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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 100137 Disassembling And Assembling Engine (Gt3) >> Disassembling Engine Down To Cylinder Housing >> Disassembling Engine

Disassembling Engine

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NOTE: Dirt and contamination
  • Risk of damage to units or components

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

Information 

Specifications for wrench sizes (a/f specifications) for screw heads are described as follows:

  1. Place separate collection pans under the engine to collect the various fluids that will emerge.
    1. 1.1. Dispose of fluids separately in accordance with the relevant legal regulations.
  2. Drain engine oil. Also loosen the oil filter at the bracket so that the remaining oil can drain more easily.

    → 170155 CHANGING ENGINE OIL AND OIL FILTER .

  3. Completely remove front and rear silencers.

    Get another person to help you to hold and remove the exhaust system components! 

    → 262519 REMOVING AND INSTALLING FRONT SILENCER .

    → 263319 REMOVING AND INSTALLING REAR SILENCER .

  4. Remove the engine carrier.

    → 103019 REMOVING AND INSTALLING ENGINE CARRIER .

  5. Remove heat shields -1-  for ignition coils. Loosen and unscrew two external Torx screws (M6 x 12) -2-  on each and remove heat shields.
    Fig 1: Identifying Heat Shield For Ignition Coils (Side 4-6)
    G09815889Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  6. Disconnect cable plugs for bar ignition modules and hall senders at the camshaft housing cover.
  7. Remove the oil line -1-  from oil tank to oil suction pump.
    1. 7.1. Loosen rubber clamp -2-  on camshaft housing cover 4-6.
    2. 7.2. Unscrew external Torx screw (M6 x 12) on the holder.
    3. 7.3. Loosen and screw off union nut (a/f 36) on the oil suction pump -arrow-  . Counter at the hexagon connection piece (a/f 32) while doing so.
      Fig 2: Locating Oil Return Line
      G09815890Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  8. Disconnect oil line at the bottom of the crankcase.
    1. 8.1. Loosen and unscrew union nut (a/f 32) and counter at the connection piece (a/f 32) while doing so.
  9. Remove the oil tank.

    → 175219 REMOVING AND INSTALLING OIL TANK .

  10. Disconnect cable plugs for engine compartment temperature sensor, electronic accelerator and tank ventilation.

    → 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE .

  11. Pull off electric control valve -2-  for the exhaust flap control box at the holder for intake-air distributor 4-6 -arrow-  .
    Fig 3: Pulling Exhaust Flap Control Valve
    G09815891Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  12. Pull off three electric control valves at the holder for intake-air distributor 1-3 and unclip the fuel line.
  13. Disconnect cable plug -1-  for the secondary-air pump.
    1. 13.1. Pull off the secondary-air hose by opening the spring band clamp -2-  .
      Fig 4: Identifying Secondary Air Line And Cable Plug
      G09815892Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  14. Open the spring band clamp and pull the vent line -1-  off the oil/water heat exchanger.
    Fig 5: Identifying Oil/Water Heat Exchanger Vent Line
    G09815893Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  15. Pull the vacuum line off the tuning flap valve for the intake-air distributor in the center (flywheel side).
  16. Remove intake-air distributor completely.

    → 244620 REMOVING AND INSTALLING INTAKE-AIR DISTRIBUTOR .

    1. 16.1. Loosen three screw-type clamps -1-  at the intake pipe support.
      Fig 6: Identifying Intake Distributor Screw-Type Clamps And Fastening Screw
      G09815894Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 16.2. Lift up the intake manifold and pull the vacuum line -1-  off the tuning flap valve on the underside of the intake-air distributor in the center.
      Fig 7: Identifying Vacuum Line And Unit
      G09815895Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 16.3. Completely remove the intake manifold.
  17. Remove intake pipe support with fuel line.
    1. 17.1. Unscrew one external Torx screw (M6 x 12) on the clamp for the fuel line at the oil-filter console.
    2. 17.2. Unscrew 24 external Torx screws (M6 x 20) and remove components.
  18. Remove combination valves for secondary air for cylinders 1-3 and 4-6.
    1. 18.1. Disconnect secondary air line on combination valve for side 1-3 -2-  and 4-6. Remove all lines.
    2. 18.2. Unscrew three hexagon socket head bolts (M6 x 20) on each, together with the captive washer -1-  . Remove valves and replace O-rings.
      Fig 8: Identifying Secondary Air Combination Valve
      G09815896Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  19. Remove the generator.

    → 272219 REMOVING AND INSTALLING GENERATOR .

  20. Unscrew two external Torx screws (M6 x 55) for the heater pipe holder -1-  and B+ line.
    Fig 9: Identifying Plastic Holder And Heater Pipes Mounting
    G09815897Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 20.1. Slide the plastic holder to the left to remove it -arrow-  .
      Fig 10: Sliding Heater Pipes Holder
      G09815898Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  21. Remove air-conditioning compressor.

    → 873419 REMOVING AND INSTALLING AIR-CONDITIONING COMPRESSOR .

    1. 21.1. Disconnect plug connection on control line for the air-conditioning compressor.
  22. Disconnect cable plug connections.
    1. 22.1. Knock sensor connectors -1-  .
    2. 22.2. Combination connector -2-  for oil pressure sensor and oil temperature sensor.
      Fig 11: Identifying Knock Sensor And Oil Pressure Sensor Cable Plug
      G09815899Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  23. Remove engine wire harness.

    → 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE .

    1. 23.1. Disconnect all cable plugs and remove the wire harness.
  24. Remove coolant lines on cylinder bank 1-3.
    1. 24.1. Open one screw-type clamp on the heater pipe return line -2-  and two screw-type clamps on the supply line for the water pump and thermostat -1-  .
      Fig 12: Identifying Coolant Lines Screw-Type Clamps
      G09815900Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 24.2. Loosen screw-type clamps -1-  on the coolant lines at the oil/water heat exchanger bracket.
      Fig 13: Identifying Heater And Heat Exchanger Bracket
      G09815901Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  25. Remove coolant pipes -2-  . Replace sealing sleeves -3-  when joining the pipes again.
    Fig 14: Identifying Coolant Pipes
    G09815902Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 25.1. Left coolant pipe: open the screw-type clamp and unscrew two external Torx screws (M6 x 20). Remove coolant pipe.
      Fig 15: Identifying Left Coolant Pipe Coolant Hose
      G09815903Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 25.2. Right coolant pipe: unscrew two external Torx screws (M6 x 20) and remove coolant pipe.
  26. Unscrew fastening screw (M6 x 16) for B+ line at the transport eyelet and remove line.
  27. Remove oil/water heat exchanger.

    → 176719 REMOVING AND INSTALLING BRACKET FOR OIL COOLER .

    1. 27.1. Replace O-rings.
    2. 27.2. Remove bracket for oil/water heat exchanger by unscrewing four internal Torx screws (M6 x 20).
  28. Loosen holder for oil-filter console.
    1. 28.1. Unscrew one external Torx screw (M6) -1-  on the holder.
      Fig 16: Identifying Rear Holder Screw
      G09815904Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 28.2. Unscrew one external Torx screw (M6) -1-  at the connection to the oil pipe.
      Fig 17: Identifying Oil Pipe Screw
      G09815905Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  29. Remove bracket for oil/water heat exchanger. Replace O-rings.
    1. 29.1. Slide the handle of a wooden hammer under the bracket and carefully lift up the bracket.
    2. 29.2. Place a clean absorbent cloth underneath to catch residual fluid.
  30. Remove secondary unit carrier. Unscrew four external Torx screws (M10 x 60) -1-  . Remove unit carrier and power-steering pump.
    Fig 18: Identifying Secondary Unit Carrier
    G09815906Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  31. Take off coolant guide housing together with water pump and oil suction pump. Collect emerging coolant.
    1. 31.1. Loosen screw-type clamps and pull off two coolant hoses.
    2. 31.2. Remove two oil suction pipes.
    3. 31.3. Replace sealing sleeves and O-rings.
  32. Remove exhaust manifold. Unscrew nine M8 screws -1-  on each. Remove exhaust manifold -2-  with metal seal.
    Fig 19: Identifying Exhaust Manifold Threaded Joint
    G09815907Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  33. Remove six ignition coils. Unscrew two Torx socket screws (M6 x 25) on each and take off the coils.
  34. Remove six spark plugs.
    1. 34.1. Use spark plug socket wrench Nr.14  and extension Nr.15  to avoid damaging the ceramic body.
  35. Remove vacuum line for brake booster.
    1. 35.1. Disconnect the line at the pump by unscrewing the M6 external Torx screws -2 and 3-  and pull off the vacuum hose -1-  .
      Fig 20: Identifying Cylinder Bank Vacuum Line (1-3)
      G09815908Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 35.2. Loosen holding clamp on the camshaft-housing cover -arrow-  .
      Fig 21: Locating Cable Plugs And Ignition Coils On Camshaft-Housing Cover
      G09815909Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 35.3. Unscrew M6 external Torx screw -2-  at the engine flange and remove the line -1-  .
      Fig 22: Identifying Engine/Transmission Flange Vacuum Line Mounting
      G09815910Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  36. Remove vacuum pump -2-  and one cover -1-  on cylinder bank 1-3.

    → 477619 REMOVING AND INSTALLING VACUUM PUMP .

    Fig 23: Locating Vacuum Pump
    G09815911Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  37. Remove covers on camshaft actuators -1 and 3-  . Unscrew M6 Torx screws and pull off covers.
    1. 37.1. Replace O-rings.
      Fig 24: Identifying Camshaft-Housing Cover (Cylinder Bank 4-6)
      G09815912Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  38. Remove solenoid hydraulic valves for camshaft control on intake and outlet side. Unscrew external Torx screws and pull out the valves.
    1. 38.1. Replace O-rings.
  39. Remove pulse sender and holder.
    1. 39.1. Unscrew two external Torx screws (one M6 x 35, one M6 x 25) -arrows-  and remove the pulse sender and cable.
      Fig 25: Removing Pulse Sender
      G09815913Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  40. Remove cover for camshaft housing.

    → 159119 REMOVING AND INSTALLING COVER FOR CAMSHAFT HOUSING - GT3 .

    1. 40.1. Unscrew 17 external Torx screws: 14 M6 x 35 -1-  , two M6 x 25 and one M6 x 75).
      Fig 26: Locating Camshaft-Housing Cover Screws
      G09815914Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 40.2. Remove all holders.
    3. 40.3. Carefully lift up the housing cover using a large screwdriver if necessary.
      Fig 27: Lifting Up Camshaft-Housing Cover
      G09815915Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  41. Remove camshafts.

    → 150520 REMOVING AND INSTALLING CAMSHAFTS (INCLUDES SETTING TIMING) - GT3 .

    CAUTION: Interchanged or dirty bucket tappets.
    • Damage to engine components.

    → The components have been run in the fitting bores in the housing, therefore do not interchange them.

    → Absolute cleanliness is essential.

  42. Remove bucket tappets and switchable tappets. Check parts for signs of wear and replace if necessary.
    1. 42.1. Lay components down in such a way that they can be inserted again at their original position during re-installation.
    2. 42.2. Label the components on a clean surface for this purpose.
      Fig 28: Example Of Laying Aside Switching Tappets
      G09815916Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  43. Remove camshaft housing.

    → 150319 REMOVING AND INSTALLING CAMSHAFT HOUSING .

    1. 43.1. Loosen 18 external Torx screws (M8 x 50) according to specifications and unscrew them. Remove housing and take out metal seal.
  44. Be careful with the aluminum sleeve -1-  on the timing chain box.
    Fig 29: Identifying Chain Box Aluminum Sleeve
    G09815917Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  45. Remove cylinder head.
    1. 45.1. Remove 12 internal serration collar nuts (M12) -1-  using socket wrench 9295  .
      Fig 30: Identifying Cylinder Head Screws
      G09815918Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 45.2. Carefully lift off the cylinder head and remove the cylinder head gasket.
  46. Replace guide and tensioning rails.
    1. 46.1. Guide rail: unscrew two bearing pins of different lengths. Top = 69 mm (chain box) -2-  , bottom = 74.5 mm (crankcase) -1-  and dispose of sealing ring.
      Fig 31: Identifying Guide Rail Bearing Pins
      G09815919Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 46.2. Lift the rail out of the chain box.
    3. 46.3. Tensioning rail: unscrew one threaded bolt with a length of 74.5 mm (crankcase) and dispose of sealing ring.
    4. 46.4. Lift the rail out of the chain box.
      Fig 32: Identifying Guide And Tensioning Rails Pins
      G09815920Courtesy of PORSCHE CARS NORTH AMERICA, INC.
      • 1 - Pin = 69 mm
      • 2 - Pin = 74.5 mm
  47. Remove chain box.
    1. 47.1. Remove five M8 screws: two M8 x 35 screws with washer (on the dowel sleeves), two M8 x 30 screws with washer, one M8 x 25 Torx screw.
    2. 47.2. Dispose of metal seal.
  48. Remove coolant connection piece on cylinder housing.
    1. 48.1. Unscrew two external Torx screws (M6 x 20), take off connection piece and replace O-rings.
  49. Carefully clean the components and sealing surfaces.

    The camshaft controllers must not be washed in a parts washer! 

    Remove cylinder bank 4-6 in the same way as cylinder bank 1-3. 

  50. For details of further disassembly work, see description below:

    → 134819 REMOVING AND INSTALLING CRANKSHAFT .

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