Preliminary Work

Information 

• When raising the vehicle, take care to maintain access to the screws for the diagonal struts in the vicinity of the rear jacking points  .

→ 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.

1. Raise the vehicle at the prescribed jacking points.
2. Place protective covers on the vehicle.
3. Evacuate the air conditioning system.

   → 870317 DRAINING AND FILLING REFRIGERANT .

4. Read out the fault memory using PIWIS Tester II 9818  .

   → WM 033500 FAULT MEMORY FOR ON-BOARD DIAGNOSIS

5. Loosen rear wheels (do not remove).

   → 440519 REMOVING AND INSTALLING WHEEL

6. Boxster Vehicles:  Move convertible top into service position.

   → 6101IN CONVERTIBLE-TOP SERVICE POSITION

7. Disconnect battery ground terminal.
8. Remove engine compartment lid.

   → 557819 REMOVING AND INSTALLING ENGINE COMPARTMENT LID

9. Remove rear wall cover.

   → 555919 REMOVING AND INSTALLING REAR WALL COVER

10. Disconnect B+ line -1-  .
    1. 10.1. Open cover on B+ box, screw off M8 hexagon nut -2-  , set line aside.
       Fig 1: Identifying B+ Line Connection Point With Hexagon Nut (Engine Compartment)

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
11. Loosen vent lines -1-  at the coolant reservoir -2-  .
    1. 11.1. Unclip a line from the retaining clip for the positive crankcase ventilation.
       Fig 2: Identifying Coolant Reservoir Vent Lines

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
12. Loosen rubber sleeve from throttle housing.
    1. 12.1. Loosen screw-type clamp -1-  and press off rubber shroud -2-  .
       Fig 3: Identifying Screw-Type Clamp And Rubber Shroud

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
13. Loosen and fold over luggage compartment trim.

    → 700619 REMOVING AND INSTALLING REAR LUGGAGE COMPARTMENT TRIM PANEL

    1. 13.1. Unclip covers at the left and right -arrow-  and remove them.
    2. 13.2. Fold luggage compartment trim towards the rear.
       Fig 4: Removing Rear Luggage Compartment Trim

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
14. Loosen cable plug for engine wire harness in luggage compartment and expose wiring harness.
    1. 14.1. Pull off large cable plug -2-  from the engine control module -1-  and expose wiring harness -3-  .
    2. 14.2. Expose ground cable by screwing off one hexagon nut -4-  .
    3. 14.3. Remove the right insulating element.
       Fig 5: Identifying DME Cable Plug, Engine Control Module, Expose Wiring Harness

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    4. 14.4. Pull off cable plug -1-  from the right connector strip and expose section -2-  of engine wire harness.
       Fig 6: Identifying Engine Wire Harness Cable Plug And Expose Section Of Engine Wire Harness

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
15. Guide wiring harness through body and into the engine compartment.
    1. 15.1. Remove the rear right cover -1-  .
       Fig 7: Identifying Engine Compartment Rear Right Cover

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 15.2. Detach rubber sleeve -1-  using a plastic wedge and guide wiring harness through to the engine compartment.
       Fig 8: Locating Rubber Sleeve

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 15.3. Place wiring harness on the engine.
16. Pull oil filler pipe -1-  out of the oil filling hose.
    1. 16.1. Open the spring band clamp -2-  and pull the oil filler pipe out of the hose.
       Fig 9: Identifying Oil Filler Pipe And Spring Band Clamp

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
17. Unscrew lid on the coolant reservoir.
18. Remove the rear underbody panelling and unscrew the two screws on the underbody panelling (center).

    → 519419 REMOVING AND INSTALLING COVER FOR REAR UNDERBODY

19. Open air-conditioning lines on the underbody and close off using stoppers.
    1. 19.1. Unscrew the fastening screws by countering with the Assembly Tool 9822  .
    2. 19.2. Close off the lines immediately and before replacing the O-rings assembly.
       1. Air-Conditioning Line
       2. Assembly Tool 9822
       3. Tool
       Fig 10: Identifying Air-Conditioning Line And Assembly Tool 9822

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
       WARNING: Caustic fluids

       • Danger of chemical burns

       → Avoid contact with caustic fluid.

       → Wear personal protective gear.

       → Ensure that there is good ventilation.

       → If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.

20. Drain coolant from the engine.

    → 193817 DRAINING AND FILLING COOLANT

21. Remove the strut together with the coolant hose holder.
    1. 21.1. Unscrew two hexagon-head bolts -1-  and remove the strut -3-  .
       Fig 11: Identifying Strut Hexagon-Head Bolts

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
22. Remove coolant hoses and collect any residual coolant. Disconnect vent line plug connection.
    1. 22.1. Remove spring clamps -2-  and pull off coolant hoses -1-  from engine.
    2. 22.2. Open spring band clamps -3-  and pull off coolant hoses.
    3. 22.3. Open coolant vent line -4-  at the plug-in coupling.
       Fig 12: Identifying Spring Clamps, Coolant Hoses, Spring Band Clamps And Coolant Vent Line Plug-In Coupling

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
23. Pull off coolant hose from the coolant regulator housing and loosen the ground strap at the cylinder head.
    1. 23.1. Open the spring band clamp -1-  , pull off the coolant hose -2-  and collect coolant.
    2. 23.2. Unscrew fastening screw -3-  and set the ground strap aside.
       Fig 13: Identifying Coolant Hose, Spring Band Clamp And Fastening Screw

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
24. Loosen vacuum line -1-  for the brake booster.
    1. 24.1. Press locking ring -2-  and pull off both line and vacuum hose -3-  .
       Fig 14: Identifying Brake Booster Vacuum Line, Vacuum Hose And Locking Ring

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
25. Unclip the oxygen-sensor plug connections -1 and 2-  from the bulkhead -arrows-  and open.
    1. 25.1. Left plug connections:
       Fig 15: Locating Oxygen Sensors Plug Connection (Left)

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 25.2. Right plug connections:
       Fig 16: Locating Oxygen Sensors Plug Connection (Right)

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
       WARNING: Highly inflammable or explosive materials

       • Danger of fire or explosion

       → Avoid contact with hot parts or sources of ignition.

       → Use suction to remove ignitable vapors.

       → Attach warning sign in a clearly visible position.

26. Open the rapid-action couplings for the fuel line -3-  and tank vent line -2-  .

    Caution: Residual Pressure Can Cause Fuel To Spray Out! 

    1. 26.1. Open retaining bar -1-  and unclip lines.
       Fig 17: Identifying Retaining Bar, Fuel Line, Tank Vent Line

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
27. Release drive shafts at transmission flange by countering at the respective rear wheel.
28. Remove rear wheels.

    Socket-Wrench Insert P300  should be used.

    Information 

    • The vehicle must not be supported by its wheels after removing the diagonal braces and support plate  .
    • If the vehicle has to be supported by its wheels, the components must be re-installed beforehand  .
29. Remove diagonal braces -1-  and support plate -2-  .

    → 421419 REMOVING AND INSTALLING SUPPORT PLATE .

    Fig 18: Identifying Diagonal Braces And Support Plate

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
30. Remove the rear axle cross member.

    → 420619 REMOVING AND INSTALLING REAR-AXLE CROSS MEMBER .

31. Removing rear anti-roll bar

    → 429019 REMOVING AND INSTALLING REAR ANTI-ROLL BAR .

32. Remove the transverse strut -2-  .
    Fig 19: Identifying Transverse Strut With Screws

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
33. Remove rear silencers.

    → 263319 REMOVING AND INSTALLING REAR SILENCER .

34. Vehicles with Porsche Doppelkupplung (PDK):  Disconnect cable plug -1-  from transmission.
    1. 34.1. Open the bayonet locks anti-clockwise and pull off the connector.
       Fig 20: Disconnecting Cable Plug From Transmission

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 34.2. Pull off cable plugs -1-  for temperature sensor and control valves -3-  , unclip line -2-  .
       Fig 21: Identifying Cable Plugs For Temperature Sensor And Control Valves

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
35. Loosen parking lock cable.
    1. 35.1. Lever off end piece -1-  using Disassembly Tool Nr. 21  .
    2. 35.2. Unclip parking lock cable from the support bracket -2-  .
       Fig 22: Disconnecting Parking Lock Cable From Double-Clutch Transmission

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
36. Vehicles With Manual Transmission: 
    1. 36.1. Lever off shift and selector cables using Disassembly Tool Nr. 21  .
    2. 36.2. Disconnect cable plug from transmission.
       1. Selector Cable
       2. Shift Cable
       3. Fixing Clips On Support
       Fig 23: Identifying Shift And Selector Cables, Fixing Clips

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
37. Unclip left and right brake-disc air guides.
    1. 37.1. The brake-disc air guides must be pressed to one side when removing the engine/transmission unit.
       Fig 24: Identifying Brake-Disc Air Guide

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.