Removing Engine

→ Avoid contact with hot parts or sources of ignition.

→ Use suction to remove ignitable vapors.

→ 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 

• 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 re-installation  .

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  .

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  .

Information 

• The pictures shown in this document may differ from the original  .

1. Release electric plug connection -1- - M -  on the DME control unit -2-  (-a-  ) and pull it off -A-  .
   Fig 1: Removing DME Control Unit Plug Connection

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Loosen fastening nut -1-  for ground point at the body and remove ground cable -2-  to the DME control unit.

   Cut the tie-wrap if necessary.

3. Remove the tie-wrap -3-  if necessary.
Fig 2: Identifying Body Ground Point
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Open the cover of the front relay box in the plenum panel. → 970955 REPLACING SUB-PART OF WIRE HARNESS IN ENGINE COMPARTMENT AT THE FRONT LEFT
5. Release and unplug the three electric plug connections -1-  on the engine wire harness.
   Fig 3: Identifying Engine Plug Connections

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6. Unclip the engine wire harness -1-  in the plenum panel from the retaining clips -2-  and remove it.
   Fig 4: Identifying Plenum Panel Engine Wire Harness

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7. Disconnect B+ transfer point at the left of the engine compartment.
   Fig 5: Removing B Positive Transfer Point

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8. Release electric plug connections -1-  at the left cross panel -a, b  and pull them off -A, B-  .
   Fig 6: Removing Left Cross Panel Plug Connections

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
9. Release electric plug connections -1-  at the right cross panel -a, b-  and pull them off -A, B-  .
   Fig 7: Removing Right Cross Panel Plug Connections

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
10. Lay the engine wire harness on the engine and secure it.
11. Remove intake pipe. → REMOVING COWL FOR THROTTLE HOUSING (Y-PIPE)
12. Drain the hydraulic fluid reservoir -1-  and the PDCC reservoir -2-  , if necessary, using a suitable tool.

    Then remove the hoses -3, 4-  at the tanks and close them off using suitable stoppers. → REMOVING RESERVOIR , → 430955 REPLACING RESERVOIR (PDCC)

    Fig 8: Identifying Hydraulic Reservoir Hoses

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
13. Loosen the fuel line -1-  at the plenum panel.
14. Release the clamp -2-  on the tank ventilation line.
15. Pull the vacuum hose -3-  off the lower part -4-  of the line.
Fig 9: Identifying Plenum Panel Lines
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16. Disconnect the coolant line -1-  from the coolant reservoir -2-  at the bleeder valve.
17. Loosen the clamp -3-  on the coolant hose -4-  at the coolant reservoir -2-  .

    Pull off the coolant hose.

    Fig 10: Identifying Coolant Reservoir Lines

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
18. Loosen clamps -1-  on the coolant hoses -2-  at the top of the engine.

    Pull off coolant hoses -2-  .

    Fig 11: Identifying Engine Coolant Hoses

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19. Loosen the clamp -1-  on the vacuum line -2-  at the vacuum pump -3-  and pull off the vacuum line.
    Fig 12: Identifying Vacuum Pump Line

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20. Raise the vehicle.
21. Unscrew fastening screws -1, 2-  for holders -3, 4-  for brake hydraulic lines.
22. Loosen holders from the wheel bearing housing -5-  .
Fig 13: Identifying Hydraulic Lines Holders
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23. Release electric plug connections -1-  for the speed sensor on the wheel bearing housing -a-  and pull them off -A-  .
    Fig 14: Locating Wheel Bearing Housing Plug Connections

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
24. Remove the brake calliper and suspend it at a suitable position in the wheel arch → Suspending brake calliper  (do not open brake hydraulics!).

    Also protect the brake calliper (e.g. with a cloth or suitable rubber mat) to prevent damage to the paintwork.

    Fig 15: Identifying Brake Caliper

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
25. Remove fastening screws -1-  for the connecting links -2-  at the bottom of the anti-roll bar -3-  .
    Fig 16: Identifying Anti-Roll Bar Connecting Link

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
26. Press out the ball joint between the wheel carrier and upper wishbone using ball joint puller T10187  .
27. Unscrew the fastening screw -2-  for the spring strut -3-  and at the same time, raise the axle support -1-  as far as required using a suitable jack -4-  so that the fastening screw can be unscrewed easily.
    Fig 17: Removing Spring Strut Mounting

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
28. Disconnect the ground point on the right longitudinal member. -arrow- 
    Fig 18: Locating Right Longitudinal Member Ground Point

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
29. Loosen the fastening screw -1-  on the holder -2-  for ATF lines -3-  at the thermostat -4-  .
    Fig 19: Identifying Thermostat To Transmission ATF Lines

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
30. Place a suitable container underneath to catch emerging ATF  .
    • Pull ATF lines out of the thermostat.
    • Close off the ATF lines and bores on the thermostat using suitable stoppers.
31. Loosen fastening screws -1-  on the heat shield -2-  at the steering gear.

    Remove heat shield -2-  .

    Fig 20: Identifying Steering Gear Heat Shield

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
32. Loosen the clamping screw -1-  on the steering column -2-  at the steering gear -3-  .

    Slide the steering column -2-  upwards -arrow-  and pull it down off the steering gear -3-  (-A-  ).

    Fig 21: Loosening Steering Column

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
33. Pull clamps -1-  off the coolant lines -2-  for the heating water heat exchanger in the engine compartment at the rear left on the wheel housing.
    Fig 22: Identifying Front Left Wheel Housing Coolant Lines

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
34. Pull off coolant hoses -2-  .
35. Loosen the fastening screw -1-  for the refrigerant line -2-  at the front left longitudinal member -3-  and pull out the line.
    Fig 23: Identifying Front Left Refrigerant Line

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
36. Remove the line -1-  from the air-conditioning compressor to the condenser -2-  .
    1. 36.1. To do this, unscrew the fastening screw -3-  for the line -1-  at the condenser -2-  .
    2. 36.2. Close off lines and connection pieces.
    Fig 24: Identifying Air-Conditioning Compressor To Condenser Line
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
37. Loosen the clamp -1-  on the hydraulic line -2-  in the front left wheel housing and pull the hose off the hydraulic line.

    Close off the line and connection piece using suitable stoppers.

    Fig 25: Identifying Front Left Hydraulic Line

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
38. Loosen the cardan shaft at the transfer gear using a mounting lever and tie it up. → REMOVING FRONT CARDAN SHAFT
39. Release electric plug connections -1, 2-  at the right of the transfer gear -a, b-  and pull them off -A, B-  .
    Fig 26: Removing Transfer Gear Plug Connections

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
40. Release electric plug connections -1, 2-  at the bottom of the transfer gear -a, b-  and pull them off -A, B-  .
    Fig 27: Removing Transfer Gear Plug Connections

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41. Mark gearshift position - N - -1-  on automatic transmission -2-  with a suitable pen -A-  .
    Fig 28: Identifying Gearshift Position Marking

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42. Remove shift cable -3-  on automatic transmission -4-  .

    → REMOVING SELECTOR LEVER CABLE

    1. 42.1. Unclip the cable -3-  at the front of the ball joint -1-  using disassembly tool Nr.21  .
    2. 42.2. Unscrew fastening screws -2-  on the shift cable -3-  .
    Fig 29: Removing Shift Cable

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
43. Loosen fastening nuts -8-  on the exhaust clamp (clamping sleeve) -3-  between the catalytic converter and exhaust system. Slide exhaust clamps onto the exhaust system. The exhaust clamps must not be re-used. → REMOVING EXHAUST SYSTEM
    Fig 30: Identifying Exhaust Clamps

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
44. Mark the installation position of the front-axle carrier diagonally at least two places on the body using a felt-tip pen. This makes it easier to correctly position the front-axle carrier on the body during reinstallation. → Marking installation position of front-axle carrier 
    Fig 31: Marking Front-Axle Carrier Position

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
45. Set up the lifting platform according to instructions

    → 100119 REMOVING AND INSTALLING ENGINE  Then position it under the engine and raise it. When you do this, ensure that the positioning guides of the lifting platform are inserted into the body. → Lifting platform under engine 

    Fig 32: Identifying Engine Lifting Platform

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46. The -arrows-  show the mounting points for the mounting frame in the front-axle carrier (view from below here).
    Fig 33: Locating Front-Axle Carrier Mounting Points

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
47. Position lifting platform in the front-axle carrier in the mounting points provided -(arrows)-  , -4 into the body-  .
    Fig 34: Lifting Platform

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
48. Secure the wheel bearing housing. To do this, turn the rubber discs upwards until they are set under the steering knuckle. Then tighten the retaining brackets on the wheel hub and lifting platform. -arrow- 
    Fig 35: Locating Wheel Bearing Housing

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
49. Mark the final position of the lifting platform -1-  on the workshop floor using a suitable tool, e.g. adhesive tape -A-  .
    Fig 36: Position Engine Lifting Platform

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50. Loosen the transmission cross member. To do this, loosen the four fastening screws -A-  .
    Fig 37: Identifying Transmission Cross Member Fastening Screws

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
51. Secure the engine/transmission unit. Then secure the mounting mandrels on the engine transverse bar with the locking screws.
52. Loosen the four fastening screws on the front-axle carrier and the two fastening screws on the engine transverse bar. -arrows- 
    Fig 38: Locating Front-Axle Carrier And Fastening Screws

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
53. Get a second mechanic to help  .

    1st mechanic: Lower the lifting platform slowly by approx. 20 to 30 cm.

    2nd mechanic: Observe the lowering process and check that the components, hoses and lines have sufficient clearance.