Installing Engine, M96/20 (2.5 I) With Tiptronic Transmission

Installing Engine, M96/20 (2.5 l) With Tiptronic Transmission







Special Tools

Item A - C1:

Item A - B:

Adjusting Tool

NOTE: If the special tool No. 9592 is being used for the first time, (four) additional threaded holes must be applied.







1. Lay the support plate No. 9592/1 on the rear of the retainer plate No. 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 No. 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 position "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.
6. Fasten complete retainer plate on the workshop jack.

Drawing shows complete engine retainer plate fitted 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. Install engine carrier again. Tighten the four fastening nuts to 65 Nm (48 ftlb.).







WARNING:
Risk of damage
- Do not turn the multiple-tooth nut -C-.







4. Install the transmission carrier and the hydraulic mount again. Tighten the M8 screws to 33 Nm (24 ftlb.) and the M10 screws to 65 Nm (48 ftlb.).







5. 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.







6. Clip the guide tube of the oil dip stick into the socket.







7. Fit the rubber sleeve of the wiring harness again.







8. Re-connect engine control module. To do so, start at the bottom. Pay attention to the plug designations on the control module.







9. Re-connect and install the Tiptronic control module. Tighten the three fastening nuts.







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 figure.







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 to 23 Nm (17 ftlb.) and the fuel supply line to 30 Nm (22 ftlb.).







16. Push the vacuum line for the brake booster in a straight line onto the flange, until the plug is heard engaging. 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 to 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. Attach oil filler neck. Push the oil filler neck back onto the flange and secure with a spring band clamp.







21. Engage the accelerator cable.







Close the deflector box.







22. Engage selector lever cable at deflection lever and at the transmission support.







23. Position the plug at the transmission socket. Disconnect the plug and turn clockwise.
24. Re-connect the plug for the multi-function switch.
25. Screw the drive shafts to the transmission again. The tightening torque is 39 Nm (29 ftlb.). Then remove the protective sheaths.







26. Re-tighten cable. Fit the engine cables 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.).







27. Connect the power-assisted steering lines. To do so, tilt the holder on one side and pull out simultaneously.







28. Detach threaded part -A- by pulling it off the nipple.







29. 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).







30. 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.







31. The correct engagement of the plug-in couplings should be checked using the special tool No. 9623. To check this, insert the special tool No. 9623 between the plug-in coupling and the screwed plug and tilt the tool slightly. The plug must not slide out.







32. 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.

33. Connect the fuel lines. Re-connect the fuel lines on the vehicle floor. The connector 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.

34. Fit all the coolant hoses again. To make fitting easier, the coolant hoses can be wetted with water in the fitting area.







Connect the hose.







Close the line.







Reconnect the hoses.







35. Check coolant dram 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.).







36. Fit vent line again.







37. Install rear-axle support again. The four fastening screws are tightened to 65 Nm (48 ftlb.).







38. 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.).







39. Connect oxygen sensors. Connect the plugs and engage the holder in the rear-axle support.







40. Install the rear V-member. The four fastening screws are tightened to 65 Nm (48 ftlb.).
41. 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 to 50 Nm (37 ftlb.). The fastening screws on the bearing surfaces are tightened to 23 Nm (17 ftlb.).







View of one of the two bearing surfaces







View of a stabilizer mount







42. Install the sheetmetal brace into the vehicle. Tighten the hexagon nuts to 65 Nm (48 ftlb.) and tighten the fastening screws to 46 Nm (34 ftlb.). Install the 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 System Tester PST 2. The headlights must then be reset. -A - Rear-axle support- -B - Angle sensor bracket- -C - Angle sensor-







43. Fit the underbody panel.







44. Install the right and left wheel housing trims again.







45. Re-install the rear spoiler.







46. Install the rear spoiler again.
47. Re-position the trim of the rear luggage compartment and press in the fastening rivets.

WARNING:
Risk of short circuit
- Pay attention to the correct seating of the rubber sleeve of the B+ lead.







48. Check the rubber sleeve. The rubber sleeve of the B+ lead must be fitted correctly and must not have slipped out of place.
49. Re-install the left seat. Tighten the four fastening screws 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-programme the power windows.







52. Seal off the upper and rear maintenance openings again. Tighten the seven fastening screws and the two fastening nuts of the rear maintenance opening to 10 Nm (7.5 ftlb.).
53. 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.
54. Fit convertible top again. To do so, take the mandrel out of the fixing bore.







55. Move the convertible top towards the rear until the linkage can be pushed back onto the pin. Then push the retaining clip into place.
56. 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.
57. Engage the cloth covering of the convertible top on the left and right into the retaining lugs.

Tightening Torques