Installing anti-run-on valve (combination valve)
WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2004 Porsche Boxster, 2003 Porsche Boxster, 2002 Porsche Boxster, 2001 Porsche Boxster, and 2000 Porsche Boxster. However, it is still accessible from the selected car via links, so may be relevant.
- Clean the sealing surfaces on both cylinder heads with a clean cloth soaked in cleaning fluid (e.g. solvent naphtha, acetone).
- Prepare new parts for installation. Mount anti-run-on valve (combination valve) with seal and 2 M6 x 16 hexagon-head bolts on the distributor housing.
Tightening torque 10 Nm (7.5 ftlb.)
Fig 1 shows the new distributor housing with anti-run-on valve (combination valve), seals and screws .
- Mount vacuum reservoir on the new distributor housing using fastening screw.
- Fix air line in installation position. Position line flange with new seal and 2 M6 x 16 hexagon-head bolts on cylinder head 4-6 -1- . See Fig 2 . Insert spacer sleeve for air conditioning compressor -2- .
- Position distributor housing with vacuum reservoir on the air line with union nut.
- Insert a new seal between the distributor housing and cylinder head 1-3, screw in and tighten 2 M6 x 20 hexagon-head bolts -1-
. See Fig 3
. Clip in the switch-over valve, attach vacuum lines to the anti-run-on valve and the vacuum reservoir.
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Tightening torque 10 Nm (7.5 ftlb.)
- Tighten 2 M6 x 16 hexagon-head bolts for the air line on cylinder head 4 - 6.
Tightening torque 10 Nm (7.5 ftlb.)
- Tighten the air line's M20 x 1.5 union nut (hexagon socket a/f 22) on the distributor housing.
Tightening torque 25 Nm (19 ftlb.)
- Fit a new connecting hose with spring band clamp on the flange of the anti-run-on valve.
- Insert oil filler neck with new O-ring and tighten with an M6 x 16 hexagon-head bolt.
Tightening torque 10 Nm (7.5 ftlb.)
- Fix tuning pipe and intake distributor centre with screw-type hose clamps. Attach positive crankcase ventilation line to the distributor and vacuum line to tuning pipe rubber sleeve. Tighten M6 fastening nut for throttle body.
Tightening torque 10 Nm (7.5 ftlb.)
- Clean sealing surfaces of intake distributor cylinder side 1 - 3. Install intake distributor. Replace molded seals and micro-encapsulated M6 x 35 hexagon-head bolts. Attach positive crankcase ventilation line to the oil mist separator, attach engine compartment temperature sensor.
Tightening torque 10 Nm (7.5 ftlb.)
- Install air guide cowl.
- Install fuel collection pipe. Replace O-rings on the injection nozzles, insert the fuel collection pipe in the intake distributor and tighten with 2 M6 x 12 hexagon-head bolts.
Tightening torque 10 Nm (7.5 ftlb.)
- Install secondary air pump. Attach cable plug and tighten hexagon nuts on the bracket.
Tightening torque 10 Nm (7.5 ftlb.)
- Fit ground cable to bracket with 1 M8 hexagon nut.
Tightening torque: 23 Nm (17 ftlb.)
- Install generator. See
REMOVING AND INSTALLING GENERATOR
.NOTE: Before installing the air conditioning compressor, check whether the spacer sleeve is inserted for the rear fastening screw.
- Install air conditioning compressor. Attach ground cable. Position the rear M8x 120 hexagon-head bolt between cylinder intake manifolds 4 and 5 -arrow-
. Position the two front M8 x 90 screws and tighten all 3 screws.
Rear fastening screw for air conditioning compressor
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Tightening torque: 23 Nm (17 ftlb.)
- Install supply tank for power steering system. Ensure that the bayonet lock is sealed securely.
- Install box for B+ connector, tighten 2 hexagon-head bolts.
Tightening torque 10 Nm (7.5 ftlb.)
- Fit and tension drive belt again. Refer to ENGINE MAINTENANCE: CHECKING POLYRIB BELT STATE
.NOTE: Note the work instructions for disconnecting and reconnecting the battery.
- Connect the battery. See WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY .
- Fill Pentosin for power steering system. Refer to CHECKING PENTOSIN CHF 11 S HYDRAULIC FLUID IN THE POWER-STEERING SYSTEM .
- Remove protective covers.
- Install engine compartment lid and maintenance cover. Refer to ENGINE MAINTENANCE: OPENING AND CLOSING ENGINE COMPARTMENT
.NOTE: A second person is required for removing/fitting the convertible-top compartment lid to avoid damage.
- Install convertible-top compartment lid. Refer to REMOVING AND INSTALLING CONVERTIBLE TOP COMPARTMENT LID .
- Install seat. Refer to REMOVING AND INSTALLING FRONT SEAT - AS OF MY 1996 .
- Close convertible top.