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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 >> Preliminary Work

Preliminary Work

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

NOTIFICATION 

Dirt and contamination 

Information 

Information 

  1. Remove the engine.

    > 100119 REMOVING AND INSTALLING ENGINE  - article on "Removing".

  2. Remove transmission.

    > 343527 REMOVING AND MOUNTING TRANSMISSION - article on "Removing".

    > 373427 REMOVING AND MOUNTING PORSCHE DOPPELKUPPLUNG (PDK) - article on "Removing".

  3. Support the engine on the engine assembly support.

    > 1001IN TOOLS FOR REMOVING/INSTALLING UNITS AND WORKING ON ASSEMBLY SUPPORT .

  4. Drain engine oil.

    > 170117 DRAINING AND FILLING ENGINE OIL - article on "Draining"

    .

    1. 4.1 Unscrew oil drain plug and collect engine oil.
    2. 4.2 Screw in and tighten screw with new seal.

      > Tightening torque 50 Nm (37 ftlb.) 

  5. Remove charge air cooler.

    > 214319 REMOVING AND INSTALLING CHARGE-AIR COOLER - article on "Removing".

  6. Remove charge-air cooler holder -1-  .

    > 214219 REMOVING AND INSTALLING CHARGE-AIR COOLER HOLDER - article on "Removing".

    G14944401Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Fastening screws on charge-air cooler holder

  7. Loosen oxygen sensor cable.
  8. Remove catalytic converter with cross tube.

    > 267319 REMOVING AND INSTALLING CATALYTIC CONVERTER - article on "Removing".

  9. Remove engine carrier bracket.

    > 103019 REMOVING AND INSTALLING ENGINE CARRIER (BRACKET)  - article on "Removing".

  10. Remove tank vent line with valve.

    > 202319 REMOVING AND INSTALLING TANK VENT VALVE - article on "Removing".

    1. 10.1 Loosen seven retaining clips and disconnect line on the intake-air distributor.
  11. Remove drive belt.

    > 137819 REMOVING AND INSTALLING DRIVE BELT - article on "Removing".

    Engine support, air-conditioning compressor, oil separator, turbocharger components: 

    Fig 1: Engine Support, Air-Conditioning Compressor, Oil Separator, Turbocharger Components Location
    G14944402Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Component overview - engine support, air-conditioning compressor, oil separator, turbocharger, B+ socket

    1. Engine support
    2. Air-conditioning compressor
    3. Oil separator
    4. Turbocharger
    5. Vibration damper (2.0-liter variant shown)
    6. B+ socket
  12. Remove engine support -1-  .
    1. 12.1 Unscrew screws - M8 (2x) and M6 (1x) - and remove engine support.
  13. Remove intake-air distributor completely.

    > 244619 REMOVING AND INSTALLING INTAKE-AIR DISTRIBUTOR - article on "Removing".

    1. 13.1 Disconnect all cable plugs and other plug connections.
      • Loosen wastegate control valve on intake-air distributor 3-4 (2 screws)
      • Cable plug for throttle housing, intake manifold pressure sensor
      • Tank vent line connection
      • Positive crankcase ventilation connection
  14. Remove air-conditioning compressor -2-  .

    > WM, 873419 REMOVING AND INSTALLING AIR-CONDITIONING COMPRESSOR

  15. Remove oil separator -3-  .

    > 105519 REMOVING AND INSTALLING OIL SEPARATOR  - article on "Removing".

    1. 15.1 Disconnect the vent lines.
    2. 15.2 Unscrew external Torx screws (M6 x 25) and pull off the oil separator.
    3. 15.3 Replace O-rings on the oil separator.
  16. Remove turbocharger -4-  with lines.

    > 213019 REMOVING AND INSTALLING TURBOCHARGER - article on "Removing".

    > 213019 REMOVING AND INSTALLING TURBOCHARGER (VTG) - article on "Installing".

    1. 16.1 Loosen line connections and disconnect cable plugs.
    2. 16.2 Loosen turbocharger at the exhaust manifold flange and remove it.
  17. Remove vibration damper -5-  .

    > 137519 REMOVING AND INSTALLING VIBRATION DAMPER (2.0 L) - article on "Removing".

    > 137519 REMOVING AND INSTALLING VIBRATION DAMPER (2.5 L) - article on "Removing".

  18. Unscrew collar nuts for B+ socket -6-  on the holder.
  19. Remove exhaust manifold -1-  .

    > 261019 REMOVING AND INSTALLING EXHAUST MANIFOLD - article on "Removing".

    Fig 2: Exhaust Manifold Assembly Components Location (2.0-Liter Engine)
    G14944403Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Assembly overview - exhaust manifold (2.0-liter engine shown)

    1. Exhaust manifold
    2. Screws, M8 x 27
    3. Seals - replace
    4. Seal - replace
    5. Studs - replace
    6. Holder for heat shield on exhaust manifold flange
    7. Screw, M8 x 20
    8. Collar nuts, M8 - replace
    9. Screw, M6 x 12 (heat shield to holder)
  20. Remove control valves with vacuum lines.
    • Control valve for wastegate
    • Wastegate control valve
    • Control valve for coolant pump and additional coolant pump
    • Control valve for sports exhaust system (if installed)
  21. Remove crankcase vent line -1-  .
    1. 21.1 Disconnect vent line at the cylinder head 1-2, oil filler pipe and oil separator connection points -arrows-  .
    G14944404Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Positive crankcase ventilation line

  22. Remove B+ wiring harness -1-  .
    1. 22.1 Pull off protection cap -3-  on the generator and unscrew collar nut -4-  .
    2. 22.2 Pull off protection cap -5-  on the starter. Unscrew hexagon nut -6-  on B+ line for the starter.
    3. 22.3 Unscrew M6 collar nut -7-  for terminal 50 on the solenoid switch for the starter.
    4. 22.4 Unclip engine wire harness -arrow-  and remove wiring harness with B+ socket -2-  and protection cap on the starter.
    G14944405Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    B+ wiring harness

    Information 

    • Photos taken with a digital camera are helpful for dealing with complicated line routing (engine wire harness). 
    • For details, see 975219 "Removing and installing engine wire harness". 
  23. Disconnect various connectors on the engine wire harness.

    > WM, 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE

    1. 23.1 Pull off the following cable plugs: 
      • Camshaft control (4x)
      • Valve lift adjustment (4x)
      • Hall sender (4x)
      • Coolant temperature sensor
      • Knock sensors (2x)
      • Generator
      • Oil pressure regulating valve
      • Ignition coils (4x)
      • Sensor for oil pressure and oil temperature (1x each)
      • Oil level sensor
      • Low-pressure sensor
      • High-pressure sensor
      • High-pressure pump
      • Exhaust temperature sensor (cylinder bank 3-4)
      • Additional coolant pump
      • Coolant regulator
      • Fuel injectors
    2. 23.2 Loosen ground cable for ignition coils and unscrew two screws.
    3. 23.3 Unscrew screws for cable duct.
    4. 23.4 Remove engine wire harness.
  24. Remove bracket with deflection roller.
    G14944406Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Overview of parts

    1. Deflection roller console
    2. Deflection roller
    3. M8 screws on unit carrier
    4. M6 screw on crankcase
  25. Remove generator.

    > 272219 REMOVING AND INSTALLING GENERATOR .

  26. Remove oil filler pipe -1-  .
    1. 26.1 Unscrew screw -2-  at the rear and unscrew screws -3-  on the crankcase flange.
    2. 26.2 Disconnect oil filler tube and replace O-ring.
    G14944407Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Oil filler pipe

  27. Remove the starter.

    > 276019 REMOVING AND INSTALLING STARTER - article on "Removing".

  28. Remove oil cooler -1-  and coolant pipe (return line for transmission) -2-  .
    1. 28.1 Unscrew screws on the oil cooler. Lift off oil cooler and replace seal.
    2. 28.2 Unscrew screw -3-  , open spring band clamp -4-  and disconnect coolant pipe from the distributor tube.
    G14944408Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Oil cooler and coolant return pipe for transmission

  29. Remove vacuum line -1-  and fuel line -2-  at low-pressure side on cylinder bank 3-4.
    1. 29.1 Unscrew screws -3-  for vacuum line and remove line.
    2. 29.2 Unscrew screws -4-  for fuel line and remove line.
    3. 29.3 Unscrew screw -5-  for turbocharger oil line and pull line out of the oil pan.
    G14944409Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Vacuum and fuel line (low-pressure), bank 3-4

  30. Remove the high-pressure pump.

    > 246319 REMOVING AND INSTALLING HIGH-PRESSURE PUMP - article on "Removing".

  31. Remove fuel line -1-  on high-pressure side.
    1. 31.1 Unscrew union nuts on the fuel collection pipes.
    2. 31.2 Unscrew screws -2 and 3-  at the mounting points and remove line.
    G14944410Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Fuel line (high-pressure side)

  32. Disconnect supply hose -1-  for heater.
    1. 32.1 Open spring band clamp -3-  at the bottom and pull off hose.
    G14944411Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Supply hose for heater

  33. Remove oil filter housing -1-  .
    1. 33.1 Unscrew screws -2-  and remove housing.
    G14944412Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Oil-filter housing

  34. Remove belt tensioner and bracket -4-  .

    > 137319 REMOVING AND INSTALLING BELT TENSIONER - article on "Removing"

    .

    1. 34.1 Unscrew M8 screws -1 and 2-  and remove belt tensioner.
    2. 34.2 Unscrew two M8 screws -5-  and one M6 screw -6-  and remove the bracket.
    G14944413Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Belt tensioner with bracket

  35. Disconnect coolant hose for directional-control valve (thermal management). Open spring band clamp and pull off the hose.
  36. Remove coolant distributor pipe.
    1. 36.1 Unscrew screws (M8 x 35 and M8 x 50) and remove coolant distributor pipe.
    2. 36.2 Replace moulded seals, check dowel sleeves for signs of damage and replace them if necessary.
  37. Remove heat shield -1-  on turbocharger/exhaust manifold.
    1. 37.1 Heat shield: Unscrew M6 -1-  and M8 screws -2-  and remove heat shield.
    G14944414Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Heat shield on turbocharger/exhaust manifold

  38. Remove holder -1-  for turbocharger/exhaust manifold and bracket -3-  .
    1. 38.1 Unscrew M8 screws -2-  and remove holder.
    2. 38.2 Unscrew M8 screws -5-  and remove bracket.
    G14944415Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Holder and bracket for turbocharger/exhaust manifold

  39. Remove coolant pipe -1-  at the belt side.
    1. 39.1 Unscrew screws -2 and 3-  .
    2. 39.2 Pull off coolant pipe and replace O-rings and seal.
    G14944416Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Coolant pipe on coolant pump

  40. Remove heat protection panel on coolant pump.
    1. 40.1 Unscrew screws -1-  and remove heat protection panel -2-  .
    G14944417Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Heat protection panel

  41. Remove additional coolant pump -1-  with coolant pipe -2-  .
    1. 41.1 Unscrew screw -3-  on coolant regulator housing -4-  .
    2. 41.2 Pull off coolant pipe and remove together with pump.
    3. 41.3 Replace O-rings.
    G14944418Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Removing additional coolant pump with coolant pipe

  42. Remove coolant pump -1-  with coolant regulator housing -2-  .
    1. 42.1 Unscrew three M8 screws -3-  and remove components.
    2. 42.2 Replace O-rings on the housing.
    G14944419Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Coolant pump with coolant regulator housing

  43. Remove ignition coils.

    > 282020 REMOVING AND INSTALLING IGNITION COILS - article on "Removing".

  44. Remove two hall senders on each cylinder bank.
    1. 44.1 Unscrew M6 screws and pull off hall senders.
  45. Remove spark plugs.

    > 287020 REMOVING AND INSTALLING SPARK PLUGS - article on "Removing".

  46. Remove fuel collection pipes.

    > 243020 REMOVING AND INSTALLING FUEL COLLECTION PIPE - article on "Removing".

  47. Disconnect vacuum line for brake booster at cylinder bank 3 - 4.
  48. Remove vacuum pump -1-  on cylinder head 3 - 4.

    > 477619 REMOVING AND INSTALLING VACUUM PUMP - article on "Removing".

    G14944420Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Mounting for vacuum pump

    1. Vacuum pump
    2. M6 screws
  49. Remove two hydraulic valves for valve lift switchover on each cylinder bank.

    > 155519 REMOVING AND INSTALLING SOLENOID HYDRAULIC VALVE FOR VALVE LIFT ADJUSTMENT - article on "Removing".

    G14944421Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Solenoid hydraulic valve for valve lift adjustment

    1. Cable plugs
    2. Screws
    3. Hydraulic valves
  50. Remove coolant pipe (on oil pan side).
    G14944422Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Coolant pipe (on oil pan side)

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