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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, M96/21 (3.2L) And M96/22 (2.7L) 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. 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
    G03092053Courtesy 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: Inserting Mandrel Through The Convertible-Top Compartment Link
    G03092054Courtesy 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. See -arrows-  in Fig 3.
    Fig 3: Removing Rear Wall Lining
    G03092055Courtesy 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
    G03092056Courtesy 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
    G03092057Courtesy of PORSCHE OF NORTH AMERICA, INC.
  14. Remove left and right wheel housing trims.
    Fig 6: Removing Left And Right Wheel Housing Trims
    G03092058Courtesy of PORSCHE OF NORTH AMERICA, INC.
  15. Remove the rear part of the underbody cover.
    Fig 7: Removing Rear Part Of Underbody Cover
    G03092059Courtesy 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
    G03092060Courtesy 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
    G03092061Courtesy 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 Bearing
    G03092062Courtesy of PORSCHE OF NORTH AMERICA, INC.
  20. Unscrew the stabilizer on the left and right of the links.
    Fig 11: Unscrewing Stabilizer Link
    G03092063Courtesy of PORSCHE OF NORTH AMERICA, INC.
  21. Detach rear cross member (aluminum V-member) on the body.
    Fig 12: Detaching Rear Cross Member
    G03092064Courtesy 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
    G03092065Courtesy of PORSCHE OF NORTH AMERICA, INC.
  23. Release drive shafts. To do so, loosen and protect the fastening nuts on the transmission.
  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 Connection From The Holders Of The Rear-Axle Support
    G03092066Courtesy 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: Removing Three Hexagon-Head Bolts On The Exhaust Bracket
    G03092067Courtesy 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
    G03092068Courtesy 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: Locating Coolant Drain Plug
    G03092069Courtesy 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
    G03092070Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 19: Opening Coolant Hose Spring Band Clamp
    G03092071Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 20: Locating Coolant Hose Clamp
    G03092072Courtesy 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
    G03092073Courtesy 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 Power-Assisted Steering Line Retaining Clips
    G03092074Courtesy 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: Unscrewing Heat Shield On Transmission
    G03092075Courtesy of PORSCHE OF NORTH AMERICA, INC.
  34. Disengage shift cables on the transmission. Disengage the cables with the commercially available tool.
    Fig 24: Disengaging Shift Cables On The Transmission
    G03092076Courtesy 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 clutch 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. 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 25: Disconnecting Electric Plug On The Hot Film Mass Air Flow Sensor
    G03092077Courtesy of PORSCHE OF NORTH AMERICA, INC.
  38. Open the spring band clamp on the oil filler hose and push it aside. Pull off the oil filler hose; heat, if necessary.
    Fig 26: Opening Spring Band Clamp On The Oil Filler Hose
    G03092078Courtesy of PORSCHE OF NORTH AMERICA, INC.
  39. 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 27: Disconnecting Fuel Supply Hose
    G03092079Courtesy of PORSCHE OF NORTH AMERICA, INC.
  40. 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.
    Fig 28: Locating Vacuum Line For The Brake Booster Snap Ring
    G03092080Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 29: Locating Inner And Outer Sleeve
    G03092081Courtesy of PORSCHE OF NORTH AMERICA, INC.
  41. Disconnect B+ separator box. To do so, undo the nut in the separator box. Remove the cable and lay to one side.
  42. 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 30: Removing Supply Tank Of Power Steering System
    G03092082Courtesy of PORSCHE OF NORTH AMERICA, INC.
    NOTE:
    • In vehicles with air conditioning, points 44 to 47 must also be carried out.
    • Never evacuate and open the air-conditioning circuit unless this is absolutely necessary.
  43. 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 31: Removing Drive (Serpentine) Belt
    G03092083Courtesy of PORSCHE OF NORTH AMERICA, INC.
  44. 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 32: Locating Rear Fastening Screw Of Air-Conditioning Compressor
    G03092084Courtesy of PORSCHE OF NORTH AMERICA, INC.
  45. Loosen air-conditioning compressor. To do so, undo the two front fastening screws -(arrows)-  . See Fig 33. Disconnect the electrical plug.
    Fig 33: Loosening Air-Conditioning Compressor Bolts
    G03092085Courtesy 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.
  46. 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.
  47. Remove the rear luggage compartment lining. To do so, lever out the rear fastening clips and remove the lining from the luggage compartment.
    Fig 34: Removing Rear Luggage Compartment Lining Clip
    G03092086Courtesy of PORSCHE OF NORTH AMERICA, INC.
  48. 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 35: Disconnecting Plug Connections Of The Engine Wiring Harness
    G03092087Courtesy of PORSCHE OF NORTH AMERICA, INC.
  49. Lock the ground point of the engine control module.
    Fig 36: Locating Ground Point Of Engine Control Module
    G03092088Courtesy of PORSCHE OF NORTH AMERICA, INC.
  50. 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 37: Unplugging Engine Control Module
    G03092089Courtesy of PORSCHE OF NORTH AMERICA, INC.
  51. 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 38: Uncovering Engine Wiring Harness Rubber Sleeve
    G03092090Courtesy of PORSCHE OF NORTH AMERICA, INC.
  52. 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 39: Disconnecting Plug Connection At The Guide Tube Of The Oil Dip Stick
    G03092091Courtesy 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.
  53. Place pre-assembled engine retainer plate with transmission support on the crankcase or transmission.
    Fig 40: View Of Engine Retainer Plate
    G03092092Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 41: Positioning Plate
    G03092093Courtesy of PORSCHE OF NORTH AMERICA, INC.
    Fig 42: Placing Car Jack Under Engine
    G03092094Courtesy of PORSCHE OF NORTH AMERICA, INC.
    CAUTION: Risk of damage
    When undoing the multi-tooth nut, the mount is destroyed!
  54. Remove the transmission support with the hydraulic mounts. Undo the two fastening nuts on the left and right.
    Fig 43: Removing Transmission Support
    G03092095Courtesy of PORSCHE OF NORTH AMERICA, INC.
  55. Undo the front engine carrier. To do so, unscrew the four fastening nuts.
    Fig 44: Removing Front Engine Carrier Fastening Nuts
    G03092096Courtesy of PORSCHE OF NORTH AMERICA, INC.
  56. 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 45: Locating VarioCam Cable
    G03092097Courtesy 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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