Installing Engine

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2016 Porsche Panamera, 2015 Porsche Panamera, 2014 Porsche Panamera, 2013 Porsche Panamera, and 2012 Porsche Panamera. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: ATF!

Possible danger of injury or damage (swollen hoses, skin irritation, danger of slipping, etc.)

→ Before lines are opened, place a cloth underneath them!

→ Components that come into contact with ATF must be cleaned IMMEDIATELY with water!

→ Take appropriate protective measures (e.g. use gloves, safety goggles, oil binding material)

→ Collect emerging ATF!

NOTE: Opened refrigerant system for repairs.

Moisture penetrated into the refrigerant system.
Soiling of refrigerant circuit.
Risk of saturation and irreparable damage to desiccator.
If the desiccator has disintegrated, the desiccator, compressor and evaporator may be damaged.

→ If the air humidity is too high and if the refrigerant circuit is open for some time, it will be necessary to replace the desiccator.

Information

Set the steering wheel with the wheels in straight-ahead position. To do this, engage the steering column lock or clamp the steering wheel in center position with a steering-wheel holder. If this is not done, the airbag contact unit will have to be moved to center position after installation of the steering gear. → 945019 REMOVING AND INSTALLING STEERING-COLUMN SWITCH

Information

The tightening specifications for the basic engine are stored centrally (→ 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES, ASSEMBLY OVERVIEWS ).

Tightening torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.

Information

Due to currently correct tightening specifications, the screw specifications can be found in the corresponding repair descriptions for the assemblies chassis, transmission, electrics, etc.

Guide the engine in under the vehicle.
Information

Check the position of all lines, hoses and cables again during and following installation. Make sure that:
- The lines, hoses and cables are not installed twisted (markings on steel flexi-pipes!)
- The lines, hoses and cables are not exposed to any mechanical strain from the outside while driving, i.e. they must not be over-strained or deformed.
- The lines, hoses and cables are not rubbing against other moving components.
- The lines, hoses and cables cannot become clamped.
1. 1.1. Move engine under the vehicle using the lifting platform.
2. 1.2. Position the wheels of the lifting platform to the position marked during removal.
3. 1.3. Guide the engine up into the engine compartment using the lifting equipment.
4. 1.4. Push the PDCC hose to one side while raising the engine.
5. 1.5. Fit the locking cable at half height (easier to access).
  → 371319 REMOVING AND INSTALLING LOCKING CABLE
  1. 1.5.1. Pull the locking cable down and engage it in the support.
  2. 1.5.2. Fit parking lock cable at the ball joint on the transmission.
Fit front-axle carrier. For tightening torques and other details, see: → 400619 REMOVING AND INSTALLING FRONT-AXLE CARRIER
1. 2.1. By adjusting the position of the lifting platform slightly, move to the marking -arrows- for the contact points for the front-axle carrier on the longitudinal members.
2. 2.2. Fit fastening screws securing front-axle carrier to the longitudinal members on both sides.
  
  Fig 1: Locating Marking And Fastening Screw On Front-Axle Carrier
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit fastening screws -arrows- on the rear transmission mount.
For tightening torques and other details, see: → 373837 DISASSEMBLING AND ASSEMBLING TRANSMISSION SUPPORT

Fig 2: Locating Fastening Screws On Transmission Mount
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit fastening screws -3 and 4- securing the anti-roll bar to the supporting plate on both sides.
For tightening torques and other details, see: → 4X00IN TIGHTENING TORQUES FOR FRONT AXLE

Fig 3: Identifying Mounting For Front-Axle Support
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit transverse struts -2- .
For tightening torques and other details, see: → 4X00IN TIGHTENING TORQUES FOR FRONT AXLE
1. 5.1. Right side: Press rear wheel housing cover -1- down -arrow- and fit the transverse strut -2- between the supporting plate and door sill.
2. 5.2. Left side: Fit transverse strut between the supporting plate and door sill.
  
  Fig 4: Installing Struts (Right Side)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit the safety hooks -arrow- for the upper wishbone on both sides.

Fig 5: Locating Safety Hooks
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Guide in and fit bolt on the lower control arm -arrow- .
For tightening torques and other details, see: → 4X00IN TIGHTENING TORQUES FOR FRONT AXLE

Fig 6: Installing Bolts On Lower Wishbone
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Remove wheel hub holder -1- on the lifting platform and remove assembly pins -2- on the wheel hub.

Fig 7: Removing Wheel Hub Holder (Steel Brake Disc)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Lower and push away engine lifting platform.
Fit universal joint -1- .
For tightening torques and other details, see: → 481519 REMOVING AND INSTALLING STEERING COLUMN
1. 10.1. Pull universal joint -1- and lower part of steering column -arrow- downwards.
2. 10.2. Fit clamping screw -2- .
3. 10.3. For vehicles with Servotronic: Insert connector -3- .
4. 10.4. Fit holder on cable of Servotronic connector.
  
  Fig 8: Installing Universal Joint
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit heat protection panel -1- between the universal joint for the steering gear and the primary catalytic converter.
1. 11.1. Insert heat shield -1- .
2. 11.2. Fit the fastening screws -2- .
  
  Fig 9: Locating Heat Shield
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit PDK wiring harness.
1. 12.1. Plug in connector on the end of the PDK wiring harness -2- on the transmission, lock it -1- and fit the retaining clip -3- .
  
  Fig 10: Connecting PDK Wiring Harness
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 12.2. Fit retaining clips -arrows- for the PDK wiring harness.
  
  Fig 11: Locating Retaining Clips On PDK Wiring Harness
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 12.3. Guide in heat shield for PDK wiring harness and fit fastening screws -arrows- on the transmission.
  
  Fig 12: Locating Heat Shield Fastening Screws For PDK Wiring Harness
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit reinforcement plate -1- .
For tightening torques and other details, see: → 400619 REMOVING AND INSTALLING FRONT-AXLE CARRIER
1. 13.1. Position reinforcement plate -1- .
2. 13.2. Screw in fastening screws -2- .
  
  Fig 13: Identifying Reinforcement Plate With Screws
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Left side: Fit return hose for hydraulic oil cooler.
1. 14.1. Connect return hose -2- on the hydraulic oil cooler.
2. 14.2. Screw in fastening screw -1- between the hose clamps.
  
  Fig 14: Connecting Return Hose For Hydraulic Oil Cooler
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Information
  
  Working with steel flexi-pipes
  - Steel flexi-pipes are particularly prone to kinking and pinching.
  - Be particularly careful with steel flexi-pipes during removal, storage and reinstallation.
  - Mark the installation position of the pipe with a paint marker during removal.
  - Steel flexi-pipes must never be installed twisted.
Left side: Fit steel flexi-pipe to the expansion hose. → Steel flexi-pipe to expansion hose
1. 15.1. Fit steel flexi-pipe to the expansion hose. Use the marking as a guide.
  
  Fig 15: Installing Steel Flexi-Pipe To Expansion Hose
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Connect cable plugs to the horn on both sides.
Fit the wastegate valves -arrow- to the charge-air coolers on both sides. Tighten clamps -1- .

Fig 16: Installing Ambient Air Valve On Charge-Air Cooler
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit suction hose -arrow- on both sides by tightening the hose clamps -arrow- .

Fig 17: Installing Suction Hose
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit pressure hose on the charge-air cooler on both sides. → Pressure hose on charge-air cooler

Fig 18: Installing Pressure Hose On Charge-Air Cooler
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Lower the vehicle halfway.
Right wheel housing: Fit fastening nut -arrow- on the ground cable for the engine at the frame carrier.
→ Tightening torque: 10 Nm (7.5 ftlb.)

Fig 19: Locating Ground Cable
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

Working with steel flexi-pipes
- Steel flexi-pipes are particularly prone to kinking and pinching.
- Be particularly careful with steel flexi-pipes during removal, storage and reinstallation.
- Mark the installation position of the pipe with a paint marker during removal.
- Steel flexi-pipes must never be installed twisted.
Fit steel flexi-pipes on the PDCC valve block at the front.
1. 22.1. The installation position of the steel flexi-pipes -2- was marked on the steel flexi-pipes and on the valve block during removal -3- .
2. 22.2. Fit cap screws on steel flexi-pipes -1- and screw them in until the markings are aligned.
  
  Fig 20: Identifying Steel Flexi-Pipes
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Left wheel housing: Fit fastening nut on holder for power-steering pressure line. → Fastening nut on holder

Fig 21: Installing Fastening Nut On Holder
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit chassis components.
1. 24.1. Fit fastening nuts -1- on the upper control arms at both sides.
  
  Fig 22: Installing Fastening Nuts On Upper Wishbones
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 24.2. Fit fastening nut on connecting link -arrow- at the spring strut on both sides.
  
  Fig 23: Installing Fastening Nut For Connecting Link
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 24.3. Fit fastening nut -1- on the lower control arm at both sides.
  
  Fig 24: Installing Fastening Nuts On Lower Control Arm
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Connect plug connection for rpm sensor -arrow- on both sides.

Fig 25: Connecting RPM Sensor
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Disconnect the secured coolant hoses and pressure hoses for the charge-air cooler from the lock carrier. → Securing hoses

Fig 26: Locating Secured Coolant And Pressure Hoses
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 26.1. Fit coolant hoses on the engine block on both sides. → Coolant hoses
  
  Fig 27: Installing Coolant Hoses
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Clip wastegate control lines to the coolant lines on both sides.
Fit hose clamps on the air box -arrows- at both sides.

Fig 28: Locating Hose Clamps
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Secure refrigerant lines.
1. 29.1. Connect the refrigerant line near the left longitudinal member.
  Fit line -3- and screw in fastening screws -1 and 2- .
  
  Fig 29: Identifying Refrigerant Line On Longitudinal Member
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 29.2. Guide in the refrigerant line and secure it at two clips. Screw in fastening screw -2- on the condenser.
  
  Fig 30: Identifying Fastening Screws For Refrigerant Lines
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit hose for hydraulic oil tank. → Hose for hydraulic oil tank

Fig 31: Installing Hose For Hydraulic Oil Tank
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit hose for coolant reservoir -arrow- .

Fig 32: Installing Hose For Coolant Reservoir
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit positive cable at the jump-lead starting point.
1. 32.1. Release flap on jump-lead starting point. -arrow-
2. 32.2. Fit positive cable for the battery at the jump-lead starting point.
3. 32.3. Lock the flap for the jump-lead starting point.
  
  Fig 33: Installing Positive Cable For Battery At Jump-Lead Starting Point
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit breather hose on the bleeder valve -arrow- .

Fig 34: Installing Breather Hose
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Guide coolant hoses into the connection point and lock with the clip. -arrows-

Fig 35: Installing Coolant Hoses
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Secure vacuum line from the vacuum pump on the connection piece. -arrow-

Fig 36: Securing Vacuum Line
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Insert the plug connections for the oxygen sensors -1- on both sides.→ 266519 REMOVING AND INSTALLING SECONDARY-AIR PUMP WITH BRACKET

Fig 37: Inserting Plug Connections For Oxygen Sensors
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install torque support.
→ Installing Torque Support
NOTE:
Aggressive fluids
- Risk of damage to components and surfaces
→ Do not spill fluids.

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

→ Replace components that are already damaged.
WARNING:
Highly inflammable or explosive materials
- Danger of fire or explosion
→ Avoid contact with hot parts or sources of ignition.

→ Use suction to remove ignitable vapors.

→ Attach warning sign in a clearly visible position.
Fit new fuel low-pressure line.
1. 38.1. Fit tank ventilation -2- and vacuum line -3- .
  
  Fig 38: Locating Tank Ventilation And Vacuum Line
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install wiring harness in the plenum panel.
1. 39.1. Fit sleeve with wiring harness into the on-board panel. → Sleeve with wiring harness
  
  Fig 39: Installing Sleeve With Wiring Harness
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install engine wire harness in the plenum panel.
1. 40.1. Plug in connector on the DME control unit -2- and lock it -1- .
  
  Fig 40: Connecting DME Control Unit Connector
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 40.2. Secure the wiring harness to the DME control unit in the plenum panel and lock the relay safety hooks in the plenum panel on both sides. -arrows-
  
  Fig 41: Securing Up Relay Fuse Box
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.