CAUTION:
Danger of slipping hoses.
Never apply a lubricant to the coolant hoses to make fitting easier!
Connect the hose
Close the line
Reconnect the hoses
33. Fit all the coolant hoses again. To make fitting easier, the coolant hoses can be wetted with water in the fitting area.
34. Check the coolant drain plug. If the drain plug is removed it should be equipped with a new seal and re-mounted. The tightening torque for the screw is from 10 to 15 Nm (7.5 to 11 ftlb.).
35. Fit vent line again.
36. Install rear-axle support again. The four fastening screws are tightened to 65 Nm (48 ftlb.).
37. Move the exhaust system to its installation position again. In the process replace all the seals at opened points. Tighten the three hexagon-head bolts again. Then tighten the screws on the exhaust manifold/catalytic converter with 25 Nm (18 ftlb.).
38. Connect the oxygen sensor cables. Connect the plugs and engage the holder in the rear-axle support.
39. Install the rear V-member. The four fastening screws are tightened to 65 Nm (48 ftlb.).
View of one of the two bearing surfaces
View of a stabilizer mount
40. Install stabilizer. To do so, insert the stabilizer on the left and right into the stabilizer mount and screw it tight to the two bearing surfaces. The fastening nuts on the mount are tightened with 46 Nm (34 ftlb.). The fastening screws on the bearing surfaces are tightened with 23 Nm (17 ftlb.).
41. Install the sheetmetal brace into the vehicle. Tighten the hexagon nuts with 65 Nm (48 ftlb.) and tighten the fastening screws with 46 Nm (34 ftlb.). Install the two diagonal braces into the vehicle. Tighten the fastening nuts to 65 Nm (48 ftlb.).
NOTE: Vehicles with automatic headlight beam adjustment. Bear in mind that the angle sensor bracket (B) must be in contact at the bottom when the bolts on the rear-axle support (A) are tightened. Once installed, the control module must be calibrated with the PST 2. The headlights must then be reset. -A- Rear-axle support- -B- Angle sensor bracket- -C- Angle sensor-
42. Mount the underside panel.
43. Install the right and left wheel housing trims again.
44. Re-install the rear spoiler.
45. Install the rear spoiler again.
46. Re-position the trim of the rear luggage compartment and press in the fastening rivets.
WARNING:
Danger of short circuit!
- Pay attention to the correct seating of the rubber sleeve of the B+ lead!
47. Check the rubber sleeve. The rubber sleeve of the B+ lead must be fitted correctly and must not have slipped out of place.
48. Seal off the maintenance openings again. Seal off the upper and rear maintenance openings again. Tighten the seven fastening screws and the two fastening nuts of the rear maintenance opening with 10 Nm (7.5 ftlb.).
49. Re-install the left seat. Tighten the four fastening nuts to 65 Nm (48 ftlb.).
50. Top up operating fluids. Check that all operating fluids (engine oil, Pentosin, coolant) are at the correct level. Both the coolant circuit and the power steering must be bled according to regulations.
51. Connect battery. Connect the battery terminals again and tighten. Subsequently, the fault memories of the vehicle must be read out and the theft codes may possibly have to be entered again. Re-teach the power windows.
52. Carry out a test drive. After the test drive, check that all the operating fluids are at the correct level. Check all circuits for leaks.
53. Fit convertible top again. To do so, take the mandrel out of the fixing bore.
54. Move the convertible top towards the rear until the linkage can be pushed back onto the pin. Then push the retaining clip into place.
55. Close convertible top. To do so, pull the tension bow towards the rear again and engage the tension cables again on the left and right.
56. Engage the cloth covering of the convertible top on the left and right into the retaining lugs.
Tightening Torques