Removing 4.8-Litre DFI Engine

→ Avoid contact with hot parts or sources of ignition.

→ Use suction to remove ignitable vapours.

→ Attach warning sign in a clearly visible position.

→ Avoid contact with caustic fluid.

→ Wear personal protective gear.

→ Ensure that there is good ventilation.

→ If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.

→ Do not spill fluids.

→ In the event of contact, wash the component or surface with water.

→ Replace components that are already damaged.

Information 

• Because of the high loosening torques, the four fastening screws on the front-axle carrier and the two screws on the engine transverse bar can now be loosened. Loosen the screws by a maximum of one turn. 

Special equipment-specific features are described in the notes. 

1. Detach DME control unit with holder.
   1. 1.1. Unscrew fastening screws -1 -  .
   2. 1.2. Unclip ground strap -2-  on holder -arrow A-  .
   3. 1.3. Slide the DME control unit and holder -3-  to one side -arrow B-  until the connectors are easily accessible.
      Fig 1: Removing DME Control Unit With Holder

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Release the latch for the engine wire harness connector -1 - (-arrows A-)  and remove from the DME control unit -arrows B-. 
   Fig 2: Removing DME Control Unit

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Disconnect ground point -1-  . Unclip rubber sleeve -3-  from the plenum panel and expose the engine wire harness -2-  .
   Fig 3: Engine Wire Harness In Plenum Panel

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Open the cover of the central electrical system on the left side of the vehicle. To do this, loosen four Torx screws -arrows-  .
   Fig 4: Locating Torx Screws For Cover Of Central Electrical System

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Disconnect two connectors for the engine wire harness (white, red) -1 and 2-  inside the central electrical system.

   Detach the wire harness from the retaining clips inside the plenum panel, remove it and then expose it.

   Fig 5: Identifying Cable Plug For Engine Wire Harness

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. For vehicles with PDCC, loosen the additional reservoir -1-  on the plenum panel and lift it up.
   Fig 6: Locating PDCC Reservoir

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. Disconnect B+ transfer point at the left of the engine compartment.
   Fig 7: Removing B+ Transfer Point

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
8. On V8 naturally aspirated engines, remove the intake pipe between the air cleaner housings. → Removing Air Box For Throttle Housing (Intake Pipe Upstream Of Throttle Valve)
9. Turbo engine: 

   Remove Y-shaped pipe ahead of the throttle valve. → Removing Air Box For Throttle Housing (Intake Pipe Upstream Of Throttle Valve)

10. Turbo engine: 

    Pull off both cable plugs for the mass air flow (MAF) sensors -1-  . Disconnect the PCV line -2-  on the right pressure pipe (PCV is positive crankcase ventilation).

    Fig 8: Locating PCV And MAF Sensor

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
11. Turbo engine: 

    Disconnect the line -1-  to the ambient air valves and expose it -2-  .

    Fig 9: Locating Line To Ambient Air Valves

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
12. Disconnect two oxygen sensor connectors at the left and right of the water splash panel and unclip the cables from the holders. Pull retaining clip straight off -arrow-  .
    Fig 10: Locating Oxygen Sensor Connector

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
13. Detach two coolant lines -1 and 2-  on the reservoir.
    Fig 11: Locating Coolant Hoses

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Loosen the torque support . To do this, remove the screw on the engine and loosen the screw on the body. Then bend the torque support up.

    Fig 12: Loosening Torque Support

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
14. Disconnect the vacuum line at the vacuum pump connector on the engine -arrow-  .
    Fig 13: Locating Vacuum Line To Vacuum Pump

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
15. Empty the power-steering fluid reservoir -1-  (and PDCC reservoir) with a syringe. Then detach hose -2 and 3-  from the reservoir. Close off open connections with stoppers.
    Fig 14: Locating Reservoir Hose Slamp

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
16. Disconnect fuel line -4-  and line from the carbon canister -2-  on the plenum panel splash panel. Disconnect vacuum line -3-  . Unclip engine wire harness -1-  and place it on the engine.
    Fig 15: Identifying Lines On Plenum Panel

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
17. Loosen three fastening screws for the spring struts at the left and right.
    Fig 16: Locating Spring Strut Screws

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 17.1. Loosen the screws from the engine compartment. Of the three screws per spring strut, one is in the plenum panel -1-  .
    2. 17.2. Replace screws.
18. Disconnect the coolant supply and return lines from the radiator.

    To do this, pull out the securing clip and pull off the connection. The clips should be fitted again immediately to ensure that the correct clip is used at the correct position.

    On V8 turbo engines, the right pressure pipe -1-  must be removed in order to reach the connection piece.

    Fig 17: Securing Clip On Connection For Coolant Pipe

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    Fig 18: Locating Boost Pressure Pipe

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
19. Lift up the top coolant pipe -1-  and clamp it at the engine.

    Remove both suction pipes -2-  (turbo engine) from the air cleaner housings and bend them to the engine. Secure in place with two rubber straps if necessary. -arrows- 

    Fig 19: Locating Suction And Coolant Pipes

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    • 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 depressurised. 
      Fig 20: Locating Compressed Air Line On Spring Strut

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    • The electric plug connection of the height sensor must be disconnected in vehicles with air suspension or automatic headlight levelling system. 
      Fig 21: Locating Electric Plug Connection For Height Sensor

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
20. Raise the vehicle halfway.
21. Disconnect electric connector for the wear indicator -1-  .
    1. 21.1. Unclip holders -2 and 3-  and expose the cable.
       Fig 22: Locating Cable Guide At Spring Strut 2

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
22. Disconnect and expose cable for the ABS sensor .
    1. 22.1. Unplug sensor on the air spring strut.
       Fig 23: Locating Cable Guide At Spring Strut 1

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
23. Disconnect brake lines -arrow-  .
    Fig 24: Locating Brake Lines In Wheel Housings

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
24. Vehicles with air suspension: 
    1. 24.1. Remove air suspension hose -arrow-  .
       Fig 25: Locating Compressed Air Line

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 24.2. Unplug cable plug -arrow-  on sensor for headlight levelling system.
       Fig 26: Locating Sensor For Headlight Levelling System

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
25. Turbo engine: 

    Remove both pressure pipes.

    Fig 27: Locating Left Pressure Pipe

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 25.1. Release the wire clips on the connection piece -1-  .
    2. 25.2. Pull off pipe and fit wire clips again.
    3. 25.3. Release spring band clamp and remove pressure pipe.
26. Disconnect the ground point -arrow-  on the right side member.
    Fig 28: Locating Ground Cable

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
27. Disconnect ATF lines on the radiator.
    1. 27.1. Loosen the fastening screw -arrow-  and pull off the lines.
    2. 27.2. Close off open lines with stoppers.
       Fig 29: Disconnecting ATF Lines

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
28. Remove heat shield on the steering gear. To do this, loosen two fastening screws -arrows-  .
    Fig 30: Locating Heat Shield On Steering Gear

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
29. Release universal joint on the steering gear -arrow-  and pull it out. The screw must not be re-used.
    Fig 31: Clamping Screw On Steering Column

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    • In the case of vehicles with Servotronic, an electric plug must also be removed from the steering gear. 
30. Disconnect electric connector -arrow-  on the steering gear (Servotronic only). Figure shows right-hand drive vehicle.
    Fig 32: Locating Servotronic Cable Plug

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
31. Disconnect the heat exchanger coolant lines at the bottom of the left wheel housing -arrows-  . Approx. 2 litres of coolant will flow out when you do this.
    Fig 33: Locating Heat Exchanger Coolant Lines In Left Wheel Housing

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
32. Remove the complete exhaust system from the connection point behind the catalytic converters as far as the tailpipes. → Removing Exhaust System
33. Loosen the catalytic converter holders on the body -1-  . The screws on the cross member -2-  remain fitted.
    Fig 34: Fastening Screws On Body And Cross Member

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
34. Remove rear cardan shaft. → WM 393519 REMOVING AND INSTALLING REAR CARDAN SHAFT
35. Release heat shield above the right electric connections -1, 2 and 3-  and disconnect them on the transmission.

    Unclip the wire harness.

    Fig 35: Locating Electric Connections On Transmission

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
36. Loosen electric connections on the transfer gear -arrow-  .
    Fig 36: Locating Connections On Transfer Gear

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
37. Detach the selector lever cable on the transmission. Do not loosen nut -2-  .
    1. 37.1. Press the ball socket -arrow-  away from the transmission.
    2. 37.2. Then pull out the top sheetmetal clip -1-  and remove the cable in an upward direction.
       Fig 37: Locating Selector Lever Cable On Transmission

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
38. Disconnect the lower line on the power-steering fluid cooler -arrow-  . Close off connections.
    Fig 38: Locating Lower Line On Power-Steering Fluid Cooler

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
39. Turbo engine: 

    Remove the hose -3-  between the ambient air valve and intake pipe -1-  on both sides  by loosening the hose clamp -2-  .

    Fig 39: Identifying Connection Between Ambient Air Valve Hose And Intake Pipe

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
40. Disconnect connections for the PDCC lines around the front axle and close off the connections.
    1. 40.1. Use two open-ended wrenches to open the two lines on the front right side member -arrows-  (counter at the hexagon).
       Fig 40: Locating Front Right PDCC Lines

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 40.2. Detach and expose lines -arrows-  from the valve block in the right wheel housing (close off connections).
       Fig 41: Locating PDCC Line In Right Wheel Housing

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 40.3. Detach line on distributor under the transfer gear and close it off.
       Fig 42: Locating PDCC Line On Distributor Under Front-Axle Final Drive

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    4. 40.4. Disconnect PDCC line on the front axle using two open-ended wrenches and expose the line.
       Fig 43: Locating PDCC Line On Front Axle

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
41. Unscrew fastening screws for refrigerant lines -1-  and pull off refrigerant lines -2 and 3- (-arrow-  ).
    Fig 44: Disconnecting Refrigerant Lines On Air-Conditioning Compressor

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    • For installation, it is a good idea to mark the installation position of the front-axle carrier diagonally at least two places on the body. To do this, place the marks vertically with respect to the floor of the body using a felt-tip pen (e.g. mark along the front-axle carrier mount with the pen). This makes it easier to correctly position the front-axle carrier on the body during reinstallation  .
42. Mark the installation position of the front-axle carrier diagonally on at least two places on the body using a felt-tip pen.
    Fig 45: Marking Installation Position Of Front-Axle Carrier

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
43. Set up the lifting platform according to instructions → Tools And Materials 

    Position the lifting platform under the engine and raise it. When you do this, make sure that the positioning guides on the lifting platform are inserted into the body.

    Fig 46: Lifting Platform Under Engine

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
44. The -arrows-  show the take-up points for the mounting frame in the front-axle carrier (view from below shown here).
    Fig 47: Locating Take-Up Points For Front-Axle Carrier

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
45. Position lifting platform in the front-axle carrier in the take-up points provided -arrows- (-1, 3 and 4 into the body-). 
    Fig 48: Lifting Platform

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
46. 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 -arrow-  on the wheel hub and lifting platform.
    Fig 49: Securing Spring Struts

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
47. Loosen the transmission cross member. To do this, loosen the four fastening screws -1-  .
    Fig 50: Fastening Screws On Transmission Cross Member

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
48. Secure the engine/transmission unit. Then secure the mounting mandrels on the engine transverse bar with the locking screws.
49. Loosen four fastening screws -arrows-  on the front-axle carrier.
    Fig 51: Locating Threaded Joint On Chassis Subframe

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
50. Loosen two fastening screws -arrow-  on the engine transverse bar.
    Fig 52: Locating Engine Carrier Mounting

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    • When lowering the engine, make sure that cables, hoses or lines are not trapped accidentally between the engine and body. To prevent this, a second person must make sure that the cables, hoses and lines do not get caught. 
51. Slowly lower the lifting platform by about 20 to 30 cm. When doing this, a second person must ensure that there is sufficient clearance around the engine compartment and spring struts in the wheel housings.