Removing Engine
Removing engine
Required tools
Removing engine
Special features that are required for the equipment or relate to the Cayenne Turbo (M48/50) are described in the notes.
Requirements:
^ Turn wheels to straight-ahead position.
^ Position the vehicle at the take-up points provided on a lifting platform.
^ Put on the protective covers.
^ Produce the OBD II log.
^ 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 struts.
View shows transverse strut
2. Release the engine guard on the underside. To do this, loosen the four fastening screws (M6 x 25).
3. Remove the front transverse strut under the radiators. 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 three fastening nuts. Remove the wipers from the drive shafts using a puller.
Puller for wiper arm
Note: The air quality sensor is located on the cover of the radiator tank. This must be un-clipped.
6. Loosen the four bayonet screws -A- on the radiator tank cover. Lift the cover in the middle, pull it out to the 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 module 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 engine wiring harness (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.
11. Pull the cover of the throttle body vertically upwards.
12. Separate the electrical connection from the throttle adjuster. To do this, press on the plug at the top and bottom and, at the same time, pull it off. Unclip the cable from the sheetmetal holder.
Note: In the Cayenne Turbo (M48150), the boost pressure sensor must also be disconnected.
13. Release the fastening bolts on the throttle body. To do this, twist both bolts through 45° in an anti-clockwise direction. The dot on the bolt must appear as illustrated in the figure.
14. Remove the fastening bolts. To do this, take hold of the bolt by the rubber ring with a pliers and pull it out.
15. Pull off the Y pipe from the throttle body.
16. Disconnect the air flow sensors. To do this, undo the hose clamps on the left and right on the bellows and pull the bellows off the air flow sensors (in the Cayenne Turbo, pull them off the pressure pipes).
Note:
^ If the engine is to be subsequently transported by crane, the right-hand design cover on cylinder bank 5-8 should be removed at this point.
^ To do this, loosen the four fastening screws. Unclip the design cover from the intake system and slide out at an angle towards the front.
17. Loosen the retaining clamps on the air cleaner housing.
Note: In vehicles with air suspension, the suction line of the compressor must also be removed on the right air cleaner cover. To do this, unclip the green cap, press snap ring -1- inwards and pull off flange -2-.
18. Remove the air cleaner covers on the right and left.
19. Remove the filter elements.
20. Disconnect the two oxygen sensor plugs (brown, black) at the left and right of the water splash panel and unclip the cable from the holders.
Note: In the Cayenne Turbo (M48150), the holder for the vacuum pump must also be undone. To do this, unscrew the two fastening screws and press the pump forward slightly.
21. Disconnect the two coolant lines and the 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 which 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. Detach the torque support. To do this, remove the screw on the engine and loosen the screw on the body. Fold up the torque support.
24. Disconnect fuel line -1- and line -2- from the carbon canister on the radiator tank splash panel.
25. Undo the three fastening screws (a/f 16) on the left and right spring struts. The screws are loosened from inside the engine compartment. One of the three screws for each spring strut is located in the radiator tank. The screws must not be reused.
26. 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 interchanged.
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.
27. Slacken the drive belt (a/f 30) and remove from the tensioning roller.
Note: In the Cayenne Turbo (M48150), the control leads of the ambient air valve on the T-piece should be pulled off.
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 fullydepressurizee.
^ The electrical plug connection of the height sensor must be disconnected in vehicles with air suspension or automatic headlight beam adjustment.
28. 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.
29. Disconnect the brake lines in the wheel well to the left and right.
30. Disconnect the ground point (a/f 13) on the right side member.
Warning: Emerging ATF!
^ Danger of slipping!
^ Collect emerging ATF!
31. 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.
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. The screw must not be reused. 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.
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 connecting clamps and slide to the rear. Then release the rubber elements at the front of the exhaust system.
37. Now 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, it is essential to observe the procedures described in the respective chapters.
^ The following points are intended 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 six fastening screws. Remove the cardan shaft from the vehicle.
42. Disconnect electrical connections -1, 2 and 3- on the transmission.
Separating the connections on the transfer box
43. Remove the heat shield on the left transmission side. To do so, undo the three fastening screws and take out the heat shield.
Note: Do not undo screw -B- .
44. 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.
45. Disconnect the lower feed line on the servo oil cooler.
Note:
^ In the Cayenne Turbo (M48150), the hose connections on the turbochargers must also be loosened. To do this, pull out locking spring -1- on the turbocharger flange. Then undo hose clamp -2- of the pressure pipe on the turbocharger.
^ Disconnect the connection on the charge air cooler. To do this, remove locking clip -1- and pull off the line. Line -2- of the ambient air valve must also be disconnected on the right-hand side of the vehicle. To do this, remove the spring band clamp and pull off the line.
Note:
^ It is easier to remove the air-conditioning compressor from its installation position if the engine has already been lowered a little.
^ The air-conditioning compressor lines must not be kinked or twisted.
46. Loosen the three fastening screws and disconnect the electric plug from the air-conditioning compressor. Set the air-conditioning compressor aside.
47. The air-conditioning compressor should be secured with a piece of wire.
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.
48. 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.
49. Secure the spring struts. To do this, turn the rubber discs upwards until they are set under the steering knuckles. Then tighten the retaining brackets on the wheel hub and elevating platform.
50. Release the transmission transverse bar. To do this, loosen the four fastening screws -A- .
51. Secure the engine/transmission unit. Then secure the mounting mandrels on the engine transverse bar with the locking screws.
52. Loosen the four fastening screws on the suspension subframe and the two fastening screws of the engine transverse bar.
53. Lower the lifting platform slowly. When this is done, a second person should ensure that there is sufficient clearance around the engine compartment and wheel housings.