Part 1

Removing engine
Tools








Tools and materials
Required tools
The following tools are described in the Workshop Equipment Manual, Chapter 3.0.13 "WE 1206" (exceptions are noted).

Lifting Platform:

Tools Overview:

Tools Overview:

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 centre position with steering wheel holder)! If this is not done, the airbag contact unit will have to be put in centre position after installation of the steering gear! --> '945019 Removing and reinstalling steering-column switch'
^ 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 the engine

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

V8 Engine:

1. Remove engine guard with transverse strut.

Coolant Drain Plug:

2. Drain coolant.
3. Remove both wiper arms.

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

Plenum Chamber Cover:

4. 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.

Engine Wire Harness:

5. 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.

Torx Screws For Cover Of Central Electrical System:

6. Open the cover of the central electrical system on the left side of the vehicle. To do this, loosen the four Torx screws.
7. 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.

B+ Transfer Point:

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

Throttle Body Cover:

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

Throttle Adjuster Electric Connection:

10. 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.

Boost-Pressure Sensor:

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

Boost-pressure sensor

Fastening Bolts On The Throttle Body:

11. 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.

Pull Out Fastening Bolt With Pliers:

12. Remove the fastening bolts. To do this, take hold of the bolt by the rubber ring with pliers and pull it out.
13. Pull off the Y-shaped pipe from the throttle body.

Mass Air Flow Connections:

14. 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).

Note:
^ 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.

Design Cover Of Cylinder Row 5-8:

^ 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.

Air Cleaner Housing Clamps:

15. Loosen the clamps on the air cleaner housing.

Circlip And Adapter:

Note: 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-.

Air Cleaner Cover:

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

Filter Elements:

17. Remove the filter elements.

Oxygen Sensor Connector:

18. 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 supports.

Fastening Screws For Vacuum Pump:

Note: In the Cayenne Turbo (M48/50), the support for the vacuum pump must also be undone. To do this, unscrew the two fastening screws and press the pump forward slightly.

Coolant Lines And Vacuum Line:

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

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)

Servo Oil Reservoir:

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

Torque Converter Support:

21. 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.

Fuel Line And Carbon Canister Line:

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.

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

Fastening Screws For Spring Struts:

23. 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.

Securing Clip On Connection For Coolant Feed And Return Lines:

24. 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.

Note:
^ 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.

Drive Belt Tensioning Pulley:

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

Control Lines Of The Ambient Air Valves:

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

Note:

Compressed Air Line On Spring Strut:

^ 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 depressurised.

Electric Plug Connection For Height Sensor:

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

Electric Plug On The Spring Struts In The Wheel Housing:

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

Brake Lines In The Wheel Housing:

27. Disconnect the brake lines in the wheel well to the left and right.

Ground Point Of Right Side Member:

28. Disconnect the ground point on the 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!

ATF Lines On Cooler: