Part 2
WM 100119 Removing and installing 3.6-litre DFI engine
Installing engine
Information
- Use a transmission jack to support the exhaust system during installation.
Special equipment-specific features are described in the notes.
The following tools are described in Tools and Equipment, Chapter 3.0.13 "WE 1206" (exceptions are noted).
Lifting platform
1. Position the lifting platform under the engine/transmission unit.
2. Raise the body to a comfortable working height with the platform lift.
Information
- Have a helper ensure the engine/transmission combination clearance when moving it into the body.
- When moving the unit into the body, ensure that the shift cable is on the transmission.
- When moving the unit into the body, fit the air-conditioning compressor at the same time.
Air-conditioning compressor
3. Raise the engine/transmission unit into the body with the lifting platform. Ensure sufficient clearance. The insertion guides -4- on the lifting platform must fit into the holes in the body.
Lifting platform
4. Fit the air-conditioning compressor when the engine is at half height => Air conditioning compressor fastening screws. For details, see -> 873419 Removing and installing air-conditioning compressor - V6 - section on "Installing" Service and Repair
Air conditioning compressor fastening screws
5. Install power-steering pump (hydraulic pump). => Hydraulic pump -> 489819 Removing and installing hydraulic pump (Cayenne V6) - section on "Installing" 48981900 Removing and installing hydraulic pump (Cayenne V6)
Hydraulic pump
6. Then insert the engine fully up into the engine compartment. => Inserting engine completely When doing so, use the markings used for removal as a positioning guide.
Inserting engine completely
7. Tighten the six new front-axle carrier/engine carrier screws => Fastening screws for front-axle carrier and engine carrier. For details, see -> 400619 Removing and installing front-axle carrier - section on "Installing" Service and Repair=> Initial tightening: 120 Nm (89 ftlb.) => Final tightening - torque angle: 180°
Fastening screws for front-axle carrier and engine carrier
8. Install transmission cross member. For details, see -> 396519 Removing and installing transfer box - section on "Installing" Service and Repair -A-.
Fastening screws for transmission cross member
9. Release the lateral supports on the wheel hubs. => Support on wheel hub
Support on wheel hub
10. Lower the lifting platform slowly and remove.
11. Connect electric connectors -1, 2 and 3- on the transmission. Fit heat shield.
Electric connectors on transmission
Connector on transfer box
12. Fit heat shield on the right of the transmission. To do this, fit three fastening screws -arrows-. => Tightening torque: 10 Nm (7.5 ftlb.)
Heat shield
13. Fit selector lever cables => Selector lever cable on the transmission. For details, see -> 371519 Removing and installing selector lever cable - section on "Installing"
Selector lever cable on the transmission
14. Push the servo oil line onto the oil cooler and fit the spring band clamp. -arrow-
Spring band clamp securing servo oil line to oil cooler
Information
- For vehicles with Servotronic, the electric connectors on the steering gear must also be connected.
Information
The slightly different illustrations between V8 and V6 show essentially the same actions.
15. Fit the steering column on the steering gear -2-. For details, see -> 489019 Removing and installing steering gear - section on "Installing" Service and Repair
Heat shield for steering gear
16. Fit the heat shield on the steering gear by means of two fastening screws -1-. => Tightening torque: 10 Nm (7.5 ftlb.)
17. Push coolant hoses onto the pipes on the transmission and fit the clips. => Coolant hoses on transmission
Coolant hoses on transmission
18. Fit exhaust system at the connection point between the centre silencer and the catalytic converters. To do this, fit both clamps -1-. => Tightening torque: 23 Nm (17 ftlb.)
Exhaust system
19. Secure exhaust system to the body -2 and 3-. => Tightening torque: 23 Nm (17 ftlb.)
20. Fit rear cardan shaft -> 393519 Removing and installing rear cardan shaft 393519 Removing and installing rear cardan shaft.
21. Fit electric connector on the steering gear (Servotronic only). -arrow-
Servotronic cable plug
22. Slide the coolant supply and return lines onto the radiator. To do this, press the top hose on the radiator flange until you feel it engage -1-. Slide on bottom hose -2-. Then fit the spring band clamp.
Coolant hoses
23. Connect the ATF lines to the radiator. Remove the plugs and fit the lines. For details, see -> 386219 Removing and installing line for ATF cooling - section on "Installing".
ATF lines on cooler
24. Fit the ground point of the generator on the right side member. => Tightening torque: 20 Nm (15 ftlb.)
Ground point of the generator to the right side member
Information
The slightly different illustrations between V8 and V6 show essentially the same actions.
25. Remove and align cardan shaft. -> 393519 Removing and installing rear cardan shaft - section on "Installing" 393519 Removing and installing rear cardan shaft
Installing cardan shaft
26. Lower the vehicle halfway.
Information
- In the case of vehicles with air suspension, the compressed air lines must also be screwed on.
Compressed air line
- Then connect the headlight levelling system sensor.
Sensor for headlight levelling system
27. Tighten the brake lines on the left and right in the wheel housings. -arrow-
Brake lines in the wheel housings
Information
- 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.
Compressed air line on spring strut
- The electric plug connection of the height sensor must be disconnected in vehicles with air suspension or automatic headlight levelling system.
Electric plug connection for height sensor
28. Fit electric connector for the wear indicator -1-. Then press in the supports -2 and 3-. Fit cable for ABS sensor => Cable guide at spring strut 1 and join connectors.
Cable guide at spring strut 1
Cable guide at spring strut 2
29. Lower the vehicle.
Information
- If the fastening screws for the spring strut cannot be positioned, the spring strut can be pushed up slightly using a garage jack.
30. Fit the three fastening screws for the spring struts at the left and right -1-. The screws are inserted from inside the engine compartment. Of the three screws per spring strut, one is in the plenum panel. The screws must be replaced. View from below -arrows-. -> 4000TW00 Tightening torques for front axle
Spring strut threaded joint
Spring strut view from the wheel housing
31. Connect the four oxygen sensor connectors at the plenum panel splash panel. -1, 2, 3 and 4-
Oxygen sensor connector on the plenum panel splash panel
32. Mount B+ transfer point on left spring dome. To do this, connect the two positive cables from the engine over the pins. Clip in cable on the bulkhead. -A and B- => Tightening torque: 23 Nm (17 ftlb.)
B+ transfer point on left spring dome
33. Connect the servo line to the reservoir and fit the spring band clamp => Servo line to reservoir. Then fill the tank with Pentosin.
Servo line to reservoir
34. Fit fuel line -1- and tank vent line from the carbon canister -2- to the plenum panel splash panel. Clip in tank vent line at the plenum panel. => Tightening torque: 35 Nm (26 ftlb.)
Tank vent and fuel line
35. Fit the two coolant lines and the vacuum line on the right side of the engine compartment. -1 to 3- Simply press on vacuum line (hold line securely below the connection).
Wiring
36. Lay the engine wire harness in the plenum panel. Fit the rubber sleeve into the middle opening. Push control unit connector onto the control unit. Fit the control unit, connector, and ground point. -arrows- => Tightening torque: 10 Nm (7.5 ftlb.)
Engine wire harness
37. Plug in the two connectors (red and white) in the central electrical system box at the left. Then fit the cover using four Torx screws.
Fastening screws for the central electrical system box cover
38. Check whether the wiring harness is laid correctly. Close all fixing clips.
39. Fit the drive belt and check that it is positioned correctly. Then remove the locking screw. For details, see -> 137819 Removing and installing drive belt - section on "Installing" Service and Repair
40. Fit air cleaner housing cover and filter element.
41. Push the air tube on the air cleaner cover.
Air tube on air cleaner cover
Subsequent work
1. On vehicles with manual transmission, work on peripheral units must be performed as described in -> 343519 Removing and installing transmission - section on "Installing" 343519 Removing and installing transmission.
2. Install intake pipe. -> 243519 Removing and installing air box for throttle housing on DFI engines (intake pipes upstream of throttle valve) - section on "Installing" Service and Repair
3. Install cover for plenum panel. -> 664419 Removing and installing cowl panel cover - section on "Installing" Service and Repair
4. Fit pneumatic spring for bonnet -> 553119 Removing and installing front gas spring Service and Repair. While doing so, fit engine compartment rubber seal -> 553319 Removing and installing front lid seal - section on "Removing" Service and Repair.
5. Fill and bleed the cooling system. -> 193817 Draining and filling in coolant (includes bleeding) - section on "Filling in" Service and Repair
6. Bleed brake system. -> 470107 Bleeding the brake system - section on "Bleeding" Service and Repair
7. Connect battery. => Work instructions after disconnecting the battery
8. Mount engine compartment covers. -> 700219 Removing and installing front cover (engine compartment) - section on "Installing"
9. Check ATF level. => Test and assembly work on power steering
10. Bleed power-assisted steering. => Test and assembly work on power steering
11. Install the front wheel housing liners. -> 505619 Removing and installing front wheel housing liner - section on "Installing" Service and Repair
12. Remove engine guard with transverse strut. -> 108019 Removing and installing engine guard (underbody panel) - section on "Removing" 108019 Removing and installing engine guard (underbody panelling)
13. Mount front wheels. -> 440519 Removing and installing wheel - section on "Installing" Removal and Replacement
14. Perform suspension alignment. => Suspension alignment, complete
15. Perform a test drive with the vehicle. Check the fluid level in the reservoir after the coolant circuit has cooled again and, if necessary, fill up to the max marking with coolant.
16. Read out DME fault memory and compare with the log you printed prior to removal.
17. Check engine oil level.