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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 >> Removing Cylinder Head Cover - Cylinder Banks 1 - 3 And 4 - 6 - USA Vehicles

Removing Cylinder Head Cover - Cylinder Banks 1 - 3 And 4 - 6 - USA Vehicles

  1. Disconnect the battery. Refer to WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY .
  2. Remove respective rear wheel. To do this, use the socket wrench insert P 300 to avoid damaging the wheel.
  3. Remove the rear underbody panel. Undo the torx screws, plastic nuts and the Centre M6 hexagon nut.
    Fig 1: Removing Rear Underbody Panel
    G03092574Courtesy of PORSCHE OF NORTH AMERICA, INC.
  4. Drain engine oil. After a dripping time of about 20 minutes, refit oil drain plug (hexagon socket a/f 8) with a new sealing ring.
    Fig 2: Draining Engine Oil
    G03092575Courtesy of PORSCHE OF NORTH AMERICA, INC.

    Tightening torque 50 Nm (37 ft.lb) 

  5. Remove side plastic strut by undoing the M6 hexagon nut -arrow-. See Fig 3.
    Fig 3: Removing Side Plastic Strut
    G03092576Courtesy of PORSCHE OF NORTH AMERICA, INC.
  6. Pull cable plug off oxygen sensor towards the front -arrow- expose the oxygen sensor cable. See Fig 3.
    Fig 4: Pulling Cable Plug Off Oxygen Sensor
    G03092577Courtesy of PORSCHE OF NORTH AMERICA, INC.
  7. Pull cable plug on cylinder head cover off oxygen sensor -1- and remove cable plug holder from cylinder head cover by undoing the M6 hexagon-head bolt -2-. See Fig 5.
    Fig 5: Pulling Cable Plug On Cylinder Head Cover Off Oxygen Sensor
    G03092578Courtesy of PORSCHE OF NORTH AMERICA, INC.
  8. Unscrew exhaust manifold with catalytic converter. Remove flange with 2 M8 hexagon nuts and 1 M8 hexagon-head bolt as well as 6 exhaust manifold screws. Remove and replace metal seals.
  9. Remove side plastic cover by undoing 2 M6 hexagon-head bolts -arrows- (cylinder bank 1 - 3). See Fig 6.
    Fig 6: Removing Side Plastic Cover
    G03092579Courtesy of PORSCHE OF NORTH AMERICA, INC.
  10. Pull cable plugs off the ignition coils, oil pressure sensor (cylinder bank 1 - 3) and magnetic hydraulic valve. See Fig 6.
  11. Cylinder bank 4 - 6: Remove the holder for the servo line by undoing the M6 hexagon-head bolt-arrow-. See Fig 7.
    Fig 7: Removing Holder For Servo Line
    G03092580Courtesy of PORSCHE OF NORTH AMERICA, INC.
  12. Remove 3 ignition coils. Unscrew 6 M6 x 25 pan-head screws (hexagon socket a/f 5), pull the ignition coils out of the spark-plug recess.
  13. Remove holder and cover for magnetic hydraulic valve. Unscrew the two M6 x 20 pan-head screws (hexagon socket a/f 5), remove the connection cable for the hydraulic valve from the sheetmetal bracket and remove the holders. Remove cover with hydraulic valve.
    CAUTION: When levering off the cylinder head cover, the cast lugs may break!
    Fig 8: Identifying Upper Cast Lug
    G03092581Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 9: Levering Off Cylinder Head Cover
    G03092582Courtesy of PORSCHE OF NORTH AMERICA, INC.
  14. Remove the cylinder head cover. To do this, unscrew 20 M6 x 30 hexagon-head bolts from the cylinder head cover. Unscrew the four M6 x 20 hexagon-head bolts on the sides of the oil extraction pump. To release the cylinder head cover, raise the cover carefully at the two protruding cast edges with a slotted screwdriver. If necessary, loosen the cover by carefully tapping it with a plastic hammer. Collect the dripping engine oil.
    NOTE:
    • After removing the oil extraction pump, check the O-ring for damage and replace if necessary.
  15. Remove oil extraction pump.
  16. Disconnect the holder for the coolant lines and carefully push the coolant lines aside. Remove cylinder head cover (cylinder bank 1 - 3). See Fig 5.
    Fig 10: Disconnecting Holder For Coolant Lines
    G03092583Courtesy of PORSCHE OF NORTH AMERICA, INC.
  17. Remove the brown closure cap (45 mm) and 2 green closure caps.
NOTE:
  • To work on cylinder bank 4 - 6, follow the steps described for cylinder bank 1 - 3 under Fig 5.
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