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Home >> Porsche >> 2016 >> Boxster Spyder >> Repair and Diagnosis >> External Pages >> Different car >> Section 176 (10 - Engine - Crankcase, Suspension -- CARRERA (997)) >> WM 100119 Removing And Installing Engine (Except Turbo Coupe, Turbo S Coupe, Turbo CABRIO, Turbo S CABRIO) >> Install Engine

Install Engine

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Information 

Information 

  1. Fit safety clip -arrow- securing Henn coupling for coolant hose to the expansion tank.
    G00590403Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    NOTE: Engine/transmission unit lowered or inserted incorrectly 
    • Risk of damage to engine/transmission unit
    • Cables and coolant hoses can be stretched and torn

    → Gradually lower or raise the engine using a jack.

    → Always check that all necessary cables were disconnected when lowering the engine/transmission unit.

    → Make sure that no cables or hoses are damaged when fitting the engine/transmission unit.

    → Get one or two more persons to help.

  2. Raise the engine/transmission unit approximately halfway on the Master Gear unit elevating platform   .
  3. Fit sheetmetal holder for the pulse sender plug connection and plastic cable holder. Fit one M6 x 12 hexagon-head bolt and tighten to Tightening torque 10 Nm (7.5 ftlb.) . Screw in cable holder and clip in cable.
    G00590404Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  4. Manual transmission: Install clutch slave cylinder → 303019 Removing and installing clutch slave cylinder. Insert cylinder and press it in. Fit screws -3- by hand and tighten to Tightening torque 23 Nm (17 ftlb.) . Clip line into the holder.
    G00590405Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  5. Raise the engine/transmission unit into installation position and tighten the collar nuts for the engine mounts to Tightening torque 85 Nm (63 ftlb.) and for the transmission mounts to Tightening torque 65 Nm (48 ftlb.) .
    G00590406Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  6. Fit transmission bracket and tighten nuts to Tightening torque 65 Nm (48 ftlb.) and screws to Tightening torque 65 Nm (48 ftlb.) .
    G00590407Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  7. Get another person to help you to completely remove the engine retainer plate.
  8. Fit hall sender on cylinder bank 4-6. Insert hall sender, secure with a new fastening screw (M6 micro-self-locking) -1- and tighten to Tightening torque 10 Nm (7.5 ftlb.) .
    G00590408Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  9. Secure ground cable for engine to the body and tighten to Tightening torque 23 Nm (17 ftlb.) .
    G00590409Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  10. Secure drive shafts to the transmission flange and tighten nut to Tightening torque 81 Nm (60 ftlb.) . On Tiptronic vehicles, insert the spacer rings.
  11. Fit B-plus line on the transmission. Connect lines to B+ box and tighten collar nut to Tightening torque 23 Nm (17 ftlb.) .
  12. Manual transmission: clip B+ line into the cable guide on the transmission bracket between the yellow markings -Arrows- .
    G00590410Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  13. Connect and clip in cable plug for reversing switch (manual transmission) or connector for Tiptronic transmission.
  14. Install chassis components:
    1. 14.1. Rear cross member: Tighten M12 hexagon collar nuts to

      → Tightening torque: 100 Nm (74 ft. lb.) 

    2. 14.2. Diagonal braces to rear cross member: Tighten hexagon-head bolt to

      → Tightening torque: 100 Nm (74 ft. lb.) 

    3. 14.3. Diagonal brace to rear axle carrier: Tighten collar nut to

      → Tightening torque: 65 Nm (48 ft. lb.) 

    4. 14.4. Diagonal brace to body: Tighten hexagon-head bolt to

      → Tightening torque: 65 Nm (48 ft. lb.) 

    G00590411Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  15. Front transverse strut - Tiptronic transmission: Tighten hexagon-head bolt to Tightening torque 65 Nm (48 ftlb.) .
    G00590412Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  16. Transverse strut - manual transmission: Tighten hexagon-head bolt to Tightening torque 65 Nm (48 ftlb.)
    G00590413Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  17. Install rear anti-roll bar

    → 429019 REMOVING AND INSTALLING REAR ANTI-ROLL BAR

    1. Engage anti-roll bar on the connecting links and then secure on the rear axle carrier by tightening two hexagon-head bolts on each to Tightening torque 23 Nm (17 ftlb.) .
    G00590414Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  18. Fit new M10 collar nuts on the connecting link joint. Counter with a Torx socket-wrench insert while tightening → Anti-roll bar to connecting link and tighten to Initial tightening - loosen by 90° 50 Nm (37 ftlb.) .
    1. Loosen collar nuts and tighten again to Final tightening 65 Nm (48 ftlb.) .
    G00590415Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  19. Fit Tiptronic selector cable → WM 371519 REMOVING AND INSTALLING SELECTOR LEVER CABLE .
  20. Fit shift cables for manual transmission → WM 341219 REMOVING AND INSTALLING SHIFT AND SELECTOR CABLES (EXCEPT TURBO) .
    G00590416Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  21. Connect servo pressure line. Press connector straight into the plug-in coupling. The connector must engage in the holder with an audible click.
    G00590417Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    • The servo line plug-in coupling is designed so that there is axial play of about 1 mm in the coupling. 
  22. Check that the plug-in coupling is engaged correctly using special tool test tool . Insert special tool into the groove and check that the connector is seated correctly in the coupling by applying slight pressure. The connector must not slide out.
    G00590418Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  23. Fit servo return hose to the line using the spring band clamp.

    Information 

    • Allocation of the engine wiring harness round connectors: 
    • Lower plug - grey inner ring 
    • Upper plug - black inner ring 
  24. Fit engine wire harness. Turn bayonet lock clockwise (approx. 90°) until the markings on the round connectors and housing are aligned. Secure the wiring harness on the holder with a new tie-wrap.
  25. Fitting air-conditioning compressor: before installing the compressor check whether the aluminium spacer sleeve -arrow- is inserted. Grease and fit sleeve. Also connect ground cable before installation.
    G00590419Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  26. Insert air-conditioning compressor and secure using three M8 Torx screws (two short ones at the rear, one long one at the front) -1- , then tighten to Tightening torque 23 Nm (17 ftlb.) .
    G00590420Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  27. Fit drive belt. Observe rolling direction of previously used belt. Check once again that the drive belt is positioned correctly on the pulleys.
    G00590421Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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