Subsequent Work

WARNING: This page does not describe the selected car, but rather 10 other vehicles, including the 2012 Porsche Cayman, 2012 Porsche Boxster, 2011 Porsche Cayman, 2011 Porsche Boxster, and 2010 Porsche Cayman. 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

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

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

Photos taken with a digital camera are helpful for dealing with complicated line routing (engine wire harness).
→ 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE .

Fit bracket for oil/water heat exchanger and heat exchanger.
1. 1.1. → Installing bracket for oil cooler .
2. 1.2. → Installing oil/water heat exchanger .
  
  Fig 1: Identifying Component Overview Of Bracket For Oil Cooler
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. Bracket for oil cooler
  2. Oil mist separator
  3. External Torx screw, M6 x 28; self-tapping screws can be used 4-5 times; metric screws can also be used
  4. Sealing ring
  5. Sealing ring
  6. Oil cooler (oil/water heat exchanger)
  7. Internal Torx screw, M6 x 20; self-tapping screws can be used 4-5 times; metric screws can also be used
  8. Sealing ring
  9. Oil filter element
  10. Sealing ring
  11. Oil filter cover
  12. Profile seal
  13. Sealing ring
  14. Sealing ring
  15. External Torx screw, M6 x 60
  16. External Torx screw, M6 x 45
Install the starter.
→ Installing starter .
2.9-litre engine only: Install secondary-air pump and lines.
→ Installing Secondary-Air Pump .

→ Installing Secondary-Air Line .
Install oil filler neck.
1. 4.1. Fit oil filler neck with a new O-ring.
2. 4.2. Fit and tighten two external Torx screws (E10, M6 x 20) -1- on the crankcase flange.
3. 4.3. Screw in external Torx screw (E10, M6 x 12) -2- on the holder.
4. 4.4. → Tightening torque: 13 Nm (9.5 ftlb.)
  
  Fig 2: Identifying Oil Filler Neck Screws
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Overview of components on belt side (installation steps described below).
1. Oil separator
2. Vacuum pump
3. Power-steering hydraulic line - return
4. Power-steering hydraulic line - supply
5. Coolant connection piece
6. Vibration damper
7. Coolant pump
8. Coolant regulator housing
9. Belt tensioner
10. Coolant distributor housing (unit carrier)
11. Generator
12. Air-conditioning lines
13. Hydraulic pump with pulley
14. Air conditioning compressor
  
  Fig 3: Components Location On Belt Side
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit high-pressure pump -1- and lines -2 + 3- .
→ Installing high-pressure pump .
1. 6.1. Fit and tighten two external Torx screws (M6 x 25) -6- on the pump.
2. 6.2. Fit support -4- : screw in and tighten two external Torx screws (E10) M6 x 25 -6- at the top and one M6 x 40 -5- at the bottom.
3. 6.3. → Tightening torque: 13 Nm (9.5 ftlb.)
  
  Fig 4: High-Pressure Pump Components
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit fuel lines to the high-pressure pump.
1. 7.1. Grease thread with OKS 1700 lubricant (Part No. 000.043.207.36) and tighten union nuts.
2. 7.2. Fit line bracket using M6 external Torx screws.
3. 7.3. First tighten the union nuts, then the screws on the line bracket.
  → Tightening torque: 20 Nm (15 ftlb.)
  
  → Tightening torque: 13 Nm (9.5 ftlb.)
Fit vacuum pump on cylinder head 4-6 with lines.
→ Installing vacuum pump .
1. 8.1. Fit and tighten three external Torx screws (M6 x 20).
2. 8.2. Attach vacuum line for brake booster with new O-ring to the pump and position it at the oil pan.
3. 8.3. Fit and tighten external Torx screws (M6 x 12) on the vacuum line holder.
4. 8.4. → Tightening torque: 13 Nm (9.5 ftlb.)
Install upper coolant distributor housing (unit carrier).
→ Installing Coolant Distributor Housing (Unit Carrier) .
1. 1 - Coolant distributor housing (unit carrier)
2. 2-4 - Moulded seal (reusable)
3. 5 - Coolant connection piece
4. 6 - External Torx screw, M6 x 25
5. 7 - External Torx screw, M8 x 70 (3 ea.)
6. 8 - External Torx screw, M8 x 50
7. 9 - External Torx screw, M8 x 35 (hydraulic pump mounting)
8. 10 - O-rings (replace)
9. 11 - External Torx screw, M8 x 35
  
  Fig 5: Coolant Distributor (Unit Carrier)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Secure coolant pipe -1- to the coolant connection piece at the cylinder head using two external Torx screws (E10, M6 x 12) -2- .
→ Tightening torque: 13 Nm (9.5 ftlb.)

Fig 6: Identifying Coolant Pipe With Hose And Connection Piece
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install bracket for coolant pump and coolant regulator housing.
→ WM 195519 REMOVING AND INSTALLING COOLANT REGULATOR COVER (EXCEPT CAYMAN BLACK EDITION, CAYMAN S SPORT, CAYMAN S BLACK EDITION & BOXSTER BLACK EDITION) .
1. Coolant regulator housing
2. Bracket for coolant pump
3. External Torx screws, M6 x 25
4. Drain plug
5. Sealing ring (replace)
6. O-ring (replace)
7. Coolant regulator cover
8. External Torx screw, M6 x 50
9. O-rings (replace when removing connection piece)
10. Connection piece
11. External Torx screw, M6 x 16
  
  Fig 7: Coolant Regulator Housing With 987 II Coolant Pump
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 11.1. Fit bracket for coolant pump -1- with new O-rings -2 + 3- .
  
  Fig 8: Identifying O-Rings For Coolant Pipes At Coolant Pump
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 11.2. Install coolant regulator housing.
Tighten fastening screws on coolant pump bracket and unit carrier.
1. 12.1. → Tightening torque: 33 Nm (24 ftlb.)
2. 12.2. → Tightening torque: 23 Nm (17 ftlb.) Coolant pump bracket
  → Tightening torque: 13 Nm (9.5 ftlb.)
3. 12.3. Turn the belt tensioner clockwise as far as it will go at the hexagon (a/f 30). Remove screw from the crankcase bore and allow the belt tensioner to slide back to normal position.
Install coolant regulator cover.
→ Installing Coolant Regulator Cover .
1. 13.1. Grease moulded seals with Kluber Gel.
2. 13.2. Fit and tighten three external Torx screws (E10, M6 x 50).
3. 13.3. → Tightening torque: 13 Nm (9.5 ftlb.)
Install coolant pipe -1- for the coolant regulator housing and secure with one external Torx screw (E10, M6 x 12) -2- .
→ Tightening torque: 13 Nm (9.5 ftlb.)

Fig 9: Identifying Coolant Connection Pipe To Thermostat Housing
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit lower coolant guide -1- .
1. 15.1. Grease moulded seals with Kluber Gel.
2. 15.2. Fit and tighten six external Torx screws (E10, M6 x 25) -2- .
3. 15.3. → Tightening torque: 13 Nm (9.5 ftlb.)
  
  Fig 10: Identifying Lower Coolant Guide Screws
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit vibration damper. Secure with a locating pin (8 mm) for countering purposes.
→ Installing Vibration Damper .
1. 16.1. Fit and tighten six external Torx screws (E12) M8 x 1 x 25 (fine thread).
  → Tightening torque: 60 Nm (44 ftlb.)
Install coolant distributor. Coat new O-rings -1- with Kluber Gel.
1. 17.1. Fit coolant distributor into coolant pipes.
  
  Fig 11: Identifying Coolant Distributor Connecting Pipes O-Rings
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 17.2. Fit coolant distributor -1- using two external Torx screws (E10, M6 x 25) -2- and tighten screws.
  → Tightening torque: 13 Nm (9.5 ftlb.)
  
  Fig 12: Identifying Coolant Distributor
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3.4-litre engine only: Fit fuel collection pipes and injectors.
→ Installing fuel collection pipe (with fuel injectors) .

→ Tightening torque: 13 Nm (9.5 ftlb.)

Fig 13: Identifying Tightening Sequence For Fuel Collection Pipe
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install hydraulic pump with reservoir.
→ Installing hydraulic pump .
Install air conditioning compressor.
→ Installing air conditioning compressor .
Install B+ wire harness (engine).
→ Installing wire harness for battery wiring .
Fit engine wire harness.
→ Installing wire harness for engine .
1. 22.1. Secure cable duct to cylinder head 1-3 and 4-6 using one external Torx screw (E12, M8 x 16) on each.
  → Tightening torque: 23 Nm (17 ftlb.)
Fit heat shields using external Torx screws (E10, M6 x 12) -1- .
→ Tightening torque: 10 Nm (7.5 ftlb.)

Fig 14: Identifying Screws On Heat Shield
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3.4-litre engine only: Fit fuel connection line (high-pressure side) to fuel collection pipe.
→ Installing fuel collection pipe (with fuel injectors) .
1. 24.1. Grease thread with OKS 1700 lubricant and tighten threaded connections -1 to 5- according to tightening sequence.
  → Tightening torque: 20 Nm (15 ftlb.)
  
  → Tightening torque: 13 Nm (9.5 ftlb.)
  
  Fig 15: Identifying Tightening Sequence For Connecting Line
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit coolant hoses and hydraulic lines at the oil/water heat exchanger.
1. 25.1. Grease coolant hoses with Kluber Gel and fit them. Connect hydraulic lines while dry.
2. 25.2. Close spring band clamps -1- .
  
  Fig 16: Identifying Hose Connections For Heat Exchanger
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install the generator.
→ Installing generator .
Install oil separator -1- .
1. 27.1. Fit and tighten two external Torx screws (E10, M6 x 25) -2- .
2. 27.2. → Tightening torque: 13 Nm (9.5 ftlb.)
  
  Fig 17: Identifying Oil Separator
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install positive crankcase ventilation line.
1. 28.1. Grease two new O-rings and fit line to bracket for oil/water heat exchanger. Tighten external Torx screw (E10, M6 x 20).
2. 28.2. Clip in line at two places and fit rapid-action couplings on cylinders 1-3, cylinders 4-6 and on the oil filler neck.
  
  Fig 18: Identifying Positive Crankcase Ventilation Line
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install intake-air distributor.
→ Installing intake-air distributor .
1. 29.1. Grease moulded seals with Kluber Syntheso Glep.
2. 29.2. Fit complete intake-air distributor and position it on the cylinder heads.
3. 29.3. Fit six external Torx screws (E10, M6 x 35) on each and tighten according to the specified tightening sequence.
  → Tightening torque: 13 Nm (9.5 ftlb.)
Connect positive crankcase ventilation line to the resonance tube and clip it in at the intake-air distributor.
1. 30.1. Tighten external Torx screws (E10, M6 x 12) used to secure the cable duct to the intake-air distributor.
Fit hydraulic pump pulley using three external Torx screws (E12, M8 x 12).
Install the drive belt.
→ Installing Drive Belt .
Tighten external Torx screws on hydraulic pump pulley.
→ Tightening torque: 23 Nm (17 ftlb.)
Fit engine carrier.
→ 103019 REMOVING AND INSTALLING ENGINE CARRIER .
1. 34.1. → Tightening torque: 46 Nm (34 ftlb.)
  1. Engine carrier
  2. Hexagon-head bolt (a/f 16, M10 x 35)
  3. Hexagon-head bolt (a/f 16, M10 x 65)
  4. Hexagon-head bolt (a/f 16, M10 x 115)
  5. Hexagon-head bolt (a/f 16, M10 x 135)
    
    Fig 19: Identifying Engine Carrier Screws
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Remove the engine from the engine assembly support.
→ 1001IN TOOLS FOR REMOVING UNITS AND WORKING ON THE ENGINE ASSEMBLY SUPPORT .
Fit flywheel with new screws.
→ Installing Flywheel - PDK Transmission .

→ Installing Flywheel .
Mount the transmission.
→ Mounting transmission .

→ Mounting Porsche Doppelkupplung (PDK) .
Install the engine.
→ 100119 REMOVING AND INSTALLING ENGINE .