Removing Engine

→ 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.

→ Let hot components cool down.

→ Wear personal protective gear.

→ 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 

After disconnecting hoses, close off all openings immediately using commercially available rubber stoppers.

When fitting parts, do not remove stoppers until shortly before installation. Likewise, do not remove the protective foil from the dryer until just before installation. The dryer absorbs moisture from the air and is then useless.

Information 

• These instructions describe how to remove and install the engine on vehicles with turbo engines with the maximum number of accessories and components. 
• Some of the steps described here may not be necessary on vehicles with naturally aspirated engines or on 2WD vehicles, for example, since these vehicles do not have certain accessories and components. 
• The slightly different illustrations between the naturally aspirated engine and the turbo engine show essentially the same tasks. 

1. Remove engine wire harness in the plenum panel.
   1. 1.1. Release relay fuse box in the plenum panel on both sides, lift it up and disconnect wiring harness for the DME control unit in the plenum panel. -arrows- 
      Fig 1: Lifting Up Relay Fuse Box

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   2. 1.2. Release connector on the DME control unit -1-  and disconnect it -2-  .
      Fig 2: Releasing DME Control Unit Connector

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   3. 1.3. Remove sealing sleeve with wiring harness -arrow-  from the plenum panel.
      Fig 3: Removing Sleeve With Wiring Harness

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      Information 

      • Before setting down removed cables, lines and components, protect the top of the engine, the intake-air distributor and the design covers from scratches using a suitable cloth. 
   4. 1.4. Place engine wire harness on the engine block.
      WARNING: Damaged fuel lines

      • Escaping fuel in the engine compartment
      • Fire in the engine compartment

      → Do not loosen hoses using sharp-edged tools.

      → Replace damaged fuel lines.

2. Disconnect fuel lines.
   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.

   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.

   1. 2.1. Disconnect fuel low-pressure line -3-  and unclip the line -arrows-  .
   2. 2.2. Disconnect the vacuum line -1-  , tank vent line -2-  and fuel line -3-  at the connection point.
   3. 2.3. Absorb escaping fuel.
   4. 2.4. The fuel low-pressure line -3-  must always be replaced after pulling off the corrugated connection piece.
      Fig 4: Locating Tank Ventilation And Vacuum Line (3.0 V6 Turbo)

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Remove upper torque support.

   → 103719 REMOVING AND INSTALLING TORQUE SUPPORT 

4. Unclip plug connections -1-  for the oxygen sensors at the left and right and remove them by pulling them up -arrows-  . Release plug connection and disconnect it.
   1. 4.1. Place connecting cable for oxygen sensors on the engine.
      Fig 5: Removing Plug Connections For Oxygen Sensors

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5. Pull vacuum line off the vacuum pump at the connection piece. -arrow- 
   Fig 6: Pulling Off Vacuum Line

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6. Release clip on coolant hoses at the plenum panel and remove them from the connection point at the plenum panel (cross panel). -arrows- 
   Fig 7: Removing Coolant Hoses

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Information 

   • Before setting down removed cables, lines and components, protect the top of the engine, the intake-air distributor and the design covers from scratches using a suitable cloth. 
7. Pull breather hose off the bleeder valve -arrow-  and set it down on the engine.
   Fig 8: Pulling Breather Hose

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8. Remove positive cable at the jump-lead starting point.
   1. 8.1. Release flap on jump-lead starting point -arrow-  .
   2. 8.2. Unscrew positive cable for battery at the jump-lead starting point and set it down on the engine. → Jump-lead starting point 
      Fig 9: Disconnecting Positive Cable For Battery At Jump-Lead Starting Point

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9. Disconnect hose for coolant reservoir underneath the valve cover (cylinder bank 2) -arrow-  .
   Fig 10: Disconnecting Hose For Coolant Reservoir

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10. Drain hydraulic oil tank until empty.

    → 430955 REPLACING RESERVOIR (PDCC)

    → 489719 REMOVING AND INSTALLING RESERVOIR

11. Release and disconnect hose for hydraulic oil tank → Hose for hydraulic oil tank  .
    Fig 11: Disconnecting Hose For Hydraulic Oil Tank

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12. Release refrigerant lines.
    1. 12.1. Unscrew fastening screw -2-  on the condenser, loosen the two clips for the refrigerant line and guide it out.
       Fig 12: Loosening Fastening Screws For Refrigerant Lines

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 12.2. Disconnect refrigerant line near the left longitudinal member.

       Unscrew fastening screws -1 and 2-  and remove line -3-  .

       Fig 13: Identifying Refrigerant Line On Longitudinal Member

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13. Loosen hose clamps -arrows-  on the air box at both sides.
    Fig 14: Locating Hose Clamps

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14. Loosen and disconnect the clamp for the coolant hoses -arrows-  on the aluminum pipes for the thermostat housing at both sides. → Coolant hoses 
    Fig 15: Removing Coolant Hoses

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15. Unclip wastegate control lines from the coolant lines at both sides.
16. Secure coolant hoses -arrows-  and the pressure hoses for the charge-air cooler to the lock carrier with tie-wraps.
    Fig 16: Identifying Coolant Hoses

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17. To relieve tension on the wishbones, fit the safety hooks -arrow-  for the upper wishbone at both sides.

    Spring compressor VW 552 

    Fig 17: Locating Safety Hooks

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18. Raise the vehicle half-way.→ 4X00IN LIFTING THE VEHICLE
19. Release and disconnect plug connection for rpm sensor -arrow-  on the wheel carrier at both sides.
    Fig 18: Disconnecting Connector For RPM Sensor

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20. Remove chassis components.
    1. 20.1. Remove fastening nuts -1-  on the upper wishbones at both sides.
       Fig 19: Removing Fastening Nuts On Upper Wishbones

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    2. 20.2. Remove fastening nut -arrow-  for the connecting link on the spring strut at both sides.
       Fig 20: Removing Fastening Nut For Connecting Link

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    3. 20.3. Loosen fastening nut -1-  on the lower wishbone at both sides, but do not remove the bolt yet.
       Fig 21: Removing Fastening Nuts On Lower Wishbones

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21. Left wheel housing: Remove fastening nut on the servo line holder -arrow-  .
    Fig 22: Removing Fastening Nut On Holder

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22. Vehicles with PDCC: 

    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 wheel housing: Disconnect steel flexi-pipes on the PDCC valve block at the front.

    1. 22.1. Mark installation position of the steel flexi-pipes -2-  on the steel flexi-pipes and on the valve block -3-  using a suitable touch-up stick.
    2. 22.2. Unscrew and remove cap screws on steel flexi-pipes -1-  .
       Fig 23: Identifying Steel Flexi-Pipes

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23. Right wheel housing: Unscrew fastening nut for ground cable -arrow-  and remove the cable.
    Fig 24: Locating Ground Cable

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24. Raise the vehicle fully. → 4X00IN LIFTING THE VEHICLE
25. Disconnect pressure hoses and suction hoses.
    1. 25.1. Disconnect pressure hoses at the charge-air coolers -arrow-  and allow the pressure hose to hang freely.
       Fig 25: Disconnecting Pressure Hose On Charge-Air Cooler

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    2. 25.2. Loosen hose clamps -arrow-  and pull off suction hoses.
       Fig 26: Identifying Suction Hose

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    3. 25.3. Disconnect the ambient air valves from the charge-air coolers on both sides.
       1. 25.3.1. Loosen clamps -1-  and pull off ambient air valves -arrow-  .
          Fig 27: Pulling Ambient Air Valve On Charge-Air Cooler

          Courtesy of PORSCHE CARS NORTH AMERICA, INC.
26. Pull cable plugs off the horn at both sides.
27. Vehicles with PDCC: 

    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. 
    1. 27.1. Left side: Disconnect steel flexi-pipe to the expansion hose → Steel flexi-pipe to expansion hose  .
       1. 27.1.1. Mark installation position of the steel flexi-pipes using a suitable touch-up stick.
       2. 27.1.2. Loosen and disconnect the steel flexi-pipe for the expansion hose -arrow-  .
          Fig 28: Disconnecting Steel Flexi-Pipe To Expansion Hose

          Courtesy of PORSCHE CARS NORTH AMERICA, INC.
28. Left side: Remove return hose for hydraulic oil cooler.
    1. 28.1. Unscrew and remove fastening screw -1-  between the hose clamps.
    2. 28.2. Disconnect return hose -2-  at the hydraulic oil cooler.
       Fig 29: Disconnecting Return Hose For Hydraulic Oil Cooler

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
29. Remove reinforcement plate -1-  .
    1. 29.1. Unscrew and remove fastening screws -2-  .
    2. 29.2. Remove reinforcement plate -1-  .
       Fig 30: Identifying Reinforcement Plate

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30. Remove PDK wiring harness.
    1. 30.1. Remove fastening screws -arrows-  on the heat shield for the PDK wiring harness on the transmission.
       Fig 31: Locating Heat Shield For PDK Wiring Harness

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    2. 30.2. Remove heat shield for PDK wiring harness.
    3. 30.3. Release and disconnect connector for PDK wiring harness -1-  on the transmission -2-  and loosen retaining clip -3-  .
       Fig 32: Disconnecting Connector For PDK Wiring Harness

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    4. 30.4. Loosen retaining clips -arrows-  and remove PDK wiring harness.
       Fig 33: Locating Retaining Clips On PDK Wiring Harness

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31. Remove parking lock cable.
    1. 31.1. Disconnect parking lock cable using disassembly tool Nr.21  . → Removing parking lock cable 
       Fig 34: Removing Parking Lock Cable

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    2. 31.2. Press fastening part on the parking lock cable -arrows-  up and pull it backwards out of the support.
       Fig 35: Pulling Parking Lock Cable From Support

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32. Remove heat shield -1-  between the universal joint for the steering gear and the primary catalytic converter.
    1. 32.1. Remove fastening screws -2-  .
    2. 32.2. Remove heat shield -1-  .
       Fig 36: Identifying Heat Shield

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       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
33. Remove universal joint -1-  .
    1. 33.1. Vehicles with Servotronic: Disconnect connector -3-  .
    2. 33.2. Detach holder on cable for the Servotronic connector and set the cable aside.
    3. 33.3. Loosen clamping screw -2-  .
    4. 33.4. Push universal joint -1-  and lower part of steering column upwards. -arrow- 
       Fig 37: Identifying Universal Joint

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       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!

34. Loosen supply and return hose for the ATF transmission oil cooler -arrows-  and drain the oil.
    Fig 38: Loosening Supply And Return Hose For Transmission Oil Cooler

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    • Before moving the lifting platform, mark the position of the wheels on the workshop floor with a piece of chalk. This makes it easier to position the platform again for re-installation. 

    Information 

    • For specific tightening torques and further details on positioning, see the operating instructions provided: Assembly fixture for Porsche Panamera on Master Gear 1.0 lifting platform 
35. Place Master Gear unit elevating platform WE 1206  under the vehicle and move all assembly drivers -1 to 6-  to the same height at the correct position.
    Fig 39: Overview Of Assembly Drivers And Supports

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    Legend for assembly drivers and supports

    Item	Designation	Explanation
    1	Transmission bracket	For mounting on the transmission mount.
    2	Assembly driver on cross panel	For mounting on the cross panel.
    3	Wheel hub holder	Prevents the axles from falling out.
    4	Steering knuckle bracket	Used together with the wheel hub holder 3  to protect the axles and spring struts from damage.
    5	Assembly driver on front-axle carrier	For mounting on the rear of the front-axle carrier.
    6	Front-axle carrier support	For mounting on the front of the front-axle carrier.

36. Get the lifting platform ready and move it to the jacking points on the front axle (supporting frame and transmission mount). Set the heights of the drivers and supports and ensure solid contact.
37. Remove bolts on lower wishbones.
    1. 37.1. Raise the lifting platform slightly in order to relieve the pressure on the bolts on the lower wishbone.
    2. 37.2. Pull out bolts on the lower wishbone -arrow-  at both sides.
       Fig 40: Pulling Out Bolts On Lower Wishbone

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38. Remove safety hooks -arrow-  for the upper wishbone at both sides.
    Fig 41: Locating Safety Hooks

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39. Loosen front-axle carrier.
    1. 39.1. Mark the position of the contact points of the front-axle carrier on the longitudinal members -arrow-  at both sides.
    2. 39.2. Remove fastening screws securing front-axle carrier to the longitudinal member on both sides.
       Fig 42: Locating Marking And Fastening Screw On Front-Axle Carrier

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40. Remove fastening screws -3 and 4-  securing the anti-roll bar to the supporting plate on both sides.
    Fig 43: Identifying Mounting For Front-Axle Support

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41. Remove transverse struts.
    1. 41.1. Right side: Press down rear wheel housing cover -1-  (-arrow-  ). Remove transverse strut -2-  between the supporting plate and door sill.
    2. 41.2. Left side: Remove transverse strut between the supporting plate and door sill.
       Fig 44: Removing Struts (Right Side)

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42. Fit wheel hub holder -1-  at both sides using assembly pins -2-  on the wheel hub.
    Fig 45: Installing Wheel Hub Holder (Steel Brake Disc)

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43. Remove fastening screws -arrows-  on the rear transmission mount.
    Fig 46: Locating Fastening Screws On Transmission Mount

    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. 

    Information 

    • Before moving the lifting platform, mark the position of the wheels on the workshop floor with a piece of chalk. This makes it easier to position the platform again for re-installation. 
44. Guide out engine.
    1. 44.1. Gradually lower the Master Gear unit elevating platform WE 1206  and engine/transmission unit.
    2. 44.2. Push the PDCC hose to one side while lowering the engine.
    3. 44.3. Move engine out from under the vehicle using the lifting platform.