Installing Engine

Information 

• Use a transmission jack to support the exhaust system during installation. 

Special equipment-specific features are described in the notes. 

Fig 1: Identifying Lifting Platform

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1. -A- - Assembly mandrel  => Height can be adjusted; used for mounting in the engine carrier; equipped with a locking screw to prevent engine from tipping and to adjust the height. Position 2 in the base carrier 
2. -B- - Wheel hub holder  => Secures the spring struts to prevent them from tipping. Inserted from the side into the second cross member from the front 
3. -C- - Assembly mandrel  => Height can be adjusted; used for mounting in the front-axle carrier at the front; equipped with a locking screw to prevent engine from tipping and to adjust the height. Position 1 in the base carrier 
4. -D- - Support  => Not used here.
5. -E- - Wishbone support  => Used in conjunction with -B-  to protect the wheel suspension and spring struts from damage.
6. -F- - Assembly mandrel  => For mounting on the front-axle carrier at the rear. Position 3 in the base carrier 
7. -G- - Assembly mandrel  => Guide for positioning the lifting platform into the body; first moves into a bore in the body for centring roughly. Position 4 in the base carrier 
8. -H- - Assembly mandrel  => For mounting on the transmission cross member. Position 5 on the base carrier 

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. 
     Fig 2: Identifying Air-Conditioning Compressor

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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.
   Fig 3: Lifting Engine/Transmission Unit

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4. Fit the air-conditioning compressor when the engine is at half height . For details, see → Installing Air Conditioning Compressor
   Fig 4: Locating Air Conditioning Compressor Fastening Screws

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5. Install power-steering pump (hydraulic pump). → Hydraulic pump → Installing Hydraulic Pump (Cayenne V6)
   Fig 5: Installing Hydraulic Pump

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6. Then insert the engine fully up into the engine compartment. When doing so, use the markings used for removal as a positioning guide.
   Fig 6: Inserting Engine Completely

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7. Tighten the six new front-axle carrier/engine carrier screws. For details, see → Installing Front-Axle Carrier → Initial tightening: 120 Nm (89 ft lbs.) → Final tightening - torque angle: 180° 
   Fig 7: Locating Front-Axle Carrier And Engine Carrier Fastening Screws

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8. Install transmission cross member. For details, see → Installing Transfer Gear-A-  .
   Fig 8: Fastening Screws For Transmission Cross Member

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9. Release the lateral supports on the wheel hubs.
   Fig 9: Releasing Support On Wheel Hub

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10. Lower the lifting platform slowly and remove.
11. Connect electric connectors -1, 2 and 3-  on the transmission. Fit heat shield.
    Fig 10: Locating Transmission Electric Connectors

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    Fig 11: Identifying Transfer Box Connectors

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12. Fit heat shield on the right of the transmission. To do this, fit three fastening screws -arrows-. → Tightening torque: 10 Nm (7.5 ft lbs.) 
    Fig 12: Locating Heat Shield Screws

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13. Fit selector lever cables . For details, see → Installing Selector Lever Cable
    Fig 13: Locating Transmission Selector Lever Cable

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14. Push the servo oil line onto the oil cooler and fit the spring band clamp. -arrow- 
    Fig 14: Locating Servo Oil Line Spring Band Clamp

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    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 → Installing Steering Gear
    Fig 15: Identifying Steering Gear Heat Shield Bolt And Screws

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16. Fit the heat shield on the steering gear by means of two fastening screws -1-. → Tightening torque: 10 Nm (7.5 ft lbs.) 
17. Push coolant hoses onto the pipes on the transmission and fit the clips.
    Fig 16: Locating Transmission Coolant Hoses

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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 ft lbs.) 
    Fig 17: Identifying Exhaust System Clamps And Bolts

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19. Secure exhaust system to the body -2 and 3-. → Tightening torque: 23 Nm (17 ft lbs.) 
20. Fit rear cardan shaft → WM 393519 REMOVING AND INSTALLING REAR CARDAN SHAFT .
21. Fit electric connector on the steering gear (Servotronic only). -arrow- 
    Fig 18: Locating Servotronic Cable Plug

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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.
    Fig 19: Identifying Coolant Hoses Spring Band Clamp

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23. Connect the ATF lines to the radiator. Remove the plugs and fit the lines. For details, see → Installing Line For ATF Cooling .
    Fig 20: Connecting ATF Lines On Cooler

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24. Fit the ground point of the generator on the right side member. → Tightening torque: 20 Nm (15 ft lbs.) 
    Fig 21: Locating Ground Point Of Generator Right Side Member

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    Information 

    The slightly different illustrations between V8 and V6 show essentially the same actions.

25. Remove and align cardan shaft. → Installing Rear Cardan Shaft
    Fig 22: Installing Cardan Shaft

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26. Lower the vehicle halfway.

    Information 

    • In the case of vehicles with air suspension, the compressed air lines must also be screwed on. 
      Fig 23: Locating Compressed Air Line

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    • Then connect the headlight levelling system sensor. 
      Fig 24: Locating Headlight Levelling System Sensor

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27. Tighten the brake lines on the left and right in the wheel housings. -arrow- 
    Fig 25: Locating Wheel Housings Brake Lines

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    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. 
      Fig 26: Locating Compressed Air Line Spring Strut

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    • The electric plug connection of the height sensor must be disconnected in vehicles with air suspension or automatic headlight levelling system. 
      Fig 27: Locating Electric Plug Connection Height Sensor

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28. Fit electric connector for the wear indicator -1-  . Then press in the supports -2 and 3-  . Fit cable for ABS sensor .
    Fig 28: Locating Cable Guide Spring Strut (1 Of 2)

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    Fig 29: Locating Cable Guide Spring Strut (2 Of 2)

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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-  . → WM 4000TW TIGHTENING TORQUES FOR FRONT AXLE (ALL MODELS)
    Fig 30: Tightening Spring Strut Threaded Joint Screws

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    Fig 31: Locating Wheel Housing Spring Struts

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31. Connect the four oxygen sensor connectors at the plenum panel splash panel. -1, 2, 3 and 4- 
    Fig 32: Identifying Oxygen Sensor Connectors

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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 ft lbs.) 
    Fig 33: Identifying Left Spring Dome B+ Transfer Points

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33. Connect the servo line to the reservoir and fit the spring band clamp . Then fill the tank with Pentosin.
    Fig 34: Connecting Servo Line To Reservoir

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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 ft lbs.) 
    Fig 35: Identifying Tank Vent And Fuel Line

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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).
    Fig 36: Identifying Coolant Lines And Vacuum Line

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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 ft lbs.) 
    Fig 37: Locating Engine Wire Harness

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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.
    Fig 38: Locating Central Electrical System Box Cover Fastening Screws

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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 → Removing And Installing Drive Belt
40. Fit air cleaner housing cover and filter element.
41. Push the air tube on the air cleaner cover.
    Fig 39: Identifying Air Tube On Air Cleaner Cover

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