Installing Engine

NOTIFICATION 

Opened refrigerant system for repairs. 

• Moisture penetrated into the refrigerant system. 
• Risk of contaminating the refrigerant circuit. 
• Risk of saturation and irreparable damage to desiccator. 
• Irreparable damage to the desiccator can damage the compressor and evaporator. 
  • The desiccator must be replaced if the air humidity is high and if the refrigerant circuit is left open for a long time.

Information 

• Set the steering wheel with the wheels in straight-ahead position. To do this, engage the steering column lock or clamp the steering wheel in centre position with a steering-wheel holder. If this is not done, the airbag contact unit will have to be moved to centre position after installation of the steering gear. 

> WM 945019 REMOVING AND INSTALLING STEERING-COLUMN SWITCH (EXCEPT PANAMERA S EXECUTIVE, PANAMERA TURBO EXECUTIVE, PANAMERA GTS)

Information 

The tightening specifications for the basic engine are stored centrally.

> TECHNICAL VALUES

/

> WM 2X00IN TECHNICAL VALUES (PANAMERA, PANAMERA S, PANAMERA S EXECUTIVE, PANAMERA 4, PANAMERA 4S, PANAMERA 4 S EXECUTIVE)

or

> 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES AND ASSEMBLY OVERVIEWS 

Tightening torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.

Information 

• Due to currently correct tightening specifications, the screw specifications can be found in the corresponding repair descriptions for the assemblies chassis, transmission, electrics, etc. 

Information 

Check the position of all lines, hoses and cables again during and following installation. Make sure that:

• The lines, hoses and cables are not installed twisted (markings on steel flexi-pipes!)
• The lines, hoses and cables are not exposed to any mechanical strain from the outside while driving, i.e. they must not be over-strained or deformed.
• The lines, hoses and cables are not rubbing against other moving components.
• The lines, hoses and cables cannot become clamped.

1. Guide the engine in under the vehicle.

   Move engine under the vehicle using the lifting platform.

   Position the wheels of the lifting platform to the position marked during removal.

   Guide the engine up into the engine compartment using the lifting equipment.

   Push the PDCC hose to one side while raising the engine.

   Only for 4.8 V8 and 4.8 V8 Turbo: 

   Gradually guide the air-conditioning lines > Air-conditioning lines  along with your hand.

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   Air-conditioning lines

   Fit the locking cable at half height (easier to access).

   > WM 371319 REMOVING AND INSTALLING LOCKING CABLE (EXCEPT PANAMERA S EXECUTIVE, PANAMERA EXECUTIVE, PANAMERA 4 S EXECUTIVE, PANAMERA TURBO EXECUTIVE, PANAMERA TURBO S EXECUTIVE, PANAMERA GTS, PANAMERA 4S SPORT EDITION, PANAMERA 4 EXECUTIVE)

   1. 1.6.1  Pull the locking cable down and engage it in the support.
   2. 1.6.2  Fit parking lock cable at the ball joint on the transmission.
2. Fit front-axle carrier.

   For tightening torques and other details, see:

   > WM 400619 REMOVING AND INSTALLING FRONT-AXLE CARRIER (EXCEPT PANAMERA GTS, PANAMERA TURBO S, PANAMERA PLATINUM ED., PANAMERA 4 PLATINUM ED.)

   By adjusting the position of the lifting platform slightly, move to the marking -arrows-  for the contact points for the front-axle carrier on the longitudinal members.

   Fit fastening bolts securing front-axle carrier to the longitudinal members on both sides.

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   Marking and fastening screw on front-axle carrier

3. Fit fastening screws -arrows-  on the rear transmission mount.

   For tightening torques and other details, see:

   > WM 373837 DISASSEMBLING AND ASSEMBLING TRANSMISSION SUPPORT (EXCEPT PANAMERA S EXECUTIVE, PANAMERA EXECUTIVE, PANAMERA TURBO S, PANAMERA 4S SPORT EDITION, PANAMERA 4 EXECUTIVE)

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   Fastening screws on transmission mount

4. Fit fastening screws -3 and 4-  securing the anti-roll bar to the supporting plate on both sides.

   For tightening torques and other details see:

   > WM 4X00IN TIGHTENING TORQUES FOR FRONT AXLE (EXCEPT PANAMERA GTS, PANAMERA TURBO S, PANAMERA PLATINUM ED., PANAMERA 4 PLATINUM ED.)

   Fig 1: Front-Axle Support Mounting Screws Tightening Sequence

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   Mounting for front-axle support

5. Fit transverse struts -2-  .

   For tightening torques and other details, see:

   > WM 4X00IN TIGHTENING TORQUES FOR FRONT AXLE (EXCEPT PANAMERA GTS, PANAMERA TURBO S, PANAMERA PLATINUM ED., PANAMERA 4 PLATINUM ED.)

   Right side: Press rear wheel housing cover down -arrow-  and fit the transverse strut -2-  between the supporting plate and door sill.

   Left side: Fit transverse strut between the supporting plate and door sill.

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   Removing struts (right side shown here)

6. Fit the safety hooks -arrow-  for the upper wishbone on both sides.

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   Safety hooks

7. Guide in and fit bolt on the lower wishbone -arrow-  .

   For tightening torques and other details see:

   > WM 4X00IN TIGHTENING TORQUES FOR FRONT AXLE (EXCEPT PANAMERA GTS, PANAMERA TURBO S, PANAMERA PLATINUM ED., PANAMERA 4 PLATINUM ED.)

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   Bolts on lower wishbone

8. Remove wheel hub holder -1-  on the lifting platform and remove assembly pins -2-  on the wheel hub.

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   Wheel hub holder (shown here on steel brake disc)

9. Lower and push away engine lifting platform.
   WARNING: Working with ATF 

   • Possible danger of injury or damage (e.g. swollen hoses, skin irritation, danger of slipping, etc.) 
     • Before lines are opened, place a cloth underneath them!
     • Components that come into contact with ATF must be cleaned IMMEDIATELY with water!
     • Take appropriate protective measures (protective clothing, safety goggles, oil binding material)
     • Collect emerging ATF!
10. 4.8 V8 and 4.8 V8 Turbo: 

    Fit supply and return hose for the ATF transmission oil cooler -arrows-  .

    For tightening torques and other details, see:

    > WM 386019 REMOVING AND INSTALLING ATF COOLER (EXCEPT PANAMERA S EXECUTIVE, PANAMERA EXECUTIVE, PANAMERA 4 S EXECUTIVE, PANAMERA TURBO EXECUTIVE, PANAMERA TURBO S EXECUTIVE, PANAMERA GTS, PANAMERA 4S SPORT EDITION, PANAMERA 4 EXECUTIVE)

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    Supply and return hose for transmission oil cooler

11. Fit universal joint -1-  .

    For tightening torques and other details, see:

    > WM 481519 REMOVING AND INSTALLING STEERING COLUMN (EXCEPT PANAMERA EXECUTIVE, PANAMERA GTS, PANAMERA TURBO S, PANAMERA 4 EXECUTIVE, PANAMERA PLATINUM ED., PANAMERA 4 PLATINUM ED.)

    Pull universal joint -1-  and lower part of steering column -arrow-  downwards.

    Fit clamping screw -2-  .

    For vehicles with Servotronic: Plug in connector -3-  .

    Fit holder on cable of Servotronic connector.

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    Fitting universal joint

12. Fit heat shield -1-  between the universal joint for the steering gear and the primary catalytic converter.

    Insert heat shield -1-  .

    Fit the fastening screws -2-  .

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    Heat shield

13. Fit PDK wiring harness.

    Plug in connectors on the end of the PDK wiring harness -2-  on the transmission, lock them -1-  and fit the retaining clip -3-  .

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    Connectors on PDK wiring harness

    Fit retaining clips -arrows-  for the PDK wiring harness.

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    Retaining clips on PDK wire harness

    Guide in heat shield for PDK wiring harness and fit fastening screws -arrows-  on the transmission.

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    Heat shield for PDK wiring harness

14. Fit reinforcement plate -1-  .

    For tightening torques and other details, see:

    > WM 400619 REMOVING AND INSTALLING FRONT-AXLE CARRIER (EXCEPT PANAMERA GTS, PANAMERA TURBO S, PANAMERA PLATINUM ED., PANAMERA 4 PLATINUM ED.)

    Position reinforcement plate -1-  .

    Screw in -2-  fastening screws.

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    Reinforcement plate

15. Left side: Fit return hose for hydraulic oil cooler.

    Connect return hose -2-  on the hydraulic oil cooler.

    Screw in fastening screw -1-  between the hose clamps.

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    Return hose for hydraulic oil cooler

    Information 

    Working with steel flexi-pipes

    • Steel flexi-pipes are particularly prone to kinking and pinching. 
    • Be particularly careful with steel flexi-pipes during removal, storage and reinstallation. 
    • Mark the installation position of the pipe with a paint marker during removal. 
    • Steel flexi-pipes must never be installed twisted. 
16. Left side: Fit steel flexi-pipe to the expansion hose. > Steel flexi-pipe to expansion hose 

    Fit steel flexi-pipe to the expansion hose. Use the marking as a guide.

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    Steel flexi-pipe to expansion hose

17. Connect cable plugs to the horn on both sides.
18. Only for 4.8 V8 Turbo: 

    Fit the wastegate valves -arrow-  to the charge-air coolers on both sides. Tighten the clamps -1-  .

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    Wastegate valve on charge-air cooler

    Fit suction hose -arrow-  on both sides by tightening the hose clamps -arrow-  .

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    Suction hose

    Fit pressure hose on the charge-air cooler on both sides. > Pressure hose on charge-air cooler 

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    Pressure hose on charge-air cooler

19. Lower the vehicle halfway.
20. Right wheel housing: Fit fastening nut -arrow-  on the ground cable for the engine at the frame carrier.

    > Tightening torque 10 Nm (7.5 ftlb.) 

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    Ground cable

    Information 

    Working with steel flexi-pipes

    • Steel flexi-pipes are particularly prone to kinking and pinching. 
    • Be particularly careful with steel flexi-pipes during removal, storage and reinstallation. 
    • Mark the installation position of the pipe with a paint marker during removal. 
    • Steel flexi-pipes must never be installed twisted. 
21. Fit steel flexi-pipes on the PDCC valve block at the front.

    The installation position of the steel flexi-pipes -2-  was marked on the steel flexi-pipes and on the valve block during removal -3-  .

    Fit cap screws on steel flexi-pipes -1-  and screw them in until the markings are aligned.

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    Steel flexi-pipes

22. Left wheel housing: Fit fastening nut on holder for power-steering pressure line. > Fastening nut on holder 

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    Fastening nut on holder

23. Fit chassis components.

    Fit fastening nuts -1-  on the upper wishbones on both sides.

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    Fastening nuts on upper wishbones

    Fit connecting link fastening nut -arrow-  to the spring strut on both sides.

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    Fastening nut on connecting link

    Fit fastening nut -1-  on the lower wishbone on both sides.

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    Fastening nuts on lower wishbones

24. Connect plug connection for rpm sensor -arrow-  on both sides.

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    Rpm sensor connector

25. Disconnect the secured coolant hoses and pressure hoses for the charge-air cooler from the lock carrier. > Securing hoses 

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    Securing hoses

    Fit coolant hoses on the engine block on both sides. > Coolant hoses 

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    Coolant hoses

26. Only for 4.8 V8 and 4.8 V8 Turbo: 

    Fit air box on throttle valve.

    Fit locking pins -arrows-  to air box.

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    Locking pins

    Plug in connector for boost pressure sensor -arrow-  .

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    Connector for boost pressure sensor

27. Fit air box hose clamps -arrows-  on both sides.

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    Hose clamps

28. Secure refrigerant lines.

    Connect the refrigerant line near the left longitudinal member.

    Fit line -3-  , screw in fastening screws -1 and 2-  .

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    Refrigerant line on longitudinal member

    Guide in the refrigerant line and secure it at two clips. Screw in fastening screw -2-  on condenser.

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    Loosening fastening screws for refrigerant lines

29. Fit hose for hydraulic oil tank. > Hose for hydraulic oil tank 

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    Hose for hydraulic oil tank

30. Fit hose for coolant reservoir -arrow-  .

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    Hose for coolant reservoir

31. Fit positive cable at the jump-lead starting point.

    Release flap on jump-lead starting point. -arrow- 

    Fit positive cable for the battery at the jump-lead starting point.

    Lock the flap for the jump-lead starting point.

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    Jump-lead starting point

32. Fit breather hose on the bleeder valve -arrow-  .

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    Breather hose

33. Guide coolant hoses into the connection point and lock with the clip. -arrows- 

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    Fitting coolant hoses

34. Secure vacuum line from the vacuum pump on the connection piece. -arrow- 

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    Vacuum line

35. Only for 4.8 V8 and 4.8 V8 Turbo Row: 

    Fit secondary-air pump.

    1. 35.1.1  Secure hose and screw in secondary-air pump.

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       Removing secondary-air pump

36. Insert the plug connections for the oxygen sensors -1-  on both sides.

    > 266519 REMOVING AND REINSTALLING SECONDARY-AIR PUMP WITH BRACKET

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    Plug connections for oxygen sensors

37. Install torque support.

    > 103719 REMOVING AND REINSTALLING TORQUE SUPPORT 

    NOTIFICATION 

    Aggressive fluids 

    • Risk of damage to components and surfaces 
      • Do not spill fluids.
      • In the event of contact, wash the component or surface with water.
      • Replace components that are already damaged.
    WARNING: Highly inflammable or explosive materials 

    • Danger of fire or explosion 
      • Avoid contact with hot parts or sources of ignition.
      • Use suction to remove ignitable vapours.
      • Attach warning sign in a clearly visible position.
      • Contain leaked media using non-flammable absorbent material and put it in a container designed for this purpose for disposal in accordance with local requirements.
      • Secure collection containers/vessels to prevent them from tipping over.
38. Fit fuel low-pressure line.

    Fit the fuel low-pressure line by countering with a wrench. -arrow-  Counter the centre piece and fit union nut on the engine side. > Tightening torque 30 Nm 

    Fit the tank ventilation and vacuum line to the connection point.

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    Fuel low-pressure line

39. Install wiring harness in the plenum panel.

    Fit sleeve with wiring harness into the on-board panel. > Sleeve with wiring harness 

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    Sleeve with wiring harness

40. Install engine wire harness in the plenum panel.

    Plug in connector on the DME control unit -2-  and lock it -1-  .

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    Connector for DME control unit

    Secure the wiring harness to the DME control unit in the plenum panel and lock the relay safety hooks in the plenum panel on both sides. -arrows- 

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    Lifting up relay fusebox