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Home >> Porsche >> 2019 >> 718 Boxster Base, Automatic DCT Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 2 (10 Engine - Crankcase, Suspension 2.5L -- 982 - BOXSTER/CAYMAN) >> WM, 1001Z1 - Disassembling Engine >> Disassembling Engine >> New Tools

New Tools

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

New tools for 4-cylinder engines: 

The piston pin tools are used in the same way as instructed for the long tools (pistons 1 and 3).

G14944423Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Tool overview - B4 engine

  1. > 9764/2 - Disassembly tool, short  (used on transmission side)
  2. >9776/2 - Assembly tool  (used on transmission side)
  3. >9776/3 - Assembly tool  (used on transmission side)
  4. >9777/2 - Disassembly tool  (used on transmission side)
  5. >9787/4 - Assembly aid for pistons  (for piston diameter 91 mm)
  6. >9787/5 - Assembly aid for pistons  (for piston diameter 102 mm)
  7. >9784/2 - Funnel  (piston diameter 102 mm for 2.5-liter engines)
  8. >9784/4 - Funnel  (piston diameter 91 mm for 2.0-liter engines)

NOTIFICATION 

Dirt and contamination 

Information 

Information 

  1. Remove the cylinder head cover.

    > 158219 REMOVING AND INSTALLING CYLINDER HEAD COVER .

  2. >9888 - Staking tool  must be fitted on the crankshaft flange using three screws.

    Information 

    • The camshafts may only be removed at the position 260° after TDC. 
    • Only at this position can you be sure that the valves are not touching against the pistons and cannot be damaged when the engine turns. 
  3. Turn the crankshaft clockwise (direction of rotation of engine)  to position 260° after TDC.
    1. 3.1 > 9888 - Staking tool-1-  must be secured to the crankshaft with three screws -2-  .
    2. 3.2 Turn the crankshaft using > 9773 - turning device  until the bores are aligned.
    3. 3.3 Fix in place using a long > 9595/1 - locating pin-3-  .
    G14944424Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Position 260° after TDC

  4. Check cam position. Data matrix code -1 and 2- on both camshafts is facing you! 
    1. 4.1 Turn the crankshaft a further 360° clockwise if necessary.
    G14944425Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Data matrix code on the camshafts

    1. Data matrix code on intake camshaft
    2. Data matrix code on outlet camshaft
  5. Remove camshafts.

    > 150520 REMOVING AND INSTALLING CAMSHAFTS (INCLUDES SETTING TIMING) - article on "Removing".

    Information 

    • Position hydraulic tappets on a surface you have prepared and labelled yourself in accordance with their installation position in the cylinder head. 
    • Components have been run in fitted bores and must not be confused. 
    • Do not use magnets for removal or installation. This can cause the components to malfunction. 
  6. Remove hydraulic tappets.
    1. 6.1 Pull hydraulic tappets out of the fitting bores in the cylinder head. Do not use magnets.
    2. 6.2 Lay components on a clean, labelled surface.
  7. Remove tensioning and guide rails.
    1. 7.1 Cylinders 1 - 2:  Unscrew one bearing pin for the tensioning rail and two bearing pins for the guide rail.
    2. 7.2 Pull out the tensioning and guide rails using flat-nosed pliers.
    3. 7.3 Lay the timing chain in the chain slot.
    4. 7.4 Cylinders 3 - 4:  Unscrew two bearing pins for the guide rail and one bearing pin for the tensioning rail.
    G14944426Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Overview of bearing pins for guide and tensioning rails

    Short bearing pin for tensioning and guide rails, cylinders 1-2

    Short bearing pin for guide rail, cylinders 3-4 and oil pump

    Long bearing pin for tensioning rail, cylinders 3-4

  8. The bearing pin for the tensioning rail on bank 3 - 4 -1-  is longer than the five other bearing pins -2-  for the timing chain rails.
    G14944427Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Difference between bearing pins

    1. Bearing pin for tensioning rail on cylinder bank 3 - 4
    2. Bearing pins for both guide rails and tensioning rail on cylinder bank 1 - 2/3 - 4 and tensioning rail for oil pump
    1. 8.1 Replace O-rings.
  9. Remove cylinder head with cylinder-head gasket.

    > 157019 REMOVING AND INSTALLING CYLINDER HEAD .

  10. Remove displacement bodies from crankcase half 1 - 2.
  11. Turn the engine at the engine assembly support so that the oil pan is at the top.
  12. Remove oil pan.

    > 175019 REMOVING AND INSTALLING OIL PAN (LOWER PART) - article on "Removing".

    > 175019 REMOVING AND INSTALLING OIL PAN (UPPER PART) - article on "Removing"

    .

  13. Remove coolant pipe.
    1. 13.1 Unscrew screws and remove coolant pipe.
    2. 13.2 Replace O-rings. 
    G14944428Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Coolant pipe (under the oil pan)

  14. Remove oil pump.

    > 172019 REMOVING AND INSTALLING OIL PUMP .

  15. Turn the engine at the engine assembly support so that cylinder bank 1 - 2 is facing upwards.
  16. Mark pistons.
    G14944429Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Marking pistons

  17. Remove pistons for cylinders 1-2.

    > 131020 REMOVING AND INSTALLING PISTONS .

  18. Remove crankcase half 1 - 2.
    1. 18.1 Unscrew external Torx screws -13 to 25-  for the outer cross bolt connection.
    2. 18.2 Loosen and unscrew through bolts (M10 x 195) -1 to 10-  in the opposite sequence to the tightening sequence.
    3. 18.3 Replace screws.
    Fig 1: Crankcase Screws Tightening Sequence
    G14944430Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Tightening sequence for crankcase

    1. 1-10  Torx screw, M10 x 195 (tighten to torque angle in 2 steps) - only use once
    2. 11-12  Screw, M8 x 35 - Threaded joint for supporting mount
    3. 13  Screw, M8 x 35
    4. 14-24  Torx screw, M6 x 40 - Threaded joint for crankcase
    5. 25  Torx screw, M8 x 120 - Threaded joint for crankcase, outer (oil pan area)
  19. Unscrew two > 9590 - mounting parts  for bolting crankcase half 1 - 2 to the engine support.
  20. Lift off crankcase 1 - 2.
    1. 20.1 To do this, put on heat-resistant gloves and heat the sealant at the joint using a hot-air gun.
    2. 20.2 Lift up crankcase half 1 - 2 at the positions shown -arrows-  using a large slotted screwdriver.
      G14944431Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Lever positions on crankcase

    3. 20.3 Slide in two pieces of wood -1-  above the oil-pump pressure channels and lift up the crankcase half using a mounting lever -items 2 and 3-  .
    G14944432Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Mounting lever position on crankcase

  21. Remove pistons with connecting rods for cylinders 3 - 4.

    > 131020 REMOVING AND INSTALLING PISTONS .

    1. 21.1 Remove connecting rods 1 - 2 on the crankshaft.
  22. Remove crankshaft sealing rings and replace during assembly.
  23. Lift crankshaft -1-  with timing chains -2-  out of crankcase half 3-4 -3-  .
    1. 23.1 Remove bearing shells from the crankcase halves and replace them before assembly.
    G14944433Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Crankshaft and timing chains in crankcase half 3-4

  24. Clean the crankcase and sealing faces.
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