LEMON Manuals: Even more car manuals for everyone
Home >> Porsche >> 2003 >> 911 Carrera 4S, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 38 (Engine) >> Engine, Crankcase >> Installing Engine, M96/20 (2.5L) With Manual Transmission >> Installing Engine

Installing Engine

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.
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.
    Fig 1: Locating VarioCam Cable
    G03091854Courtesy of PORSCHE OF NORTH AMERICA, INC.
  2. Push the engine wiring harness through the bulkhead and into the luggage compartment before the final installation position is reached.
    Fig 2: Pushing Engine Wiring Harness Through The Bulkhead And Into The Luggage Compartment
    G03091855Courtesy of PORSCHE OF NORTH AMERICA, INC.
  3. Tighten engine mount. Tighten the four engine mount fastening screws to 46 Nm (34 ft.lb).
    Fig 3: Tightening Engine Mount Fastening Screws
    G03091856Courtesy of PORSCHE OF NORTH AMERICA, INC.
    WARNING: Risk of damage!
    • Do not turn the multiple-tooth nut -C-!
  4. Install the transmission carrier and the hydraulic mount again. The M8 screws are tightened to 33 Nm (24 ft.lb).
    Fig 4: Installing Transmission Carrier And Hydraulic Mount
    G03091857Courtesy of PORSCHE OF NORTH AMERICA, INC.
  5. Install engine carrier again. Tighten the four fastening screws to 65 Nm (48 ft.lb).
    Fig 5: Installing Engine Carrier
    G03091858Courtesy of PORSCHE OF NORTH AMERICA, INC.
  6. 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.
    Fig 6: Removing Engine-Transmission Retainer Plate
    G03091859Courtesy of PORSCHE OF NORTH AMERICA, INC.
  7. Clip the guide tube of the oil dipstick into the socket.
    Fig 7: Clipping Guide Tube Of Oil Dipstick Into Socket
    G03091860Courtesy of PORSCHE OF NORTH AMERICA, INC.
  8. Fit the rubber sleeve of the wiring harness again.
    Fig 8: Fitting Rubber Sleeve Of Wiring Harness
    G03091861Courtesy of PORSCHE OF NORTH AMERICA, INC.
  9. Re-connect engine control module. Start from the bottom and pay attention to the plug designations on the control module.
    Fig 9: Connecting Engine Control Module
    G03091862Courtesy of PORSCHE OF NORTH AMERICA, INC.
  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.
    Fig 10: Connecting Plug Connections Of The Engine Wiring Harness
    G03091863Courtesy of PORSCHE OF NORTH AMERICA, INC.
  11. Connect the ground point of the control module again and tighten the fastening nut.
    Fig 11: Connecting Ground Point Of Control Module
    G03091864Courtesy of PORSCHE OF NORTH AMERICA, INC.
  12. Install the luggage compartment lining of the rear luggage compartment.
    Fig 12: Installing Luggage Compartment Lining
    G03091865Courtesy of PORSCHE OF NORTH AMERICA, INC.
  13. Screw air-conditioning compressor tight. Tighten the three fastening screws to 23 Nm (17 ft.lb).
    Fig 13: Installing Air-Conditioning Compressor Screws
    G03091866Courtesy of PORSCHE OF NORTH AMERICA, INC.
  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 following illustration. See Fig 14.
    Fig 14: Drive (Serpentine) Belt Fitting Sequence
    G03091867Courtesy of PORSCHE OF NORTH AMERICA, INC.
  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 with 23 Nm (17 ft.lb).
    Fig 15: Tightening Fuel Line On The Engine
    G03091868Courtesy of PORSCHE OF NORTH AMERICA, INC.
  16. Push the vacuum line for the brake booster in a straight line on to the flange, until the plug is heard to engage. Then install the grey snap ring again. Check that the line is seated properly by pulling on it gently.
    Fig 16: Installing Vacuum Line For The Brake Booster
    G03091869Courtesy of PORSCHE OF NORTH AMERICA, INC.
  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.
    Fig 17: Installing Expansion Tank Of Power Steering
    G03091870Courtesy of PORSCHE OF NORTH AMERICA, INC.
  18. Lay the B+ line of the alternator over the connecting bolt and tighten the fastening screw with 10 Nm (7.5 ft.lb). 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.
    Fig 18: Connecting Hot Film Mass Air Flow Meter
    G03091871Courtesy of PORSCHE OF NORTH AMERICA, INC.
  20. Fit the oil filler line. Push the oil filler line back onto the flange and secure with a spring band clamp.
    Fig 19: Fitting Oil Filler Line
    G03091872Courtesy of PORSCHE OF NORTH AMERICA, INC.
  21. Engage the accelerator cable.
    Fig 20: Connecting Accelerator Cable
    G03091873Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 21: Closing Deflector Box
    G03091874Courtesy of PORSCHE OF NORTH AMERICA, INC.
  22. Refit clutch slave cylinder. Insert the cylinder back into the opening in the transmission. Tighten the fastening screw with 23 Nm (17 ft.lb).
  23. Lay shift cables. Lay the shift cables in the engine compartment once more and clip them into the holder on the transmission. Then check once more that they are seated properly. Finally, press the shift cables back into the shift linkage. Check that the shift cables are installed correctly.
  24. Screw heat shield tight. Fit the shield over the Tucker bolts and tighten the two sheetmetal nuts.
  25. Screw the drive shafts on to the transmission again with new screws. The tightening torque is 39 Nm (29 ft.lb.) for the Boxster 2.7L and 81 Nm (60 ft.lb.) for the Boxster 3.2L. Subsequently remove the protective sheath.
  26. Retighten cable. Fit the engine cable 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 ft.lb).
    Fig 22: Tightening Engine Cable With Wrench
    G03091875Courtesy of PORSCHE OF NORTH AMERICA, INC.
  27. Connect the power-assisted steering lines. To do so, tilt the holder on one side and pull out simultaneously.
    Fig 23: Connecting Power-Assisted Steering Lines
    G03091876Courtesy of PORSCHE OF NORTH AMERICA, INC.
  28. Detach threaded part -A- by pulling it off the nipple. See Fig 24.
    Fig 24: Detaching Threaded Part -A- By Pulling It Off Nipple
    G03091877Courtesy of PORSCHE OF NORTH AMERICA, INC.
  29. Insert the holder -C- into the threaded part -A- and screw both into the plug-in coupling -B- and tighten. See Fig 25. Make sure to counter with a wrench when tightening. The tightening torque for the steering pressure line is 30 Nm (22 ft.lb.) (wrench size 15). The tightening torque for the steering return line is 40 Nm (30 ft.lb.) (wrench size 19).
    Fig 25: Inserting Holder -C
    G03091878Courtesy of PORSCHE OF NORTH AMERICA, INC.
  30. Insert the screwed plug into the plug-in coupling in a straight line. The plug must audibly engage in the holder.
    Fig 26: Inserting Screwed Plug
    G03091879Courtesy of PORSCHE OF NORTH AMERICA, INC.
    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 9623. To check this, insert the special tool 9623 between the plug-in coupling and the screwed plug and tilt the tool slightly. The plug must not slide out.
    Fig 27: Checking Plug-In Couplings Using Special Tool 9623
    G03091880Courtesy of PORSCHE OF NORTH AMERICA, INC.
  32. Install the servo lines, the return line and the vacuum hose for the brake booster again and insert the retaining clip.
    Fig 28: Installing Servo Lines
    G03091881Courtesy of PORSCHE OF NORTH AMERICA, INC.
    CAUTION: Risk of damage!
    The fuel lines must not be kinked.
  33. Connect the fuel lines. Re-connect the fuel lines on the vehicle underbody. The plug 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.
    Fig 29: Fitting Coolant Hose
    G03091882Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 30: Installing Coolant Hose Spring Clip
    G03091883Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 31: Connecting Coolant Hoses
    G03091884Courtesy of PORSCHE OF NORTH AMERICA, INC.
  35. Check the coolant drain 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 ft.lb).
    Fig 32: Locating Coolant Drain Plug
    G03091885Courtesy of PORSCHE OF NORTH AMERICA, INC.
  36. Fit vent line again.
    Fig 33: Fitting Vent Line
    G03091886Courtesy of PORSCHE OF NORTH AMERICA, INC.
  37. Install rear-axle support again. The four fastening screws are tightened to 65 Nm (48 ft.lb).
    Fig 34: Installing Rear-Axle Support
    G03091887Courtesy of PORSCHE OF NORTH AMERICA, INC.
  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 ft.lb).
    Fig 35: Locating Hexagon-Head Bolts
    G03091888Courtesy of PORSCHE OF NORTH AMERICA, INC.
  39. Connect the oxygen sensor cables. Connect the plugs and engage the holder in the rear-axle support.
    Fig 36: Connecting Oxygen Sensor Cables
    G03091889Courtesy of PORSCHE OF NORTH AMERICA, INC.
  40. Install the rear V-member. The four fastening screws are tightened to 65 Nm (48 ft.lb).
    Fig 37: Installing Rear V-Member
    G03091890Courtesy of PORSCHE OF NORTH AMERICA, INC.
  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 with 46 Nm (34 ft.lb). The fastening screws on the bearing surfaces are tightened with 23 Nm (17 ft.lb).
    Fig 38: Locating Stabilizer Mount Screws
    G03091891Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 39: Identifying Stabilizer Mount
    G03091892Courtesy of PORSCHE OF NORTH AMERICA, INC.
  42. Install the sheetmetal brace into the vehicle. Tighten the hexagon nuts with 65 Nm (48 ft.lb) and tighten the fastening screws with 46 Nm (34 ft.lb). Install the two diagonal braces into the vehicle. Tighten the fastening nuts to 65 Nm (48 ft.lb).
    Fig 40: Installing Sheetmetal Brace
    G03091893Courtesy of PORSCHE OF NORTH AMERICA, INC.
    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 PST 2. The headlights must then be reset. -A- Rear-axle support- -B - Angle sensor bracket- -C - Angle sensor- see Fig 41.
    Fig 41: Identifying Automatic Headlight Beam Adjustment Angle Sensor
    G03091894Courtesy of PORSCHE OF NORTH AMERICA, INC.
  43. Mount the underside panel.
    Fig 42: Installing Underside Panel
    G03091895Courtesy of PORSCHE OF NORTH AMERICA, INC.
  44. Install the right and left wheel housing trims again.
    Fig 43: Installing Right And Left Wheel Housing Trims
    G03091896Courtesy of PORSCHE OF NORTH AMERICA, INC.
  45. Re-install the rear spoiler.
    Fig 44: Installing Rear Spoiler
    G03091897Courtesy of PORSCHE OF NORTH AMERICA, INC.
  46. Install the rear spoiler again.
    Fig 45: Installing Rear Spoiler
    G03091898Courtesy of PORSCHE OF NORTH AMERICA, INC.
  47. Re-position the trim of the rear luggage compartment and press in the fastening rivets.
    WARNING: Danger 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.
    Fig 46: Checking Rubber Sleeve Of The B+ Lead
    G03091899Courtesy of PORSCHE OF NORTH AMERICA, INC.
  49. Seal off the maintenance openings again. Seal off the upper and rear maintenance openings again. Tighten the seven fastening screws and the two fastening nuts of the rear maintenance opening with 10 Nm (7.5 ft.lb).
    Fig 47: Tightening Maintenance Opening Fastening Screws
    G03091900Courtesy of PORSCHE OF NORTH AMERICA, INC.
  50. Re-install the left seat. Tighten the four fastening nuts to 65 Nm (48 ft.lb).
  51. 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.
  52. 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-teach the power windows.
  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.
    Fig 48: Locating Convertible Top Linkage Retaining Clip
    G03091901Courtesy of PORSCHE OF NORTH AMERICA, INC.
  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.
scientia non olet · About LEMON Manuals