Preliminary Work

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

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.

WARNING: Vehicle can fall down

Risk of squashing or crushing
Risk of damage to the vehicle
- → 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.

Raise the vehicle at the prescribed jacking points.
Place protective covers on the vehicle.
Read out the fault memory using the PIWIS Tester.
> The appropriate Service Information for Fault memory for on-board diagnosis.
Evacuate the air conditioning system.
> WM, 870317 DRAINING AND FILLING REFRIGERANT R134A or WM, 870317 DRAINING AND FILLING REFRIGERANT R1234YF
Boxster vehicles: Move convertible top into service position.
> WM, 6101IN CONVERTIBLE TOP IN SERVICE POSITION
Disconnect battery ground terminal.
Remove engine compartment lid.
> WM, 557819 REMOVING AND INSTALLING ENGINE COMPARTMENT LID
Remove rear wall cover.
> WM, 555919 REMOVING AND INSTALLING REAR WALL FLAP
Vehicles with particle filter:
Disconnect differential pressure sensor hoses -1- .
1. 9.1 Loosen spring band clamps -2- using > VAS 6890 - Spring Band Clamp Pliers and disconnect hoses -1- .
2. 9.2 Close off line openings using suitable stoppers.
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Differential pressure sensor hoses
Disconnect B+ line.
1. 10.1 Open cover -1- on the box, screw off M8 hexagon nut -2- and set line aside.
2. 10.2 Mask contact -3- !
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B+ line connection
Remove air cleaner housing -1- .
> 242519 REMOVING AND INSTALLING AIR CLEANER HOUSING .
1. 11.1 After removing the air cleaner housing, remove the air guide -2- .
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Air guide for air cleaner housing
1. Air cleaner housing
2. Raw air guide
Pull off vent line -1- on the coolant reservoir.
1. 12.1 Press locking lugs -arrows- and pull off quick connector.
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Vent line on coolant reservoir
Pull off oil filler hose -1- .
1. 13.1 Press locking ring on the bars -arrows- and pull off quick connector.
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Oil filling hose connection point
Loosen and fold over luggage compartment trim.
> WM, 700619 - REMOVING AND INSTALLING REAR LUGGAGE COMPARTMENT TRIM PANEL .
1. 14.1 Unclip covers at the left -1- and right -2- and remove them -arrows- .
2. 14.2 Fold luggage compartment trim towards the rear.
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Rear luggage compartment cover (shown on the Boxster)
Remove air guide -1- for cooling the DME control unit.
1. 15.1 Unscrew plastic nuts -2- and remove air guide and felt.
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Air guide for DME control unit
Loosen cable plug for engine wire harness in luggage compartment and expose wiring harness.
1. 16.1 Loosen DME control unit -1- , unscrew upper screw -2- , but only loosen the lower screws -3- .
2. 16.2 Disconnect ground cable, unscrew M8 hexagon nut -4- and disconnect two cable plugs -5- .
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Loosening DME control unit in the luggage compartment
Tilt control unit -1- slightly to the rear, then release and disconnect main cable plug at the top -2- .

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Tilting DME control unit
Guide wiring harness -1- through the body and into the engine compartment.
1. 18.1 Disconnect wiring harness at the tucker stud.
2. 18.2 Detach rubber sleeve -2- using a plastic wedge and guide wiring harness through to the engine compartment.
3. 18.3 Set wiring harness down on the intake-air distributor.
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Bushing in body for engine wire harness
Unclip shift cable -2- and selector cable -1- or parking lock cable (double clutch transmission) in the engine compartment.

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Unclipping shift and selector cables or parking lock cable in engine compartment

Loosen upper spring struts.

20.1 Unclip cable plug -1- and disconnect it using a small screwdriver -arrow- .

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Opening plug connection

20.2 Screw off collar nuts -1- .

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Upper spring strut mount

Remove rear wheels.
> 440519 REMOVING AND INSTALLING WHEEL .

> P300 - Socket-wrench insert should be used.

Loosen and secure brake callipers.

> 427119 REMOVING AND INSTALLING REAR SPRING STRUT .

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Holder on wheel carrier

22.1 Disconnect cable plug -1- for electric parking brake by unclipping the cable -2- .
22.2 Disconnect cable plug for rpm sensor.
22.3 Unscrew M6 screw -4- on the line bracket.

22.4 Unscrew screws on the brake calliper -arrows- .

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Fastening screws on brake calliper

22.5 Secure brake calliper -1- with welding wire or a tie-wrap -2- .

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Securing brake calliper

Remove the rear underbody panelling and unscrew the two screws on the underbody panelling (center).
> WM, 519419 REMOVING AND INSTALLING COVER FOR REAR UNDERBODY
Open air-conditioning lines on the underbody and close off using stoppers.
1. 24.1 Unscrew the fastening screws by countering with the > 9822 - assembly tool-2- .
2. 24.2 Pull off lines and close them off immediately before replacing the O-ring assembly.
3. 24.3 Unclip lines from the holder on the body (bulkhead).
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Underbody air-conditioning lines
1. Air-conditioning line
2. Assembly tool 9822
3. Tool
WARNING:
Caustic fluids
- Danger of chemical burns
  - → Wear personal protective gear.
  - → Ensure that there is good ventilation.
  - → Avoid contact with caustic fluid.
  - → If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.

Drain coolant from the engine.

> 193817 DRAINING AND FILLING COOLANT .

Collect emerging coolant!

25.1 After draining coolant at the filler neck on the coolant reservoir using the > 9696/2 - filling adapter-1- with compressed-air gun, "blow out" remaining coolant through the drain outlet.

Set compressed air to max. 1.5 bar!

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Blowing out coolant through adapter on the cap

Filling adapter 9696/2
Compressed-air gun
Compressed air hose

25.2 After draining coolant, screw in drain plug with a new sealing ring.
> Tightening torque 25 Nm (19 ftlb.) +/- 2 Nm (1.5 ftlb.)

Remove strut -1- and open plug connection for the oxygen sensors -3 and 4- .
1. 26.1 Unscrew M10 screws -2- and remove strut.
2. 26.2 Pull plug connections for oxygen sensors out of the holder and open them.
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Strut, plug connections for oxygen sensors
1. Strut
2. M10 screws
3. Oxygen sensor connector (blue cable) on cylinder bank 1-2
4. Regulating sensor connector (black cable)
Disconnect vacuum line -1- for brake booster and open plug connection for oxygen sensor.
1. 27.1 Press locking rings -2- and pull off line, then pull off vacuum hose -3- .
2. 27.2 Pull plug connection -4- for oxygen sensor out of the holder and open it.
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Brake booster line, plug connection for oxygen sensor
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 vapours.
  - → Attach warning sign in a clearly visible position.
  - → Contain leaked media using non-flammable absorbent material and put it in a container designed for this purpose for disposal in accordance with local requirements.
  - → Secure collection containers/vessels to prevent them from tipping over.
Open the rapid-action couplings for the fuel line -1- and tank vent line -3- .
CAUTION: Residual pressure can cause fuel to spray out! Wear protective goggles.
1. 28.1 Open the line clip.
2. 28.2 Push lock -2- for fuel line up and release quick connector, then disconnect lines.
3. 28.3 Release quick connector -3- on vent line -right arrow- and disconnect lines.
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Connection point for fuel supply line and tank vent line
Loosen ground strap -1- for engine.
1. 29.1 Unscrew M8 screw -2- and move strap aside.
  If you are replacing the engine, unscrew ground strap at the cylinder head -3- .
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Engine ground strap

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.
Loosen diagonal braces -1- on the body.
1. 30.1 Unscrew M10 screws -2- .
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Diagonal braces on body
Loosen connecting strut -1- .
1. 31.1 Unscrew M10 screws -2- .
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Connecting strut on body
Loosen longitudinal arm -3- at the body.
1. 32.1 Unscrew M12 x 90 screw -2- .
2. 32.2 Remove heat shield on the right-hand side (in direction of travel) with the screw.
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Diagonal arm mounting

Secure diagonal arm -1- with a tie-wrap -2- .

33.1 Left side:

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Securing diagonal arm at the left with a tie-wrap

33.2 Right side:

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Securing longitudinal arm at the right with a tie-wrap

Diagonal arm on right side
Tie-wrap

Vehicles with manual transmission:
1. 34.1 Lever off shift cable -1- and selector cable -2- using > VAS 6933 - Disassembly tool .
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Shift and selector cables on transmission
1. Selector cable
2. Shift cable
3. Fixing clips on support
4. Connecting lever
Open electric plug connections at the bottom.
- Main cable plug for manual transmission
- Cable plug for adaptive transmission mounts on both sides (if fitted)
- Pull off cable plug for angle sensor (headlight levelling system) and cable clip on the holder
- Cable plug for control valve for adaptive engine mounts at the left (if fitted)
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Electric plug connections, bottom
1. A Right side:
  1. Main cable plug for manual transmission
  2. Cable plug for adaptive transmission mounts
  3. Connector for sensor for headlight levelling system, right
2. B Left side:
  1. Cable plug for adaptive transmission mounts
  2. Connector for sensor for headlight levelling system, left
  3. Control valve for transmission mount vacuum

Vehicles with Porsche Doppelkupplung (PDK) : Disconnect cable plug -1- from transmission.

36.1 Open the bayonet locks anti-clockwise and pull off the connector.

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PDK electric plug connections on transmission

36.2 Disconnect cable plugs for temperature sensor -1- and control valves -2- and unclip line.

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Cable plugs for temperature sensor and control valves

Loosen parking lock cable.
1. 37.1 Lever off end piece -1- using > VAS 6933 - Disassembly tool .
2. 37.2 Unclip parking lock cable from the support bracket -2- (-arrow- ).
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Disconnecting parking lock cable from double-clutch transmission

All vehicles:
Unclip and pull off vacuum line -1- for transmission mount control valve.

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Vacuum line for transmission mount
Pull coolant hose -1- off the coolant collection unit.
1. 39.1 Pull off safety clip -2- , disconnect coolant hose and re-insert safety clip.
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Coolant hose on coolant collection unit

Open plug connection for coolant hoses on the engine.

40.1 Pull off spring clamp -2- at the left and disconnect coolant hose -1- on the left side (in direction of travel!).

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Coolant hose on engine at the left (in direction of travel)

40.2 Open spring clamps (large -2- and small -4- ) and pull off coolant hoses -1 and 3- .

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Coolant hoses at top of engine, right side

Secure large coolant hoses -1- with a tie-wrap -2- .
1. 41.1 Check O-rings -3- for damage and replace them if necessary.
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Securing coolant hoses with a tie-wrap

Disconnect coolant hoses and vent line on the charge-air cooler.

IMPORTANT: Emerging coolant!

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Coolant hoses on charge-air cooler and vent line

42.1 Open spring band clamp at the right connection piece -3- and pull off coolant hose -2- .

42.2 Blow out remaining coolant in the charge-air cooler (set compressed air to max. 1 bar).

> 214319 REMOVING AND INSTALLING CHARGE-AIR COOLER .

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Blowing out charge-air cooler

Hose piece (100 mm long), sold by the meter, internal diameter 16 mm
Coolant hose to front connection piece
Adapter piece, plastic
Hose piece (approx. 1 meter), sold by the meter, internal diameter 16 mm; insert hose into collection container.
Compressed-air gun

42.3 Pull off coolant hose -1- going to the rear (left connection piece) by opening the spring band clamp. Disconnect vent line -4- .

Close off coolant hoses -1- and connection piece -2- .

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Coolant hoses on charge-air cooler