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Home >> Porsche >> 2000 >> Boxster Base, Standard >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine >> Removing And Installing Cylinder Head Covers - Engine Installed, As Of My 2003 >> INSTALLING CYLINDER HEAD COVER - CYLINDER BANKS 1 - 3 AND 4 - 6 - USA vehicles

INSTALLING CYLINDER HEAD COVER - CYLINDER BANKS 1 - 3 AND 4 - 6 - USA vehicles

NOTE:
  • The sealing surfaces of the cylinder heads as well as the cylinder head covers must be cleaned carefully before the new sealant is applied. Avoid damage!
  1. Clean sealing surfaces. Remove any sealant residue from the sealing surfaces on the cylinder head and the cylinder head cover thoroughly. Then rub down with a clean cloth soaked in a decreasing agent (e.g. acetone, solvent naphtha). Make sure that no sealant residue can enter the cylinder head.
    NOTE:
    • Replace the seals for the spark-plug recesses.
  2. Insert the 3 seals for the spark-plug recesses.
    Fig 1: Locating Spark-Plug Recess Seals
    G03092584Courtesy of PORSCHE OF NORTH AMERICA, INC.
    NOTE:
    • Only if the camshaft adjustment valve was removed:
    • Pull the oil strainer -arrow- out using pointed-nose pliers and replace! See Fig 2.
    Fig 2: Pulling Oil Strainer
    G03092585Courtesy of PORSCHE OF NORTH AMERICA, INC.

    Only the following sealants may be used to seal the cylinder head cover (these are available from the Porsche Parts Service): 

    • "Drei Bond" silicone - type 1209
    • Loctite 5900
    NOTE:
    • When applying the sealant, always make sure that the oil ducts in the cylinder head are not blocked!
  3. Carefully apply a thin bead of sealant on the cylinder head cover. See Fig 3. The bead should not be higher than 1.5 mm.
    Fig 3: Identifying Sealant Area On Cylinder Head Cover
    G03092586Courtesy of PORSCHE OF NORTH AMERICA, INC.
  4. Push the coolant lines aside and fix cylinder head cover. Fasten coolant lines.
    Fig 4: Pushing Coolant Lines Aside
    G03092587Courtesy of PORSCHE OF NORTH AMERICA, INC.
  5. Position 20 M6 x 30 hexagon-head bolts on the cylinder head cover.
  6. Tighten the 20 hexagon-head bolts in the specified tightening sequence to the specified torque.
    Fig 5: Identifying Cylinder Head Cover Tightening Sequence
    G03092588Courtesy of PORSCHE OF NORTH AMERICA, INC.

    Tightening torque 13 Nm (9.5 ft.lb) 

    NOTE:
    • If the O-ring of the oil extraction pump needs to be replaced, insert the pump after fastening the cylinder head cover and then position the 4 M6 x 20 hexagon-head bolts.
    • Identification on the oil extraction pump in the Figure cylinder side 1 - 3 faces the crankcase. See Fig 6.
    • The screws for the oil extraction pump are micro-encapsulated and are therefore to be replaced.
    Fig 6: Identification Mark On The Oil Extraction Pump - Cylinder Bank 1-3
    G03092589Courtesy of PORSCHE OF NORTH AMERICA, INC.
  7. Carefully remove excess sealant before installing the oil extraction pump. Insert oil extraction pump in the fitting bore.
  8. Position 4 M6 x 20 hexagon-head bolts (micro-encapsulated) on the oil extraction pump and tighten to the specified torque.

    Tightening torque 13 Nm (9.5 ft.lb) 

    NOTE:
    • Replace all plastic closure caps on the cylinder head/cylinder head cover joint.
  9. For each cylinder head, place a new, brown, dry closure cap (45 mm) on the bore for the exhaust camshaft and press in until they are flush.
  10. Insert 2 new, green, dry closure caps for each cylinder head into the small bores and press in until they are flush.
  11. Insert camshaft adjustment valve with a new O-ring again (installation position: ensure that dowel pin is in the cylinder head bore!).
    NOTE:
    • Replace cover with integral seal for the camshaft adjustment valve!
  12. Slide the new cover over the camshaft adjustment valve, place holder with 2 M6 x 20 pan-head screws (hexagon socket a/f 5) on cylinder head cover and tighten. Push cable plug onto camshaft adjustment valve.

    Tightening torque 10 Nm (7.5 ft.lb) 

  13. Fit ignition coils. Insert 3 ignition coils into the spark-plug recesses for each cylinder bank. Position 2 M6 x 25 pan-head screws for each ignition coil hexagon socket a/f 5) on the cylinder head cover and tighten to the specified torque. Connect cable plug to ignition coils.

    Tightening torque 10 Nm (7.5 ft.lb) 

  14. Cylinder bank 1 - 3: Connect cable plug to oil pressure sensor.
  15. Cylinder bank 1 - 3: Fit side plastic cover by screwing two M6 hexagon-head bolts -arrows-  into place. See Fig 7.
    Fig 7: Locating Side Plastic Cover Hexagon-Head Bolts
    G03092590Courtesy of PORSCHE OF NORTH AMERICA, INC.

    Tightening torque 10 Nm (7.5 ft.lb) 

  16. Cylinder bank 4 - 6: Attach the holder for the servo line by tightening the M6 hexagon-head bolt -arrow-  . See Fig 8.
    Fig 8: Locating Holder For The Servo Line Hexagon-Head Bolt - Cylinder Bank 4-6
    G03092591Courtesy of PORSCHE OF NORTH AMERICA, INC.

    Tightening torque 10 Nm (7.5 ft.lb.) 

    NOTE:
    • Always replace the metal seals on the exhaust manifold and flange.
    • The M8 x 28 exhaust manifold screws are to be replaced.
    • Replace the screws and nuts on the flange if necessary.
  17. Install exhaust manifold with catalytic converter. To do this, screw the exhaust manifold into place on the catalytic converter using 2 M8 hexagon nuts and one M8 hexagon-head bolt and on the cylinder head using 6 new M8 x 28 hexagon-head bolts. Replace metal seals.

    Tightening torque 23 Nm (17 ft.lb.) 

  18. Attach oxygen sensor cable plug holder to cylinder head cover by tightening the M6 hexagon-head bolt. Lay oxygen sensor cable and clip in to sheetmetal bracket. Connect both oxygen sensor cable plugs in front of and behind the catalytic converter.

    Side oxygen sensor cable plug in front of catalytic converter 

    Fig 9: Connecting Both Oxygen Sensor Cable Plugs
    G03092592Courtesy of PORSCHE OF NORTH AMERICA, INC.

    Tightening torque screw for holder 10 Nm (7.5 ft.lb) 

    Side oxygen sensor cable plug behind catalytic converter 

    Fig 10: Locating Side Oxygen Sensor Cable Plug
    G03092593Courtesy of PORSCHE OF NORTH AMERICA, INC.
  19. Attach side plastic strut by tightening the M6 hexagon nut -arrow-  . See Fig 11.
    Fig 11: Attaching Side Plastic Strut
    G03092594Courtesy of PORSCHE OF NORTH AMERICA, INC.

    Tightening torque 10 Nm (7.5 ft.lb) 

  20. Fit the rear underbody panel. Position the torx screws, plastic nuts and the Centre M6 hexagon nut and tighten.
    Fig 12: Fitting Rear Underbody Panel
    G03092595Courtesy of PORSCHE OF NORTH AMERICA, INC.
  21. Mount respective rear wheel. To do this, use the socket wrench insert P 300 to avoid damaging the wheel.

    Tightening torque 130 Nm (96 ft.lb). 

  22. Fill engine oil according to specifications. Refer to ENGINE MAINTENANCE: OIL CHANGE WITH FILTER CHANGE or CHANGING THE ENGINE OIL AND OIL FILTER -- AS 2003 .
  23. Connect the battery. Refer to WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY .
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