Removing Engine

WM 100119 Removing and installing V8 4.5-liter engine

Tools and materials

Required tools

Lifting platform

Tools overview

Preliminary work

Preliminary work

Special equipment-specific features are described in the notes.

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-liter engine

Removing engine

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

1. Drain coolant.

Coolant drain plug

2. Remove both wiper arms.

Information:
The air quality sensor is located on the cover of the radiator tank. This must be unclipped.

3. 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.

Plenum chamber cover

4. 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.

Engine wire harness

5. Open the cover of the central electrical system on the left side of the vehicle. To do this, loosen the four Torx screws.

Torx screws for cover of central electrical system

6. 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.
7. Disconnect B+ transfer point at the left of the engine compartment.

B+ transfer point

8. Pull the cover of the throttle body up and off.

Throttle body cover

9. 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.

Throttle adjuster electric connection

Information:
In the Cayenne Turbo (M48/50), the boost pressure sensor must also be disconnected.

Boost-pressure sensor

10. 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.

Fastening bolts on throttle body

11. Remove the fastening bolts. To do this, take hold of the bolt by the rubber ring with pliers and pull it out.

Pull out fastening bolt with pliers

12. Pull off the Y-pipe from the throttle body.
13. 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).

Mass air flow connections

Information:
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.

Design cover of cylinder row 5 - 8

14. Loosen the clamps on the air cleaner housings.

Air cleaner housing clamps

Information:
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-.

Circlip and adapter

15. Remove the air cleaner covers on the right and left.

Air cleaner cover

16. Remove the filter elements.

Filter elements

17. 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 holders.

Oxygen sensor connector

18. Disconnect the 2 coolant lines and vacuum line on the right side of the engine compartment.

Coolant lines and vacuum line

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)

19. Empty the servo oil reservoir with a syringe. Next, remove the hose from the reservoir. Close the open connections with plugs.

Servo oil reservoir

20. 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.

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.

21. Disconnect fuel line -1- and line -2- from the carbon canister on the plenum panel splash panel.

Fuel line and carbon canister line

22. 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.

Fastening screws for spring struts

23. 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.

Securing clip on connection for coolant feed and return lines

Information:
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.
The lines of the air-conditioning compressor remain mounted, so the refrigerant does not need to be evacuated.
On vehicles with an air-conditioning compressor installed, e.g. through PDCC lines, the air-conditioning system has to be evacuated. The dismantling and assembly work on the engine must be continued while draining and refilling refrigerant in the air-conditioning system.

24. Slacken the drive belt (a/f 30) and remove from the tensioning roller.

Drive belt tensioning roller

Information:
In the Cayenne Turbo (M48/50), the control lines of the ambient air valves on the T-piece should be pulled off.

Control lines of the ambient air valves

Information:
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.

Compressed air line on spring strut

The electric plug connection of the height sensor must be disconnected in vehicles with air suspension or automatic headlight levelling system.

Electric plug connection for height sensor

25. Disconnect electric plug -1- on the spring struts in the wheel housing. Then unclip the holders -2 and 3-. Tie the cable on the spring strut.

Electric plug on the spring struts in the wheel housing

26. Disconnect the brake lines in the wheel housing to the left and right.

Brake lines in the wheel housing

27. Disconnect the ground point on the right side member.

Ground point of 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!

28. Disconnect the ATF lines on the radiator. To do this, loosen the fastening screw and pull off the lines. Seal open lines with a plug.

ATF lines on radiator

29. Remove the heat protection shield on the steering gear connection. To do this, loosen the 2 fastening screws.

Heat protection shield on steering gear connection

Information:
In the case of vehicles with Servotronic, an electric plug must also be removed from the steering gear.

30. Loosen the clamping screw from the steering column on the steering gear and remove it. Turn it slightly in position. The screw must not be re-used. Force the steering column up and off the steering gear.

Clamping screw on steering column

31. Disconnect the electric plug on the steering gear (Servotronic only).
32. Disconnect the heat exchanger coolant lines in the left wheel housing below. Approx. 2 liters of coolant will flow out when you do this.

Heat exchanger coolant lines in the left wheel housing

33. Remove the complete exhaust system from the connection point on the catalytic converter to the tailpipes.
34. Loosen the catalytic converter holders on the body. The screws on the cross member remain fitted.

Fastening screws to body and cross member

35. Remove rear cardan shaft.
36. Disconnect electrical connections -1,2 and 3- on the transmission and unclip the wiring harness.

Electric connections on the transmission

Connections on transfer gear

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.

Fastening screws for heat protection shield

Information:
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.

Selector lever cable on the transmission

Information:
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.

Lower line on servo oil cooler

Information:
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.

Locking spring on turbocharger adapter and hose clamp of turbocharger pressure pipe

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.

Locking clip and line of ambient air valve

Information:
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.

40. Loosen the three fastening screws and disconnect the electric plug from the air-conditioning compressor. Set the air-conditioning compressor aside.

Fastening screws and electric connector of air-conditioning compressor

41. The air-conditioning compressor must be secured with a piece of wire.

Air-conditioning compressor

Information:
For installation, it is a good idea to mark the installation position of the front axle carrier diagonally 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.

Marking installation position of front-axle carrier

Information:
Because of the high loosening torques, the four fastening screws on the front-axle carrier and the two screws on the engine transverse bar 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.

Elevating platform

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.

Securing spring struts

45. Loosen the transmission cross member. To do this, loosen the 4 fastening screws -A-.

Fastening screws for transmission cross member

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.

Fastening screws for front-axle carrier and fastening screws for engine transverse bar

Information:
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.