Removing Engine
Removing and installing V8 4.5 l engineTools
Tools and materials
Required tools
The following tools are described in the Workshop Equipment Manual, Chapter 3.0.13 "WE 1206" (exceptions are noted).
Preliminary work
Special equipment-specific features are described in the notes.
^ If the engine is to be replaced by a new one, make sure the air conditioner is evacuated and the existing air-conditioning compressor removed during removal of the engine as the replacement engine is delivered with the new compressor mounted.
^ Fix steering wheel with wheels in straight-ahead position (engage steering column lock or clamp steering wheel in center position with steering wheel holder)! If this is not done, the airbag contact unit will have to be put in center position after installation of the steering gear!
^ 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 engine compartment covers.
^ Allow engine to cool down.
Removing V8 4.5 l engine
Removing engine
Special features that are required for the equipment or relate to the Cayenne Turbo (M48/50) are described in the notes.
1. Remove engine guard with transverse strut.
2. Drain coolant.
3. Remove both wiper arms.
Note: The air quality sensor is located on the cover of the radiator tank. This must be unclipped.
4. Loosen the 4 bayonet screws -A- on the plenum panel cover. Then lift the cover in the middle, release left and right and remove from the vehicle.
5. Disconnect the engine wire harness on the right-hand side of the vehicle. To do this, unplug the control unit and disconnect the ground point.
6. Open the cover of the central electrical system on the left side of the vehicle. To do this, loosen the four Torx screws.
7. Disconnect the connectors from the engine wire harness (white, red, black and brown). Remove the wiring harness from the retaining clips and lay it down on the engine.
8. Disconnect B+ transfer point at the left of the engine compartment.
9. Pull the cover of the throttle body up and off.
10. Separate the electric 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 (M48/50), the boost pressure sensor must also be disconnected.
11. 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.
12. Remove the fastening bolts. To do this, take hold of the bolt by the rubber ring with pliers and pull it out.
13. Pull off the Y-shaped pipe from the throttle body.
14. Disconnect the mass air flow connections. To do this, loosen the hose clamps to the left and right on the bellows and pull the bellows off the mass air flow (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 row 5 - 8 should be removed at this point.
^ To do this, loosen the 4 fastening screws. Unclip the design cover from the intake system and slide out at an angle towards the front.
15. Loosen the 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 circlip -1- inwards and pull off adapter -2-.
16. Remove the air cleaner covers on the right and left.
17. Remove the filter elements.
18. Disconnect the 2 respective oxygen sensor connectors (brown, black) at the left and right of the water splash panel and unclip the cable from the supports.
Note: In the Cayenne Turbo (M48/50), the support for the vacuum pump must also be undone. To do this, unscrew the two fastening screws and press the pump forward slightly.
19. Disconnect the 2 coolant lines and vacuum line on the right side of the engine compartment.
WARNING Servo oil is aggressive!
^ Possible danger of injury or damage (swollen hoses, skin irritation, danger of slipping, etc.)
^ Before lines are opened, place a cloth underneath them!
^ Components that come into contact with servo oil must be cleaned IMMEDIATELY with water!
^ Take suitable protective measures (e.g. gloves, safety goggles, oil binding material)
20. Empty the servo oil reservoir with a syringe. Next, remove the hose from the reservoir. Close the open connections with plugs.
21. Loosen the torque support. To do this, remove the screw on the engine and loosen the screw on the body. Then pivot up the torque support.
DANGER Fuel can escape when fuel line is disconnected.
^ Risk of fatal injury!
^ Damage to skin
^ Do not work on fuel system if engine is hot!
^ Do not smoke, avoid fire and naked flames!
^ Wear fuel-resistant protective gloves and goggles.
^ Attach warning sign to vehicle in a clearly visible position.
22. Disconnect fuel line -1- and line -2- from the carbon canister on the plenum panel splash panel.
23. Loosen the 3 fastening screws 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 panel. Replace screws.
24. Disconnect the coolant feed and return lines from the radiator. To do this, pull out the securing clip and pull off the connection. The clips 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.
^ If the engine is to be replaced by a new one, make sure the air conditioner is evacuated and the existing air-conditioning compressor removed during removal of the engine as the replacement engine is delivered with the new compressor mounted.
25. Slacken the drive belt (a/f 30) and remove from the tensioning roller.
Note: In the Cayenne Turbo (M48/50), the control lines of the ambient air valves on the T-piece should be pulled off.
Note:
^ In the case of vehicles with air suspension, the compressed air line on the spring strut must also be disconnected. Loosen the line carefully and allow the remaining pressure to escape. Loosen the threaded joint completely only when the line is fully depressurized.
^ The electric plug connection of the height sensor must be disconnected in vehicles with air suspension or automatic headlight leveling system.
26. Disconnect electric plug -1- on the spring struts in the wheel housing. Then unclip the support -2 and 3-. Tie the cable on the spring strut.
27. Disconnect the brake lines in the wheel well to the left and right.
28. Disconnect the ground point on the right side member.
WARNING ATF!
^ Possible danger of injury or damage (swollen hoses, skin irritation, danger of slipping, etc.)
^ Before lines are opened, place a cloth underneath them!
^ Components that come into contact with ATF must be cleaned IMMEDIATELY with water!
^ Take suitable protective measures (e.g. gloves, safety goggles, oil binding material)
^ Collect emerging ATF!
29. Disconnect the ATF lines on the cooler. To do this, loosen the fastening screw and pull off the line. Seal open lines with a plug.
30. Remove the heat protection shield on the steering gear connection. To do this, loosen the 2 fastening screws.
Note: In the case of vehicles with Servotronic, an electric plug must also be removed from the steering gear.
31. 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.
32. Disconnect the electric plug on the steering gear (Servotronic only).
33. Disconnect the heat exchanger coolant lines in the left wheel housing below. Approx. 2 liters of coolant will flow out when you do this.
34. Remove the complete exhaust system from the connection point on the catalytic converter to the tailpipes.
35. Remove rear cardan shaft.
36. Disconnect electrical connections -1,2 and 3- on the transmission and unclip the wiring harness.
37. Remove the heat shield on the left transmission side. To do so, loosen the 3 fastening screws and take out the heat protection shield.
Note: Do not loosen nut.
38. 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 housing and front cardan shaft should be removed at this point, since access to the lifting platform will be impaired.
WARNING Servo oil is aggressive!
^ Possible danger of injury or damage (swollen hoses, skin irritation, danger of slipping, etc.)
^ Before lines are opened, place a cloth underneath them!
^ Components that come into contact with servo oil must be cleaned IMMEDIATELY with water!
^ Take suitable protective measures (e.g. gloves, safety goggles, oil binding material)
39. Disconnect the lower line on the servo oil cooler.
Note:
^ On the Cayenne Turbo (M48/50), the hose connections on the turbochargers must also be loosened. To do this, pull out locking spring -1- on the turbocharger adapter. Then loosen 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 when the engine has already been lowered a little.
^ The air-conditioning compressor lines must not be kinked or twisted.
^ The lines of the air-conditioning compressor remain mounted, so the refrigerant does not need to be evacuated.
^ If the engine is to be replaced by a new one, make sure the air conditioner is evacuated and the existing air-conditioning compressor removed during removal of the engine as the replacement engine is delivered with the new compressor mounted.
40. Loosen the 3 fastening screws and disconnect the electric plug from the air-conditioning compressor. Set the air-conditioning compressor aside.
41. The air-conditioning compressor must be secured with a piece of wire.
Note: For installation, it is a good idea to mark the installation position of the front axle carrier diagonally at at least two places on the body. To do this, place the marks vertically with respect to the floor of the body using a felt-tip pen (e.g. mark along the front-axle carrier mount with the pen).
42. Mark the installation position of the front axle carrier diagonally at at least two places on the body.
Note: Because of the high loosening torque, the 6 fastening screws on the front-axle carrier can now be loosened. Loosen the screws by a maximum of one turn.
43. 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.
44. 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.
45. Loosen the transmission cross member. To do this, loosen the 4 fastening screws -A-.
46. Secure the engine/transmission combination. Then secure the mounting mandrels on the engine transverse bar with locking screws.
47. Loosen the 4 fastening screws on the front-axle carrier and the 2 fastening screws on the engine transverse bar.
Note: When lowering the engine, make sure that cables or lines do not get mounted accidentally between engine and body. Thus a second person should make sure that the cables and lines do not get caught.
48. 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.