Installing Engine
Installing V8 4.5 l engineInstalling engine
Special features that are required for the equipment or relate to the Cayenne Turbo (M48/50) are described in the notes.
1. Suspend the engine at the jacking points provided on a workshop crane and set down on the front-axle carrier.
2. Secure the engine against tipping. To do this, attach the locks on the engine cross member and raise the support under the oil pan until it touches the oil pan.
3. Fit the transmission onto the engine.
4. Install pre- and main catalytic converters.
5. Tighten the fastening screw on the catalytic converter support. Tightening torque: 23 (17 ft-lb.) Nm
6. Bolt the main catalytic converter supports onto the transmission cross member.
7. Remove the support from under the oil pan and remove the tipping protection from the engine cross member.
8. Clip the oxygen sensor cable of the rear oxygen sensors into the supports and place the connector on the engine.
9. Pre-fit the drive belt. Mount the drive belt on the pulleys as far as possible.
10. Position the lifting platform under the body.
11. Raise the body to a comfortable working height with the platform lift.
Note:
^ When moving the unit into the body, ensure that the shift cable is on the transmission.
^ When moving the unit into the body, put the air-conditioning compressor into installation position.
^ If the engine is to be replaced by a new one, make sure the air conditioner is evacuated before removing the engine and the new air-conditioning compressor is connected during installation of the engine as the replacement engine is delivered with the new compressor mounted.
Note: Position the front-axle carrier back in the original, marked installation position and be careful not to damage adjacent parts.
12. Raise the engine/transmission combination into the body with the lifting platform. Ensure sufficient clearance. The insertion guides on the lifting platform must fit into the holes in the body.
13. Tighten the 6 new front-axle carrier engine carrier screws. Initial tightening: 120 (89 ft-lb.) Nm Final tightening - torque angle: 180°
14. Install transmission cross member.
15. Loosen the lateral supports on the wheel hubs.
16. Lower the lifting platform slowly and remove.
17. Connect electric connector -1, 2 and 3- on the transmission and clip in the wiring harness.
18. Mount selector lever cable.
Note:
^ In the Cayenne Turbo (M48/50), the hose connections on the turbochargers must also be fastened. To do this, connect pressure pipe -2- and tighten the hose clamp. Then fit the lead of the charge air cooler. The connection piece must engage audibly. Ensure that sheetmetal clip -1- is fitted correctly.
^ Connect the hose line on the left charge air cooler. Ensure that locking clip -1- is mounted correctly. Then connect the line to the ambient air valve -2- and fit the spring-band clamp.
19. Push the servo oil line onto the oil cooler and mount the spring band clamp.
Note: For vehicles with Servotronic, the electric connector on the steering gear must also be connected.
20. Fit the steering column onto the steering gear.
21. Fit the heat protection shield on the steering gear by means of 2 fastening screws. Tightening torque: 10 (7.5 ft-lb.) Nm
22. Slide the heater coolant lines on the left side member and mount the clips.
23. Push on the coolant connection piece on the lower left on the radiator. The connection piece must engage audibly.
24. Connect the ATF lines to the radiator. Remove the plugs and mount the lines.
25. Mount the ground point of the generator on the right side member. Tightening torque: 20 (15 ft-lb.) Nm
26. Tighten the catalytic converter fastening on the body.
27. Install cardan shaft.
28. Install the exhaust system. Move the exhaust system to its installation position using a transmission jack.
29. Install the front transverse strut under the radiators. To do this, tighten the four fastening screws. Tightening torque: 23 (7.5 ft-lb.) Nm
30. Screw the front apron onto the transverse strut. Tightening torque: 5 (3.5 ft-lb.) Nm
31. Lower the vehicle halfway.
Note:
^ In the case of vehicles with air suspension, the compressed air lines must also be screwed on.
^ Then connect the headlight leveling system sensor.
32. Tighten the brake lines on the left and right in the wheel housings.
33. Fit the electric connections of the spring struts. To do this, connect cable -1- and then fasten supports -2 and 3-.
34. Lower the vehicle.
35. Mount the three fastening screws on the left and right spring struts from above (engine compartment side). -arrows-.
36. Mount B+ transfer point on left spring dome. Tightening torque: 23 (17 ft-lb.) Nm
37. Connect the servo line to the reservoir and mount the spring band clamp. Then fill the container with Pentosin.
38. Connect the line from carbon canister -2- to the plenum panel splash panel until it audibly engages and tighten fuel line -1-. Tightening torque: 35 (26 ft-lb.) Nm
39. On the left and right of the plenum panel splash panel, connect the oxygen sensor plug connections in front of and behind the catalytic converter and lay the cables so they are not subject to chafing.
Note: In the Cayenne Turbo, the support for the vacuum pump must also be screwed into position. Tightening torque: 7.5 ft-lb.
40. Connect the vacuum line to the right spring dome and mount the spring band clamp. Then mount the 2 lines on the coolant reservoir and secure with spring band clamps.
41. Lay the engine wire harness into the plenum panel. Mount the rubber sleeve into the middle opening. Then guide the control unit connector to the right. Connect the control unit, connector, and ground point. Tightening torque: 10 (7.5 ft-lb.) Nm
42. Plug in the 4 connectors (red, brown, white and black) in the left-hand central electrical system box. Then mount the cover using 4 Torx screws.
43. Check whether the wiring harness is laid correctly. Close all fixing clips.
44. Mount the plenum chamber cover. Do not forget the electric connector for the air-quality sensor. Mount the 4 bayonet screws -A-.
45. Position and tighten drive belt on all pulleys.
46. Connect the upper left coolant connection piece to the radiator. The connection piece must engage audibly.
47. Mount the torque support with new lock nuts. Tightening torque: 60 (44 ft-lb.) Nm Tightening torque: 60 (44 ft-lb.) Nm
48. Insert the air-cleaner element.
Note: In the case of vehicles with air suspension, the line of the air compressor must also be connected on the left air cleaner cover.
49. Mount both air cleaners with cover. Insert the air cleaners in the housings and slide on the covers from the top downwards. Then close the two respective sheetmetal clips. The coolant overflow hose must also be clipped onto the air cleaner housing of cylinder bank 1-4. Connect the electric connectors of the hot film mass air flow sensors.
Note: In the Cayenne Turbo (M48/50), the control lines of the ambient air valve on the T-piece must also be connected.
Note: Clip on the leads when mounting the Y-shaped pipe on the bottom.
50. Attach the vacuum line to the underside of the Y-shaped pipe.
51. Fit the Y-shaped pipe to the left and right and tighten the hose clamps.
Note: In the Cayenne Turbo (M48/50), the boost pressure sensor -3- must also be connected.
52. Slide the Y-shaped pipe onto the throttle adjuster. Then insert the left and right fastening bolts. Turn both bolts 45° clockwise.
53. Connect the throttle adjuster. The connector must engage audibly. Clip the connecting cable into the sheetmetal holder.
54. Press the 4 rubber elements in the cover onto the 4 ball head supports. The mounts must be felt to engage.
Subsequent work
1. Fill and bleed the cooling system.
2. Bleed brake system.
3. Connect battery.
4. Mount the wiper arms.
5. Mount engine compartment covers.
6. Check ATF level.
7. Bleed power-assisted steering.
8. Bleed off road stabilizer if necessary.
9. Mount front wheels.
10. If the engine has been replaced by a new one, the air conditioner must be filled in accordance with the instructions as a result of the change of air conditioning compressor.'
11. Perform suspension alignment.
12. Fit engine guard.
13. Perform a test drive with the vehicle. Check the fluid level in the reservoir after the coolant circuit has cooled again and, if necessary, fill up to the max marking with coolant.
14. Check engine oil level.