Removing Engine

WARNING: Caustic fluids

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.

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.

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.

Loosen the clamp -1- on the coolant hose -2- .

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Left coolant pipe
Pull coolant hose -2- off the left coolant pipe -3- and drain off remaining coolant.
Loosen clamps -1- on the coolant hoses -2- .

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Left coolant pipes
Pull coolant hoses -2- off the left coolant pipes -3- and drain off remaining coolant.
Release coolant hose -1- on the right coolant pipe -2- (-arrow-) and drain off remaining coolant.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Right coolant hose
Unscrew fastening screws -1- and fastening nuts -2- on the lower part of the fuel filter -3-.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Lower part of fuel filter
Lift lower part of fuel filter -3- up slightly -arrow- and set it aside.
Unscrew fastening screw -1-, disengage the fuel cooler -2- from the holder -3- (-arrow-) and set it aside.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Fuel cooler
Open the cover over the B+ distributor.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

B+ transfer point
Unscrew the B+ line to the starter and generator and expose the line.
Remove the air guide hose at the clamps -arrows- .

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Air guide hose
Unscrew fastening screws -2- ,

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Throttle housing
Pull off electric connector -4- and remove throttle housing -5- from the intake-air distributor.
Information

Place a cloth under the connection point to catch escaping hydraulic oil.
Clamp the hydraulic hose for the power-steering pump -1- with a > 3094 - hose clamp .

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Hydraulic lines

Information

Close off open lines and connections with clean stoppers or protection caps to prevent dirt and moisture from getting in.
Pull hydraulic hose -1- off the power-steering pump.
Loosen fastening screw -A- and remove the refrigerant lines -arrow- . Do not remove the refrigerant lines until you have lowered the unit from the compressor.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Refrigerant line to air-conditioning compressor
Unscrew fastening screw -A- and loosen the refrigerant line at the holder -arrow- .

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Refrigerant line to air-conditioning compressor

Information

Close off open lines and connections with clean stoppers or protection caps to prevent dirt and moisture from getting in.
Unscrew fastening screw -B- and remove the refrigerant lines -arrow- .
Remove the top air guide hose at the positions marked -2 and 3-.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Air guide hose at the top and bottom
Remove the right air guide hose on the turbocharger -arrow- .

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Air guide hose
Take the electric plug connection -arrow- out of the holder and disconnect it.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Electric plug connection with holder
Disconnect the vacuum hose -arrow- for the brake booster.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Vacuum hose
Pull off the breather hose -arrow- on the coolant reservoir.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Breather hose
Disconnect the fuel supply line -1- and fuel return line -2- at the bulkhead.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Supply and return hose
Pull electric plug connection for the oxygen sensor -1- out of the holder and disconnect it.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Plug connection for oxygen sensor
Expose the wire harness for the oxygen sensor.
Pull electric plug connection for the exhaust temperature sensor out of the holder and disconnect it.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Plug connection for exhaust temperature sensor
Expose the wire harness for the exhaust temperature sensor.
Open the cover of the central electrical system on the left side of the vehicle. To do this, loosen the fastening screws -arrows- .

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Fastening screws for the central electrical system cover
Remove the windscreen wiper arms if necessary.
Disconnect the connectors for the engine wire harness -1, 2 and 3- (red, white and black) inside the central electrical system. Loosen the wire harness from the retaining clips inside the plenum panel, remove it and set it down on the engine.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Engine wire harness
Disconnect the engine wire harness on the right side of the vehicle. To do this, unclip, lift up and disconnect the control unit. Disconnect the ground point -arrows- .

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Engine wire harness
Loosen the fastening screws for the spring struts at the left and right -1- . The fastening screws are loosened from inside the engine compartment. One of the three fastening screws on each spring strut is located in the plenum panel. The fastening screws must not be re-used.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Spring strut threaded joint

Information

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Compressed air line on spring strut

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Electric plug connection for height sensor
- 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 depressurized.
- The electric plug connection of the height sensor must be disconnected in vehicles with air suspension or automatic headlight levelling system.
Disconnect electric connector for the wear indicator -1- . Then unclip the holders -2 and 3- , Expose the cable. Disconnect and expose the cable for the ABS sensor -arrow- .

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Cable guide at spring strut 1

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Cable guide at spring strut 2
Disconnect the brake lines -arrow- in the wheel housings at the left and right.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Brake lines in wheel housings
Unscrew ground connection -1- from the right longitudinal member.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Ground connection
Place collecting pan underneath the vehicle.
Disconnect the ATF lines on the ATF thermostat -arrow- . To do this, loosen the fastening screw (a/f 10) and pull off the lines. Close off open lines with a stopper.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

ATF lines on radiator

Information

Close off open lines and connections with clean stoppers or protection caps to prevent dirt and moisture from getting in.
Clamp the hydraulic line -1- for the servo oil cooler with a > 3094 - hose clamp .

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Hydraulic line
Loosen the clamp and pull off the hydraulic line -1- .
Unscrew the fastening screw -2- and set the additional coolant pump -1- aside.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Additional coolant pump
Disconnect electric connections -1, 2 and 3- on the transmission.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Electric connections on transmission
Pull off cable plug on the servo motor -1, 2- and release the cable holder.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Cable plugs on servo motor
Disconnect electric connector on the steering gear (Servotronic only) -arrow- . (Figure shows right-hand drive vehicle)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Servotronic cable plug
Remove the heat shield on the steering gear connection. To do this, loosen the fastening screws -1- , (Figure shows right-hand drive vehicle)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Heat shield for steering gear
Loosen the clamping screw -2- from the steering column on the steering gear and remove it. The fastening screw must not be re-used. Force the steering column up and off the steering gear.
Loosen the rear cardan shaft for the transfer gear.
> WM 393519 REMOVING AND INSTALLING REAR CARDAN SHAFT (ALL MODELS)
Unscrew fastening screws -1, 2 and 3- on the heat shield and swivel the heat shield slightly to the side.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Left heat shield
Remove safety clip -A- on the holder.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Selector lever cable connection
Unscrew selector lever cable from the ball joint using > VAS 6933 - Disassembly tool .

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Removing selector lever cable
Mark the installation position of the front-axle carrier diagonally on at least two places on the body using a felt-tip pen. This makes it easier to correctly position the front-axle carrier on the body during reinstallation.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Marking installation position of front-axle carrier

Information
- Because of the high loosening torque, the six fastening screws on the front-axle carrier can already be loosened now. Loosen the screws by a maximum of one turn.
Place the lifting platform under the engine and raise it. When you do this, ensure that the positioning guides of the lifting platform are inserted into the body.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Lifting platform under engine
The -arrows- show the mounting points for the mounting frame in the front-axle carrier (view from below here).

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Mounting points for front-axle carrier
Position the lifting platform in the front-axle carrier in the take-up points provided -(arrows)- (-4 into the body-) .

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Lifting platform
Secure the spring struts. To do this, turn the rubber discs upwards until they are set under the steering knuckle. Then tighten the retaining brackets on the wheel hub and lifting platform -arrow- .

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Securing spring struts
Loosen the transmission cross member. To do this, loosen the four fastening screws -A- .

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Transmission cross member
Secure the engine/transmission unit. Then secure the mounting mandrels on the engine transverse bar with the locking screws.
Loosen the four fastening screws on the front-axle carrier and the two fastening screws on the engine transverse bar -arrows- .

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Front-axle carrier and engine transverse bar (center)
Lower the lifting platform slowly by approx. 20 to 30 cm. When doing this, a second person should ensure that there is sufficient clearance around the engine compartment and spring struts in the wheel housings. Then disconnect and expose the refrigerant lines if necessary.
Information

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

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
- 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.
Lower the lifting platform fully. When doing this, a second person should ensure that there is sufficient clearance around the engine compartment and wheel housings.