Part 2

WM 100119 Removing and installing engine

Installing engine

Information

- The tightening specifications for the basic engine are stored centrally. -> 1001IN Tightening torques, tightening sequences, assembly overviews [1][2]Specifications. 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.

Information

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

- However, this does not affect the validity and relevance of the pictures.

1. Raise the body to a comfortable working height with the platform lift.
2. Slide the lifting platform -1- with the engine/transmission assembly to the marked positions -A- on the workshop floor.





Position of lifting platform

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 (the lines must not be trapped). The insertion guides -4- on the lifting platform must fit into the holes in the body. When doing so, use the markings used for removal as a positioning guide.





Lifting platform





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

4. Tighten the fastening screws -arrows- on the front-axle carrier. -> 4X00IN Tightening torques for front axle 4X00IN Tightening torques for front axle





Fastening screws for front-axle carrier and engine carrier

5. Fit fastening screws -A- for transmission cross member.





Fastening screws for transmission cross member

6. Loosen the lateral supports on the wheel hubs. => Wheel hub support
7. Fit the brake caliper. -> 473919 Removing and installing front brake caliper - section on "Installing" 473919 Removing and installing front brake calliper 473919 Removing and installing front brake calliper (PCCB)





Wheel hub support

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-





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-.





Plug connections for transfer gear at the right

11. Push new exhaust clamps (clamping sleeves) -3- onto the exhaust pipes. The threaded joint must be pointing downwards.
Tighten fastening screws. -> 260119 Removing and installing exhaust system - section on "Installing" Service and Repair





Fitting clamps

12. Fit shift cable -3- on automatic transmission -4-. -> 371519 Removing and installing selector lever cable - section on "Installing" Service and Repair





Shift cable on automatic transmission

12.1. Clip in shift cable -3- at the ball joint -1-.
12.2. Fit the fastening screws -2-.
13. Fit rear cardan shaft on the transfer gear. -> 390219 Removing and installing cardan shaft - section on "Installing" 390219 Removing and Installing Front Cardan Shaft
14. Slide hose onto the hydraulic line -2- in the front left wheel housing and position the clamp -1-.





Front left hydraulic line

15. Fit the coolant line -1- from the air-conditioning compressor to the condenser -2-. -> 874319 Removing and installing compressor-condenser line - section on "Installing" 874319 Removing and installing air-conditioning compressor/condenser line
Use a new sealing ring.
Make sure that the guide pin at the connection point fits into the mounting for the refrigerant line.





Line from air-conditioning compressor to condenser

15.1. Fit the coolant line -1- on the condenser -2- and screw in the fastening screw -3-.
16. Position front part of refrigerant line -2- from the compressor to the evaporator at the longitudinal member -3- at the left. -> 874419 Removing and installing condenser/evaporator line - section on "Installing" 874419 Removing and installing condenser/evaporator line
Use a new sealing ring.
Make sure that the guide pin at the connection point fits into the mounting for the refrigerant line.





Front left refrigerant line

Screw in fastening screw -1-.
17. Attach hoses -2- to the coolant lines in the engine compartment at the rear left and position the clamps -1-.





Coolant lines in front left wheel housing

18. Fit the steering column -2- on the steering gear -3-. -> 481519 Removing and installing steering column - section on "Installing" 481519 Removing and installing steering column





Installing steering column

18.1. Fit the steering column -2- from above -arrow- onto the steering gear -3- ( -A- ).
18.2. Fit clamping screw. -> 4X00IN Tightening torques for steering. [1][2]Specifications
Always use a new clamping screw.
19. Position the heat shield -2- on the steering gear and fit the fastening screws -1-.





Heat shield for steering gear

20. Fit ATF lines at the thermostat. -> 386219 Removing and installing line for ATF cooling - section on "Installing" Service and Repair





ATF lines from thermostat to transmission

20.1. Insert ATF lines -3- into the thermostat -4-.
20.2. Position holder -2- for ATF lines -3- to the ATF thermostat -4-.
Ensure that the lines are seated correctly.
20.3. Fit the fastening screw -1-.
21. Fit the ground point on the right longitudinal member.





Ground point on right longitudinal member

22. Fit the wheel bearing housing on the ball joint of the upper trailing arm. -> 401519 Removing and installing upper trailing arm (steel springs) - section on "Installing" 401519 Removing and installing upper trailing arm (steel springs)
23. 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.





Spring strut threaded joint

24. Fit the fastening screw -2- for the spring strut -3- and trailing arm -2-. -> 4X00IN Tightening torques for front axle - section on "Installing" 4X00IN Tightening torques for front axle
25. Plug in electric plug connection -1- for the speed sensor on the wheel bearing housing -A- and lock it -a-.





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

26. Position and fit the brake caliper on the brake disc at the wheel bearing housing. -> 473919 Removing and installing front brake caliper - section on "Installing" 473919 Removing and installing front brake calliper 473919 Removing and installing front brake calliper (PCCB)
27. Fit the holders -1, 2- for the hydraulic lines on the wheel bearing housing -3-.





Mounting for hydraulic lines

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





Connecting link for anti-roll bar

29. Lower the vehicle.
30. Attach vacuum line -2- to the vacuum pump -3- and lock the connection -1-.





Vacuum pump line

31. Attach coolant hoses -2- at the top of the engine and fit the clamps -1-.





Coolant hoses at top of engine

32. Fit the intake pipe. -> 243519 Removing and installing air box for throttle housing (Y-shaped pipe) - section on "Installing" 243519 Removing and installing cowl for throttle housing (Y-pipe)
33. Slide the coolant line -4- at the bottom onto the coolant reservoir -2- and lock the clamp -3-.





Coolant lines at the reservoir

34. Attach the coolant hose -1- to the bleeder valve and lock the clamp.
35. Plug in electric plug connections -1- at the right cross panel -A, B- and lock them -a, b-.





Plug connections at right cross panel

36. Plug in electric plug connections -1- at the left cross panel -A, B- and lock them -a, b-.





Plug connection at left cross panel

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





Engine wire harness in plenum panel

38. Fit B+ transfer point on the left in the engine compartment. => B+ transfer point





B+ transfer point

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





Plug connections in relay box

40. Close the relay box. -> 970909 Loosening and securing main wire harness in engine compartment at the left 970909 Loosening and securing main wire harness in engine compartment at the left
41. Fit the fuel line -1- at the plenum panel.





Plenum panel lines

42. Attach tank vent lines and lock the clamp -2-.
43. Attach vacuum hose -3- to the lower part -4- of the vacuum line.
44. 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.





Ground point on body

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





Plug connection for engine control unit

46. Fit hydraulic lines -3, 4- at the hydraulic fluid reservoir -1- and at the PDCC reservoir -2- if necessary.





Hoses for hydraulic reservoir

Subsequent work

Subsequent work for removing and installing engine

1. On vehicles with 19-inch brake system: Fit the air guide at the anti-roll bar. -> 407719 Removing and installing anti-roll bar - section on "Installing" 407719 Removing and installing anti-roll bar
2. Fit front wheel housing liners. -> 505619 Removing and installing front wheel housing liner - section on "Installing" Service and Repair
3. Fit wheels. -> 440519 Removing and installing wheel - section on "Installing" Removal and Replacement
4. Install right cross panel. -> 508119 Removing and installing cross panel - section on "Installing" Service and Repair
5. Fit torque support. -> 103719 Removing and installing torque support - section on "Installing" Service and Repair
6. Fit design cover on the throttle valve. -> 108319 Removing and installing engine cover - section on "Installing" 108319 Removing and installing engine cover (design cover).
7. Connect the battery. -> 2X00IN Work instructions after disconnecting the battery 2X00IN Work instructions after disconnecting the battery
8. Fill the air conditioning system. -> 870317 Adding refrigerant and removing by suction Service and Repair
9. Check engine-oil level. -> 170117 Changing engine oil and oil filter Removal and Replacement
10. Bleed the cooling system. -> 193817 Draining and filling coolant (includes bleeding) - section on "Filling" Service and Repair
11. Bleed the power steering. -> 4890IN Test and assembly work on power steering Testing and Inspection
12. Bleed the PDCC system if necessary. -> 430300 Bleeding Porsche Dynamic Chassis Control (PDCC) 430307 Bleeding Porsche Dynamic Chassis Control (PDCC)
13. Check ATF level and top up if necessary. -> 370235 Checking and topping up ATF 370235 Checking and Topping Up ATF
14. Move bonnet out of service position.
15. Fit engine compartment trim panels. -> 700219 Removing and installing front trim (engine compartment) - section on "Installing"
16. Perform suspension alignment. -> 4400IN Suspension alignment, complete
17. The high-pressure adaptation must be reset when replacing the engine.
18. Read out DME fault memory and compare with the log you printed prior to removal.