2020 Porsche Boxster S (986) F6-3.2L Technical Service Bulletin # 9/00 Date: 001221
Engine - MIL ON/Oil Leaks/Rough Idle
Boxster
9/00 1715
Binder - 1, Engine, Part 2
12-22-00
New Design Oil Filler Hose
Vehicle Type:
Boxster, Boxster S
Model Year:
As of 1997 (V) / 2000 (Y)
Concern:
Oil filler hose between the crankcase and the service unit.
Information:
The oil filler hose (arrow, figure 1) can crack causing the following conditions:
^ Check Engine warning light lights up.
^ Engine oil leak on the crankcase in the area of the oil filler hose.
^ Rough running (rough idling, increased idle speed).
As a result of the incoming secondary air, the following fault code~ may be stored in the DME fault memory:
2020 Porsche Boxster S (986) F6-3.2L Page 84
^ DME 5.2, P1123 to P1130
^ DME 7.2, P1126, P1128, P1130, P1133
The new style hose was installed in production as of August 18, 2000 from the following VINs:
98 31S 62 0152 - Boxster
98 61S 66 0156 - Boxster S
98 81U 62 0474 - Boxster
98 91U 66 0382 - Boxster S
In case of complaints, the new style hose should be installed.
Parts Information:
Tools:
Changeover ratchet with extension
Socket wrench a/f 10
Small / large slotted screwdriver
Pointed-nose pliers
Hot-air gun
Spring-band clamp pliers
Work Procedure:
Installation of a new oil filler hose. To make replacement of the hose easier, the service unit (coolant expansion tank, dipstick, and oil filler neck)
should be unbolted from its mounting points and moved back. Enlist the help of a second person to help with the following procedure.
1.0 Place the body covers on the rear side sections and the rear bumper.
1.1 Move convertible top to service position. Disengage the convertible-top compartment lid and set it in a vertical position. Remove the upper
engine compartment lid panel and the upper engine compartment lid.
1.2 Remove the rear wall lining and the underside panel in the rear luggage compartment.
1.3 Remove the dipstick. Unclip the dipstick guide tube from the service unit.
1.4 Open the spring-band clamp at the connection point between the oil filler hose and the crankcase flange and push the clamp up on the oil
filler hose. Pull the oil filler hose off the crankcase.
1.5 Disconnect the electrical plug connection for the coolant-level indicator on the service unit. Unscrew the 4 fastening screws/nuts of the
service unit and pull it out approx. 1-1/2 inches into the luggage compartment. The spring-band clamp on the oil filler hose is now accessible.
1.6 A second person is required for the following operation: Open the spring-band clamp at the connection point between the oil filler hose and
the service unit (oil filler neck) and hold the clamp open. Have the 2nd person remove the oil filler hose from the oil filler neck.
1.7 Clean the flanges on the crankcase and the oil filler neck with a clean cloth.
1.8 Push a spring-band clamp on to the new oil filler hose on the crankcase side.
1.9 To make the assembly of the new oil filler hose on the oil filler neck easier, observe the following procedure:
2020 Porsche Boxster S (986) F6-3.2L Page 85
A. Mark the position of the locking tab (Figure 2, arrow A) on the oil filler hose. This is because the locking tab can not be seen during
installation (the locking tab points downward). Using a ballpoint pen, place a mark opposite the locking tab at the connection seam of
the oil filler hose (Figure 2, arrow B). During installation, this line marking must coincide with the connection seam of the oil filler
neck.
B. Heat the new oil filler hose in the area of the connection to the oil filler neck.
!CAUTION
The oil filler hose may be damaged/deformed by excessive heating with a hot-air gun.
> Heat the oil filler hose in the connection area to approximately 104 degrees F (lukewarm) with the hot-air gun.
1.10 Thread the spring-band clamp on to the oil filler neck and hold the clamp open.
1.11 Install the heated oil filler hose. A second person is required for this operation.
1.12 Secure the oil filler hose on the service unit with the spring-band clamp.
!CAUTION
Incorrect installation of the oil filler hose will increase the assembly time/costs. If the oil filler hose is incorrectly installed, the locking tab on
the crankcase side will not coincide with the flange.
> The locking tab attached to the oil filler hose must point vertically downwards on the oil filler neck side.
> Make sure the second person knows how to position the oil filler hose, so that the installation position is achieved correctly.
> During installation, make sure that the line marking on the oil filler hose coincides with the connection seam on the oil filler neck. Push the
hose into place as far as the stop markings on the oil filler neck.
1.13 Install the oil filler hose on the crankcase side and secure with the spring-band clamp.
1.14 Move the service unit back into position. Fasten it with the nuts/bolts. Engage the dipstick guide tube and insert the dipstick.
1.15 Reinstall the remaining parts.