Subsequent Work

→ Do not place any solid objects under the raised vehicle.

→ Ensure that the lifting platform is prevented from lowering.

→ Remove solid objects before lowering the vehicle.

→ Raise the vehicle only at the jacking points provided.

→ The outer jacking points should be used primarily.

Information 

Always replace gaskets and O-rings.

• Grease all gaskets (except for the cooling system) with Kluber Syntheso Glep (Part No. 000.043.204.68). 

Information 

• Grease O-rings, hoses and lines in the cooling system with Kluberplus Gel (Part No. 000.043.205.93). 

1. Attach coolant hoses and position spring band clamps.
   Fig 1: Identifying Spring Band Clamps For Coolant Hoses

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2. Fit large coolant hoses.
   1. 2.1. Fit coolant hoses into the Henn couplings. Ensure that the spring clamps are seated correctly -1-  .
   2. 2.2. Clip in plastic holder -3-  . Fit moulded part -2-  .
      Fig 2: Identifying Coolant Supply And Return Lines

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3. Connect fuel supply line -1-  and tank vent line -2-  to the underbody along with the lines for the fuel tank and carbon canister.
   Fig 3: Identifying Fuel Lines

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4. Join hydraulic lines for power-steering at the underbody and secure with holders.
   Fig 4: Securing Holder For Hydraulic Lines On Underbody

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5. Manual transmission:  Engage shift and selector cables in the support and push onto ball pins.
   Fig 5: Engaging Shift And Selector Cables

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6. Porsche Doppelkupplung (PDK):  Fit locking cable -1-  .
   Fig 6: Fitting Parking Lock Cable

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7. Connect vacuum line -1-  with connecting piece -2-  to the vacuum pump.
   Fig 7: Identifying Vacuum Connection For Brake Booster

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8. Fit drive shafts.

   → Installing drive shaft .

   1. 8.1. Fit and tighten six M10 hexagon socket head bolts on each.
      Fig 8: Identifying Drive Shaft

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9. Position ground strap -2-  and tighten external Torx screw (M8 x 20) -1-  .

   → Tightening torque: 23 Nm (17 ftlb.) 

   Fig 9: Engaging Ground Strap

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10. Install rear axle cross member.

    → 420619 REMOVE AND INSTALL REAR AXLE CROSS MEMBER .

11. Install exhaust manifold with catalytic converter.

    → Installing Exhaust Manifold With Catalytic Converter .

12. Install exhaust system.

    → Installing Complete Exhaust System (Both Rear Silencers) .

13. Connect and clip in connector -1-  for oxygen sensors downstream of catalytic converter.
    Fig 10: Connecting Clip In Connector For Oxygen Sensor Downstream Of Catalytic Converter

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14. Fit oxygen sensors ahead of catalytic converter at the exhaust manifold.

    → Installing oxygen sensor upstream of catalytic converter .

15. Guide restraining cable holder through the bores and tighten M8 nuts.
    1. 15.1. The cable must be countered with a suitable wrench and must not be twisted.

       → Tightening torque: 23 Nm (17 ftlb.) 

       Fig 11: Restraining Cable

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16. Fit anti-roll bar.

    → 429019 REMOVING AND INSTALLING REAR ANTI-ROLL BAR .

    1. 16.1. Engage connecting link and fit M10 nuts -2-  .
    2. 16.2. Fit and tighten hexagon-head bolts (M8 x 40) -1-  on the anti-roll bar mount.

       → Tightening torque: 23 Nm (17 ftlb.) 

    3. 16.3. Tighten connecting link at the anti-roll bar - initial tightening.

       → Tightening torque, Stage 1: 50 Nm (37 ftlb.) 

    4. 16.4. Loosen nuts by 90° and tighten to the prescribed torque - final tightening.

       → Tightening torque, Stage 2: 65 Nm (48 ftlb.) 

       Fig 12: Identifying Anti-Roll Bar And Nuts

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17. Position V-strut and tighten hexagon-head bolts (M10 x 70) -arrows-  . → Tightening torque: 65 Nm (48 ftlb.)  .
    Fig 13: Locating V-Strut And Bolts

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18. Install support plate -2-  and diagonal braces -1-  .

    → Installing support plate .

    Fig 14: Installing Support Plate And Diagonal Braces

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19. Pull in rubber sleeve -1-  for engine wire harness. Check that the rubber sleeve is seated correctly.
    Fig 15: Fitting Rubber Sleeve

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20. Plug in connectors for engine wire harness -1-  and -2-  above the left wheel arch.
    Fig 16: Identifying Connectors For Engine Wire Harness

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21. Position ground strap and tighten M6 nut -1-  . → Tightening torque: 10 Nm (7.5 ftlb.) 
22. Plug in connectors at the engine control module → Installing DME control unit .
    Fig 17: Identifying Engine Control Unit And Nut

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23. Vehicle with Porsche Doppelkupplung (PDK):  Connect and lock two combination connectors on the transmission control unit.
24. Insert connectors for luggage compartment light.
25. Install rear luggage compartment trim.

    → 700619 REMOVING AND INSTALLING REAR LUGGAGE COMPARTMENT TRIM (CARPET LINING) .

    1. 25.1. Clip in fixing clips.
    2. 25.2. Fit luggage compartment lid seal.
26. Fit rubber sleeve between the mass air flow sensor and throttle housing.
    1. 26.1. Connect cable plug for mass air flow sensor.
27. Connect vent line for cooling system.
28. Plug in connector -1-  for purge-air fan -2-  .
    Fig 18: Identifying Connector On Purge-Air Fan

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29. Fit B+ box for terminal 30 line in the engine compartment.
    1. 29.1. Tighten two hexagon nuts -1-  .

       → Tightening torque: 10 Nm (7.5 ftlb.) 

       Fig 19: Identifying Junction Point For Terminal 30 Line In Engine Compartment

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30. Install air-conditioning compressor lines at the underbody with new O-rings.

    → Installing compressor-condenser line .

    Fig 20: Installing Air-Conditioning Compressor Lines

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31. Fill the air-conditioning system with refrigerant.

    → 87031700 DRAINING AND FILLING IN REFRIGERANT .

32. Install both rear wheels.

    → Installing wheel .

    1. 32.1. Socket-wrench insert 300  should be used.
33. Connect battery ground strap.

    → 2X00IN02 WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY .

34. Bleed and fill the cooling circuit.

    → Filling Coolant .

35. Fill new hydraulic fluid (Pentosin) into the power-steering reservoir.

    → 48020150 CHECKING POWER-STEERING FLUID LEVEL .

    1. 35.1. Start the engine. Turn the steering wheel from stop to stop while the engine is running in order to bleed the steering system.
36. Check all fluid levels and seal tightness after the engine test run.
37. Install center underbody cover.

    → Installing cover for center underbody .

38. Install rear underbody cover.

    → Installing cover for rear underbody .

39. Install rear wall cover.

    → Installing rear wall cover .

    Fig 21: Locating Cover With Grommet

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40. Install engine compartment lid.

    → Installing engine compartment lid .

    Fig 22: Locating Engine Compartment Lid And Screws

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41. Boxster:  Close the hood.
42. Install linings (carpet for rear wall cover and engine cover).

    → Installing trim panel for convertible top compartment/engine compartment lid .

    → Installing rear-wall trim panel .

43. Perform suspension alignment.

    → 44950300 SUSPENSION ALIGNMENT, COMPLETE .

44. Read out fault memory and correct any faults that are present. Erase the fault memory.

    → 033500 ON-BOARD DIAGNOSIS (OBD) .

45. Perform a test drive.