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Home >> Porsche >> 2019 >> 718 Boxster Base, Automatic DCT Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 18 (15 Engine - Cylinder Head, Valve Drive 2.5L -- 982 - BOXSTER/CAYMAN) >> WM, 157037 - Disassembling And Assembling Cylinder Head >> Disassembling Cylinder Head >> Notes

Disassembling Cylinder Head: Notes

WARNING: This page is about a different variant/trim than selected.

NOTIFICATION 

Dirt and contamination 

Recommended tools:  > VAS 5161A - Removal and Installation Device for Valve Keys  and > VAS 5161A/33 - Supplement Set for Valve Key Assembly 

Component overview of cylinder head: 

Fig 1: Cylinder Head Components Location
G14944726Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Overview of individual cylinder head parts

  1. Outlet valve
  2. Lower valve-spring plate (outlet)
  3. Valve-stem seal
  4. Inner valve spring
  5. Outer valve spring (outlet)
  6. Upper valve-spring plate (outlet)
  7. Valve keys
  8. Upper valve-spring plate (intake)
  9. Outer valve spring (intake)
  10. Inner valve spring (intake)
  11. Upper valve-spring plate (intake)
  12. Intake valves
  13. Cylinder head
  1. Fit guide sleeve PO/18 -1-  for the intake and outlet side into the valve slot.
    G14944727Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Guide sleeve for valve key disassembly and assembly

  2. Loosen valve disc from the valve keys using the impact mandrel PO/3  .
    1. 2.1 Tap the valve disc using a plastic hammer and the impact mandrel.

    Information 

    Reusable inner parts of the cylinder head must always be cleaned thoroughly and assigned to their original installation location.

  3. With cylinder head removed: 
    1. 3.1 > VAS 6419 - Cylinder head tensioning device  must be fitted on > VAS 6095A - Engine and Gearbox Support  .
    2. 3.2 Secure cylinder head -1-  using supports -3-  to > VAS 6419 - Cylinder head tensioning device-2-  .
    3. 3.3 > VAS 6419 - Cylinder head tensioning device  must now be connected to compressed air.
    4. 3.4 Push air cushion with the lever under the relevant combustion chamber.
    5. 3.5 Allow as much compressed air as required to flow into the air cushion until it is touching the valve discs.
    G14944728Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Cylinder head on cylinder head tensioning device VAS 6419

  4. Fit valve key disassembly tools from > VAS 5161A - Removal and Installation Device for Valve Keys  on the cylinder head.
    1. 4.1 Screw engaging lock into the appropriate threaded bore.
    2. 4.2 Check that the guide bush -4-  is fitted fully.
    3. 4.3 Fit assembly cartridge -1-  into the guide bush. Position tips of the assembly cartridge at the valve key gaps.
    4. 4.4 Engage pressure fork -2-  with lever -3-  at a suitable position on the engaging lock and support it on the assembly cartridge.
    G14944729Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Valve key disassembly and assembly tool

    Information 

    • The flexible rotating head of the assembly cartridge must be positioned almost on the assembly cartridge. 
    • If this is not the case, the valve key mounting will not be positioned over the valve stem and it will not be possible to fit the valve keys. 
  5. Remove valve keys using pressure fork VAS 5161/2, engaging lock VAS 5161/5  and assembly cartridge AS VAS 5161/8  .
    1. 5.1 Press valve springs together by pressing the pressure forks.
    2. 5.2 Loosen valve keys from the valve stem by turning and pressing the rotary head -1-  on the assembly cartridge.
    3. 5.3 Pull rotary head up and slowly guide pressure fork upwards. This should secure the valve keys in the assembly cartridge.
    G14944730Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Removing/fitting valve keys

  6. If the valve keys are not in the cartridge, repeat Step 6  .
    1. 6.1 If only one valve key is in the cartridge, use universal pressure piece PO/0 and PO/02  from > VAS 5161A/33 - Supplement Set for Valve Key Assembly  to press the valve disc downwards and remove the valve key using a bar magnet.

      Proceed as described for pressure fork in Step 6! 

    G14944731Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Valve key tool for removing one valve key

    1. Pressure fork
    2. Universal pressure piece
    3. Press lever
  7. Remove valve springs and upper valve-spring plate using a bar magnet.
    1. 7.1 Always assign valve springs to the correct valve slot! 
    2. 7.2 Markings -arrows-  on the valve springs must be facing the observer!
    G14944732Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Valve spring markings

    1. Outer valve spring
    2. Inner valve spring

    Arrows  Markings

  8. Replace valve-stem seals.
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