Installing Engine
WM 100119 Removing and installing V8 4.5-liter engine (continued)Installing V8 4.5-liter engine
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 jacking points provided on a workshop crane and set down on the front-axle carrier.
Lifting the engine with a workshop crane
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.
5. Tighten the fastening screw on the catalytic converter support.
Catalytic converter support
6. Bolt the main catalytic converter holders onto the transmission cross member.
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 connector on the engine.
Oxygen sensor cable for the rear oxygen sensors
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.
Information:
When moving the unit into the body, ensure that the shift cable is on the transmission.
When moving the unit into the body, put the air-conditioning compressor into installation position.
Air-conditioning compressor
Information:
Position the front-axle carrier back in the original, marked installation position and be careful not to damage adjacent parts.
12. Raise the engine/transmission unit 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.
Guiding engine/transmission unit into body using lifting platform
13. Tighten the six new front-axle carrier engine carrier screws. - Initial tightening: 120 Nm (89 ftlb.) - Final tightening - torque angle: 180°
Fastening screws for front-axle carrier and engine carrier
14. Install transmission cross member -A-.
Fastening screws for transmission cross member
15. Loosen the lateral supports on the wheel hubs.
Support for wheel hub
16. Lower the lifting platform slowly and remove.
17. Connect electric connector -1, 2 and 3- on the transmission and clip in the wiring harness.
Connector on transmission
Connector on transfer gear
18. Mount selector lever cable.
Information:
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.
Hose clamp and sheetmetal clip
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.
Locking clip and line to ambient air valve
19. Push the servo oil line onto the oil cooler and mount the spring band clamp.
Spring band clamp on servo line
Information:
For vehicles with Servotronic, the electric connector on the steering gear must also be connected.
20. Fit the steering column onto the steering gear.
Steering column on steering gear
21. Fit the heat protection shield on the steering gear by means of 2 fastening screws. - Tightening torque: 10 Nm (7.5 ftlb.)
Fastening screws for heat protection shield to steering gear
22. Slide the heater coolant lines on the left side member and mount the clips.
Heater coolant lines on the left side member
23. Push on the coolant connection piece on the lower left on the radiator. The connection piece must engage audibly.
Coolant connection piece
24. Connect the ATF lines to the radiator. Remove the plugs and mount the lines.
ATF lines
25. Mount the ground point of the generator on the right side member. - Tightening torque: 20 Nm (15 ftlb.)
Generator ground point
26. Tighten the catalytic converter fastening on the body.
Catalytic converter on elbow
27. Install cardan shaft.
Installing cardan shaft
28. Install the exhaust system. Move the exhaust system to its installation position using a transmission jack.
Exhaust system on transmission jack
29. Install the front transverse strut under the radiators. To do this, tighten the four fastening screws. - Tightening torque: 23 Nm (17 ftlb.)
Fastening screws of front transverse strut
30. Screw the front apron onto the transverse strut. - Tightening torque: 5 Nm (3.5 ftlb.)
Front apron fastening screw on transverse strut
31. Lower the vehicle halfway.
Information:
In the case of vehicles with air suspension, the compressed air lines must also be screwed on.
Compressed air line
Then connect the headlight levelling system sensor.
Sensor for headlight levelling system
32. Tighten the brake lines on the left and right in the wheel housings.
Brake lines in the wheel housings
33. Fit the electric connections of the spring struts. To do this, connect cable -1- and then secure holders -2 and 3-.
Electric connections of the spring struts
34. Lower the vehicle.
35. Mount the three fastening screws on the left and right spring struts from above (engine compartment side) -arrows-.
Mounting the fastening screws of the spring struts
Spring strut view from the wheel housing
36. Mount B+ transfer point on left spring dome. - Tightening torque: 23 Nm (17 ftlb.)
B+ transfer point on left spring dome
37. Connect the servo line to the reservoir and mount the spring band clamp. Then fill the container with Pentosin.
Spring band clamp on servo line to reservoir
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: 35 Nm (26 ftlb.)
Line from carbon canister and fuel line
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.
Plug connections for oxygen sensors
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.
Vacuum line and lines on coolant reservoir
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: 10 Nm (7.5 ftlb.)
Control unit, connector, and ground point
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.
Fastening screws for the central electrical system box
43. Check whether the wiring harness is laid correctly. Close all fixing clips.
44. Mount the plenum chamber cover. Do not forget the electric connector for the air-quality sensor. Mount the 4 bayonet screws -A-.
Bayonet screws for plenum chamber cover
45. Position and tighten drive belt on all pulleys.
Drive belt
46. Connect the upper left coolant connection piece to the radiator. The connection piece must engage audibly.
Upper left coolant connection piece
47. Mount the torque support with new lock nuts. - Tightening torque: 60 Nm (44 ftlb.) - Tightening torque: 60 Nm (44 ftlb.)
Torque support
48. Insert the air-cleaner element.
Air-cleaner element
Information:
In the case of vehicles with air suspension, the line of the air compressor must also be connected on the left air cleaner 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.
Air cleaner with cover
Information:
In the Cayenne Turbo (M48/50), the control lines of the ambient air valve on the T-piece must also be connected.
Control lines of the ambient air valves on T-piece
Information:
Clip on the leads when mounting the Y-shaped pipe on the bottom.
Clipping in lines
50. Attach the vacuum line to the underside of the Y-pipe.
Vacuum line
51. Fit the Y-pipe to the left and right and tighten the hose clamps.
Hose clamps on the Y-pipe
Information:
In the Cayenne Turbo (M48/50), the boost pressure sensor -3- must also be connected.
Boost-pressure sensor
52. Slide the Y-pipe onto the throttle adjuster. Then insert the left and right fastening bolts. Turn both bolts 45° clockwise.
Fastening bolt Y-pipe on throttle adjuster
53. Connect the throttle adjuster. The connector must lock with an audible click. Clip the connecting cable into the sheetmetal holder.
Connecting cable to throttle adjuster
54. Press the 4 rubber elements in the cover onto the 4 ball head supports. The mounts must be felt to engage.
Rubber elements in cover on ball head support
Subsequent work
Subsequent work
1. Fill and bleed the cooling system.
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.
11. Fit engine guard.
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.