Removing Engine
- 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.
- Danger of chemical burns
- Wear personal protective gear.
- Ensure that there is good ventilation.
- Avoid contact with caustic fluid.
- If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.
- Risk of burns
- Let hot components cool down.
- Wear personal protective gear.
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.
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
After disconnecting hoses, close off all openings immediately using commercially available rubber stoppers.
When fitting parts, do not remove stoppers until shortly before installation. Likewise, do not remove the protective foil from the dryer until just before installation. The dryer absorbs moisture from the air and is then useless.
Information
- These instructions describe how to remove and install the engine on vehicles with turbo engines with the maximum number of accessories and components.
- Some of the steps described here may not be necessary on vehicles with naturally aspirated engines or on 2WD vehicles, for example, since these vehicles do not have certain accessories and components.
- The slightly different illustrations between the naturally aspirated engine and the turbo engine show essentially the same tasks.
- Remove engine wire harness in the plenum panel.
Release the relay fusebox in the plenum panel on both sides, lift it up and disconnect the wiring harness for the DME control unit in the plenum panel, -arrows-
Lifting up relay fusebox
Release the connector on the DME control unit -1- and disconnect it -2- .
Connector for DME control unit
Remove sealing sleeve with wiring harness -arrow- from the plenum panel.
Sleeve with wiring harness
Information
- Before setting down removed cables, lines and components, protect the top of the engine, the intake-air distributor and the design covers from scratches using a suitable cloth.
Place engine wiring harness on the engine block.
- Disconnect the fuel lines.
Release the tank vent line and vacuum line at the connection point.
Release the fuel low-pressure line -arrow- by countering with a wrench and disconnect it.
Fuel low-pressure line
- Remove upper torque support.
- Unclip plug connections -1-
for the left and right oxygen sensors and remove them by pulling them up -arrows-
. Release plug connection and pull it off.
Place connecting cable for oxygen sensors on the engine.
Plug connections for oxygen sensors
Only for 4.8 V8 and 4.8 V8 Turbo Row:
- Remove secondary-air pump.
Unscrew secondary-air pump and pull off hose
> 266519 REMOVING AND INSTALLING SECONDARY-AIR PUMP WITH BRACKET
Place the secondary-air pump on the engine and secure it with tie-wraps to prevent it from falling down.
Removing secondary-air pump
- Pull vacuum line off the vacuum pump at the connection piece. -arrow-
Vacuum line
- Release clip on coolant hoses at the plenum panel and remove them from the connection point at the plenum panel (cross panel). -arrows-
Removing coolant hoses
Information
- Before setting down removed cables, lines and components, protect the top of the engine, the intake-air distributor and the design covers from scratches using a suitable cloth.
- Pull breather hose off the bleeder valve -arrow-
and set it down on the engine.
Breather hose
- Remove positive cable at the jump-lead starting point.
Release flap on jump-lead starting point -arrow- .
Unscrew positive cable for battery at the jump-lead starting point and set it down on the engine. > Jump-lead starting point
Jump-lead starting point
- Disconnect hose for coolant reservoir underneath the valve cover (cylinder bank 2) -arrow-
.
Hose for coolant reservoir
- Drain hydraulic oil tank until empty.
> Refer to 489755 Replacing reservoir
- Release and disconnect hose for hydraulic oil tank > Hose for hydraulic oil tank.
Hose for hydraulic oil tank
- Release refrigerant lines.
Unscrew the fastening screw -2- on the condenser, release the two clips to undo the refrigerant line and guide it out.
Loosening fastening screws for refrigerant lines
Disconnect the refrigerant line near the left longitudinal member.
Unscrew fastening screws -1 and 2- , remove line -3- .
Refrigerant line on longitudinal member
- Release hose clamps -arrows-
on the air box on both sides.
Hose clamps
- Only for 4.8 V8 and 4.8 V8 Turbo:
Remove air box for throttle housing.
Release both locking pins -arrows- on the air box and pull them out.
Locking pins
Release and unplug connector for boost pressure sensor -arrow- .
Connector for boost pressure sensor
- Release and disconnect the clamp on the coolant hoses -arrows-
on the aluminium pipes for the thermostat housing on both sides. > Coolant hoses
Coolant hoses
- Secure coolant hoses -arrows-
and the pressure hoses for the charge-air cooler to the lock carrier with tie-wraps.
Securing hoses
- To relieve the wishbones, fit the safety hooks -arrow-
for the upper wishbone on both sides.
> VW552 - Spring tensioner
Safety hooks
- Raise the vehicle halfway.
- Release and disconnect plug connection for rpm sensor -arrow-
on the wheel carrier on both sides.
RPM sensor connector
- Remove chassis components.
Remove fastening nuts -1- on the upper wishbones on both sides.
Fastening nuts on upper wishbones
Remove fastening nut -arrow- on the spring strut connecting link on both sides.
Fastening nut on connecting link
Loosen fastening nut -1- on the lower wishbone on both sides, but do not remove the bolt yet.
Fastening nuts on lower wishbones
- Left wheel housing: Remove fastening nut on the servo line holder -arrow-
.
Fastening nut on holder
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.
- Vehicles with PDCC:
Left wheel housing: Disconnect steel flexi-pipes on the PDCC valve block at the front.
Mark the installation position of the steel flexi-pipes -2- on the steel flexi-pipes and on the valve block -3- using a suitable touch-up stick.
Unscrew cap screws on steel flexi-pipes -1- .
Steel flexi-pipes
- Right wheel housing: Remove the ground cable fastening nut -arrow-
, take off the cable.
Ground cable
- Raise the vehicle fully.
- Only for 4.8 V8 Turbo:
Disconnect the pressure hoses on the charge-air coolers -arrow- and allow the pressure hose to hang freely.
Pressure hose on charge-air cooler
Loosen hose clamps -arrow- and pull off suction hoses.
Suction hose
Disconnect the ambient air valves from the charge-air coolers on both sides.
- Pull off cable plugs from horn on both sides.
- Vehicles with PDCC:
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.
Left side: Disconnect steel flexi-pipe to the expansion hose > Steel flexi-pipe to expansion hose.
- Left side: Remove return hose for hydraulic oil cooler.
Unscrew fastening screw -1- between the hose clamps.
Disconnect return hose -2- on the hydraulic oil cooler.
Return hose for hydraulic oil cooler
- Remove reinforcement plate -1-
.
Undo fastening screws -2- .
Remove reinforcement plate -1- .
Reinforcement plate
- Remove PDK wiring harness.
Remove the fastening screws -arrows- on the heat shield for the PDK wiring harness on the transmission.
Heat shield for PDK wiring harness
Remove heat shield for PDK wiring harness.
Release and disconnect PDK wiring harness -1- connectors on the transmission -2- and loosen the retaining clip -3- .
Connectors on PDK wire harness
Loosen retaining clips -arrows- and remove PDK wiring harness.
Retaining clips on PDK wire harness
- Remove parking lock cable.
Disconnect parking lock cable using > VAS 6933 - Disassembly tool . > Removing parking lock cable
Removing parking lock cable
Press fastening part on the parking lock cable -arrows- up and pull it backwards out of the support.
Parking lock cable support
- Remove heat shield -1-
between the universal joint for the steering gear and the primary catalytic converter.
Remove fastening screws -2- .
Remove heat shield -1- .
Heat shield
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.
- Remove universal joint -1-
.
Vehicles with Servotronic:
Pull off connector -3- .
Detach holder on cable for the Servotronic connector and set the cable aside.
Undo clamping screw -2- .
Slide universal joint -1- and lower part of steering column upwards, -arrow-
Removing universal joint
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!
- Possible danger of injury or damage (e.g. swollen hoses, skin irritation, danger of slipping, etc.)
- Loosen supply and return hose for the ATF transmission oil cooler -arrows-
and drain the oil.
Supply and return hose for transmission oil cooler
Information
Adhesive tape markings on the workshop floor
- Before moving the unit elevating platform, mark the position of the wheels on the workshop floor with adhesive tape. This makes it easier to position the platform again for re-installation.
Information
- For specific tightening torques and further details on positioning, see the operating instructions provided: Assembly fixture for Porsche Panamera on Master Gear 1.0 lifting platform
- Place > VAS 6832 - Master Gear unit elevating platform
under the vehicle and move all assembly drivers -1 to 6-
to the same height in the correct position.
Overview of assembly drivers
Legend for assembly drivers and supports
Item Designation Explanation 1 Transmission bracket For mounting on the transmission mount. 2 Assembly driver on cross panel For mounting on the cross panel. 3 Wheel hub holder Prevents the axles from falling out. 4 Peering knuckle bracket Used together with the wheel hub holder 3 to protect the axles and spring struts from damage. 5 Assembly driver on front-axle carrier For mounting on the rear of the front-axle carrier. 6 Front-axle carrier support For mounting on the front of the front-axle carrier. - Get the lifting platform ready and move it to the jacking points on the front axle (supporting frame and transmission mount). Set the heights of the drivers and supports and ensure solid contact.
- Remove bolts on lower wishbones.
Raise the lifting platform slightly in order to relieve the pressure on the bolts on the lower wishbone.
Pull out bolts on the lower wishbone -arrow- on both sides.
Bolts on lower wishbone
- Remove the safety hooks -arrow-
for the upper wishbone on both sides.
Safety hooks
- Detach front-axle carrier.
Mark the position of the contact points of the front-axle carrier on the longitudinal members -arrow- on both sides.
Remove fastening bolts securing front-axle carrier to the longitudinal member on both sides.
Marking and fastening bolts on front-axle carrier
- Remove fastening screws -3 and 4-
securing the anti-roll bar to the supporting plate on both sides.
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Mounting for front-axle support
- Remove transverse struts.
Right side: Press down rear wheel housing cover -1-arrow- . Remove the transverse strut -2- between the supporting plate and door sill.
Left side: Remove transverse strut between the supporting plate and door sill.
Removing struts (right side shown here)
- Fit wheel hub holder -1-
on both sides using assembly pins -2-
on the wheel hub.
Wheel hub holder (shown here on steel brake disc)
- Remove fastening screws -arrows-
on the rear transmission mount.
Fastening screws on transmission mount
Information
- When lowering the engine, make sure that no cables, hoses or lines are fitted between the engine and body.
- Get a second person to help you check this.
Information
Adhesive tape markings on the workshop floor
- Before moving the unit elevating platform, mark the position of the wheels on the workshop floor with adhesive tape. This makes it easier to position the platform again for re-installation.
- Guide out engine.
Gradually lower the > VAS 6832 - Master Gear unit elevating platform and engine/transmission unit.
Only for 4.8 V8 and 4.8 V8 Turbo:
Gradually guide the air-conditioning lines > Air-conditioning lines along with your hand.
Air-conditioning lines
Push the PDCC hose to one side while lowering the engine.
Move engine out from under the vehicle using the lifting platform.