Removing
WM 100119 Removing and installing engine as from MY 02 (Manual transmission)
Warning
Emerging fuel when fuel line is disconnected!
-> Smoking, fire and naked flames are forbidden!
-> Attaching warning sign to vehicle in a clearly visible position (see Figure)!
Caution
-> Pentosin is hazardous to the health!
-> Wear protective gloves and goggles. If the eyes or skin come into contact with the fluid, wash immediately with water!
-> Collect emerging Pentosin!
-> Protect the leads against soiling and damage with caps!
-> Clean hoses which come into contact with Pentosin thoroughly!
Caution
Coolant is hazardous to the health and irritates the skin!
-> When handling coolant, wear protective gloves and goggles!
-> In case of contact with the skin or eyes, wash immediately with plenty of water!
Removing engine
Engine type M 96 / 03
The entire engine-transmission unit is removed in downward direction.
1. Read out or print out the fault memory with the Porsche System Tester 2.
2. Open engine compartment lid.
3. Position protective supports on the body to avoid damage.
4. Disconnect the battery and cover terminals or battery.
5. Undo the wheel bolts of the left and right rear wheels (do not unscrew the bolts!). Use the prescribed special tool socket wrench insert p 300 to avoid damage to the wheels.
Caution
Danger of material damage if the vehicle is raised incorrectly!
^ Raise the vehicle at the prescribed jacking points!
Information
^ Please note the accessibility of the front threaded parts for the diagonal braces and of the screws for the side covers in the area of the rear vehicle take-up points!
6. Raise vehicle to working height.
7. Remove the rear spoiler.
8. Remove the side retaining brackets (heat shield) on the left and right and the rear bumper.
9. Remove the complete air cleaner housing. Unscrew 1 hexagon head bolt M6.
10. Disconnect plug connection on the hot film mass air flow meter. Press together the locking lever on the plug and pull the plug off the flange. Unclip the connection lead at the cable guide.
11. Undo the screw-type hose clamp on the throttle body. Open the spring band clamp on the vacuum line for the brake booster with spring-band clamp pliers, pull off the hose and remove the rubber element from the throttle body. Remove air cleaner housing.
12. Disconnect several suction lines in the left of the engine compartment.
- a. Open the cap of the coolant expansion tank briefly, to release the pressure in the cooling system. Then close the cap again.
- b. Relieve the spring band clamp on the ventilation hose of the coolant expansion tank -1- and remove the hose.
- c. Press the unlocking buttons on the tank ventilation lead -2- and remove the lead.
- d. Remove the plastic retaining clip from the vacuum line for the brake booster -3-, remove the line and then replace the retaining clip.
- e. Remove the connecting hose of the secondary air pump -4-.
Information
^ Lay the oxygen sensor connecting leads with plugs (e.g. between the engine and the engine strut) so that no damage can occur when the engine is lowered.
13. Unclip both of the oxygen sensor plug connections (1 + 2) on the left and right of the preliminary and main catalytic converters from the holder and disconnect the plugs.
14. In vehicles with air conditioning, the following work operations must be performed:
Direction of rotation of the tensioning roller to release the drive belt
- a. Remove the drive belt from the belt pulley of the air conditioning compressor. Mark the running direction of the belt with a colored pen. Slacken belt by turning the tensioning pulley (wrench size 24) clockwise, hold still and simultaneously take the drive belt off the belt pulley of the air-conditioning compressor. Carefully allow the tensioning roller to turn back into tensioning position.
- b. Disconnect battery positive lead -1- at B+ disconnection point. Unscrew the hexagon nut M8 and remove the positive lead. Then unscrew the hexagon-head bolt M6x12 -2- at the holder and lay the holder and box to one side.
- c. Extract Pentosin fluid from the servo-tank with a pump. Dispose of extracted Pentosin according to the relevant regulations. Lay a cloth under the tank to collect any emerging Pentosin. Open the bayonet lock anti-clockwise and remove the tank. Immediately seal the lower tank opening with a plug (diameter approx. 30mm).
Information
^ After removal, place the air-conditioning compressor on a suitable protective support (e.g. foam, neoprene, etc.).
Front threaded part, air-conditioning compressor
- d. Remove the air-conditioning compressor. Tool recommendation: 1/4 inch -Figure 14/d3-. 3 hexagon-head bolts M8: Unscrew two at rear -1-, one at front -2-. For better access to the front threaded part -2- remove the engine compartment temperature sensor with the rubber sleeve at the right intake distributor. Remove the aluminum spacer sleeve. Disconnect the ground cable at the plug connection. Lift out the compressor and lay it on a protective support.
Figure 14/d3: recommended 1/4 inch tool for the front compressor screw
- e. Lift out the air-conditioning compressor with the leads connected and lay to one side on a protective support. Also secure against falling down (tie wraps).
15. Disconnect engine wiring harnesses (2 round connectors with bayonet lock) at the plug connections on the right side in the engine compartment. To open, turn the bayonet anti-clockwise. Cut through the tie wraps at the wire retainer and lay the wiring harness on the engine.
16. Open the holder for the servo lines.
17. Raise the vehicle, unscrew the already loosened wheel bolts on the left and right with special tool socket wrench insert p 300 and remove the wheels.
18. Undo the drive shafts from the outside. Undo 6 hexagon socket head bolts M10 in each case on the transmission side with a commercially available 1/2 inch extension 800 mm and a socket for a hexagon socket a/f 10 (a second person should actuate the brake pedal in the vehicle to counter). Slide a suitable protector -arrow- (e.g. open plastic tube, old coolant hose - approx. 30 mm diameter) over the drive shaft or place a styrofoam base underneath it.
19. Raise the vehicle and remove the underside panel, the left side member and the side covers, see Figure.
^ Underside panel, middle: component no. 4
^ Underside panel, rear (air guide): component no. 5
^ Cover: component no. 9
^ Side covers, left and right: components no. 13 and 14. In order to remove the upper sheet metal screw (No. 10 on clip 17), the outer wheel housing liner must be raised slightly.
20. Disconnect the ground strap on the underside between the engine and the body. Unscrew 1 hexagon nut M8. Pull the ground strap off the threaded pin.
21. Remove the rear stabilizer. Unscrew 1 hexagon nut M10 and 2 hexagon-head bolts M8x40 on both the left and right and then remove the stabilizer.
22. Remove the front transverse strut -A-, both the diagonal braces -B- and the rear cross member -C-.
- Front transverse strut -A-: unscrew 2 hexagon-head bolts M10x40.
- Diagonal braces -B-: Unscrew 2 hexagon-head bolts M12x30 on the rear cross member, 2 hexagon-head bolts M10x40. at the front and 2 hexagon nuts M10 on the rubber mounts.
- Rear cross member -C-: Unscrew 2 hexagon nuts M12 from the hexagon-head bolts M12x80 at the bottom, pull both bolts out of the bores (if necessary, drive out with a drift). Only undo the two upper hexagon-head bolts M12 x 80 slightly (long slots on cross member) and then remove the cross member downwards.
23. Remove clutch slave cylinder, see chapter. Unscrew 2 M8 hexagon-head bolts on transmission and unclip clutch line from the holder. Guide clutch slave cylinder out of the transmission housing.
24. Remove the connection of the lever linkage for the shift and selector cables from the transmission. Lever off ball joint with commercially available removal tool.
25. Detach shift and selector cables on the support bracket. Press the retaining clip -A- together and pull the cable sleeves out of the support bracket.
26. Disconnect plug connection for reverse gear switch.
27. Remove the Hall sensor from cylinder bank 4-6. Unscrew 1 hexagon socket head bolt M6 (micro encapsulated), then pull the Hall sensor out of the bore and hang it to one side (to avoid a collision during lowering).
28. Install the manual transmission engine retainer plate on the engine.
- Secure special tool retainer plate 9592 -A- on the engine underside.
- Screw the support cylinder -C1- for the manual transmission on to the support plate 9592/1 -C- with 1 hexagon head bolt M8x16.
- Screw the pre-assembled support plate 9592/1 -C- with 4 hexagon-head bolts M8x20 on the retainer plate in position -9592-.
- Connect special tool adapter 9163/2 -B- to the retainer plate with 4 hexagon-head bolts M8x25 in the designated position -996- on the support plate.
Assembly plate completely fitted on the underside of the engine (view from rear).
29. Remove the transmission support. Unscrew 4 hexagon nuts M10 and 2 hexagon-head bolts M10x55 and remove the transmission support.
30. Undo the screw connection of the transmission bracket. Only slightly undo 2 M10 hexagon-head bolts on the transmission bracket (do not unscrew completely!)
31. Drain coolant. Place collecting container onto a transmission jack and position below the drain bore. Unscrew drain plug (M10 hexagon socket head bolt) and drain coolant.
32. Seal 2 coolant hoses (heating) with hose clamps.
33. Relieve spring-band clamps with a pair of pliers and remove hoses. Hold the container for collecting the emerging coolant underneath and then seal both hoses.
34. First seal the coolant hose on the shut-off valve, then relieve the spring band clamp with a pair of pliers and remove and subsequently seal.
Remove coolant hose on the shut-off valve.
35. Lift coolant collecting container off the transmission jack and place it on the floor underneath the drain bore. Push transmission jack away from the lifting platforms area. Lower the vehicle.
36. Unscrew closure cap of coolant expansion tank to allow the remaining coolant to drain off. Screw M10 hexagon socket head bolt into the drain bore with a new sealing ring and tighten.
Tightening torque: 10 Nm (7.5 ftlb.)
37. Remove secondary air pump. Undo 2 M6 hexagon-head bolts but only completely unscrew right screw, unscrew 1 M6 hexagon nut, pull pump out of the rear screw connection and set aside.
Information
^ The spring band clamp is possibly vulcanized on the coolant supply hose of the coolant expansion tank to the engine! Do not pull off as this may damage the hose!
38. Remove coolant supply hose on coolant expansion tank. Place the collecting container underneath the vehicle. Relieve spring band clamp with a pair of pliers and remove hose from the flange.
39. Remove coolant hose on the coolant pipe in the left engine compartment. Remove the spring clip of the henn clutch with a screwdriver and pull off hose. Refit spring clip onto the clutch.
40. Remove coolant hose on the coolant guide housing in the right engine compartment. Place the collecting container underneath the vehicle. Open screw-type hose clamp and pull off hose.
Information
^ When using fuel, a warning sign should be attached or mounted on the vehicle in a clearly visible position!
41. Disconnect fuel pipe. Unclip line from the holder on the coolant expansion tank, undo fuel line fast connection, collect emerging fuel.
42. Lift vehicle slightly on the lifting platform, insert trolley jack underneath the vehicle and position on the adapter of the engine retaining plate. Slightly tension jack.
43. Unscrew 2 M10 hexagon-head bolts on the transmission bracket.
44. Undo 2 M12 hexagon nuts on the engine carrier (wrench size 18) and unscrew.
Information
^ Have a second person observe the engine-transmission clearance during the lowering process!
45. Carefully and gradually lower the engine/transmission unit halfway out using the car jack.
46. Disconnect 2 servo lines (pressure line and return line) in the right engine compartment. Undo the plug-in couplings of the lines using an open-ended wrench -A-. Counter with a second open-ended wrench to do this -B-. Screw on coupling. Collect emerging Pentosin with a small container (observe note on using Pentosin!)
Information
^ Replace both O-rings before assembling the plug-in couplings!
^ If the holding collars have to be replaced, the special tool Assembly aid 9622 is contained in the parts set.
47. Prepare both plug-in couplings for assembly:
- a. Tilt retaining collar -C- on one side and simultaneously pull to disengage. Remove old O-ring.
- b. Detach threaded part -A- by pulling it off the nipple. Fit new O-ring.
- C. Insert retaining collar -C- into the threaded part -A- using the special tool Assembly aid 9622 to affix. Screw threaded part -A-with the collar and the new O-ring into the plug-in coupling -B- and tighten. It must be countered when tightening. Remove assembly aid.
Tightening torque of pressure line (wrench size 15): 30 Nm (22 ftlb.).
Tightening torque of return line (wrench size 19): 40 Nm (30 ftlb.).
48. Remove cable retainer and plate holder for the plug connection of the pulse sender. Unscrew 1 hexagon-head bolt M6x12, unclip cable from the cable retainer and unscrew it. Put plug connection with cable to one side.
Information
^ Have a second person observe the engine-transmission clearance during the lifting process!
^ Also guide the oil filler neck and different hose lines in the left engine compartment when lowering!
49. Completely lower the engine/transmission unit using a car jack.
Information
^ If the vehicle is placed on its wheels or moved in the workshop, the rear cross member should be refitted under all circumstances to maintain the structural strength!