Removing Engine

Removing engine














Required tools

Removing engine
Special equipment-specific features are described in the notes.

Requirements:
^ Turn wheels to straight-ahead position.
^ In the case of vehicles with air suspension, the compressed air must be released using the Porsche System Tester.
^ Position the vehicle at the take-up points provided on a lifting platform.
^ Put on the protection covers.
^ Produce the OBD II log.
^ Bleed the air suspension with the Porsche System Tester.
^ Move the Tiptronic's selector lever to position N .
^ Remove ignition key.
^ Disconnect battery.
^ Remove front wheels.
^ Remove the front wheel housing liners.
^ Remove the engine compartment covers.





1. Remove engine guard with transverse strut.





View shows transverse strut





2. Release the engine guard on the underside. To do this, loosen the 4 fastening screws (M6 x 25).





3. Remove the front transverse strut under the radiator. To do this, loosen the two fastening screws (M8 x 25) to the left and right.





4. Unscrew the coolant drain plug from the radiator and drain off the coolant. Screw in the drain plug again when completed.





5. Remove both wipers. To do this, loosen the 3 fastening nuts. Remove the wipers from the drive shaft using a puller.

Puller for wiper arm





Note: The air quality sensor is located on the cover of the radiator tank. This must be unclipped.





6. Loosen the four bayonet screws -A- on the radiator tank cover. Then lift the cover in the middle, release left and right and remove from the vehicle.





7. Disconnect the engine wiring harness on the right-hand side of the vehicle. To do this, unplug the control unit and disconnect the ground point.





8. Open the cover of the central electrical system on the left side of the vehicle. To do this, loosen the four Torx screws.
9. Disconnect the plugs from the wiring harness plug (white, red, black and brown). Remove the wiring harness from the fastening clips and lay it down on the engine.





10. Disconnect B+ transfer point at the left of the engine compartment. To do this, disconnect the two connecting cables -A and B- for the engine.





11. Pull engine cover vertically upwards and off.





12. Remove connector tube from air cleaner to engine. To do this, loosen the tube clamp on the engine, unplug the electric connector on the mass air-flow meter and remove the two fastening pins on the air cleaner cover.





13. Remove the vacuum line on the throttle body from the connector tube. Then take the pressure pipe out of the engine compartment.

Note: The air line is only present in vehicles with air suspension.





14. Remove air line on air cleaner cover. To do this, unclip the green cap. Insert a screwdriver into the notch of the cap and lever the cap off.





15. Push the snap ring into the flange -1- and then pull it off together with the flange -2- .




16. Clip the green cap on again after disassembly.





17. Loosen the retaining clamps on the air cleaner housing.
18. Remove the air cleaner cover.





19. Remove the filter elements.





20. Disconnect the four oxygen sensor plugs (brown, black) at the right of the water splash panel and unclip the cable from the holders.





21. Disconnect the 2 coolant lines and vacuum line on the right side of the engine compartment.

Warning: Servo oil is aggressive!
^ Before lines are opened, place a cloth underneath them!
^ Components that come into contact with servo oil must be cleaned immediately!





22. Empty the servo oil reservoir with a syringe. Next, remove the hose from the reservoir. Close the open connections with plugs.





23. Disconnect fuel line -1- and line -2- from the carbon canister on the radiator tank splash panel. Then pull off the vacuum line -3- .





24. Undo the 3 fastening screws (a/f 16) on the left and right spring struts. The screws are loosened from inside the engine compartment. Of the 3 screws per spring strut, one is in the plenum chamber. The screws must not be re-used.





25. Disconnect the coolant feed and return lines from the radiator. To do this, pull out the safety bracket and pull off the connection. The brackets should be mounted again immediately so that they are not confused.

Note:
^ The drive belt must be slackened so that the air-conditioning compressor can be removed later.
^ If at all possible, the air-conditioning system should not be opened.





26. Slacken the drive belt. To do this, screw a screw (M8 x 50) into the tensioner until the belt can be removed from the tensioning roller.





Note:
^ In the case of vehicles with air suspension, the compressed airline on the spring strut must also be disconnected. Loosen the line carefully and allow the remaining pressure to escape. Undo the screws completely only when the line is fully depressurize.





^ The electrical plug connection of the height sensor must be disconnected in vehicles with air suspension or automatic headlight beam adjustment.





27. Disconnect electric plug -1- on the spring struts in the wheel well. Next, unclip holders -2 and 3- . Tie the cable on the spring strut.





28. Disconnect the brake lines in the wheel well to the left and right.





29. Disconnect the ground point (a/f 13) on the right side member.

Warning: Emerging ATF!
^ Danger of slipping!
^ Collect emerging ATF!





30. Disconnect the ATF lines on the cooler. To do this, loosen the fastening screw (a/f 10) and pull the lines off. Seal open lines with plugs.





31. Detach secondary air pump hose. To do this, pull off the plug on the pump in the right wheel housing.





32. Remove the heat shield on the steering gear connection. To do this, loosen the two fastening screws (a/f 10).

Note: In the case of vehicles with Servotronic, an electric plug must also be removed from the steering gear.





33. Loosen the clamping screw from the steering column on the steering gear and remove it. The screw must not be re-used. Force the steering column up and off the steering gear.
34. Disconnect the electric plug on the steering gear (Servotronic only).





35. Disconnect the heat exchanger coolant lines in the left wheel housing. Approximately 2 liters of coolant will flow out when you do this.





Note: In vehicles with an off road stabilizer, the two hydraulic lines under the steering gear must be disconnected. Counter with an open-ended wrench when doing this.





36. Remove the complete exhaust system from the connection point on the catalytic converter to the tailpipes. To do this, support the exhaust system with a transmission jack. Loosen the connection clip and slide to the rear. Then release the rubber elements at the front of the exhaust system.





37. Release the rubber elements at the rear of the exhaust system and remove the exhaust system.





38. Release the catalytic converter holders on the body (two screws each). If it is necessary to remove the catalytic converters for subsequent work, the four fastening screws on the transmission cross member can now be unscrewed.

Note:
^ When removing and installing the cardan shaft, is essential to observe the procedures described in the respective chapters.
^ The following points serve only to jog the memory.





^ The cardan shaft is balanced with the transmission flange in the factory. When components are removed, their position must be marked using a felt tip pen.





39. Remove the rear cardan shaft. Release the cardan shaft with compensating disc from the transmission flange.





40. Detach cardan shaft at the rear axle differential.

Note: When removing the cardan shaft, first press it away from the transmission flange.





41. Release the center bearing. To do this, loosen the 6 fastening screws. Remove the cardan shaft from the vehicle.





42. Disconnect the electrical connections -1, 2 and 3-.





Separating the connections on the transfer box

Note: Do not undo screw -B-.





43. Detach the selector lever cable on the transmission. To do this, press the ball socket away from the transmission. Then pull out top sheetmetal clip -A- and remove the cable in an upward direction.

Note: If the transmission is to be separated from the engine after removal, the two lower fastening screws on the transmission bell housing and front cardan shaft should be removed at this point, since access to the lifting platform will be impaired.





44. Disconnect the lower feed line on the servo oil cooler.





45. Disconnect the electric plug on the off road stabilizer at the front left.

Note: Because of the high loosening torque, the six fastening screws on the suspension subframe can now tee loosened. Loosen the screws bye maximum of one turn.





46. Place the elevating platform under the engine and raise it. When you do this, ensure that the positioning guides of the elevating platform are inserted into the body.





47. Secure the spring struts. To do this, turn the rubber discs upwards until they are set under the steering knuckle. Then tighten the retaining brackets on the wheel hub and elevating platform.





48. Release the transmission transverse bar. To do this, loosen the 4 fastening screws -A- .
49. Secure the engine/transmission combination. Then secure the mounting mandrels on the engine transverse bar with the retaining screws.





50. Loosen the four fastening screws on the suspension subframe and the two fastening screws on the engine transverse bar.
51. Lower the lift truck slowly by approximately 20 to 30 cm. When this is done, a second person should ensure that there is sufficient clearance around the engine compartment and wheel housings.

Note:
^ It is easier to remove the air-conditioning compressor from its installation position when the engine has already been lowered a little.
^ The air-conditioning compressor lines must not be kinked or twisted.

52. Loosen power steering pump. To do so, undo the two front fastening screws and turn the belt pulley as required. Then loosen the rear fastening screw.





53. Loosen the three fastening screws and disconnect the electric plug from the air-conditioning compressor. Set the air-conditioning compressor aside.





54. The air-conditioning compressor must be secured with a piece of wire.

Note: Before moving the lift truck, mark the position of the wheels on the workshop floor with a piece of chalk. This makes it easier to position the truck again for re-installation.





55. Lower the lift truck fully. When doing this, a second person should ensure that there is sufficient clearance around the engine compartment and wheel housings.