Removal and Replacement
Removing and Installing the EngineNOTE: The procedure for removing engine from the 911 Carrera 2 version is identical to procedure for 911 Carrera 4 version. For Carrera 2 version disregard steps pertaining to the all wheel drive components.
NOTE: The engine/transmission assembly is removed complete from below.
REMOVING
1. Raise the vehicle at the jacking points.
NOTE: Adjust the right-hand rear jacking point in such a way that the transmission guard can be removed later.
2. Disconnect the battery ground cable.
3. Disconnect the plug for the differential lock control/pump assembly (in the area of the luggage compartment lock panel).
4. Disconnect the plugs (5) from the intake distributor and remove the cable clip from the air-flow sensor.
5. Remove the hot-air blower
6. Disconnect the following plug connections / lines on the left-hand side of the engine department
1- To the carbon canister
2- To the reference mark sensor
3- To the knock sensor
4- To temperature sensor II (cylinder 3) 5 - Fuel return line
6- Plug connection - cruise control
7- Plug connection - Lambda probe
CAUTION: To prevent fuel running out if the fuel tank is full, join the disconnected line to Special Tool 9507 connection line, order No. 000 721 950 70 and pinch the connection line with a standard hose clamp.
7. Remove the cover from the engine electrics board. Pull off both multiple connectors.
8. Pull off both ignition cables 4 and the plugs from the dual ignition distributor.
9. Pull off the plug from the pulley control unit.
10. Disconnect the vent line.
11. For vehicles with air-conditioner, disassemble the compressor from the console and, with lines still connected, laid it on the adequately protected left-hand rear fender.
12. Remove the air filter cover with filter insert.
13. Disconnect the fuel supply line to the fuel filter, while bracing. Catch the escaping fuel.
14. Empty the reservoir for the power steering pump. Draw-off fluid.
a. Undo the hose clip and pull off the upper line, catch any oil.
b. Release the lower line and remove with bracket, catch any oil.
15. Remove the rear wheel.
16. Undo the upper fastening screw for the central pipe - transmission; for this, remove the rear tray from the transmission tunnel console. Remove the layer of PVC and take off the cover.
NOTE: The cover can also be pushed out from below. Illustration shows section without console.
17. Disconnect the throttle operating cable from the reverse-transfer lever of the foot controls, and remove the spherical head.
18. Remove engine, transmission and central pipe guard.
19. Drain engine oil from the thermostat housing.
NOTE: If an engine is being overhauled, also drain the engine oil from the crankcase.
20. Undo the oil line in the rear right-hand wheel house with Special Tool 9501, bracing under all circumstances. Remove the retaining clip for the line from the wheel house. Block the line.
21. Disconnect the drive shaft at the flange from the differential. Left-hand side: remove the profiled sheet beforehand.
22. Detach the heater lines from the heat exchanger.
23. Disconnect the ground strap between body and starter from the lower starter fastening point.
24. Disconnect cable terminal 30 from the starter.
25. Detach the clutch slave cylinder and, with line still attached, lay aside.
26. Remove stabilizer.
27. Pull the rubber sleeve forwards over the shift rod coupling and undo the body4it screw.
28. Undo both Allen screws for the clamping sleeve and slide the sleeve forwards along the central shaft.
29. Pull the throttle operating cable out of the guide tube in the floor group.
30. Mount a self-made flat steel tool. (to support the central tube when disconnecting the flange).
Sketch of the self-made tool
31. Undo the fastening nuts from the slave cylinder for the wheel-to-wheel differential lock. Do not undo the line.
32. Undo the Allen screw from the slave cylinder for the interaxle differential lock and pull out the lock. Do not undo the line.
33. Unclip the connecting line at the transmission and suspend both cylinders on one side with the lines still connected.
34. Undo the oil hose from the oil line in the rear right-hand wheel house and block the oil line.
35. Undo the bracket for the engine guard, remove It and retighten the hexagon nuts or hexagon screws. (Contact surface for the engine mounting plate)
36. Position the jack with engine mounting plate under the vehicle with a certain amount of preload. Make sure that the adapter is in the right position. (Engine/transmission horizontal)
37. Undo the lower fastening screws from the central transmission pipe flange.
38. Undo the transmission cross members (6 screws).
39. Remove the cap from the engine mount assembly hole in the rear engine cover panel and undo the hexagon nuts from the engine bearings from below.
40. Lower the engine/transmission assembly until the central tube makes contact with the self-made flat steel tool. Pull off the multiple connector from the airflow sensor.
41. Pull the engine/transmission assembly slightly to the rear and lower carefully.
NOTE: Pay attention to the drive shafts and slave cylinder.
INSTALLATION.
Install in reverse order of installation noting the following:
Do not pinch the heating lines, slide on to the heat exchanger shortly before the engine/transmission assembly has reached the correct installation position.
Make sure that the inner rubber seal of the connector is seated correctly.
Tightening Torques:
Engine mount to engine bearing M 12 85 Nm (62 ft lbs)
Transmission mount to body M 12 46 Nm (34 ft lbs)
Central tube to transmission M 12 85 Nm (52 ft lbs)
Twin clamping sleeve to the central shaft 75 Nm (65 ft lbs)
Shift rod (body-fit screw) 23 Nm (17 ft lbs)
Drive shaft to transmission flange 42 Nm (31 ft lbs)
Stabilizer to stabilizer mount M 10 46 Nm (34 ft lbs)
Oil drain plug in thermostat housing 60 Nm (44 ft lbs)
Oil drain plug in crankcase 70 Nm (51 ft lbs)
Oil line to oil filter housing 80 Nm (59 ft lbs)