Removing Engine
Removing and installing engine
Tools for removal
Item Designation of the special tool Explanation
1
2
3 To compensate for the engine retainer plate in the necessary horizontal position
4 Separate the wooden supports and only fasten one half in each case on the support plate
5 Required only for removal or installation with Tiptronic transmission. The additional support prevents the engine-transmission unit from tilting off the engine plate
Item Designation of the special tool Explanation
A Removal tool Commercially available
Removing engine
1. Read out the fault memory with the Porsche System Tester 2 and print it out if necessary.
2. Open engine compartment lid.
3. Install protective supports.
4. Disconnect the battery and cover terminal or battery.
Caution: Danger of material damage if the vehicle is raised incorrectly!
^ Raise the vehicle at the prescribed jacking points!
^ Raise the vehicle by means of a workshop jack on the engine and move the mounting plate of the lifting platform into the highest position!
Note:
^ Make sure the outer screw connections for the diagonal braces are accessible!
Warning: Danger of injury if the clutch pressure line is undone or disconnected without pressure reduction beforehand!
^ Reduce pressure in the clutch system!
^ Actuate clutch pedal at least 25 times for this purpose!
5. Pull off the right and left pressure hoses; to do so, lever off the retaining clips.
6. Undo hexagon-head bolt M6 x 34.
7. Remove the complete air cleaner assembly.
8. In order to remove the pressure pipe, loosen the hexagon-head bolts, the hose clamp and the plug.
9. Disconnect vacuum hose from the switchover valve and remove the switchover valve from the holder.
After removing the pressure hose, refit the retaining clip.
10. Detach the holder over the air-conditioning compressor.
11. Undo the fuel supply line on the fuel cooler. It is very important to counter when performing this step.
- Union nut a/f 17, counter with a/f 14.
12. Unscrew the hexagon-head bolts M8 x 12 on the belt pulley by approximately. half a revolution.
13. Relieve drive belt and remove from the belt pulley of the hydraulic pump.
14. Remove belt pulley.
15. Disconnect the hydraulic lines with plug-in coupling on the expansion tank.
Note:
^ Wear protective gloves!
^ Collect emerging Pentosin!
^ Protect the line against dirt and scratches with a cap!
^ If hoses come into contact with Pentosin, clean them thoroughly without delay!
- Insert tool between line and the red unlocking ring and unlock by pulling black line to the right and simultaneously pressing the tool against the red unlocking ring.
16. Unscrew the 2 fastening screws (M8 x 25 with hexagon socket head bolts) on the tank.
17. Unscrew 3 screws (M8) and 1 screw (M6) between the hydraulic pump and the bracket.
18. Pull the expansion tank with hydraulic pump out of the bracket and lay to the side.
19. Remove throttle body.
20. Remove the compressor.
Note:
^ Always use the protective support!
- Disconnect the electrical plug connection.
- Lift out compressor and set it down with the hoses connected.
21. Undo engine wiring harnesses (2 round connectors with bayonet lock) on the right side in the engine compartment.
22. To do this, turn round plugs counterclockwise and pull them off.
23. Disconnect oxygen sensor plug connections using a screwdriver.
24. Disconnect oxygen sensor plug connections on the rear closing panel.
25. Unscrew the stabilizer.
26. Remove the front cross member and both diagonal braces.
27. Remove the rear cross member. To do this, only loosen the two upper hexagon-head bolts (M12 x 83) (there are slots in the cross member).
Note:
^ Remove hexagon-head bolts in order to avoid damage to the reference mark sender cable or the oil tank when the engine-transmission unit is subsequently lowered.
28. Unscrew and remove the halfshafts.
Note:
^ Always use the protective support!
29. Pull off plug for reversing light on the transmission.
30. Detach and remove the transmission support.
31. Detach cardan shaft on transmission flange.
Note:
^ A second person should counter the cardan shaft when it is being removed!
32. Pull cardan shaft out of the front-axle final drive and set it aside.
33. Disengage shift cables with removal tool.
34. Remove starter.
- Pull off protective cap.
- Detach terminals 30 and 50.
- Undo upper fastening screw with 3/8 inch tool, two short extensions, universal joint, hexagon wrench insert a/f 15.
- Undo the lower fastening screw.
- Remove starter.
35. Loosen both intake pipes on the exhaust turbocharger.
- Also disconnect the plug for the boost pressure check on the left hand side.
- Remove intake pipes.
36. Undo ground strap between engine and right side member (in area above cylinder 6).
37. Disconnect the clutch pressure line.
Warning: Danger of injury if the clutch pressure line is undone or disconnected without pressure reduction beforehand!
^ Reduce pressure in the clutch system!
^ Actuate clutch pedal at least 25 times!
Note:
^ The joint is located on the rear left side member (inside)!
^ When undoing the screw coupling at the screw connection -A- , counter simultaneously at screw connection -B-!
- Disengage lead out of the holder.
- Plug lines.
38. Screw closure cap off coolant expansion tank.
39. Undo coolant drain plug on right and left and drain the coolant.
40. Equip drain plugs with new sealing rings.
Tightening torque: 10 + 5 Nm (7.5 + 3.5 ft. lbs.)
41. Remove coolant hoses.
42. Place workshop jack and preassembled engine retainer plate underneath with slight load.
Spacer9111/5 fitted
- Engage support lever in horizontal position.
43. Undo transmission support.
44. Separate engine carrier from the engine mounts (wrench size 18).
45. Carefully and in steps, lower the engine-transmission unit by approximately. 10 cm.
46. The following parts must be undone or removed from this position:
- Disconnect plug connection of tank vent.
- Press unlocking buttons and simultaneously pull off the line.
47. Disconnect vacuum line for the brake booster
- Remove snap ring of vacuum line for the brake booster.
- Push the inner sleeve -(arrow 1)- against the outer sleeve -(arrow 2)- and pull off both sleeves together in the direction of the arrow.
- Undo the fuel supply line (1) and fuel return line (2) in the engine compartment (left).
- Disengage fuel filter.
Note:
^ Always counter when undoing the fuel supply line and fuel return line!
48. The intake air distributor is detached from the engine and remains in the engine compartment.
49. Undo the hose clamp and remove from the intake air distributor.
50. Undo the hexagon-head bolt and lift the complete intake air distributor up and out of the support pins.
51. Suspend intake air distributor in the engine compartment.
Note:
^ While lowering, have a second person observe the engine-transmission clearance, especially in the area of the oil container and the detached intake air distributor!
^ 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!