Removing Hydraulic Pump

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WARNING: Danger of injury and material damage when using Pentosin.

Risk of skin irritation and damage to skin.
Damage to hoses and wiring.

→ Wear protective gloves and goggles.

→ In the event of contact (eyes or skin), wash immediately with water.

→ Collect emerging Pentosin.

→ Use caps to protect the wiring against soiling and damage.

→ Clean hoses and wiring immediately.

Information

Cover engine openings (e.g. intake openings, crankcase, lines, open containers, etc.) with a cloth to prevent dirt and foreign bodies from getting into the openings.

The air-conditioning lines on the compressor do not need to be opened in order to remove the hydraulic pump. After removal, place the air-conditioning compressor on a suitable protective support (e.g. foam or neoprene).

Fig 1: Overview Of Hydraulic Pump

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Reservoir
M8 screw
Pulley (plastic)
Hydraulic pump
Holder
M8 screw
M6 screw

Remove drive belt and pulley.
Loosen the M8 screws on the pulley before removing the drive belt.

→ 137819 REMOVING AND INSTALLING DRIVE BELT .
1. 1.1. Loosen screws -2- on the pulley -1- .
  
  Fig 2: Identifying Pulley With Screw
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 1.2. Turn the tensioner -3- clockwise at the hexagon (a/f 30) using a ring wrench -2- and take off the drive belt -1- .
  
  Fig 3: Removing Drive Belt
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 1.3. Allow the tensioner to slide back to its initial position.
Remove the engine vent hose.
1. 2.1. Release the engine vent hose -1- on the engine vent pipe -2- and pull it off.
  
  Fig 4: Identifying Engine Vent Hose Clamp
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 2.2. Remove the engine vent hose -1- from the clip holder.
3. 2.3. Unscrew screw -3- and pull the engine vent hose -1- out of the oil separator housing.
4. 2.4. Release the engine vent hose -1- at the oil filler neck -4- and on cylinder bank 4-6 -5- and pull it off.
  
  Fig 5: Identifying Engine Vent Hose At Oil Filler Neck
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Disconnect and remove air conditioning compressor.
1. 3.1. Partially detach hydraulic pump.
  Unscrew M8 x 30 screws -1- and detach the holder and fuel hose -2- at the hydraulic pump -3- .
  
  Fig 6: Identifying Hydraulic Pump With Screws
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 3.2. Remove B+ box on the air conditioning compressor.
  
  Fig 7: Identifying B+ Box With Mounting Bolts
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. 3.2.1. Open lid -1- of B+ box. Loosen and unscrew M8 nut -2- and remove B+ cable.
  2. 3.2.2. Loosen and unscrew nuts -3- on the B+ box. Remove B+ box and set it aside.
3. 3.3. Disconnect electric cable plug on the air conditioning compressor.
  Pull off electric cable plug -1- and pull connector housing out of the holder -arrow- .
  
  Fig 8: Disconnecting Electric Cable Plug On Air Conditioning Compressor
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. 3.4. Disconnect air conditioning compressor.
  1. Air conditioning compressor
  2. Screw, M8 x 170
  3. Screw, M8 x 90
  4. Holder
  Unscrew screws -2, 3- and remove the holder -4- .
  
  Fig 9: Identifying Air Conditioning Compressor Components
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. 3.5. Remove air conditioning compressor.
  Guide the air-conditioning lines -2- towards the cut-out on the right -arrow- in such a way that the air-conditioning lines -2- are not strained. Swivel air conditioning compressor -1- out backwards and set it down.
  
  Fig 10: Removing Air Conditioning Compressor
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Drain hydraulic fluid at underbody connection point.
1. 4.1. Remove rear underbody panelling.
  Replace fastening nuts -2- following removal.
  
  Fig 11: Identifying Rear Underbody Panelling Components
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 4.2. Remove underbody panel at the left side.
  Replace fastening nuts -3- following removal.
  
  Fig 12: Identifying Side Cover Components
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 4.3. Open the plug-in couplings for the steering hydraulic system on the underbody. Collect emerging Pentosin in a suitable container.
Fig 13: Locating Pressure And Return Lines Coupling
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 4.3.1. Follow the instructions for disconnecting lines: → 4X00IN PLUG-IN COUPLINGS FOR HYDRAULIC LINES - AS OF MODEL YEAR 2009 .
  
  Fig 14: Identifying Special Tool 9780
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 4.3.2. Open hydraulic lines using release tool 9780 .
  Re-connect the hydraulic lines -1, 2- immediately after draining them. Make sure that the supply and return hydraulic lines are not confused and that the connecting couplings lock with an audible click when you connect them.
  
  Fig 15: Removing Plug-In Coupling
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 4.3.3. Drain remaining fluid from the reservoir.
  Extract Pentosin fluid from the supply tank with a pump. Dispose of extracted Pentosin according to the relevant regulations. Lay a cloth under the tank to collect any emerging Pentosin.
  
  Fig 16: Identifying Collecting Pentosin
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Remove hydraulic pump.
1. 5.1. Disconnect return line to the reservoir for the hydraulic pump (release and pull it out at the same time).
  Disassembly tool, universal NR.21
  
  If you do not have a special tool to hand, press the circlip -center arrow- forward using two plastic spatulas or an open-ended wrench (a/f 12) and pull the return line -right arrow- out at the same time.
  
  Fig 17: Removing Return Line And Holder On Pump
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 5.2. Close off the return bore on the reservoir -2- with a stopper -1- .
  
  Fig 18: Identifying Reservoir With Stopper
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 5.3. Unscrew screw -1- on holder for hydraulic pump.
  
  Fig 19: Identifying Holder For Compressor
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. 5.4. Remove hydraulic pump.
  
  Fig 20: Identifying Hydraulic Pump With Screws
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. 5.4.1. Loosen and unscrew pressure line -1- on the hydraulic pump -3- . Counter at the connection piece (a/f 27) when detaching the pressure line -1- (a/f 16).
  2. 5.4.2. Unscrew M8 x 30 screw -2- on the hydraulic pump -3- and remove hydraulic pump -3- and reservoir.