LEMON Manuals: Even more car manuals for everyone
Home >> Porsche >> 2015 >> Macan Turbo >> Repair and Diagnosis >> External Pages >> Different car >> Section 182 (10 - Engine - Crankcase, Suspension -- CARRERA (997)) >> WM 1001Z1 Disassembling The Engine (Except Turbo Coupe, Turbo S Coupe, Turbo CABRIO & Turbo S CABRIO) >> Preliminary Work

Preliminary Work

WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2013 Porsche 911, 2012 Porsche 911, 2011 Porsche 911, 2010 Porsche 911, and 2009 Porsche 911. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Dirt and contamination
  • Risk of damage to units or components

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

Information 

Information 

Information 

  1. Remove the engine.

    → 100119 REMOVING AND INSTALLING ENGINE .

  2. Remove the transmission

    → WM 343527 REMOVING AND MOUNTING TRANSMISSION .

    → 373427 REMOVING AND MOUNTING PORSCHE DOPPELKUPPLUNG (PDK) .

  3. Remove the flywheel.

    → 136019 REMOVING AND INSTALLING FLYWHEEL - PDK TRANSMISSION .

    → 136019 REMOVING AND INSTALLING DUAL-MASS FLYWHEEL .

  4. Mount the engine on the engine assembly support.

    → 1001IN TOOLS FOR REMOVING UNITS AND WORKING ON THE ENGINE ASSEMBLY SUPPORT .

  5. Remove front silencer.

    → 262519 REMOVING AND INSTALLING FRONT SILENCER .

  6. Remove rear silencer.

    → 263319 REMOVING AND INSTALLING REAR SILENCER .

  7. Remove engine carrier.

    → 103019 REMOVING AND INSTALLING ENGINE CARRIER .

    Fig 1: Identifying Front Silencer Engine Carrier And Holder
    G09815697Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  8. Remove exhaust manifold with catalytic converter.

    → 261019 REMOVING AND INSTALLING EXHAUST MANIFOLD WITH CATALYTIC CONVERTER .

  9. Drain engine oil.
    1. 9.1. Unscrew drain plug and collect emerging oil.
    2. 9.2. Then screw in drain plug with a new sealing ring and tighten to the specified torque.

      → Tightening torque: 50 Nm (37 ft. lb.) 

  10. Loosen three external Torx screws (E10, M8 x 12) on the hydraulic pump pulley (do not unscrew fully).
  11. Remove the drive belt.

    → 137819 REMOVING AND INSTALLING DRIVE BELT .

    1. 11.1. Unscrew screws for hydraulic pump pulley and remove the pulley.
  12. Disconnect cable plugs -1 and 3-  on the intake-air distributor on cylinder bank 1-3. Unscrew one external Torx screw (E10, M6 x 12) -2-  used to secure the cable duct.
    1. Cable plug on engine compartment temperature sensor
    2. Cable duct mounting on cylinder bank 1-3
    3. Cable plug on control valve for tank ventilation
    Fig 2: Identifying Intake-Air Distributor Cable Plugs
    G09815698Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 12.1. 3.8-litre engine only:  Pull off cable plug and vacuum line on control valve for tuning flap.
      1. Cable plug on control valve for tuning flap on the resonance tube.
      2. Pull off line on control valve.
        Fig 3: Identifying Tuning Flap Control Valve
        G09815699Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  13. Disconnect positive crankcase ventilation line on the resonance tube -1-  and unclip it at the intake-air distributor -arrows-  . Turn the line towards the rear.
    Fig 4: Locating Positive Crankcase Ventilation Line (Cylinder Bank 4-6)
    G09815700Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 13.1. Unscrew one external Torx screw (E10, M6 x 12) -2-  used to secure the cable duct to the intake-air distributor.
  14. Loosen holder at the oil-fill pipe. To do this, unscrew three external Torx screws (E10, M6 x 12) -2-  .
    Fig 5: Identifying Oil-Fill Pipe Holder And Positive Crankcase Ventilation Line
    G09815701Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 14.1. Unclip positive crankcase ventilation line -3-  at the oil-fill pipe.
  15. Completely remove intake-air distributor.

    → 244619 REMOVING AND INSTALLING INTAKE-AIR DISTRIBUTOR .

    1. 15.1. Unscrew six external Torx screws (E10, M6 x 35).
    2. 15.2. Completely remove the intake-air distributor and resonance tube.
    3. 15.3. Clean sealing faces and close off ducts with adhesive tape or stoppers.
    4. 15.4. Replace molded seals.
  16. Remove oil filler neck -1-  .
    1. 16.1. Unscrew two external Torx screws (E10, M6 x 20) -2-  and pull the connection piece out of the crankcase.
      Fig 6: Identifying Oil Filler Neck
      G09815702Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 16.2. Close off opening with adhesive tape or a stopper.
    3. 16.3. Replace O-ring.
  17. Remove the generator.

    → 272219 REMOVING AND INSTALLING GENERATOR .

    1. 17.1. Pull off cable plug and unscrew M8 hexagon nut on the B+ line. Remove B+ line.
    2. 17.2. Loosen external Torx screws (E12, M8) by two to three turns -1-  and fit screw insert (E12) with short extension on the screw head. Loosen threaded sleeves in the unit carrier by tapping gently with a plastic hammer.
      Fig 7: Identifying Heat Shield Upper Part
      G09815703Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 17.3. Unscrew the right-hand screw, leave the left-hand screw in place and take out the generator.
  18. Remove upper heat shields -1-  for ignition coils.

    → 261219 REMOVING AND INSTALLING HEAT SHIELD .

    1. 18.1. Unscrew two external Torx screws (E10, M6 x 12) -2-  on each and remove the heat shields.
      Fig 8: Loosening Generator Fastening Screws
      G09815704Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  19. Unplug several cable plugs and disconnect ground straps for ignition coils.
    1. Connectors for ignition coils
    2. Internal Torx screws (T40) securing ground connection for ignition coils
    3. Hall sender
    4. Solenoid hydraulic valve for valve lift adjustment
      Fig 9: Identifying Cylinder Head Cover Cable Plugs
      G09815705Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  20. Remove holder for rear silencer -1-  .
    1. 20.1. Unscrew four external Torx screws (E12, M8 x 20) -2-  and remove holder.
      Fig 10: Identifying Rear Silencer Holder
      G09815706Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  21. Disconnect B+ line -1-  and control line for solenoid switch (terminal 50) -2-  at the starter.

    → 276019 REMOVING AND INSTALLING STARTER .

    Fig 11: Removing Starter Fastening Nuts
    G09815707Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  22. Remove positive crankcase ventilation line -1-  (air conditioning compressor remains in the vehicle when you remove the engine).
    1. 22.1. Open rapid-action couplings by pressing the locking ring -3-  and unclip line from the holder -arrow-  .
    2. 22.2. Replace O-rings on the connection point to the bracket for the oil/water heat exchanger.
      Fig 12: Locating Positive Crankcase Ventilation Line
      G09815708Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  23. Remove hydraulic pump -1-  together with the pressure line -2-  and return line -3-  .

    → 489819 REMOVING AND INSTALLING HYDRAULIC PUMP .

    Fig 13: Identifying Hydraulic Pump And Lines
    G09815709Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  24. Remove housing cover for coolant regulator -1-  and coolant intake tube -5-  (from the coolant reservoir).
    1. 24.1. Unscrew one external Torx screw (E10) M6 x 40 -2-  , three M6 x 50 screws -3-  and take off the cover and thermostat.
    2. 24.2. Unscrew two external Torx screws (E10, M6 x 12) -4-  and pull off the intake tube. Replace O-rings.
      Fig 14: Identifying Intake Tube And Coolant Regulator Housing
      G09815710Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  25. Remove oil separator -1-  .
    Fig 15: Identifying Oil Separator
    G09815711Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 25.1. Unscrew two external Torx screws (E10, M6 x 25) -2-  and pull off the oil separator. Replace O-rings.
  26. Remove coolant pipe with coolant hose and connection piece (Henn coupling).
    1. 26.1. Unscrew three external Torx screws (E12, M8 x 70) -2-  on the unit carrier.
      Fig 16: Unit Carrier Screws Loosening Sequence
      G09815712Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 26.2. Unscrew two external Torx screws (E10, M6 x 12) -2-  and remove the coolant pipe and connection piece -1-  .
      Fig 17: Identifying Heat Exchanger Coolant Hoses
      G09815713Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  27. Remove the coolant distributor and coolant hoses (on the oil/water heat exchanger).
    1. 27.1. Open two spring band clamps -1-  and pull the hoses -2-  off the oil/water heat exchanger.
      Fig 18: Identifying Coolant Pipe With Hose And Connection Piece
      G09815714Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 27.2. Unscrew two external Torx screws (E10, M6 x 25) -2-  and pull up the distributor -1-  .
      Fig 19: Identifying Coolant Distributor Screws
      G09815715Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Coolant distributor -1-  and pipes -2-  for the coolant pump and thermostat housing.

      Fig 20: Identifying Coolant Distributor And Connecting Pipes
      G09815716Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 27.3. Replace O-rings -1-  and grease new O-rings with Kluberplus Gel (Part No. 000.043.205.93).
      Fig 21: Identifying Connecting Pipes O-Rings (Coolant Distributor)
      G09815717Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  28. Unplug several cable plugs at the engine, unclip all cable holders and unscrew two external Torx screws (E12, M8 x 16) on the cable duct.

    → 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE .

    • Solenoid hydraulic valve for camshaft control (top of cylinder head)
    • Fuel pressure sensor on fuel collection pipe, cylinder bank 4-6
    • Oil pressure and temperature sensor on bracket for oil/water heat exchanger
    • Fuel injectors
    • Knock sensors
    • Flow control valve on high-pressure pump
    • Coolant temperature sensor on unit carrier
    • Pressure-regulating valve and oil-level sender on oil pan
    1. 28.1. Remove engine wire harness.
  29. Remove transport eyebolt.
    1. 29.1. Unscrew two external Torx screws (E10, M6 x 25).
  30. Remove fuel connection line -1-  to the fuel collection pipes.
    1. 30.1. Loosen two external Torx screws (E10, M6 x 12) at the clamps.
    2. 30.2. Unscrew two external Torx screws (E10) on the fuel line holders. One screw on the center holder M6 x 16 -3-  and one screw on the right holder M6 x 60 (screw point for bracket for oil/water heat exchanger) -2-  .
    3. 30.3. Screw off three union nuts (a/f 17) -4-  and remove the line. Collect emerging fuel with a cloth.
      Fig 22: Identifying Fuel Connection Line And Fuel Collection Pipes
      G09815718Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  31. Remove oil/water heat exchanger -1-  .
    1. 31.1. Unscrew six internal Torx screws (T30, M6 x 20) -2-  and remove heat exchanger.
    2. 31.2. Collect any drops of fluid with a clean cloth and clean the sealing faces.
    3. 31.3. Replace O-rings.
      Fig 23: Identifying Oil/Water Heat Exchanger
      G09815719Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    • The bracket for the oil/water heat exchanger must not be removed at an angle or levered off at one side. 
    • The bracket's aluminum supports can break off in the crankcase. 
  32. Remove bracket for oil/water heat exchanger -1-  .
    1. 32.1. Unscrew six external Torx screws (E10): four M6 x 45 screws -2-  and two M6 x 60 screws -3-  . Pull the bracket up and out.
    2. 32.2. Close off oil ducts with stoppers.
    3. 32.3. Replace two O-rings at the top -4-  and four O-rings on the underside.
      Fig 24: Identifying Oil/Water Heat Exchanger Bracket
      G09815720Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  33. Remove fuel collection pipes.
    1. 33.1. Unscrew four external Torx screws (E10, M6 x 30) -1-  and pull the fuel collection pipes -2-  out of the cylinder heads.
      Fig 25: Identifying Fuel Collection Pipe Threaded Joint
      G09815721Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 33.2. Close off fitted bores in the cylinder head with stoppers.
  34. Remove knock sensors (mark installation position using a water-resistant marker).
    1. 34.1. Unscrew one external Torx screw (E12, M8 x 16) on each sensor and remove sensors.
  35. Remove fuel lines for the high and low-pressure side.
    1. 35.1. Loosen and screw off hexagon union nuts on the high-pressure pump -1-  . Low-pressure line -2-  : a/f 17, high-pressure line -4-  : a/f 14.
    2. 35.2. Unscrew one external Torx screw (E10) M6 x 16 -3-  and one M6 x 12 screw -5-  at the retaining points and remove the lines.
      Fig 26: Identifying High/Low-Pressure Connection Fuel Lines
      G09815722Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  36. Remove high-pressure pump.

    → 246319 REMOVING AND INSTALLING HIGH-PRESSURE PUMP .

    Fig 27: Identifying High-Pressure Pump Heat Shield
    G09815723Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 36.1. Unscrew three external Torx screws (E10, M6 x 12) on the heat shield and remove the heat shield.
    2. 36.2. Unscrew three external Torx screws (E10) on the support: two M6 x 25 screws -1-  and one M6 x 40 screw -2-  .
    3. 36.3. Unscrew two external Torx screws (E10, M6 x 25) -3-  and pull out the pump.
    4. 36.4. Replace O-ring.
  37. Remove vacuum line -1-  for brake booster.

    → 477755 REPLACING VACUUM LINE FOR BRAKE BOOSTER (SECTION AT ENGINE) .

    1. 37.1. Unscrew external Torx screws (E10, M6 x 12) -2-  and pull out line at the vacuum pump.
      Fig 28: Identifying Brake Booster Vacuum Line
      G09815724Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  38. Remove vacuum pump.

    → 477619 REMOVING AND INSTALLING VACUUM PUMP .

  39. Remove lower coolant guide -1-  .
    1. 39.1. Unscrew six external Torx screws (E10, M6 x 25) -2-  .
    2. 39.2. Check molded seals and replace if necessary.
      Fig 29: Identifying Lower Coolant Guide
      G09815725Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  40. Use turning device 9773 -1-  to turn the engine clockwise at the vibration damper until the TDC 1/4  marking on the vibration damper is aligned with the bore in the crankcase.
    Fig 30: Identifying TDC Marking On Cylinder
    G09815726Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 40.1. Secure the engine using one of the locating pins 9595/1 -2-  on the vibration damper.
  41. Remove vibration damper.

    → WM 137519 REMOVING AND INSTALLING VIBRATION DAMPER .

    1. 41.1. Loosen and unscrew six external Torx screws (E12, M8 x 25 x 1) and remove the vibration damper.
    2. 41.2. Check dowel sleeve and crankshaft flange for damage.
  42. Loosen bracket for coolant pump -1-  .
    1. 42.1. Turn the belt tensioner clockwise as far as it will go at the hexagon (a/f 30). Lock the tensioner at the crankcase bore using an M8 screw (e.g. M8 x 50) -2-  .
    2. 42.2. Unscrew four external Torx screws: one M8 x 70 (E12) -3-  , one M8 x 50 (E12) -4-  , one M6 x 20 (E10) -5-  and one M8 x 25 (E12) -6-  .
      Fig 31: Identifying Coolant Pump Bracket
      G09815727Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 42.3. Unscrew one M10 threaded bolt (engine carrier mounting) -7-  (two M10 lock nuts).
  43. Remove coolant connection pipe -1-  to the thermostat housing.
    1. 43.1. Unscrew one external Torx screw (E10, M6 x 12) -2-  on the retaining bracket for the crankcase.
      Fig 32: Identifying Coolant Connection Pipe And Thermostat Housing
      G09815728Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 43.2. Pull out pipe -1-  on the thermostat housing.
  44. Remove thermostat housing -2-  .
    1. 44.1. Unscrew three external Torx screws (E10) M6 x 25 -4-  and one M6 x 50 -3-  .
      Fig 33: Removing Thermostat Housing
      G09815729Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 44.2. Turn bracket for coolant pump slightly to the right.
    3. 44.3. Pull the thermostat housing -1-  down at the unit carrier (double O-ring seal) and lift it off at the connecting tube -2-  to the coolant pump at the same time.
    4. 44.4. Pull off bracket for coolant pump -1-  . Replace O-rings -2 + 3-  . Check seal for damage and replace it if necessary.
      Fig 34: Identifying Coolant Pipes O-Rings (Coolant Pump)
      G09815730Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    5. 44.5. Replace molded seal on the connecting tube -3-  .
      Fig 35: Identifying Thermostat Housing And Connecting Tube (Coolant Pump)
      G09815731Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  45. Remove unit carrier (coolant distributor housing). The screws for the engine connection piece -2-  and the additional attachment for the coolant pump bracket -3 (left) and 5-  have already been removed.
    1. 45.1. Unscrew another external Torx screws M8 x 50 -3 (right)-  and one M8 x 35 -4-  . Remove carrier, check dowel sleeve for damage and replace if necessary.
    2. 45.2. Replace molded seals.
      Fig 36: Identifying Unit Carrier Seals
      G09815732Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  46. Remove cover for positive crankcase ventilation.
    1. 46.1. Cover on cylinder bank 1-3 -1-  : Unscrew three external Torx screws (M6 x 20) -4-  and replace O-ring -3-  and molded seal -2-  .
      Fig 37: Removing Positive Crankcase Ventilation Cover (1-3)
      G09815733Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 46.2. Cover on cylinder bank 4-6 -1-  : Unscrew two external Torx screws (M6 x 20) -3-  and replace O-ring -2-  .
      Fig 38: Removing Positive Crankcase Ventilation Cover (4-6)
      G09815734Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  47. Remove solenoid hydraulic valves for camshaft control.
    1. 47.1. Unscrew two external Torx screws (E8, M5 x 12) on each valve and pull off the valves.
    2. 47.2. Replace O-rings.
  48. Remove hall senders on the cylinder head cover.

    → 283919 REMOVING AND INSTALLING HALL SENDER .

    1. 48.1. Unscrew one external Torx screw (T40, M6 x 16) on each and pull off the hall senders.
    2. 48.2. Replace O-ring.
  49. Remove solenoid hydraulic valves for valve lift adjustment.

    → 155519 REMOVING AND INSTALLING SOLENOID HYDRAULIC VALVE FOR VALVE LIFT ADJUSTMENT .

    1. 49.1. Unscrew two external Torx screws (E8, M5 x 12) on each valve and pull off the valves.
scientia non olet · About LEMON Manuals