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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 TIPTRONIC 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. Detach 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: Disengaging Convertible-Top Compartment Link Clips
    G03091938Courtesy 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.
    Fig 2: Inserting Mandrel Into Convertible-Top Compartment Link Bores
    G03091939Courtesy 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 Torx 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. (See Fig 3).
    Fig 3: Locating Rear Wall Cover Screws
    G03091940Courtesy of PORSCHE OF NORTH AMERICA, INC.
    CAUTION: Risk 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
    G03091941Courtesy 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
    G03091942Courtesy of PORSCHE OF NORTH AMERICA, INC.
  14. Remove left and right wheel housing trims.
    Fig 6: Removing Left And Right Wheel Housing Trims
    G03091943Courtesy of PORSCHE OF NORTH AMERICA, INC.
  15. Remove the rear part of the underbody cover.
    Fig 7: Removing Rear Part Of Underbody Cover
    G03091944Courtesy 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
    G03091945Courtesy 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
    G03091946Courtesy of PORSCHE OF NORTH AMERICA, INC.
  18. Remove stabilizer. To do so, unscrew the two fastening screws on the left and right of the two bearing surfaces and unscrew the stabilizer on the left and right from the links.
    Fig 10: Removing Stabilizer Mount
    G03091947Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 11: Removing Stabilizer Link
    G03091948Courtesy of PORSCHE OF NORTH AMERICA, INC.
  19. Detach rear cross member (aluminum V-member) on the body.
    Fig 12: Detaching Rear Cross Member
    G03091949Courtesy of PORSCHE OF NORTH AMERICA, INC.
  20. 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
    G03091950Courtesy of PORSCHE OF NORTH AMERICA, INC.
  21. Release drive shafts. To do so, loosen and protect the fastening nuts on the transmission.
  22. 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 Connection From The Holders Of The Rear-Axle Support
    G03091951Courtesy of PORSCHE OF NORTH AMERICA, INC.
  23. 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
    G03091952Courtesy of PORSCHE OF NORTH AMERICA, INC.
  24. Remove the front lining in the rear luggage compartment. Lever off plastic clips using a commercially available removal tool..
  25. 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
    G03091953Courtesy of PORSCHE OF NORTH AMERICA, INC.
  26. 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: Locating Coolant Drain Plug
    G03091954Courtesy of PORSCHE OF NORTH AMERICA, INC.
  27. 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
    G03091955Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 19: Opening Coolant Hose Spring Band Clamp
    G03091956Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 20: Pulling Off Coolant Hose
    G03091957Courtesy of PORSCHE OF NORTH AMERICA, INC.
    CAUTION: Danger of fire!
    • Collect emerging fuel.
    • Avoid ignition sources and naked flames.
  28. 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.
  29. Disconnect the steering lines. Remove the small undersealing on the left vehicle side (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
    G03091958Courtesy of PORSCHE OF NORTH AMERICA, INC.
  30. 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
    G03091959Courtesy of PORSCHE OF NORTH AMERICA, INC.
  31. Disconnect the plug connection of the multifunction switch.
  32. Disconnect plug from transmission socket. The plug must be turned anti-clockwise. Then pull off the plug.
    Fig 23: Disconnecting Plug From Transmission Socket
    G03091960Courtesy of PORSCHE OF NORTH AMERICA, INC.
  33. Detach selector lever cable at deflection linkage and at the transmission support.
    Fig 24: Detaching Selector Lever Cable
    G03091961Courtesy of PORSCHE OF NORTH AMERICA, INC.
  34. Disengage the accelerator cable. Remove the cover on the deflector box and disengage the accelerator cable.
    Fig 25: Removing Cover On Deflector Box
    G03091962Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 26: Disengaging Accelerator Cable
    G03091963Courtesy of PORSCHE OF NORTH AMERICA, INC.
  35. 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 The Hot Film Mass Air Flow Sensor
    G03091964Courtesy of PORSCHE OF NORTH AMERICA, INC.
  36. 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
    G03091965Courtesy of PORSCHE OF NORTH AMERICA, INC.
  37. 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 of the secondary air pump.
    Fig 29: Disconnecting Fuel Supply Hose & Ground Cable
    G03091966Courtesy of PORSCHE OF NORTH AMERICA, INC.
  38. 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 On Vacuum Line For The Brake Booster
    G03091967Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 31: Locating Inner And Outer Sleeve
    G03091968Courtesy of PORSCHE OF NORTH AMERICA, INC.
  39. Disconnect B+ separator box. To do so, undo the hexagon nut in the separator box. Remove the cable and lay to one side.
  40. Remove 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: Removing Supply Tank Of Power Steering System
    G03091969Courtesy of PORSCHE OF NORTH AMERICA, INC.
    NOTE:
    • In vehicles with air conditioning, points 42 to 45 must also be carried out.
    • Never evacuate and open the air-conditioning circuit unless this is absolutely necessary.
  41. Remove drive belt. Mark the running direction of the drive belt with a colored pen. Slacken the belt. 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
    G03091970Courtesy of PORSCHE OF NORTH AMERICA, INC.
  42. 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 Air-Conditioning Compressor
    G03091971Courtesy of PORSCHE OF NORTH AMERICA, INC.
  43. 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 Bolts
    G03091972Courtesy 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.
  44. 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.
  45. 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
    G03091973Courtesy of PORSCHE OF NORTH AMERICA, INC.
  46. 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
    G03091974Courtesy of PORSCHE OF NORTH AMERICA, INC.
  47. Remove the Tiptronic control module. Undo the three -fastening nuts-  and pull off the control module plug.
    Fig 38: Removing Tiptronic Control Module
    G03091975Courtesy of PORSCHE OF NORTH AMERICA, INC.
  48. Disconnect control module. Disconnect the plugs of the Tiptronic control module. At the same time, lock the ground point of the engine control module.
    Fig 39: Disconnecting Control Module Ground Point
    G03091976Courtesy of PORSCHE OF NORTH AMERICA, INC.
  49. Disconnect 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 40: Disconnecting Engine Control Module
    G03091977Courtesy of PORSCHE OF NORTH AMERICA, INC.
  50. 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 41: Locating Engine Wiring Harness Rubber Sleeve
    G03091978Courtesy of PORSCHE OF NORTH AMERICA, INC.
  51. Disconnect the plug connection at the guide tube of the oil dip stick. To do so, press the two tabs together and unclip the tube.
    Fig 42: Disconnecting Plug Connection At The Guide Tube Of The Oil Dip Stick
    G03091979Courtesy 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.
    • The support C1 should rest against the transmission oil pan under a slight pre-load. If necessary, fit the included spacer plate.
  52. Place pre-assembled engine retainer plate with transmission support on the crankcase or transmission.
    Fig 43: View Of Engine Retainer Plate
    G03091980Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 44: Identifying Engine Retainer Plate Positioned And Fastened
    G03091981Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 45: Identifying Car Jack Placed Underneath Engine
    G03091982Courtesy of PORSCHE OF NORTH AMERICA, INC.
    CAUTION: Risk of damage
    When undoing the multi-tooth nut, the mount is destroyed!
  53. Remove the transmission support with the hydraulic mounts. Undo the two fastening nuts on the left and right.
    Fig 46: Removing Transmission Support
    G03091983Courtesy of PORSCHE OF NORTH AMERICA, INC.
  54. Undo engine carrier. Undo the front engine carrier. To do so, unscrew the four fastening nuts.
    Fig 47: Unscrewing Engine Carrier Fastening Nuts
    G03091984Courtesy of PORSCHE OF NORTH AMERICA, INC.
  55. 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 48: Locating VarioCam Cable
    G03091985Courtesy 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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