Boxster Engine Rotation Direction

17 IS IS emoving and Fns.afJrng oiE extraction pump - engine instated Oil extraction pump of cylinder bank 1 - 3 (flywheel side 2. Remove diagonal braces and strut panel. 3. Remove exhaust manifold of cylinder bank 4 - 6. 4. Pull plug connections of the oxygen sensors up and out out of the holders on the rear-axle support. 5. Detach cable between engine and rear-axle support at the rear-axle support. When loosening, hold with a second wrench (a f 13). 5. Unscrew four fastening screws on both...

Overview of repair groups

Saies check On-board diagnosis DME diagnosis iiptronic diagnosis ABS diagnosis Airbag diagnosis Heating diagnosis Alarm system diagnosis Engine - Crankcase, suspension Engine - Crankshaft, pistons Engine - Cylinder head, vaive drive Engine - Lubrication Engine - Cooling Fuel system, electronic injection Exhaust system Starter, power supply, cruise control Ignition system Manual transmission - Actuation, housing Manual transmission - Gears, shafts, int. gearsh. Final drive - Differential,...

Overview of repair groupsBoxster

Front wheel suspension, drive shafts 40 Rear wheel suspension, drive shafts 42 Wheels, tyres, suspension alignment 44 Anti-Lock Brake System (ABS) 45 Brakes - Hydraulics, regulator, booster 47 Door front, central locking system 57 Group S Body equipment, exterior 6 Group 7 Body equipment, Interior 7 Group 8 Air conditioning 8 Auxiliary air conditioning system 88 Radio, telephone, on-board computer, navigation 91 Windshield wiper and washer system 92 Lights, lamps, switches exterior 94 Lights,...

Disassembling arEcfl assembling cylinder head

Oil valve stem and install valve. Push plastic assembly sleeve over the valve stem. Oil sealing lip of the valve stem seal and push onto the assembly sleeve or valve guide by hand. Carefully press the valve stem seal as far as it will go onto the valve guide using the press-on tool, VW special tool 3365

Installation

Shift sliding sleeve accordingly and lay the valve collets in the assembly head. Lightly oil valve collets, valve-stem end and valve spring seat. 2. Insert valve spring support disc, valve spring and valve spring seat into cylinder head and press together with the assembly head. With slight pressure, allow valve collets to engage. The valve collets are then automatically positioned at the right point.

Removal

Pan-head screw with captive washer M6 x 35 Shield fitted only on cylinder head 1 - 3) Relieve with the special tool, tensioning screw 9632, before removal of the camshafts Do not interchange store in suitable place Remove tensioning screw 9632 only after the camshafts or tensioning element has been fastened on the cylinder head Check for wear (scoring), observe identification Check for wear (scoring), observe identification Tightening sequence tighten from the inside to the outside. Check for...

Note

Inspect for wear marks and replace if necessary Inspect for wear marks and replace if necessary Observe allocation to the camshafts two chain links identified Tightening torque 10 Nm (7.5 fUt .) Observe installation position slot faces the crankshaft 1 set - 2 ea. (use short fixing pin) Auxiliary chain tensioner for valve tinning adjustment Locking device for camshafts in timing position 3. Turn engine by 90 on assembly support until cylinder bank 1 - 3 faces upwards.

Explanation

Refer to Workshop Equipment Manual, Chapter 2.4, No. 88 As of engine number M962065X02485 (modified cylinder head screws) The gaskets are identified by Zyl. 1 - 3 or Zyl. 4 - 6 with OBEN TOP, plus the corresponding part number. Ensure correct seating of dowei sleeves in crankcase. Put on gaskets. 2. Fasten cylinder heads. Moisten cylinder-head screws thinly with engine oil. Tightening sequence of the cylinder-head screws Initial tightening or tightening to flatten 2nd step Completely loosen...

Removing and installing camshafts

Tensioning screw (Tensioning screw is already fitted on new chain tensioner at the transport lock) Pan-head screw with captive washer M6 x 95 Protect sealing surface against damage Attach holding down device (special tool 9611) before unscrewing the pan-head screws Apply silicone Type 1209 from Messrs. Drei Bond on sealing surface. Compare pairing numbers with cylinder head and bearing saddles Remove any emerging silicone material. Fit cover dry. Drive on cover with a plastic hammer as far as...

Assembly instructions

The inlet camshaft, outlet camshaft, chain tensioner and chain must be preassembled before installation in the cylinder head. Inlet camshaft 221.04 2.5 IN 13 Outlet camshaft 222,04 2.5 EX 13 Inlet camshaft 216.04 2,5 IN 46 Outlet camshaft 218.04 2.5 EX 46 Identification of the chain tensioner for cylinder bank 1 - 3 8 Solenoid valve surface colour black identification of the chain tensioner for cylinder bank 4 - 6 refer to next page. Identification of the tensioning element for cylinder bank 4...

Adjusting feircg at cylinder [baulk 4

Turn engine to installation position on assembly support, Advance crankshaft 360 clockwise until the bore 1 OT (top dead centre) in the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595. 3. Check camshaft adjustment at cylinder bank 4 - S The groove in the camshaft must face inward toward the crankcase. 4. Turn engine 90 counterclockwise on the assembly support. Cylinder bank 4 - 6 faces upward. 5. If the allocation is...

Removing valve tappets of cylinder bank 1

Farmall Valve Tappit Hold Down Bolt

The groove in the camshaft must face outward toward the cylinder-head cover. View from the flywheel side 52537 View from the flywheel side 52537 2. Turn engine on assembly support until cylinder bank 1 - 3 faces upwards. 3. Unscrew chain tensioner of cylinder bank 1 - 3. 4. Detach and remove oil extraction pump at cylinder head 1-3 on flywheel side. 5. Unscrew hexagon-head bolts M6 x 20 2 ea. . Remove closure cap from tensioning element VarioCam . 6. Remove...

Porsche Tool 9599

Porsche 986 Chain Guide Picture

E Searing saddle for inlet camshaft wujss A Bearing saddle for exhaust camshaft 8. Fit tensioning element VarioCam . Tighten 3 M6 x 95 pan-head screws. Tightening torque 10 Nm 7.5 fffb. 9. Unscrew tensioning screw, special tool 9532, from the tensioning element. 10. Remove tie wrap and fit sprocket wheel with chain on the flange of the exhaust camshaft. 11. Position drive plate or driver star on the sprocket wheel. Fit hexagon-head Tighten hexagon-head bolt by hand only. 12. Fit auxiliary chain...

Adjusting timing ai cylinder [bank 1 3 Requirements

Three auxiliary chain tensioners fitted with correct pretension. 1. Turn engine to installation position on assembly support. Advance crankshaft 360 clockwise until the bore 1 OT top dead centre in the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin short of special tool 9595. 3. Check basic camshaft adjustment of cylinder bank 1 -3 The groove in the camshaft must face outward toward the cylinder-head cover. 6. Fasten blocking device special tool...

Removing and installing coolant pump Tools

Saltus Torque Wrench

No. 3094, from Saltus Mubea G0-190, from Muhr amp Bender' Refer to Workshop Equipment Manual Clamp shut coolant hoses with hose clamps by Saltus, order numbers 3093 and 3094. Undo drain plug at water guide housing and collect coolant Undo spring-band clamps with pliers type MUBEA G0-190 Disconnect electrical plug connection. Undo four Torx screws with socket E12 3 8 inch . Remove service cover at passenger Remove rear-wall lining. Undo nine hexagon-head bolts...

Engine Cylinder head valve drive

15 70 37 Disassembling and assembling cylinder 15 65 19 Removing and installing valve 15 63 19 Removing and installing valve stem seal 15 05 19 Removing and installing 15 59 20 Removing and installing valve tappets engine removed 15-21 15 05 33 Completing 15 91 51 Sealing cover for camshaft housing cylinder head cover 15-47 15 59 02 Checking guide for vaive 15 46 19 Removing and installing oil protection tube engine installed 15-51 15 59 20 Removing and installing valve tappet engine installed...

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Tool 9599 Auxiliary Chain Tensioners

Bearing saddle for inlet m camshaft A - Bearing' saddle for exhaust camshaft 7. Fit tensioning element VarioCam . Tighten 3 M6 x 95 pan-head screws. Tightening torque 10 Nm 7.5 ftlb. . 8. Unscrew tensioning screw special tool 9632 from the tensioning element 9. Remove tie wrap and fit sprocket wheel with chain on the flange of the exhaust camshaft. 10. Position drive plate or driver star on the sprocket wheel. Fit hexagon-head bolts M6x 15 10.9 . Tighten hexagon-head bolts by hand only. 11....

Installing coolant pump

Porsche 924

Install rear-wall lining, service cover and left-hand seat Undo hexagon-head bolts. The lower right hexagon-head bolt is difficult to reach. To undo it, use flexible-head socket wrench 4001-10 by Stahlwille. Cut old metal seal between coolant pump and water guide housing at the connecting webs. Cut new spare metal seal combination seal for coolant pump and water guide housing at the connecting webs. Fit new sea and coolant pump simultaneously and fasten. Tightening torque 10 Nm 7 ftlb. . Fit...

Porsche 986 Engine Direction Of Rotation

The compression springs of the auxiliary chain tensioners should be relieved after measurement. Unscrew thrust screw wrench size 19 mm . Installation position of oil extraction pump at cylinder head 4 - 6 belt pulley side The arrow for the direction of rotation or the marking 4 - 6 must face the crankcase. Fit oil extraction pump. Use new sealing ring and new micro-encapsulated hexagon socket head screws. Tightening torque 10 Nm 7.5 ftib. Installation position of the chain tensioners A - Chain...

Instating camshafts Requirements

Porsche 911 Carrera Exhaust Tappet

Oil pump with coolant guide housing, intermediate-shaft flange, belt pulley and guide rails fitted on the crankcase. 1. Move camshaft to basic position. Turn crankshaft clockwise until the bore 1 OT top dead centre in the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin short of special tool 9595. 3. Turn engine by 90 on assembly support until cylinder bank 1 - 3 faces upwards. 4. Fit cylinder head gasket The gasket is identified by Zyl. 1 - 3 and...

Installing camshafts of cylinder bank 4 S

Turn engine to installation position on assembly support. Remove fixing pin. Advance crankshaft 360 clockwise until the bore 1 OT top dead centre in the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin short of special tool 9595. 1.1 Turn engine 90 counterclockwise on the assembly support until cylinder bank 4 - 6 faces up. 2. Fit cylinder head. Observe identification on the cylinder head. 2.1 Fit cylinder head gasket. The gasket is identified by...