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Home >> Porsche >> 2016 >> Boxster S, Automatic DCT Trans >> Repair and Diagnosis >> External Pages >> Different car >> Section 289 (10 - Engine - Crankcase, Suspension -- 911 CARRERA (991)) >> WM 1001Z1 Disassembling Engine (Except CARRERA "Edition", CARRERA Cabriolet "Edition", CARRERA 4 "Edition", CARRERA 4 Cabriolet "Edition", Gt3, Gt3 RS) >> Preliminary Work

Preliminary Work

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2019 Porsche 911, 2018 Porsche 911, 2017 Porsche 911, 2016 Porsche 911, and 2015 Porsche 911. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Dirt and contamination
  • Risk of damage to units or components

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

Information 

Information 

Information 

  1. Remove engine.

    → 100119 REMOVING AND INSTALLING ENGINE .

  2. Remove transmission.

    → 343527 REMOVING AND MOUNTING TRANSMISSION

    → 373427 REMOVING AND MOUNTING PORSCHE DOPPELKUPPLUNG (PDK) .

  3. Remove flywheel.

    → 136019 REMOVING AND INSTALLING FLYWHEEL - PORSCHE DOPPELKUPPLUNG (PDK) .

    → 136019 REMOVING AND INSTALLING FLYWHEEL .

  4. Mount the engine on the engine assembly support.

    → 1001IN TOOLS FOR REMOVING UNITS AND WORKING ON THE ENGINE ASSEMBLY SUPPORT .

  5. Remove front silencer.

    → 262519 REMOVING AND INSTALLING FRONT SILENCER .

  6. Remove rear silencer.

    → 263319 REMOVING AND INSTALLING REAR SILENCER .

  7. Remove engine carrier -1-  .

    → 103019 REMOVING AND INSTALLING ENGINE CARRIER .

    Fig 1: Identifying Engine Carrier Screws
    G09990334Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  8. Drain engine oil.

    → 170155 CHANGING ENGINE OIL AND OIL FILTER

  9. Remove cover for drive belt -1-  and generator -2-  .

    → 138419 REMOVING AND INSTALLING COVER FOR DRIVE BELT .

    1. 9.1. Do not loosen the connecting screws between the two covers.
      Fig 2: Identifying Drive Belt Covers Screws
      G09990335Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  10. Vehicles with Porsche Dynamic Chassis Control (PDCC):  Loosen three external Torx screws on the pulley (do not unscrew fully).
  11. Remove drive belt.

    → 137819 REMOVING AND INSTALLING DRIVE BELT .

    1. 11.1. Only for PDCC:  Unscrew screws for pulley and remove pulley.
  12. Remove the generator.

    → 272219 REMOVING AND INSTALLING GENERATOR .

    Fig 3: Loosening Generator Fastening Screws
    G09990336Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  13. Disconnect cable plugs for tank ventilation -3-  and engine temperature sensor -1-  on the intake-air distributor on bank 1-3. Unscrew screw -2-  for cable duct mounting.
    Fig 4: Identifying Intake-Air Distributor Cable Plugs (1-3)
    G09990337Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  14. 3.8-litre engine only:  Pull off vacuum line on vacuum unit for tuning flap.
  15. Disconnect positive crankcase ventilation line -1-  at the resonance tube and unclip it at the intake-air distributor -arrows-  .
    1. 15.1. Unscrew screw -2-  for cable duct mounting on the intake-air distributor on bank 4-6.
      Fig 5: Locating Positive Crankcase Ventilation Line On Cylinder Bank (4-6)
      G09990338Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  16. Loosen holder at the oil-fill pipe.
    1. 16.1. Unscrew two screws -2-  .
    2. 16.2. Unclip positive crankcase ventilation line -3-  at the oil-fill pipe and cylinder head 1-3.
      Fig 6: Identifying Oil Filler Tube And Positive Crankcase Ventilation Line Holder
      G09990339Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  17. Unscrew three fastening screws for the engine wire harness cable duct at the cylinder head (1-3 and 4-6).
  18. Completely remove intake-air distributor.

    → 244619 REMOVING AND INSTALLING INTAKE-AIR DISTRIBUTOR .

  19. Remove positive crankcase ventilation line -1-  .
    1. 19.1. Unclip connection at cylinder head 4-6 -item 3 (right)-  and unscrew fastening screw -2-  on the oil module.
    2. 19.2. Disconnect line, unclip it from the holder and remove it.
    3. 19.3. Replace O-rings.
      Fig 7: Identifying Positive Crankcase Ventilation Line
      G09990340Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  20. Remove oil filler neck -1-  .
    1. 20.1. Unscrew two external Torx screws -2-  and pull the connection piece out of the crankcase.
    2. 20.2. Close off opening with adhesive tape or a stopper.
    3. 20.3. Replace O-ring.
      Fig 8: Identifying Oil Filler Neck
      G09990341Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  21. Remove air-conditioning compressor.

    → 873419 REMOVING AND INSTALLING AIR-CONDITIONING COMPRESSOR .

  22. Vehicles without Porsche Dynamic Chassis Control (PDCC):  Remove console with deflection roller -1-  .
    1. 22.1. Unscrew three fastening screws -2 and 3-  and remove console.
      Fig 9: Identifying Deflection Roller Console Screws
      G09990342Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  23. Vehicles with Porsche Dynamic Chassis Control (PDCC):  Remove pump together with the pressure line and return line.

    → 430619 REMOVING AND INSTALLING PUMP (PDCC) .

    1. Hydraulic pump (PDCC)
    2. Pressure line
    3. Return line
    Fig 10: Identifying Hydraulic Pump And Lines
    G09990343Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  24. Remove oil separator -1-  .
    1. 24.1. Unclip B+ line at the oil separator.
    2. 24.2. Unscrew external Torx screws -2-  and pull off the oil separator.
    3. 24.3. Replace O-rings.
      Fig 11: Identifying Oil Separator Screws
      G09990344Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  25. Remove heat shields -1-  for ignition coils.
    1. 25.1. Unscrew external Torx screws -2-  and remove heat shields.
      Fig 12: Identifying Heat Shield Screws
      G09990345Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  26. Unplug cable plugs at the cylinder head and disconnect ground straps for ignition coils.
    1. Connectors for ignition coils
    2. Screws for ground connection for ignition coils
    3. Hall sender
    4. Solenoid hydraulic valve for valve lift adjustment
    Fig 13: Identifying Cylinder Head Cover Cable Plugs
    G09990346Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  27. Disconnect B+ line and control line for solenoid switch (terminal 50) at the starter.
    1. 27.1. Screw off M8 -1-  and M6 -2-  collar nuts and remove lines.
    2. 27.2. Remove B+ wire harness.
      Fig 14: Removing Starter Cable Shoe Nut
      G09990347Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  28. Remove engine wire harness by disconnecting several cable plugs at the engine and unclipping the cable holder.

    → 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE .

    • Solenoid hydraulic valve for camshaft control (top of cylinder head)
    • Pressure sensor at fuel collection pipe, bank 4-6
    • Oil pressure and temperature sensor on bracket for oil-water heat exchanger
    • Fuel injectors
    • Knock sensors
    • Flow control valve on high-pressure pump
    • Coolant temperature sensor at cylinder head 1-3
    • Pressure-regulating valve and oil-level sender on oil pan
    1. 28.1. Remove wire harness.
  29. Remove holder for rear silencer -1-  .
    1. 29.1. Unscrew external Torx screws -2-  and remove holder.
      Fig 15: Identifying Rear Silencer Holder
      G09990348Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  30. Remove ignition coils.
    1. 30.1. Unscrew internal Torx screws and pull off ignition coils.
  31. Remove hall sender.
    1. 31.1. Unscrew screw and pull off hall sender.
  32. Remove spark plugs.

    → 287020 REMOVING AND INSTALLING SPARK PLUGS .

  33. Remove fuel connection line -1-  .
    1. 33.1. Loosen external Torx screws -2 and 3-  at the clamps.
    2. 33.2. Unscrew union nuts -4-  and remove line. Soak up emerging fuel with a cloth.
      Fig 16: Identifying Fuel Connection Line
      G09990349Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  34. Remove coolant collection unit and coolant hoses (on the oil-water heat exchanger) -2-  .
    1. 34.1. Open spring band clamps -1-  and pull off hoses.
      Fig 17: Identifying Oil-Water Heat Exchanger Coolant Hoses
      G09990350Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 34.2. Unscrew external Torx screws -2-  and pull coolant collection unit -1-  up and off.
      Fig 18: Identifying Coolant Collection Unit
      G09990351Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 34.3. Coolant collection unit -1-  and connecting pipes -2-  for the coolant pump and thermostat housing.
      Fig 19: Identifying Coolant Collection Unit And Connecting Pipes
      G09990352Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    4. 34.4. Replace O-rings -1-  and grease new O-rings with Kluberplus Gel (Part No. 000.043.205.93).
      Fig 20: Identifying Connecting Pipes O-Rings
      G09990353Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  35. Remove the starter.

    → 276019 REMOVING AND INSTALLING STARTER .

  36. Remove fuel collection pipes -2-  with fuel injectors.
    1. 36.1. Spray the fuel injector seats in the cylinder head with anti-rust agent.
    2. 36.2. Unscrew external Torx screws -1-  .
    3. 36.3. Pull fuel collection pipe -2-  with fuel injectors out of the cylinder heads.
    4. 36.4. Close off fitting bores in the cylinder head with stoppers.
      Fig 21: Identifying Fuel Collection Pipe Screws
      G09990354Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  37. Remove oil-water heat exchanger -1-  .
    1. 37.1. Unscrew internal Torx screws -2-  and remove heat exchanger.
    2. 37.2. Soak up any drops of fluid with a clean cloth and clean the sealing faces.
    3. 37.3. Replace O-rings.
      Fig 22: Identifying Oil-Water Heat Exchanger
      G09990355Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    • The bracket for the oil/water heat exchanger must not be removed at an angle or levered off at one side. 
    • The bracket's aluminum supports can break off in the crankcase. 
  38. Remove bracket -1-  for oil-water heat exchanger.
    1. 38.1. Unscrew external Torx screws -2 and 3-  . Pull the bracket up and out.
    2. 38.2. Close off oil ducts with stoppers.
    3. 38.3. Replace O-rings at the top -4-  and on the underside.
      Fig 23: Identifying Oil-Water Heat Exchanger Bracket
      G09990356Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  39. Remove knock sensors (mark installation position using a water-resistant marker).
    1. 39.1. Unscrew external Torx screw and remove sensors.
  40. Remove exhaust manifold with catalytic converter.

    → 261019 REMOVING AND INSTALLING EXHAUST MANIFOLD .

  41. Remove cover -1-  on positive crankcase ventilation line.
    1. 41.1. Cylinder bank 1-3: Unscrew external Torx screws -4-  and replace O-ring -3-  and molded seal -2-  .
      Fig 24: Identifying Positive Crankcase Ventilation Cover (1-3)
      G09990357Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 41.2. Cylinder bank 4-6: Unscrew external Torx screws -3-  and replace O-ring -2-  .
      Fig 25: Identifying Positive Crankcase Ventilation Cover (4-6)
      G09990358Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  42. Remove vacuum line -1-  for the vacuum pump (cylinder bank 4-6).
    1. 42.1. Unscrew external Torx screws -2-  and remove line.
      Fig 26: Identifying Brake Booster Vacuum Line
      G09990359Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  43. Remove vacuum pump.

    → 477619 REMOVING AND INSTALLING VACUUM PUMP .

  44. Remove support for high-pressure pump.
    1. 44.1. Unscrew external Torx screws on the heat shield and remove heat shield.
    2. 44.2. Unscrew external Torx screws -1 and 2-  and remove support.
      Fig 27: Identifying High-Pressure Pump Support
      G09990360Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  45. Remove high-pressure pump -1-  and fuel lines -2 and 4-  .
    1. 45.1. Unscrew external Torx screws -3 and 5-  at the mounting points.
    2. 45.2. Unscrew external Torx screws at the pump, pull out the pump and remove together with the lines.
    3. 45.3. Replace O-ring.
      Fig 28: Identifying High-Pressure Pump And Fuel Lines
      G09990361Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  46. Remove wastegate with coolant pipe.
    1. 46.1. Unscrew fastening screw -2-  for the coolant pipe -1-  .
      Fig 29: Identifying Lower Coolant Pipe
      G09990362Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 46.2. Unscrew fastening screws -4-  for the wastegate -3-  .
      Fig 30: Identifying Wastegate With Coolant Connection Piece
      G09990363Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 46.3. Pull off wastegate and pull coolant pipe out of the coolant regulator housing.
  47. Remove coolant distributor housing (unit carrier) -1-  with coolant connection piece.

    → 195919 REMOVING AND INSTALLING COOLANT DISTRIBUTOR HOUSING .

    1. 47.1. Check molded seals and replace if necessary.
      1. Coolant distributor housing (unit carrier)
      2. Screws, M8 x 70 - on coolant connection piece
      3. Screws, M8 x 50
      4. Screw, M8 x 35
      Fig 31: Identifying Coolant Distributor Housing
      G09990364Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  48. Remove belt tensioner.

    → 137319 REMOVING AND INSTALLING BELT TENSIONER .

  49. Remove coolant regulator housing -1-  .
    Fig 32: Identifying Coolant Regulator Housing
    G09990365Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 49.1. Unscrew external Torx screw -3-  on the intake tube holder -4-  .
    2. 49.2. Unscrew external Torx screw -2-  on the coolant pump holder -1-  .
      Fig 33: Identifying Coolant Pump Holder Screw
      G09990366Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 49.3. Unscrew external Torx screws -4-  on the coolant pump connection piece.
      Fig 34: Pulling Coolant Pipe Housing
      G09990367Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    4. 49.4. Unscrew external Torx screws -3-  on the housing, pull the housing off the coolant pipe -1-  and replace O-rings.
    5. 49.5. Replace molded seal -3-  on the connecting tube -2-  .
      Fig 35: Identifying Coolant Regulator Housing And Connecting Tube
      G09990368Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  50. Remove coolant guide -1-  at the bottom.
    1. 50.1. Unscrew external Torx screws -2-  .
    2. 50.2. Check molded seals and replace if necessary.
      Fig 36: Identifying Lower Coolant Guide
      G09990369Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  51. Use turning device 9773  to turn the engine clockwise at the vibration damper until the TDC 1/4  marking on the vibration damper is aligned with the bore in the crankcase.
    1. 51.1. Stake using a locating pin 9595/1  on the vibration damper.
      Fig 37: Turning Vibration Damper
      G09990370Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  52. Remove vibration damper.
    1. 52.1. Loosen and unscrew external Torx screws and remove the vibration damper.
    2. 52.2. Check dowel sleeve and crankshaft flange for damage.
  53. Remove bracket for the coolant pump -1-  .
    1. 53.1. Unscrew external Torx screws -2 to 5-  . Unscrew threaded bolt -6-  .
      Fig 38: Identifying Coolant Pump Bracket
      G09990371Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 53.2. Replace O-rings -2 and 3-  on the coolant pipe -4-  and coolant connection piece.
      Fig 39: Identifying Coolant Pipes O-Rings
      G09990372Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  54. Remove coolant connecting tube (for coolant regulator housing) -1-  .
    1. 54.1. Unscrew external Torx screw -2-  on the retaining bracket for the crankcase.
      Fig 40: Identifying Coolant Connecting Tube
      G09990373Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  55. Remove hydraulic valves for camshaft control.

    → 153719 REMOVING AND INSTALLING SOLENOID HYDRAULIC VALVE FOR CAMSHAFT CONTROLLERS .

  56. Remove hydraulic valves for valve lift switchover.

    → 155519 REMOVING AND INSTALLING HYDRAULIC VALVE FOR VALVE LIFT SWITCHOVER .

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