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Pelican Technical Article:

Porsche Boxster / 996 Engine Teardown & Disassembly
Page 9

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Difficulty Level: 4
Difficulty scale: Adding air to your tires is level one
Rebuilding a Porsche Motor is level ten

  This article is one in a series that have been released in conjunction with Wayne's new book, 101 Performance Projects for Your Porsche Boxster.  The book contains 312 pages of full color projects detailing everything from performance mods to changing your brake pads.   With more than 950+ full-color glossy photos accompanying extensive step-by-step procedures, this book is required reading in any Boxster owner's collection. The book is currently available and in stock now. See The Official Book Website for more details. 
Figure
Figure 1
Here's a photo of a slip-in locating pin that is used to align the heads with the case.  These easily fall out, so pluck it out and put it in a safe spot before you lose it.
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Figure 2
Another shot of the pin on the opposite side.
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Figure 3
You should be able to simply pull out the pin.
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Figure 4
Moving to the bottom of the case, remove the remaining nuts on the bottom sump plate, and gently tap on the bottom of the case - it should easily come off.
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Figure 5
Here's what the bottom looks like.  These black plastic attachments are oil baffle plates, designed to channel and funnel oil in the sump of the engine.
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Figure 6
Here's what it looks like down inside the bottom of the engine.  On each side of the engine is an air/oil separator, and in the middle is an oil pickup tube.
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Figure 7
Here's one of the air-oil separators.  There are two of them, and they are identical to each other.  The purpose of these units is to remove air from the oil (defoam it and/or remove bubbles from it).  Good consistency of the oil is required to keep air out of the hydraulic lifters, which may be adversely affected by air bubbles (they won't achieve their proper lift).
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Figure 8
A few nuts removed, and you can remove the air-oil separators from the bottom of the case.
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Figure 9
Here's what the bottom of the case looks like with the separators removed.
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Figure 10
Here's one of the separators on the workbench.  Surprisingly enough, they are a two-piece unit, although you can only order the two pieces as a single part number from Porsche.
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Figure 11
In the center is an oil pickup tube with a built-in screen.
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Figure 12
Moving now to separate the case, here we are removing all of the case perimeter bolts.
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Figure 13
More perimeter bolts.
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Figure 14
There are some more bolts to be removed in the bottom area of the case.
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Figure 18
Another shot of the bottom of the case.
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Figure 19
Also another shot of the bottom of the case.
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Figure 20
There are some more case bolts to be removed on this side.
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Figure 24
More case bolts removed.
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Figure 25
There are some case bolts also located near the flywheel seal.
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Figure 27
If you haven't already, pull out the chain rail bolts so that you can remove the chain ramps from the case.
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Figure 28
With the bolt removed, you should be able to simply pull the chain ramp up and out of the case.
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Figure 29
Yuck!  This is what oil and coolant and engine bits look like when they are all mixed together.
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Figure 30
Before splitting the case, we moved the arms on the engine stand so that we had three points of support instead of two.  This engine stand is a generic one, and thus doesn't support the engine as well as a Porsche factory tool.
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Figure 31
Another shot of the block attached to the engine stand.  Make sure that you attach the stand to the half of the engine that has the water pump.  This will allow you to easily lift the opposite side off of the engine.
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