Removing and installing engine (vehicle with Tiptronic transmission): Removal

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2005 Porsche 911, 2004 Porsche 911, 2003 Porsche 911, 2002 Porsche 911, and 2001 Porsche 911. However, it is still accessible from the selected car via links, so may be relevant.

Put body-protection covers on vehicle.
Disconnect the battery and cover terminal or battery.
Before the vehicle is raised, the side covers of the underside panel must be removed in the rear area of the jacking points.

Fig 1: Removing Side Covers Of Underside Panel
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Raise vehicle at the prescribed jacking points and remove the rear wheels. Remove the center and rear underside panels.
Remove rear spoiler.

Fig 2: Removing Rear Spoiler
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Remove side retaining brackets (heat shield).

Fig 3: Removing Side Retaining Brackets (Heat Shield)
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Unscrew coolant reservoir cap.
Undo coolant drain plug and drain the coolant; remove the coolant hoses. After draining the coolant, fit a new sealing ring on the drain plug. Tightening torque 10 (+) 5 Nm (7.5 (+) 3.5 ftlb.).

Fig 4: Identifying Coolant Drain Plug
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Remove air cleaner assembly:
1. Undo hexagon-head bolt M6 x 34.
  
  Fig 5: Locating Air Cleaner Assembly Hexagon-Head Bolt M6 X 34
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2. Undo hose clamp on throttle body and pull plug off the mass air flow meter. Unclip wire on air cleaner housing and remove air cleaner assembly.
  
  Fig 6: Removing Hose Clamp On Throttle Body And Mass Air Flow Meter Plug
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Disconnect oxygen sensor plug connections.

Fig 7: Disconnecting Oxygen Sensor Plug Connections
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Detach and remove right-hand coolant hose.

Fig 8: Removing Right-Hand Coolant Hose
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Detach and remove left-hand coolant hose.

Fig 9: Removing Left-Hand Coolant Hose
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In vehicles with air conditioning, the following assembly operations must be performed:
1. Suck Pentosin fluid out of the reservoir until the level is just below the joint. Turn bayonet lock in the direction indicated by the arrow and pull off the reservoir.
  Immediately seal the lower reservoir with a suitable plug (30 mm "PHI").
  
  Bayonet lock closed
  
  Fig 10: Identifying Bayonet Lock Closed
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  Bayonet lock open
  
  Fig 11: Identifying Bayonet Lock Open
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2. Disconnect battery positive at B+ disconnection point. Undo the hexagon nuts and set the box aside.
  
  Fig 12: Disconnecting Battery Positive At B+ Disconnection Point and Hexagon Nuts
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3. Remove drive belt. Mark belt travel direction with a colored pen. Slacken belt by turning the tensioning pulley (wrench size 24 mm) clockwise, hold still and simultaneously take the belt off the drive pulleys.
  
  Fig 13: Identifying Drive (Serpentine) Belt
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  Fig 14: Turning Drive (Serpentine) Belt Tensioning Pulley Clockwise (Wrench Size 24 Mm)
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4. Undo front compressor fastening screws (2 ea.). Undo rear fastening screw between the intake pipes of cylinders 4 and 5. Disconnect the electrical plug connection.
  
  Fig 15: Identifying Rear Fastening Screw Between Intake Pipes Of Cylinders 4 And 5
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5. Lift the compressor out, set it down with the hoses connected and secure it against being dropped.
Disconnect plug-in couplings of the steering pressure line and the steering return line. The plug-in couplings are opened by unscrewing. (Return line = large diameter/pressure line = small diameter.) Collect Pentosin residues.

Fig 16: Disconnecting Plug-In Couplings Of Steering Pressure Line And Steering Return Line
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Fig 17: Identifying Power Steering Line Couplings
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NOTE: The steering lines also can be detached immediately after the engine-transmission unit has been lowered out of the vehicle (better accessibility).
Undo engine wiring harnesses (round connectors with bayonet lock) on the right side in the engine compartment.

Fig 18: Undoing Engine Wiring Harnesses On Right Side In Engine Compartment
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Disconnect vacuum line for the brake booster. Press the black unlocking ring (arrow) and simultaneously pull the line off.

Fig 19: Disconnecting Vacuum Line For Brake Booster
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Disconnect plug connection of tank vent. Press unlocking buttons and simultaneously pull off the line.

Fig 20: Disconnecting Plug Connection Of Tank Vent
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Undo the fuel supply line and fuel return line in the engine compartment (left). It is very important to counter when performing this step. Collect residual fuel.

Fig 21: Identifying Fuel Supply Line And Fuel Return Line In Engine Compartment (Left)
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Raise the vehicle and remove the rear-axle drive shafts, diagonal braces, and front and rear cross members.

Fig 22: Removing Rear-Axle Drive Shafts, Diagonal Braces, And Front And Rear Cross Members
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Undo ground strap between engine and body. Undo the strap at the engine (cylinder head, near cylinder 6).

Fig 23: Identifying Ground Strap Between Engine And Body
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Undo accelerator cable. To do this turn the left-hand rotary sleeve in the direction indicated by the arrow.

Fig 24: Identifying Accelerator Cable
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1. Unclip right-hand accelerator cable mount sleeve and disengage the accelerator cable.
  
  Fig 25: Unclipping Right-Hand Accelerator Cable Mount Sleeve
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Disengage Tiptronic plug and disconnect plug connection.

Fig 26: Disengaging Tiptronic Plug And Disconnecting Plug Connection
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Disengage Tiptronic selector lever cable.

Fig 27: Disengaging Tiptronic Selector Lever Cable
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1. Disengage Tiptronic selector lever cable from the mount. Pull off coolant line.
  
  Fig 28: Disengaging Tiptronic Selector Lever Cable From Mount
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Remove coolant hoses.

Fig 29: Removing Coolant Hoses
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Turn round electrical connector (bayonet lock) in the direction indicated by the arrow and pull it off.

Fig 30: Turning Round Electrical Connector (Bayonet Lock) In Direction
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Prepare retainer plate (A) - special tool 9592 - for the removal operation. Place adapter (B) 9163/2 on the area of the support plate (C) 9592/1 that is identified "996" and screw the adapter together with the retaining plate 9592 (A). Screw support (D) together with the support plate.

Fig 31: Identifying Special Tools
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Fig 32: Assembling View Of Special Tool
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Place pre-fitted retainer plate on the crankcase. It is recommended that the retainer plate be fitted to the crankcase first. Only then should the workshop car jack be fitted. Place car jack underneath under slight load.

Fig 33: Placing Pre-Fitted Retainer Plate On Crankcase
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Fig 34: Placing Car Jack Underneath Under Slight Load
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Undo transmission support.

Fig 35: Identifying Transmission Support Screws (1 Of 2)
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Fig 36: Identifying Transmission Support Screws (2 Of 2)
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Separate engine carrier from the engine mounts (wrench size 18).

Fig 37: Identifying Engine Mount Nuts
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Lower the engine-transmission unit carefully and in steps. Have a second person observe the engine-transmission clearance at the same time.
NOTE: Important: If the vehicle is placed on its wheels or moved in the workshop, the rear cross member should be fitted under all circumstances to maintain the structural strength.