Part 1
WM 100119 Removing and installing engine
Tools
Technical values
Preliminary work
DANGER
Vehicle can fall down
- Risk of squashing or crushing
- Risk of damage to the vehicle
-> Do not place any solid objects under the raised vehicle.
-> Ensure that the lifting platform is prevented from lowering.
-> Remove solid objects before lowering the vehicle.
-> Raise the vehicle only at the take-up points provided.
-> The outer take-up points should be used primarily.
Information
- When raising the vehicle, take care to maintain access to the screws for the diagonal struts in the vicinity of the rear jacking points.
1. Raise the vehicle at the prescribed jacking points.
-> 4X00IN01 Lifting the vehicle Service and Repair.
2. Put protective covers on vehicle.
3. Evacuate the air conditioning system.
-> 87031700 Draining and filling in refrigerant Service and Repair.
3.1. After evacuating the system: Unscrew two M8 cheese head bolts -3 and 4- at the air-conditioning lines (rear right underbody).
Removing line
3.2. Immediately seal open air-conditioning lines with suitable stoppers.
3.3. Replace O-rings before joining the lines again.
4. Read out fault memory.
-> 033500 On-board diagnosis (OBD) 033500 On-board diagnosis (OBD).
Repeat Steps 5 and 6 for Boxster vehicles only.
5. Move hood into service position.
-> 6101IN Hood in service position Procedures Locations.
6. Remove hood compartment lid.
-> 619019 Removing and installing hood compartment lid 619019 Removing and installing hood compartment lid.
7. Disconnect ground lead of battery -> 2706IN Work instructions after disconnecting the battery External Power Connection, Jump Lead Starting.
8. Remove linings (carpet for rear wall cover and engine cover).
-> 700819 Removing and installing trim panel for hood compartment/engine compartment lid .
9. Remove engine compartment lid.
-> 557819 Removing and installing engine compartment lid 557819 Removing and Installing Engine Compartment Lid
10. Remove rear wall cover.
-> 555919 Removing and installing rear wall cover Service and Repair.
Cover with grommet
11. Detach B+ box for terminal 30 line in the engine compartment.
11.1. Loosen two M6 fastening nuts -1-.
11.2. Remove B+ box and the two spacer sleeves -2- and lay them and the connected lines aside.
Junction point for terminal 30 line in engine compartment
12. Remove rubber sleeve -1- between the mass air flow sensor and throttle housing.
12.1. Loosen two screw-type clamps -2- and remove rubber sleeve.
Rubber sleeve for air intake system to throttle housing
13. Disconnect cable plug for mass air flow sensor -2-.
Mass air flow sensor
14. Pull off connecting hose -2- to the oil filler neck by opening the spring band clamp -1- and pulling off the hose.
Connecting hose between service tray and oil filler neck
15. Unscrew cap on coolant reservoir.
16. Disconnect vent line at the rapid-action coupling.
Vent line
17. Remove rear luggage compartment trim panel.
-> 700619 Removing and installing rear luggage compartment trim (carpet lining) .
17.1. Pull off luggage compartment lid seal and lever off the rear fixing clips.
17.2. Pull cable plug off the luggage compartment light.
18. Release and pull off connectors on the engine control unit.
-> 247019 Removing and installing DME control unit Service and Repair.
18.1. Mark the position of the connectors on the engine control unit to facilitate allocation during installation.
18.2. 3.4-litre engine: Unscrew three M6 collar nuts -1- on the control unit and remove the control unit.
DME control unit and holder (3.4-litre engine)
18.3. Release and pull off connectors.
18.4. 2.9-litre engine:Release and pull off connectors.
Engine control unit - 2.9-litre engine
18.5. Unscrew M6 hexagon nut -1- and remove ground straps.
18.6. Release and pull off connectors -1- and -2- above the left wheel arch.
Connectors for engine wire harness
19. Vehicle with Porsche Doppelkupplung (PDK):
19.1. Remove moulded part -2- in front of the transmission control unit. Unscrew one plastic screw -1- and remove the moulded part.
Insulating element
19.2. Release combination connector -2- on the transmission control unit -1- and pull it off.
Connector on control unit for PDK transmission
19.3. Remove cable holder -1- under the service tray using disassembly tool Nr.21 -2-.
Cable attached to control unit for PDK transmission
19.4. Lever off cable clip -1- using disassembly tool Nr.21 -2-.
Cable clip on line for PDK control unit
All vehicles:
20. Press rubber sleeve -1- on the rear wall of the luggage compartment inwards and feed the engine wire harness -2- out towards the engine compartment.
Removing rubber sleeve
20.1. Also guide out cable link for transmission control unit on vehicles with Porsche Doppelkupplung.
21. Remove rear wheels.
21.1. Use the prescribed special tool socket-wrench insert 300 to avoid damaging the rims.
-> 440519 Removing and installing wheel Removal and Replacement.
22. Remove rear underbody cover.
-> 519419 Removing and installing cover for rear underbody 519419 Removing and Installing Cover for Rear Underbody.
23. Remove centre underbody cover.
-> 519319 Removing and installing cover for centre underbody 519319 Removing and installing Cover For Centre Underbody.
24. Drain power-steering fluid at the hydraulic lines on the underbody.
-> 4X00IN Plug-in couplings for hydraulic lines - as of model year 2009 Procedures.
24.1. Open the locking bar on three plastic holders on the underbody.
Holder for hydraulic lines on the underbody
24.2. Open servo lines using special tool loosening tool 9780 -1- and collect the fluid.
Hydraulic lines with tool 9780
24.3. Close off lines with stoppers.
25. Drain coolant. Collect coolant in a container.
-> 193817 Draining and filling coolant Service and Repair.
25.1. Unscrew the drain plug -1- on the thermostat housing. Replace seal.
Coolant drain plug on thermostat housing
25.2. Remove foam part -2- and release plastic holder -3- for coolant hoses at the underbody.
Coolant supply and return lines
25.3. Remove spring clamps -1- using a screwdriver and pull off coolant hoses. Re-fit spring clamps.
25.4. Close off open lines using suitable stoppers.
26. Pull off coolant hoses for the heater and heat exchanger.
26.1. Clamp coolant hoses using hose clamps -1-.
Clamping coolant hoses
26.2. Open spring band clamps -1 to 3- on the coolant hoses and pull off hoses.
Spring band clamps for coolant hoses
Open spring band clamps -1- using an assembly pliers Nr.72 Pos.1 -2-.
Opening spring band clamp
27. Remove exhaust system.
-> 263319 Removing and installing rear silencer Service and Repair.
28. Pull oxygen sensor plug connections on the rear-axle cross member at the left and right out of the brackets.
28.1. Pull connectors -1- and lines -2- out of the bracket.
Oxygen sensor connectors
28.2. Release and disconnect plug connections.
28.3. Loosen the line from the holder -1- on the cylinder head.
Retaining clip on oxygen sensor line
29. Remove oxygen sensors ahead of catalytic converter at the exhaust manifold.
29.1. For this purpose, cut each tie-wrap on the heat shield for the cylinder head.
30. Remove exhaust manifold with catalytic converter.
-> 261019 Removing and installing exhaust manifold with catalytic converter 261019 Removing and installing exhaust manifold with catalytic converter.
31. Detach the vacuum line for the brake booster.
31.1. Press locking ring together and pull off the line.
31.2. Pull off vacuum hose -1- and rapid-action coupling -2- on the connecting piece.
Vacuum connection for brake booster
32. Open fuel lines -1- at the underbody. Collect emerging fuel in a suitable container.
Fuel lines
32.1. Close off open lines using suitable stoppers.
33. Porsche Doppelkupplung (PDK): Disengage parking lock cable -1-. Press off cable using disassembly tool Nr.21 -2-.
Parking lock cable
33.1. Unclip operating cable from the bracket. Press locking tabs together and pull the operating cable out of the bracket -arrows-.
34. Manual transmission: Disconnect reversing light switch -arrow-.
Reversing light switch
34.1. Manual transmission: Lever shift cable (grey sealing cap) -1- and selector cable (blue sealing cap) -2- off the ball pin using disassembly tool Nr.21 and disengage from the support bracket.
Shift and selector cables - 6-speed
35. Pull off cable plug -1- on purge-air fan -2- in the engine compartment.
Cable plug for purge-air fan
35.1. Pull off cable plug for engine coolant level sensor.
36. Detach engine ground strap.
36.1. Unscrew one external Torx screw (E12, M8 x 20) -1- on cylinder head 1-3 and hang cable -2- to one side.
Engine ground strap
37. Remove diagonal braces -1- and support plate -2- with V-strut.
-> 42141900 Removing and installing support plate 42141900 Removing and installing support plate.
37.1. Unscrew four M10 lock nuts and one hexagon-head bolt (M12 x 40) with a washer on each and remove diagonal braces.
37.2. Also unscrew two hexagon-head bolts (M10 x 25) on the cross member and two M10 lock nuts on the V-strut. Remove support plate.
Diagonal braces and support plate
37.3. Unscrew two hexagon-head bolts (M10 x 70) -arrow- and remove the V-strut.
V-strut
38. Remove anti-roll bar.
-> 429019 Removing and installing rear anti-roll bar 429019 Removing and installing rear anti-roll bar.
38.1. Unscrew two hexagon-head bolts (M8 x 40) -arrows- on each anti-roll-bar mount shell.
Anti-roll bar mount shells
38.2. Unscrew M10 hexagon nuts on the suspension/stabiliser and disengage connecting link.
Connecting link on anti-roll bar
39. Loosen drive shafts on the transmission.
-> 422119 Removing and installing drive shaft Service and Repair.
Drive shaft
39.1. Counter using special tool adapter plate 9510/1 -1-.
Retaining tool for drive-shaft bolts
39.2. Unscrew six hexagon socket head bolts (M10 x 50) joining each drive shaft and transmission flange.
39.3. Secure drive shafts to the rear axle carrier with tie-wraps -1-.
Securing drive shafts
40. Unscrew two M8 hexagon nuts for the restraining cable. Counter with an open-ended wrench to prevent the cable from turning.
Restraining cable
41. Remove the rear axle carrier.
-> 420619 Remove and install rear axle cross member 420619 Removing and installing rear-axle cross member.
41.1. Remove protective cover -2-.
Heat protection cover
41.2. Loosen M10 collar nuts and pull out screws (M10 x 45) on the cross member -arrows-.
Rear axle cross member
41.3. Remove cross member in a downward direction. Take care with the range adjustment system holder (if fitted).