Installing Engine

Installing M48/00 engine














Required tools

Installing engine
Special features that are required for the equipment or relate to the Cayenne Turbo (M48/50) are described in the notes.





1. Suspend the engine at the mounting points provided on a workshop crane and set down on the suspension subframe.
2. Secure the engine against tipping. To do this, attach the safety locks on the engine cross member and raise the support under the oil pan until it touches the oil pan.
3. Install the transmission and connect it to the engine.
^ Tightening torque, transmission screw fittings: 80 Nm (59 ft. lbs.).
^ Tightening torque, converter screw fittings: 85 Nm (63 ft. lbs.); replace screws.





4. Install pro- and main catalytic converters with new seals. Tighten the 3 fastening screws on the manifold flange to 23 Nm (17 ft. lbs.)





5. Tighten the fastening screws on the catalytic converter support to 23 Nm (17 ft. lbs.).
6. Bolt the main catalytic converter holders onto the transmission cross member. Tightening torque 23 Nm (17 ft. lbs.).
7. Remove the support from under the oil pan and remove the tipping protection from the engine cross member.





8. Clip the oxygen sensor cable of the rear oxygen sensors into the holders and place the plug on the engine.
9. Pre-fit the drive belt. Mount the drive belt on the belt pulleys as far as possible.
10. Position the lift truck under the body.
11. Raise the body to a comfortable working height with the lifting platform.





Note:
^ When moving the unit into the body, ensure that the selector cable is on the transmission.
^ When moving the unit into the body, fit the air conditioning compressor at the same time.





12. Raise the the engine/transmission combination into the body with the lift platform. Ensure sufficient clearance. The insertion guides on the lift truck must fit into the holes in the body.





13. Tighten the 6 new suspension subframe engine carrier screws. Tightening torques: 100 Nm (74 ft. lbs.) + 180°





14. Secure transmission cross member with new screws -A-. Tightening torque: 50 Nm (37 ft. lbs.) + 90°





15. Release the lateral supports on the wheel hubs.
16. Lower the lift truck slowly and remove.





17. Connect the electrical plugs -1, 2 and 3- to the transmission.





Plugs on the transfer box -1, 2 and 3





18. Mount the selector cable.





19. Fit the heat shield. Tighten the 3 fastening screws to 10 Nm (7.5 ft. lbs.).





20. Tighten the air conditioning compressor. Tighten the front screws with 23 Nm (17 ft. lbs.), the rear screws with 46 Nm (34 ft. lbs.). Then mount the electrical plugs.





Note:
^ In the Cayenne Turbo (M48150), the hose connections on the turbochargers must also be fastened. To do this, connect pressure pipe -2- and tighten the hose clamp. Then fit the lead of the charge air cooler. The connection piece must engage audibly. Ensure that sheetmetal clip -1- is mounted correctly.





^ Connect the hose line on the left charge air cooler. Ensure that locking clip -1- is mounted correctly. Connect the lead to ambient air valve -2- and fit the spring band clamp.





21. Push the servo oil line onto the oil cooler and mount the spring band clamp.

Note: In the case of vehicles with Servotronic, the electronic plugs on the steering gear must also be connected.





22. Slide the steering column onto the steering gear and tighten the new screw. Tightening torque: 35 Nm (26 ft. lbs.) + 90°





23. Fit the heat shield on the steering gear by means of 2 fastening screws. Tightening torque: 10 Nm (7.5 ft. lbs.).





24. Slide the heater coolant lines on the left side member and mount the space-saving clamps.





25. Push on the coolant connection piece on the lower left on the radiator. The connection piece must engage audibly.





26. Connect the ATF lines to the cooler. Remove the sealing plugs and mount the top line first. Subsequently, mount the bottom line and tighten the fastening screws with 10 Nm (7.5 ft. lbs.).





27. Mount the ground point of the generator on the right side member. Tightening torque: 23 Nm (17 ft. lbs.)





28. Tighten the catalytic converter fastening on the body. Tightening torque: 23 Nm (17 ft. lbs.)





29. Installing cardan shaft.
30. Slide the new exhaust clamps onto the tailpipes of the catalytic converters.

Note: Use a transmission jack to support the exhaust system during installation.





31. Install the exhaust system. Move the exhaust system to its installation position using a transmission jack.





32. Tighten the fastening screws in the middle section and at the front to 23 Nm (17 ft. lbs.).





33. Tighten the two fastening screws at both the left and right of the rear muffler. Tightening torque: 23 Nm (17 ft. lbs.)





34. Connect the exhaust system. Slide the new exhaust clamps rearward from the catalytic converter and over the exhaust pipes. The screw connection points must point vertically downwards. Exhaust clamp fighting torque: 60 Nm (44 ft. lbs.).





35. Install the front cross-member under the radiator. Tighten the 4 fastening screws (M8 x 25) to 23 Nm (17 ft. lbs.).





36. Screw the engine guard onto the transverse strut.
37. Lower the vehicle halfway.





Note:
^ In the case of vehicles with air suspension, the compressed air lines must also be screwed on.





^ Then connect the headlight beam adjustment sensor.





38. Tighten the brake lines on the left and right in the wheel wells.





39. Fit the electrical connections of the spring struts. To do this, connect cable -1- and then fasten holders -2 and 3-.
40. Lower the vehicle.





41. Mount the 3 fastening screws (M10 x 37) of the left and right spring struts from above. Tightening torque 50 Nm (37 ft. lbs.) + 90°.





42. Mount B+ transfer point on left spring dom. Tightening torque: 23 Nm (17 ft. lbs.)





43. Connect the servo line to the expansion tank and mount the spring band clamp. Then fill the tank with Pentosin.





44. On the radiator tank splash panel, tighten carbon canister wire -2- and fuel line -1- to 35 Nm (26 ft. lbs.).





45. Connect the oxygen sensor plug connectors on the left and right in front of and behind the catalytic converter and lay the cables so they are not subject to chafing.





Note: In the Cayenne Turbo, the holder for the vacuum pump must also be screwed into position. Tightening torque: 10 Nm (7.5 ft. lbs.)





46. Connect the vacuum line to the right spring dome and mount the spring band clamp. Then mount the 2 lines on the coolant expansion tank and secure with spring band clamps.





47. Lay the engine wiring harness in the plenum chamber. Mount the rubber sleeve in the middle opening. Then guide the control module plug to the right. Connect the control unit, plug and ground point. Ground point tightening torque: 10 Nm (7.5 ft. lbs.).





48. Plug in the 4 plugs (red, brown, white and black) in the left-hand central electrical system box. Then mount the cover using four Torx screws.
49. Check whether the wiring harness is laid correctly. Close all fastening clips.





50. Mount the plenum chamber cover. Do not forget the electric plug. Mount the four bayonet screws -A- .





51. Place the drive belt on all pulleys and tension. Then check whether the installation is correct.





52. Connect the upper right coolant connection piece to the radiator. The connection piece must engage audibly.





53. Mount the torque support with new screws. Tightening torques: on the body 60 Nm (44 ft. lbs.); on the engine 60 Nm (44 ft. lbs.).





54. Insert the air filter element.

Note: In the case of vehicles with air suspension, the line of the air compressor must also be connected on the left air cleaner cover.





55. Mount both air cleaners with cover. Insert the air cleaners in the housings and slide on the covers from the top downwards. Then close the two respective metal clamps. The coolant overflow hose must also be clipped onto the air cleaner housing of cylinder bank 1-4. Connect the electric plugs of the hot film mass air flow sensors.





View of the coolant overflow hose





Note: In the Cayenne Turbo (M48150), the control leads of the ambient air valve on the T-piece must also be connected.





Note: Clip on the leads when mounting the Y pipe on the bottom.





56. Attach the vacuum line to the underside of the Y pipe.





57. Fit the Y pipe to the left and right and tighten the hose clamps.





Note: In the Cayenne Turbo (M48150), boost pressure sensor-3- must also be connected.





58. Slide the Y pipe onto the throttle adjuster. Then insert the left and right fastening bolts. Turn both bolts 45° clockwise.





59. Connect the throttle adjuster. The connector must engage audibly. Clip the connecting cable into the sheetmetal holder.





60. Press the 4 rubber elements in the cover onto the 4 ball socket holders. The fastening elements must be felt to engage.
61. Bleed and fill the cooling circuit.
62. Bleed the brake system
63. Connect battery.
64. Install the windscreen wipers. Switch on the wiper motor briefly. Then mount the wiper arms. Tightening torque 32 Nm (24 ft. lbs.).
65. Fit the engine compartment cover.
66. Check ATF level.
67. Bleed power-assisted steering.
68. Mount front wheels. Tightening torque: 160 Nm (118 ft. lbs.).
69. Perform suspension alignment.





70. Install underride guard.
71. Install seat. Tightening torque: 45 Nm (33 ft. lbs.).








Torques