Installing Engine

Installing engine.
Tools

Tools and materials
Required tools
The following tools are described in the Workshop Equipment Manual, Chapter 3.0.13 "WE 1206" (exceptions are noted).

Lifting Platform:

Tools Overview:

Installing engine

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

Overview Of V8 Engine:

Lifting The Engine With A Workshop Crane:

1. Suspend the engine at the jacking points provided on a workshop crane and set down on the front-axle carrier.
2. Secure the engine against tipping. To do this, attach the locks on the engine cross member and raise the support under the oil pan until it touches the oil pan.
3. Fit the transmission onto the engine.
4. Install pre- and main catalytic converters.

Catalytic Converter Support:

5. Tighten the fastening screw on the catalytic converter support. Tightening torque 17 ft. lbs..
6. Bolt the main catalytic converter supports onto the transmission cross member.
7. Remove the support from under the oil pan and remove the tipping protection from the engine cross member.

Oxygen Sensor Cable For The Rear Oxygen Sensors:

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

Note:
^ When moving the unit into the body, ensure that the shift cable is on the transmission.

Air-Conditioning Compressor:

^ When moving the unit into the body, put the air-conditioning compressor into the installation position.

Note: Position the front-axle carrier back in the original, marked installation position and be careful not to damage adjacent parts.

Guiding The Engine/Transmission Combination Into The Body With The Lifting Platform:

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

Fastening Screws For Front-Axle Carrier And Engine Carrier:

13. Tighten the 6 new front-axle carrier engine carrier screws' Initial tightening 89 ft. lbs.. Final tightening - torque angle 180°.

Fastening Screws For Transmission Cross Member:

14. Install transmission cross member.

Support Of Wheel Hub:

15. Loosen the lateral supports on the wheel hubs.
16. Lower the lifting platform slowly and remove.

Connector To Transmission:

Connector To Transfer Box:

17. Connect electric connector -1, 2 and 3- on the transmission and clip in the wiring harness.
18. Mount selector lever cable.

Note:

Hose Clamp And Sheetmetal Clip:

^ In the Cayenne Turbo (M48/50), 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 fitted correctly.

Locking Clip And Line To Ambient Air Valve:

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

Spring Band Clamp On Servo Line:

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

Note: For vehicles with Servotronic, the electric connector on the steering gear must also be connected.

Steering Column On Steering Gear:

20. Fit the steering column onto the steering gear.

Fastening Screws For Heat Protection Shield To Steering Gear:

21. Fit the heat protection shield on the steering gear by means of 2 fastening screws. Tightening torque 7.5 ft. lbs.

Heater Coolant Lines On The Left Side Member:

22. Slide the heater coolant lines on the left side member and mount the clips.

Coolant Connection Piece:

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

ATF Lines:

24. Connect the ATF lines to the radiator. Remove the plugs and mount the lines.

Generator Ground Point:

25. Mount the ground point of the generator on the right side member. Tightening torque 15 ft. lbs..

Catalytic Converter On Elbow:

26. Tighten the catalytic converter fastening on the body.

Installing Cardan Shaft:

27. Install cardan shaft. --> '393519 Removing and installing rear cardan shaft - section on "Installing"'.

Exhaust System On Transmission Jack:

28. Install the exhaust system. Move the exhaust system to its installation position using a transmission jack. --> '260119 Removing and installing exhaust system - section on "Installing"'.

Fastening Screws Of Front Transverse Strut:

29. Install the front transverse strut under the radiators. To do this, tighten the four fastening screws. Tightening torque 17 ft. lbs.

Front Apron Fastening Screw On Transverse Strut:

30. Screw the front apron onto the transverse strut. Tightening torque 3.5 ft. lbs..
31. Lower the vehicle halfway.

Note:

Compressed Air Line:

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

Sensor For Headlight Leveling System:

^ Then connect the headlight levelling system sensor.

Brake Lines In The Wheel Housings:

32. Tighten the brake lines on the left and right in the wheel housings.

Electric Connections Of The Spring Struts:

33. Fit the electric connections of the spring struts. To do this, connect cable -1- and then fasten supports -2 and 3-.
34. Lower the vehicle.

Mounting The Fastening Screws Of The Spring Struts:

Spring Strut View From The Wheel Housing:

35. Mount the three fastening screws on the left and right spring struts from above (engine compartment side). -arrows- --> 'Tightening torques for front axle'

B+ Transfer Point On Left Spring Dome:

36. Mount B+ transfer point on left spring dome. Tightening torque 17 ft. lbs..

Spring Band Clamp On Servo Line To Reservoir:

37. Connect the servo line to the reservoir and mount the spring band clamp. Then fill the container with Pentosin.

Line From Carbon Canister And Fuel Line:

38. Connect the line from carbon canister -2- to the plenum panel splash panel until it audibly engages and tighten fuel line -1-. Tightening torque 26 ft. lbs..

Plug Connections For Oxygen Sensors:

39. On the left and right of the plenum panel splash panel, connect the oxygen sensor plug connections in front of and behind the catalytic converter and lay the cables so they are not subject to chafing.

Fastening Screws For Vacuum Pump Support:

Note: In the Cayenne Turbo, the support for the vacuum pump must also be screwed into position. Tightening torque 7.5 ft. lbs..

Vacuum Line And Lines On Coolant Reservoir:

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

Control Unit, Connector, And Ground Point:

41. Lay the engine wire harness into the plenum panel. Mount the rubber sleeve into the middle opening. Then guide the control unit connector to the right. Connect the control unit, connector, and ground point. Tightening torque 7.5 ft. lbs..

Fastening Screws For The Central Electrical System Box:

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

Bayonet Screws For Plenum Chamber Cover:

44. Mount the plenum chamber cover. Do not forget the electric connector for the air-quality sensor. Mount the 4 bayonet screws -A-.

Drive Belt:

45. Position and tighten drive belt on all pulleys.

Upper Left Coolant Connection Piece:

46. Connect the upper left coolant connection piece to the radiator. The connection piece must engage audibly.

Torque Converter Support:

47. Mount the torque support with new lock nuts. Tightening torque 44 ft. lbs.. Tightening torque 44 ft. lbs..

Air-Cleaner Element:

48. Insert the air-cleaner 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.

Air Cleaner With Cover:

49. 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 sheetmetal clips. The coolant overflow hose must also be clipped onto the air cleaner housing of cylinder bank 1-4. Connect the electric connectors of the hot film mass air flow sensors.

Control Lines Of The Ambient Air Valves On T-Piece:

Note: In the Cayenne Turbo (M48/50), the control lines of the ambient air valve on the T-piece must also be connected.

Clipping In Lines:

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

Vacuum Line:

50. Attach the vacuum line to the underside of the Y-shaped pipe.

Hose Clamps On The Y-Shaped Pipe:

51. Fit the Y-shaped pipe to the left and right and tighten the hose clamps.

Boost-Pressure Sensor:

Note: In the Cayenne Turbo (M48/50), the boost pressure sensor -3- must also be connected.

Fastening Bolt Y-Shaped Pipe On Throttle Adjuster:

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

Connecting Cable To Throttle Adjuster:

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

Rubber Elements In Cover On Ball Head Support:

54. Press the 4 rubber elements in the cover onto the 4 ball head supports. The mounts must be felt to engage.

Subsequent work
Installing engine - subsequent work
1. Fill and bleed the cooling system. --> Filling the cooling system (includes bleeding)'
2. Bleed brake system.
3. Connect battery.
4. Mount the wiper arms.
5. Mount engine compartment covers.
6. Check ATF level.
7. Bleed power-assisted steering.
8. Bleed off road stabilizer if necessary.
9. Mount front wheels
10. Perform suspension alignment.

Engine Guard:

11. Fit engine guard.
12. Perform a test drive with the vehicle. Check the fluid level in the reservoir after the coolant circuit has cooled again and, if necessary, fill up to the max marking with coolant.
13. Check engine oil level.