Checking Camshaft Timing - Engine Installed - As Of My 2003: Notes

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.

Engine type M 96/23 and M 96/24

CAUTION: Do not turn crankshaft against the engine's direction of operation! Ensure everything is clean when working on the engine!

NOTE:

The timing should always be checked simultaneously on both cylinder banks.
The check is performed with the standard chain tensioners installed.

Unscrew the four plastic nuts of the carpeted rear wall and pull the rear wall upwards out of the vehicle. Open the maintenance cover behind the seats. To do so, unscrew the 7 fastening screws and the 2 fastening nuts and remove the maintenance cover. Refer to ENGINE MAINTENANCE: OPENING AND CLOSING ENGINE COMPARTMENT .

Fig 1: Removing Maintenance Cover In Passenger Compartment
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Turn the engine clockwise at the pulley of the crankshaft to the TDC marking of cylinder 1. Fix with special tool (fixing pins) 9595/1 (short fixing pin).

Fig 2: Installing Special Tool (9595) Into Belt Pulley
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Drain engine oil. Then equip the drain plug with a new sealing ring, screw it in and tighten it to the specified tightening torque.
Tightening torque of the M18 hexagon socket head screw: 50 Nm (37 ft.lb)
Remove the rear underbody panel. Undo the torx screws, plastic nuts and the Centre M6 hexagon nut.

Fig 3: Removing Rear Underbody Panel
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Remove side plastic strut by undoing the M6 hexagon nut -arrow- . See Fig 4.

Fig 4: Removing Side Plastic Strut
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Remove all four green caps on the camshaft housing covers on both cylinder heads. See REMOVING AND INSTALLING CLOSURE CAP FOR CAMSHAFT BORE - ENGINE INSTALLED . Press a small screwdriver into the Centre of the piercing point of the each cap and lever out the cap.

Fig 5: Locating Camshaft Housing Covers
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Check the cylinder side that is at overlapping TDC first (the smaller circular cutout on the milled groves of the inlet and exhaust camshafts points faces the cylinder head cover) -arrows- using setting gauge 9686. Then turn the engine 360° further and check the other cylinder side as well. See Fig 6.
Position of the camshafts in overlapping TDC of cylinder 1 or 4 (the smaller circular cutout on the milled grooves of the inlet and exhaust camshafts faces the cylinder head cover)

Fig 6: Positioning Camshafts In Overlapping TDC Of Cylinder 1 Or 4
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig 7: Inserting Setting Gauge (9686) Into Camshafts
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Remove setting gauge 9686 and fit two new green caps on each of the camshaft housing covers.
Fit side plastic strut with the M6 hexagon nut -arrow- . See Fig 8.

Fig 8: Fitting Side Plastic Strut
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Tightening torque 10 Nm (7.5 ft.lb)
Fit the rear underbody panel. Position the torx screws, plastic nuts and the Centre M6 hexagon nut and tighten.

Fig 9: Fitting Rear Underbody Panel
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Remove special tool fixing pins 9595/1 on the pulley of the crankshaft.
Fit the maintenance cover behind the seats. To do so, screw in and tighten the 7 fastening screws and the 2 fastening nuts. Refer to ENGINE MAINTENANCE: OPENING AND CLOSING ENGINE COMPARTMENT .
Tightening torque 10 Nm (7.5 ft.lb)
Fit carpeted rear wall. To do this, tighten the four plastic nuts.
Fill in engine oil. Refer to ENGINE MAINTENANCE: OIL CHANGE WITH FILTER CHANGE or CHANGING THE ENGINE OIL AND OIL FILTER -- AS 2003 .