Part 2
WM 100119 Removing and installing engine (continued)Installing engine
Installing engine
Information
The engine/transmission unit is installed in the reverse order of its removal. The following work steps are specially repeated here to avoid faulty installation or damage.
Information
The ground cable on the holder of the plug connection of the impulse sender must always also be screwed on!
1. Attach safety clip -arrow- securing Henn coupling for coolant hose to coolant expansion tank.
Coolant pipe feeder hose
Notice
Engine/transmission unit lowered or inserted incorrectly
Risk of damage to engine/transmission unit
Cables and coolant hoses can be stretched and torn
- Gradually lower or raise the engine using a jack.
- Always check that all necessary cables were disconnected when lowering the engine/transmission unit.
- Make sure that no cables or hoses are damaged when fitting the engine/transmission unit.
- Get one or two more persons to help.
Notice
Engine/transmission unit lowered or inserted incorrectly
Risk of damage to engine/transmission unit
Cables and coolant hoses can be stretched and torn
- Gradually lower or raise the engine using a jack.
- Always check that all necessary cables were disconnected when lowering the engine/transmission unit.
- Make sure that no cables or hoses are damaged when fitting the engine/transmission unit.
- Get one or two more persons to help.
Notice
Engine/transmission unit lowered or inserted incorrectly
Risk of damage to engine/transmission unit
Cables and coolant hoses can be stretched and torn
- Gradually lower or raise the engine using a jack.
- Always check that all necessary cables were disconnected when lowering the engine/transmission unit.
- Make sure that no cables or hoses are damaged when fitting the engine/transmission unit.
- Get one or two more persons to help.
2. Lift the engine/transmission unit about half-way into the engine on the unit lifting platform.
3. Fit sheet metal holder for the plug connection of the pulse sender and the plastic cable holder. Position and tighten one M6x12 hexagon-head bolt - Tightening torque: 10 Nm (7.5 ftlb.) Screw in cable holder and clip in cable.
Pulse sender holder and connector
4. Manual transmission: install clutch slave cylinder. Insert cylinder and push in. Position both screws by hand and tighten. Clip line into holder. - Tightening torque: 23 Nm (17 ftlb.)
Clutch slave cylinder
Notice
Engine/transmission unit lowered or inserted incorrectly
Risk of damage to engine/transmission unit
Cables and coolant hoses can be stretched and torn
- Gradually lower or raise the engine using a jack.
- Always check that all necessary cables were disconnected when lowering the engine/transmission unit.
- Make sure that no cables or hoses are damaged when fitting the engine/transmission unit.
- Get one or two more persons to help.
Notice
Engine/transmission unit lowered or inserted incorrectly
Risk of damage to engine/transmission unit
Cables and coolant hoses can be stretched and torn
- Gradually lower or raise the engine using a jack.
- Always check that all necessary cables were disconnected when lowering the engine/transmission unit.
- Make sure that no cables or hoses are damaged when fitting the engine/transmission unit.
- Get one or two more persons to help.
Notice
Engine/transmission unit lowered or inserted incorrectly
Risk of damage to engine/transmission unit
Cables and coolant hoses can be stretched and torn
- Gradually lower or raise the engine using a jack.
- Always check that all necessary cables were disconnected when lowering the engine/transmission unit.
- Make sure that no cables or hoses are damaged when fitting the engine/transmission unit.
- Get one or two more persons to help.
5. Raise the engine/transmission unit into installation position and tighten the collar nuts for the engine and transmission mount. - Tightening torque: 85 Nm (63 ftlb.) - Tightening torque: 65 Nm (48 ftlb.)
Unit lifting platform engine mounting
Alldata editors note:
A. 997 Carrera/Cabriolet/Targa 4/4S AWD Vehicles Only: Install cardan shaft.
Cardan shaft threaded joint
B. Fit four M10 hexagon nuts and two M10 x 55 hexagon-head bolts -arrows- on the transmission bracket and tighten them.
- Tightening torque: 65 Nm (48 ftlb.)
6. Fit transmission support. - Tightening torque: 65 Nm (48 ftlb.)
Transmission support
7. Enlisting the assistance of a second person, completely detach the engine retainer plate.
8. Install the hall sender in cylinder bank 4-6. Insert hall sender and fasten using a new M6 hexagon socket head bolt (micro-encapsulated) -1-. - Tightening torque: 10 Nm (7.5 ftlb.)
Hall sender cylinder side 4-6
9. Attach engine ground cable to body. - Tightening torque: 23 Nm (17 ftlb.)
Engine ground strap
10. Fasten drive shafts to transmission flange. In Tiptronic vehicles, insert the spacer rings. - Tightening torque: 81 Nm (60 ftlb.)
11. Attach B-Plus line to transmission. Connect lines to B-Plus box and fasten using collar nuts. - Tightening torque: 23 Nm (17 ftlb.)
12. Manual transmission: clip the B-Plus lines into the cable guide on the transmission bracket between the yellow markings -arrows-.
Manual transmission B-Plus line
13. Connect and clip in cable plug of reversing switch (manual transmission)/connector for Tiptronic transmission.
14. Install chassis components:
14.1. Rear cross member: M12 hexagon-collar nuts - Tightening torque: 100 Nm (74 ftlb.)
14.2. Diagonal braces on rear cross member: hexagon-head bolt - Tightening torque: 100 Nm (74 ftlb.)
14.3. Diagonal brace on rear-axle support: collar nut - Tightening torque: 65 Nm (48 ftlb.)
14.4. Diagonal brace to body: hexagon-head bolt - Tightening torque: 65 Nm (48 ftlb.)
Cross member with accessories
15. Front transverse strut, Tiptronic transmission: hexagon-head bolt - Tightening torque: 65 Nm (48 ftlb.)
Transverse strut, Tiptronic
16. Transverse strut, manual transmission: hexagon-head bolt - Tightening torque: 65 Nm (48 ftlb.)
Transverse strut, manual transmission
17. Install rear anti-roll bar.
17.1. Engage anti-roll bar in connecting rods and then secure to rear-axle support using two hexagonal-head bolts. - Tightening torque: 23 Nm (17 ftlb.)
Rear anti-roll bar mount
18. Position new M10 collar nuts on the connecting rod joint. Make sure to counter with a Torx socket wrench insert when tightening. - Tightening torque initial tightening: 50 Nm (37 ftlb.)
18.1. Loosen collar nuts and tighten them again. - Tightening torque final tightening: 50 Nm (37 ftlb.)
Anti-roll bar to connecting rod
19. Install Tiptronic selector cable.
20. Install shift cables for manual transmission.
Shift cables for manual transmission
21. Connect servo pressure pipe. Push plug into the plug-in coupling in a straight line. The plug must audibly engage in the holder.
Connecting servo pressure pipe
Information
The servo line plug-in coupling is designed so that there is an axial play of approx. 1 mm in the coupling.
22. Inspect correct engagement of the plug coupling with special tool test tool 9623. Insert special tool into the groove and check that the plug is seated correctly in the coupling by applying slight pressure. The plug must not slide out.
Test tool 9623
23. Attach servo return hose to the line using the spring band clamp.
Information
Allocation of the engine wiring harness round connectors:
Lower plug - grey inner ring
Upper plug - black inner ring
24. Fit engine wire harness. Turn bayonet lock in clockwise direction (approx. 90 degrees), until the markings of the round connector and the housing correspond. Fix the wire harness onto the holder with a new tie-wrap.
25. Installing air conditioning compressor: before installing the compressor check whether the aluminium spacer sleeve -arrow- is inserted. Grease and fit sleeve. Also connect ground cable before installation.
Front air conditioning compressor fastening screw and sleeve
26. Fit air conditioning compressor and fasten using three M8 Torx screws (two short ones at the rear, one long one at the front) -1-. - Tightening torque: 23 Nm (117 ftlb.)
Air conditioning compressor mount
27. Fit drive belt. Pay attention to operating direction of used belts. Double-check that the position of the belt on the belt pulleys is correct.
Drive belt
Subsequent work for installing engine
Subsequent work for installing engine
1. Top up coolant and bleed cooling system.
2. Position rear apron support with M6 hexagon-head bolt on the body -2-, do not tighten until after fitting the rear apron. - Tightening torque: 10 Nm (7.5 ftlb.)
Support for rear apron
3. Install lateral retaining brackets (heat shields) for rear apron.
4. Install rear apron.
5. Fit rear wheels. Use special tool socket-wrench insert 300 to tighten the wheel bolts. - Tightening torque: 130 Nm (96 ftlb.)
6. Connect the battery.
7. Warm up engine to operating temperature and recheck the coolant level. Inspect all cooling system connections that were opened during removal for leaks.
8. Check power steering fluid level (Pentosin) and top up if necessary.
9. Check engine oil level and top up if necessary.
10. Remove protective covers.