Installing Engine

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. 

Special equipment-specific features are described in the notes. 

Tool setup - > VAS 6832 - Master Gear unit elevating platform  with suitable setup kit.

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Lifting platform 

1. Assembly mandrel  => Height can be adjusted; used for mounting in the engine carrier; equipped with a locking screw to prevent engine from tipping and to adjust the height. Item 2 in base carrier 
2. Wheel hub holder  => Secures the spring struts to prevent them from tipping. Inserted from the side into the second cross member from the front 
3. Assembly mandrel  => Height can be adjusted; used for mounting in the front-axle carrier at the front; equipped with a locking screw to prevent engine from tipping and to adjust the height. Item 1 in base carrier 
4. Support  => Not used here.
5. Wishbone support  => Used in conjunction with -B-  to protect the wheel suspension and spring struts from damage.
6. Assembly mandrel  => For mounting on the front-axle carrier at the rear. Item 3 in base carrier 
7. Assembly mandrel  => Guide for positioning the lifting platform into the body; first moves into a bore in the body for centering roughly. Item 4 in base carrier 
8. Assembly mandrel  => For mounting on the transmission cross member. Item 5 on base carrier 

1. Slide the lifting platform -1-  with the engine/transmission assembly to the marked positions -A-  on the workshop floor.

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   Position of lifting platform 

2. Raise the body to a comfortable working height with the platform lift.
3. Raise the engine/transmission unit into the body using the lifting platform > Guiding engine/transmission unit into the body with the lifting platform.  Make sure there is sufficient clearance. The freely-suspended lines (e.g. PDCC) must be routed in such a way that they do not go back into the installation position (he lines must not be trapped). The insertion guides -4-  on the lifting platform must fit into the holes in the body. When doing this, use the markings made during removal as a positioning guide.

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   Lifting platform 

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   Guiding engine/transmission unit into the body with the lifting platform 

4. Then insert the engine fully up into the engine compartment. > Inserting engine completely  When doing this, use the markings made during removal as a positioning guide.

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   Inserting engine completely 

5. Tighten the six new front-axle carrier and engine carrier screws > Fastening screws for front-axle carrier and engine carrier. For details see

   > WM 400619 REMOVING AND INSTALLING FRONT-AXLE CARRIER (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0))

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   Fastening screws for front-axle carrier and engine carrier 

6. Install transmission cross member. For details see

   > WM 396519 REMOVING AND INSTALLING TRANSFER GEAR (ALL MODELS)

   -A-  .

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   Fastening screws for transmission cross member 

7. Loosen the lateral supports on the wheel hubs. > Support on wheel hub 

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   Support on wheel hub 

8. Lower the lifting platform slowly and remove it.
9. Plug in electric plug connections -1, 2-  at the bottom of the transfer gear -A, B-  and lock them -a, b- 

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   Plug connections for transfer gear at the bottom 

10. Plug in electric plug connections -1, 2-  at the right of the transfer gear -A, B-  and lock them -a, b-  .

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    Plug connections for transfer gear at the right 

11. Fit heat shield on the right of the transmission. To do this, screw in the fastening screws -arrows-  . > Tightening torque 10 Nm (7.5 ftlb.) 

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    Heat shield 

12. Fit shift cable -3-  on automatic transmission -4-  .

    > WM 371519 REMOVING AND INSTALLING SELECTOR LEVER CABLE (ALL MODELS)

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    Shift cable on automatic transmission 

    1. Clip in shift cable -3-  at the ball joint -1-  .
    2. Fit the fastening screws -2-  .
13. Fit the coolant line -1-  from the air-conditioning compressor to the condenser -2-  .

    > WM 874319 REMOVING AND INSTALLING AIR-CONDITIONING COMPRESSOR/CONDENSER LINE (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0))

    Use a new sealing ring. 

    Make sure that the guide pin at the connection point fits into the mounting for the refrigerant line.

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    Line from air-conditioning compressor to condenser 

    1. Fit the coolant line -1-  on the condenser -2-  and screw in the fastening screw -3-  .
14. Position front part of refrigerant line -2-  from the compressor to the evaporator at the longitudinal member -3-  at the left.

    > WM 874419 REMOVING AND INSTALLING CONDENSER/EVAPORATOR LINE (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0))

    Use a new sealing ring. 

    Make sure that the guide pin at the connection point fits into the mounting for the refrigerant line.

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    Front left refrigerant line 

    Screw in fastening screw -1-  .

15. Slide hose onto the hydraulic line -2-  in the front left wheel housing and position the clamp -1-  .

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    Front left hydraulic line 

16. Attach hoses -2-  to the coolant lines in the engine compartment at the rear left and position the clamps -1-  .

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    Coolant lines in front left wheel housing 

17. Fit the steering column -2-  on the steering gear -3-  .

    > WM 481519 REMOVING AND INSTALLING STEERING COLUMN (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0))

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    Installing steering column 

    1. Fit the steering column -2-  from above -arrow-  onto the steering gear -3- (-A-)  .
    2. Fit clamping screw.

       > WM 4X00IN TIGHTENING TORQUES FOR STEERING (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0))

       Always use a new clamping screw. 

18. Fit ATF lines at the thermostat.

    > WM 386219 REMOVING AND INSTALLING LINE FOR ATF COOLING (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE (3.0))

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    ATF lines from thermostat to transmission 

    1. Insert ATF lines -3-  into the thermostat -4-  .
    2. Place holder -2-  for ATF lines -3-  to the ATF thermostat -4-  in position.

       Ensure that the lines are seated correctly.

    3. Fit the fastening screw
19. Fit the cardan shaft

    > WM 393519 REMOVING AND INSTALLING REAR CARDAN SHAFT (ALL MODELS)

20. Push new exhaust clamps (clamping sleeves) -3-  onto the exhaust pipes. The threaded joint must be pointing downwards. Tighten fastening screws.

    > WM 260119 REMOVING AND INSTALLING EXHAUST SYSTEM (CAYENNE TURBO, CAYENNE TIP, CAYENNE S, CAYENNE TURBO S, CAYENNE S DIESEL, CAYENNE TURBO S & CAYENNE TIP "PLATINUM EDITION")

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    Fitting clamps 

    Information 

    • For vehicles with Servotronic, the electric connectors on the steering gear must also be connected. 
21. Fit electric connector on the steering gear (Servotronic only). -arrow- 

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    Servotronic cable plug 

22. Slide the coolant supply and return lines onto the radiator. To do this, press the top hose on the radiator flange until you feel it engage Slide on bottom hose -2-  . Then fit the spring band clamp.

    Connect the small breather hose.

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    Coolant hoses 

23. Mount the ground point of the generator on the right side member. > Tightening torque 20 Nm (15 ftlb.) 

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    Ground point of the generator to the right side member 

    Information 

    The slightly different illustrations between V8 and V6 show essentially the same actions.

24. Fit the wheel bearing housing on the ball joint of the upper trailing arm.

    > WM 401519 REMOVING AND INSTALLING UPPER TRAILING ARM (STEEL SPRINGS) (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0))

25. Raise the axle support -1-  as far as required using a suitable jack -4-  until the fastening screw -2-  slides easily through the spring strut -3-  and axle support.

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    Spring strut threaded joint 

26. Fit the fastening screw -2-  for the spring strut -3-  and trailing arm -2-  .

    > WM 4X00IN TIGHTENING TORQUES FOR FRONT AXLE (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0))

27. Plug in electric plug connection -1-  for the speed sensor on the wheel bearing housing -A-  and lock it -a-  .

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    Electric plug connection for speed sensor (shown as an example) 

28. Position and fit the brake calliper on the brake disc at the wheel bearing housing.

    > WM 473919 REMOVING AND INSTALLING FRONT BRAKE CALLIPER (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0))

29. Fit the holders -1, 2-  for the hydraulic lines on the wheel bearing housing -3-  .

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    Mounting for hydraulic lines 

30. Fit the connecting link -2-  on the anti-roll bar -3-  and screw in the fastening screw -1-  .

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    Connecting link for anti-roll bar 

31. Lower the vehicle halfway.
32. Connect the four oxygen sensor connectors at the radiator tank splash panel. -1, 2, 3 and 4- 

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    Oxygen sensor connector on the plenum panel splash panel 

33. Mount B+ transfer point on left spring dome. To do this, connect the two positive cables from the engine using the pins. Clip in cable on the bulkhead. -A and B-  > Tightening torque 23 Nm (17 ftlb.) 

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    B+ transfer point on left spring dome 

34. Fit the hoses -3, 4-  to reservoirs.

    Fill the hydraulic fluid reservoir -1-  and the PDCC reservoir -2-  , if necessary, to the correct fluid level.

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    Hoses for hydraulic reservoir 

35. Fit fuel line -1-  and tank vent line from the carbon canister -2-  to the plenum panel splash panel. Clip in tank vent line at the plenum panel. > Tightening torque 35 Nm (26 ftlb.) 

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    Tank vent and fuel line 

36. Slide the coolant line -4-  at the bottom onto the coolant reservoir -2-  and lock the clamp -3-  .

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    Coolant lines at the reservoir 

37. Fit the two coolant lines and the vacuum line on the right side of the engine compartment. -1 to 3-  Simply press on the vacuum line (hold line securely below the connection).

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    Wiring 

38. Route the engine wire harness -1-  in the plenum panel and clip it into the retaining clips -2-  .

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    Engine wire harness in plenum panel 

39. Plug in and lock the electric plug connections -1-  for the engine wire harness in the relay box.

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    Plug connections in relay box 

40. Close the relay box.

    > WM 970909 LOOSENING AND SECURING MAIN WIRE HARNESS IN ENGINE COMPARTMENT AT THE LEFT

41. Attach tank vent lines and lock the clamp -2-  .
42. Fit the ground strap -2-  in the plenum panel at the body and screw on the fastening nut -1-  . Secure the ground strap to the engine wire harness with tie-wraps -3-  if necessary.

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    Ground point on body 

43. Plug in electric plug connection -1-  on the engine control unit -2- (-A-)  and lock it -a-  .

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    Plug connection for engine control unit 

44. Fit air cleaner housing cover and filter element.
45. Push the air line on the air cleaner cover.

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    Air line on air cleaner cover