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Home >> Porsche >> 2003 >> 911 Carrera 4S, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 38 (Engine) >> Engine, Crankcase >> Removing Engine, M96/20 (2.5L) With Manual Transmission >> Removing Engine

Removing Engine

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NOTE:
  • The engine is removed downwards complete with the manual transmission.
  1. Position the vehicle at the specified points on a lifting platform.
  2. Open both the luggage compartment lids.
  3. Cover the vehicle. Cover the vehicle with protective covers in such a way that the body can not be damaged.
  4. Move convertible top or convertible-top compartment lid to service position. Open the convertible top until the convertible-top compartment lid is half open.
  5. Detaching cloth covering. Disengage the rear strip on the left and right sides of the cloth covering in downward direction.
  6. Detach tension cables. Press the ball socket of the tension cable out of the ball head of the adjusting piece on the left and right.
  7. Move convertible top to service position. To do so, press the tension bow of the convertible top towards the main bow, until it reaches its locking point.
  8. Move the convertible-top compartment lid to service position and secure. Disengage the convertible-top compartment links at the extreme bottom. To do so, disengage the clips at the left and right and pull the links off the bolt.
    Fig 1: Detaching Tension Cables
    G03091797Courtesy of PORSCHE OF NORTH AMERICA, INC.
  9. Press the convertible-top compartment links forwards until the two bores coincide and a 5 mm mandrel can be pushed through them.
    Fig 2: Pushing Mandrel Through Hole
    G03091798Courtesy of PORSCHE OF NORTH AMERICA, INC.
  10. Remove left-hand seat. For better accessibility, remove the left-hand seat of the car. Unscrew the four internal-serration screws, disconnect all the electrical plug connections and remove the seat.
  11. Open the rear wall cover. To do so, remove the oddments tray behind the seats and remove the rear wall lining. Then undo the 6 fastening screws and the 2 fastening nuts -arrows-  . (See Fig 3).
    Fig 3: Locating Rear Wall Cover Screws
    G03091799Courtesy of PORSCHE OF NORTH AMERICA, INC.
    CAUTION: Danger of short circuit!
    • First remove the ground terminal.
    • Cover the terminals.
    • Never connect (short circuit) the terminals.
  12. Disconnect battery. Before disconnecting, find out the relevant theft codes (e.g. radio) if necessary. At the battery, disconnect the ground terminal and remove the ground cable. Refer to WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY . Remove the rear spoiler. REMOVING AND INSTALLING REAR SPOILER .
    Fig 4: Removing Rear Spoiler
    G03091800Courtesy of PORSCHE OF NORTH AMERICA, INC.
  13. Remove rear bumper. While doing so, pay attention to the connection for the number plate lighting. Refer to REMOVING AND INSTALLING REAR SPOILER .
    Fig 5: Removing Rear Bumper
    G03091801Courtesy of PORSCHE OF NORTH AMERICA, INC.
  14. Remove left and right wheel housing trims.
    Fig 6: Removing Left And Right Wheel Housing Trims
    G03091802Courtesy of PORSCHE OF NORTH AMERICA, INC.
  15. Remove the rear part of the underbody cover.
    Fig 7: Removing Rear Part Of Underbody Cover
    G03091803Courtesy of PORSCHE OF NORTH AMERICA, INC.
  16. Lift the vehicle. Before lifting, check that all fastening points of the diagonal braces are easily accessible. Pay particular attention to the threaded part -C-  . See Fig 8.
    Fig 8: Locating Fastening Points Of The Diagonal Braces
    G03091804Courtesy of PORSCHE OF NORTH AMERICA, INC.
  17. Undo the fastening screw -C-  and the collar nuts -D.-  and remove the diagonal braces -B-  together with the holder -E-  . See Fig 9.
    Fig 9: Locating Fastening Points Of The Diagonal Braces
    G03091805Courtesy of PORSCHE OF NORTH AMERICA, INC.
  18. Remove stabilizer.
  19. To do so, unscrew the two fastening screws at each of the two bearing surfaces on the left and right.
    Fig 10: Removing Stabilizer Bearings
    G03091806Courtesy of PORSCHE OF NORTH AMERICA, INC.
  20. Unscrew the stabilizer on the left and right of the links.
    Fig 11: Unscrewing Stabilizer On Left And Right Of Links
    G03091807Courtesy of PORSCHE OF NORTH AMERICA, INC.
  21. Detach rear cross member (aluminum V-member) on the body.
    Fig 12: Detaching Rear Cross Member
    G03091808Courtesy of PORSCHE OF NORTH AMERICA, INC.
  22. Undo the cable. Undo the engine cable on the rear-axle support. The cable must be countered with a suitable wrench and must not be twisted.
    Fig 13: Countering Engine Cable With Wrench
    G03091809Courtesy of PORSCHE OF NORTH AMERICA, INC.
  23. Undo halfshafts. To do so, undo the fastening screws of the halfshafts on the transmission. Fit protection on to the halfshafts.
  24. Unclip and detach the oxygen sensor plug connection from the holders of the rear-axle support. On an OBD II vehicle, additionally disconnect the oxygen sensor plug connection in the rear wing area. Press the heat shield aside and disconnect the plugs.
    Fig 14: Detaching Oxygen Sensor Plug From The Holders Of The Rear-Axle Support
    G03091810Courtesy of PORSCHE OF NORTH AMERICA, INC.
  25. Remove rear mufflers. To do so, secure the rear mufflers with a transmission jack. Then undo the flange connection between the catalytic converters and the exhaust manifold. Undo the three hexagon-head bolts on the exhaust bracket.
    NOTE:
    • When lowering, do not damage the oxygen sensors, cables and plugs.
    • Attach protective sleeves around the oxygen sensor plugs.
    Fig 15: Locating Exhaust Bracket Bolts
    G03091811Courtesy of PORSCHE OF NORTH AMERICA, INC.
  26. Remove the front lining in the rear luggage compartment. Lever off plastic clips using a commercially available removal tool.
  27. Remove the rear-axle support. Unscrew the four fastening screws and remove the rear-axle support to one side.
    Fig 16: Removing Rear-Axle Support
    G03091812Courtesy of PORSCHE OF NORTH AMERICA, INC.
  28. Drain coolant. To do so, remove the screw plug of the coolant circuit on the coolant guide housing. Collect coolant in a clean container.
    Fig 17: Removing Screw Plug Of Coolant Circuit On The Coolant Guide Housing
    G03091813Courtesy of PORSCHE OF NORTH AMERICA, INC.
  29. Disconnect coolant hoses. Open the supply and return lines for coolant on the engine and pull them off. Then close all openings. Collect emerging coolant in a clean container.
    Fig 18: Disconnecting Coolant Hoses
    G03091814Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 19: Opening Spring Band Clamp
    G03091815Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 20: Pulling Off Hose
    G03091816Courtesy of PORSCHE OF NORTH AMERICA, INC.
    CAUTION: Danger of fire!
    • Collect emerging fuel.
    • Avoid ignition sources and naked flames.
  30. Detach the fuel return line. Disconnect the fuel return line under the vehicle floor by pressing gently on the button and pull apart. Collect emerging fuel. Close off the open ends of the line immediately. Then open the holder on the body and remove the line.
  31. Disconnect the steering lines. Remove the small undersealing on the left vehicle underside (six plastic nuts). Disconnect the two hydraulic lines of the power steering on the vehicle floor. To do so, undo the threaded part and disconnect. Any emerging Pentosin must be collected.
    Fig 21: Disconnecting Steering Lines
    G03091817Courtesy of PORSCHE OF NORTH AMERICA, INC.
  32. Disengage the retaining clips for the power-assisted steering lines and the brake vacuum hose and remove the lines.
    Fig 22: Disengaging Retaining Clips For The Power-Assisted Steering Lines
    G03091818Courtesy of PORSCHE OF NORTH AMERICA, INC.
  33. Unscrew the heat shield on the transmission. To do so, unscrew the two fastening nuts and remove the plate.
    Fig 23: Locating Screws For Heat Shield On The Transmission
    G03091819Courtesy of PORSCHE OF NORTH AMERICA, INC.
  34. Disengage shift cables on the transmission. Disengage the cables with the commercially available tool.
    Fig 24: Disengaging Cables With Commercially Available Tool
    G03091820Courtesy of PORSCHE OF NORTH AMERICA, INC.
  35. Detach the shift cables. Unclip the shift cables on the transmission mount. Then pull the shift cables upwards out of the engine compartment and set them aside.
    WARNING: Risk of damage!
    • When the slave cylinder is removed, do not actuate the clutch again.
  36. Uncouple clutch slave cylinder. To do so, unscrew the fastening screw and remove the clutch slave cylinder. Tie the cylinder with a wire.
  37. Disengage the accelerator cable. Remove the cover on the deflector box and disengage the accelerator cable.
    Fig 25: Removing Cover On Deflector Box
    G03091821Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 26: Disengaging Accelerator Cable
    G03091822Courtesy of PORSCHE OF NORTH AMERICA, INC.
  38. Disconnect the electric plug on the hot film mass air flow sensor. Then disconnect the connecting hose between the hot film mass air flow sensor and the throttle body. To do so, disconnect the hose clamp on the hot film mass air flow sensor.
    Fig 27: Disconnecting Electric Plug On Hot Film Mass Air Flow Sensor
    G03091823Courtesy of PORSCHE OF NORTH AMERICA, INC.
  39. Press the spring band clamp on the oil filler hose apart and push it aside. Pull off the oil filler hose; heat, if necessary.
    Fig 28: Pulling Off Oil Filler Hose
    G03091824Courtesy of PORSCHE OF NORTH AMERICA, INC.
  40. Disconnect the fuel supply hose. Make sure without fail to counter with a suitable wrench when doing this. Collect emerging residual fuel. Then disconnect the ground cable.
    Fig 29: Disconnecting Ground Cable
    G03091825Courtesy of PORSCHE OF NORTH AMERICA, INC.
  41. Disconnect vacuum line for the brake booster. To do so, remove the grey snap ring. Then push the inner sleeve -1-  against the outer sleeve -2-  and pull off both sleeves together in the direction of the arrow. See Fig 30.
    Fig 30: Locating Snap Ring For Vacuum Line For The Brake Booster
    G03091826Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 31: Locating Inner And Outer Sleeve
    G03091827Courtesy of PORSCHE OF NORTH AMERICA, INC.
  42. Disconnect B+ separator box. To do so, undo the hexagon nut in the separator box. Remove the cable and lay to one side.
  43. Remove the supply tank of the power steering system. To do so, suck fluid out as much as possible. Then open the bayonet lock on the bottom of the expansion tank and remove the tank. Close the opening in the servo pump with a clean plug.
    Fig 32: Opening The Bayonet Lock On The Bottom Of The Expansion Tank
    G03091828Courtesy of PORSCHE OF NORTH AMERICA, INC.
    NOTE:
    • In vehicles with air conditioning, the points 45 to 48 must also be carried out.
    • Never evacuate and open the air-conditioning circuit unless this is absolutely necessary.
  44. Remove drive belt. Mark the running direction of the drive belt with a colored pen. Slacken belt by turning the tensioning pulley (wrench size 24 mm) clockwise, hold still and simultaneously take the belt off the drive pulleys.
    Fig 33: Removing Drive Belt
    G03091829Courtesy of PORSCHE OF NORTH AMERICA, INC.
  45. Undo the rear fastening screw of the air-conditioning compressor from above. The screw is positioned between the intake manifolds of the fifth and sixth cylinders.
    Fig 34: Locating Rear Fastening Screw Of The Air-Conditioning Compressor
    G03091830Courtesy of PORSCHE OF NORTH AMERICA, INC.
  46. Loosen air-conditioning compressor. To do so, undo the two front fastening screws -(arrows)-  . See Fig 35. Disconnect the electrical plug.
    Fig 35: Loosening Air-Conditioning Compressor Front Fastening Screws
    G03091831Courtesy of PORSCHE OF NORTH AMERICA, INC.
    NOTE:
    • The air-conditioning compressor can be removed from the vehicle more easily if the engine has already been lowered.
  47. Set the air-conditioning compressor with the hoses connected to one side or lift it out of the engine compartment and set it on a suitable base.
  48. Remove the rear luggage compartment lining. To do so, lever out the rear fastening clips and remove the lining from the luggage compartment.
    Fig 36: Removing Rear Luggage Compartment Lining Clip
    G03091832Courtesy of PORSCHE OF NORTH AMERICA, INC.
  49. Disconnect the plug connections (X3/1, X3/2 and X59) of the engine wiring harness. To do so, raise the lock at the side and pull the plug out.
    Fig 37: Disconnecting Plug Connections Of The Engine Wiring Harness
    G03091833Courtesy of PORSCHE OF NORTH AMERICA, INC.
  50. Lock the ground point of the engine control module.
    Fig 38: Locating Ground Point Of Engine Control Module
    G03091834Courtesy of PORSCHE OF NORTH AMERICA, INC.
  51. Unplug the engine control module. Open the topmost plug by actuating the side button and pull out. Remove the other plugs from the top down. To do so, press the locking button in and push the locking bar upwards.
    Fig 39: Removing Engine Control Module
    G03091835Courtesy of PORSCHE OF NORTH AMERICA, INC.
  52. Uncover the engine wiring harness. To do so, press the rubber sleeve on the luggage compartment rear wall inwards and guide the wiring harness towards the engine compartment, if the engine is to be lowered later.
    Fig 40: Uncovering Engine Wiring Harness
    G03091836Courtesy of PORSCHE OF NORTH AMERICA, INC.
  53. Disconnect the plug connection at the guide tube of the oil dipstick. To do so, press the two tabs together and unclip the tube.
    Fig 41: Disconnecting Plug Connection At The Guide Tube Of The Oil Dipstick
    G03091837Courtesy of PORSCHE OF NORTH AMERICA, INC.
    NOTE:
    • It is recommended to position the complete retainer plate using a transmission jack first. Only then should the workshop car jack be placed underneath.
  54. Place pre-assembled engine retainer plate with transmission support on the crankcase or transmission.
    Fig 42: View Of Engine Retainer Plate
    G03091838Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 43: Placing Engine Retainer Plate With Transmission Support On The Crankcase Or Transmission
    G03091839Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 44: Identifying Car Jack Placed Underneath Engine
    G03091840Courtesy of PORSCHE OF NORTH AMERICA, INC.
    CAUTION: Risk of damage!
    When undoing the multi-tooth nut, the mount is destroyed!
  55. Remove the transmission support with the hydraulic mounts. Undo the two fastening nuts on the left and right.
    Fig 45: Locating Transmission Support Fastening Nuts
    G03091841Courtesy of PORSCHE OF NORTH AMERICA, INC.
  56. Undo the front engine carrier. To do so, unscrew the four fastening nuts.
    Fig 46: Locating Front Engine Carrier Nuts
    G03091842Courtesy of PORSCHE OF NORTH AMERICA, INC.
  57. Lower the engine-transmission unit carefully. Ensure that there is sufficient clearance for the components. The engine wiring harness must be guided during the lowering procedure.
    Fig 47: Locating VarioCam Cable
    G03091843Courtesy of PORSCHE OF NORTH AMERICA, INC.
    WARNING: Risk of damage!
    Only place the vehicle on its wheels or push it after the rear-axle support, the sheetmetal brace and both the diagonal braces have been installed.
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