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Joined: 21 Mar 2011
Posts: 162

PostPosted: Tue Mar 22, 2011 10:11 am    Post subject: 996: Replacing Variocan 'Lids' or Flanges O/S Reply with quote

Replaced the offside seal today.

The offside one is more tricky to get to, you can't get to it through the wheel arch, so it's time to lie under the offside tailpipe and manifold.

It was very hard to take any pictures on this side because most of this work is done looking through a small gap between the manifold and rear silencer, and with my left arm up between the manifold and the block twisted at all angles!

First look up above the vaccum oil unit, and pull the electrical connector for the variocam solenoid off of the retaining bracket, next unclip (you can do this one handed, press the lever in, and it unclips, you can then pull apart the two with your fingers):

Pull the wire out of the way, I pulled down between the manifold and rear silencer:

You can place a 10mm socket on the bottom bolt, then slide the ratchet between the manifold and back box attaching it, then remove the lower bolt from the flange:

The top bolt is a little more tricky, there is no room to get a ratchet connected to a socket as the heatsheilds are in the way, and can't be removed without removing the silencer, but there is plenty of room to get a 10mm spanner on it and get your hand up between the block and the manifold, once undone twist and pull the flange off revealing the solenoid (sorry about the quality of picture here):

Grease inside of new flange seal, slip over the connecting wire you pulled down which will guide the flange up to the solenoid:

Push flange over solenoid and twist flange to correct position for threads. Grease bolts slightly and start them top and bottom using fingers between the block and manifold. You can tighten the bottom and top in the same was as before, here you can just about see my fingers turning a spanner on the top bolt:

Reconnecting the solenoid connector block requires some patience, as it is up so high, you will need to simply persevere reaching up, and using two fingers to hold the top part of the block whilst pushing the bottom together. It's too high up to use pliers to hold the top to steady it. Next push back onto clip and you’re done.


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