Removing Engine

1. 1.1. Unscrew M8 fastening screws -2-  on the high-pressure and low-pressure lines and counter with assembly tool 9822  while doing this.
2. 1.2. Replace O-rings.
   Fig 1: Identifying Air-Conditioning Lines

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→ 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.

1. 2.1. Remove spring clamp -1-  and pull off the coolant hose -2-  .
2. 2.2. Close off the opening with a clean cloth or stopper. Re-fit spring clamp.
3. 2.3. Check O-ring and replace it if necessary.
   Fig 2: Identifying Coolant Hose And Spring Clamp

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→ Avoid contact with hot parts or sources of ignition.

→ Use suction to remove ignitable vapors.

→ Attach warning sign in a clearly visible position.

1. 4.1. Soak up emerging fuel with a cloth.
2. 4.2. Press locking lugs on the plug-in coupling -arrow-  and pull off the line.
   Fig 4: Locating Fuel Low-Pressure Line Connection

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1. 5.1. Press locking lugs on the coolant vent line and pull off line to the engine.
2. 5.2. Press locking lug on the tank vent line and pull off the line.
   Fig 5: Identifying Coolant And Tank Vent Lines

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1. 6.1. Place cloths underneath.
2. 6.2. Remove spring band clamp -2-  and pull off the supply hose.
3. 6.3. Open rapid-action coupling -3-  for the heating hose by pressing the locking lugs.
   Fig 6: Locating Coolant Supply Hose

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1. 7.1. Remove spring clamp -2-  and pull off the coolant hose.
   Fig 7: Identifying Coolant Hose

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2. 7.2. Close off the opening with a clean cloth or stopper. Re-fit spring clamp.
3. 7.3. Check O-ring and replace it if necessary.

→ 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.

Raise the vehicle.

Only for vehicles with Porsche Dynamic Chassis Control (PDCC): 

• Remove holder -1-  for PDCC lines at the right.
• Unscrew two M6 fastening screws -2-  .
  Fig 8: Identifying PDCC Lines Holder

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• Unclip PDCC lines -1 and 2 -  at the right -arrows-  .
• Remove fixing clip -3-  .
  Fig 9: Locating PDCC Lines Clip

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• Disconnect and close off PDCC lines on the distributor.
• Loosen union nuts -1-  on the pressure lines.
  Fig 10: Identifying Distributor PDCC Lines

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• Close off lines and secure them at the side with a tie-wrap.
  Fig 11: Locating PDCC Lines

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• Disconnect plug-in couplings -1 and 2-  for the steering hydraulic system on the valve block. Collect Pentosin that leaks out in a suitable container.
  Fig 12: Identifying Valve Block PDCC Lines

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• Open the return line -1-  using special tool -2- loosening tool 9780  .
  Fig 13: Opening PDCC Return Line On Valve Block Using Tool (9780)

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• Open the pressure line -1-  using an open-ended wrench (a/f 15). Press thrust ring towards the valve block using an open-ended wrench and pull off the line.
  Fig 14: Opening PDCC Pressure Line

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• Close off PDCC lines and secure them with a tie-wrap.
  Fig 15: Locating PDCC Lines

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All vehicles: 

1. 10.1. Unscrew two hexagon-head bolts (M12 x 30) and washer at the front -2-  .
2. 10.2. Unscrew two hexagon-head bolts (M12 x 40) at the rear -3-  .
3. 10.3. Unscrew two internal serration screws (M10 x 45) -4-  and remove braces.
   Fig 18: Identifying Engine Diagonal Braces

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1. 11.1. Unscrew M12 collar nut -2-  and counter at the screw -3-  .
   Fig 19: Identifying Wheel Carrier Cross Member Brace

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1. 12.1. Unscrew M10 collar nut and counter at the internal Torx screw while doing this.

→ 420619 REMOVING AND INSTALLING REAR-AXLE CROSS MEMBER .

It is advisable to get a second person to help you to remove the cross member. 

1. 13.1. Slide a transmission support under the cross member.
2. 13.2. Unscrew two hexagon-head bolts (M12 x 95) -2-  at the right.
   Fig 20: Identifying Right Cross Member Threaded Joint

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3. 13.3. Unscrew two hexagon-head bolts (M12 x 95) -2-  at the left.
   Fig 21: Identifying Left Cross Member Threaded Joint

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4. 13.4. Lower the cross member and anti-roll bar with the transmission support and set them down.

Vehicles with Porsche Doppelkupplung (PDK): 

1. 14.1. Press end piece of cable off the ball head of the parking lock lever using disassembly tool Nr.21  (-arrow-  ).
2. 14.2. Disconnect cable plug at the top by turning the bayonet lock anti-clockwise.
   Fig 22: Pressing Parking Lock Cable And PDK Cable Plug

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1. 16.1. Unclip line -arrows-  .
   Fig 24: Locating Control Valve And Temperature Sensor Cable Plugs

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1. 17.1. Open the bayonet lock by turning it anti-clockwise.
   Fig 25: Locating Bottom PDK Cable Plug And Cable Guide

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1. 18.1. Open cover -1-  , unscrew M8 hexagon nut -2-  and remove line -3-  .
   Fig 26: Identifying B+ Line

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1. 19.1. Press locking ring together and pull off the vacuum line -arrow-  .
   Fig 27: Locating Brake Booster Vacuum Line

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

1. 20.1. Observe installation position.
   Fig 28: Identifying Master Gear Unit Elevating Platform (WE 1206)

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   1. Master Gear unit elevating platform WE 1206 
   2. Support 9769/1  for Porsche Doppelkupplung (PDK) and 7-speed manual transmission
   3. Support 9769/2  for 6-speed manual transmission (2nd generation 997)
   4. Retainer plate 9769  for engine

Fig 29: Supporting Engine Using Unit Elevating Platform

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1. 21.1. The tilt angle -3-  of the elevating platform plate can be changed to suit the installation position of the engine/transmission unit.
2. 21.2. Mounting points -arrows-  for the retainer plate supports.
   Fig 30: Locating Engine Mounting Points

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3. 21.3. Support 9769/1  must be positioned under the transmission.
4. 21.4. Support the engine/transmission unit slightly with the elevating platform.

1. 23.1. Unscrew six hexagon-head bolts (M10 x 40) -2-  on the brace plate and remove plate and brace.
2. 23.2. Unscrew two hexagon-head bolts (M10 x 50) -3-  on the transmission bracket.
3. 23.3. Unscrew two M10 collar nuts -4-  on the gear support.
   Fig 32: Identifying Brace Plate And Transmission Bracket

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→ 390219 REMOVING AND INSTALLING CARDAN SHAFT .

Fig 34: Identifying Engine Carrier Collar Nuts

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→ Get one or two more people to help.