Part 1
WM 100119 Removing and installing engine
Tools
Technical values
Preliminary work
1. Drain refrigerant from the air conditioning system.
-> 870317 Draining and filling refrigerant Service and Repair
2. Remove cowl panel cover.
-> 508719 Removing and installing cowl panel cover Service and Repair
3. Remove transverse control arm cover.
-> 852219 Removing and installing plenum panel cover 852219 Removing and installing plenum panel cover
4. Remove rear profile seal.
-> 553319 Removing and installing front lid seal Service and Repair
Removing rear profile seal
5. Drain coolant.
-> 193817 Draining and filling coolant Service and Repair
Coolant drain plug
6. Remove underbody panelling.
-> 519219 Removing and installing cover for front underbody 519219 Removing and installing Cover For Front Underbody
-> 519319 Removing and installing cover for centre underbody 519319 Removing and Installing Cover for Centre Underbody
-> 519419 Removing and installing cover for rear underbody 519419 Removing and Installing Cover for Rear Underbody
7. Remove the cardan shaft.
-> 393519 Removing and installing rear cardan shaft Service and Repair
8. Remove brake caliper, but do not remove the brake line.
Suspend brake caliper in the wheel housing with a tie-wrap or a piece of wire.
-> 473919 Removing and installing front brake caliper 473919 Removing and installing front brake calliper
-> 473919 Removing and installing front brake caliper (PCCB) 473919 Removing and installing front brake calliper (PCCB)
9. Disconnect battery ground strap.
-> 9X00IN Work instructions after disconnecting the battery 9X00IN Work instructions after disconnecting the battery
10. Remove front part of front wheel housing liner at both sides.
-> 505619 Removing and installing front wheel housing liner Service and Repair
11. Remove front left wheel housing liner completely on vehicles with PDCC.
-> 505619 Removing and installing front wheel housing liner Service and Repair
12. Lower the vehicle.
Removing engine
WARNING
Caustic fluids
- Danger of chemical burns
-> 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.
CAUTION
Hot components
- Risk of burns
-> Let hot components cool down.
-> Wear personal protective gear.
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. Release the relay fuse box in the plenum panel at both sides, lift it up and disconnect the wire harness for the DME control unit in the plenum panel. -arrows-
Lifting up relay fuse box
1.2. Release the connector on the DME control unit -1- and disconnect it -2-.
Connector for DME control unit
1.3. Remove sealing sleeve with wire harness -arrow- from the plenum panel. => Sleeve with wire harness
Sleeve with wire harness
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.
1.4. Place engine wire harness on the engine block.
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 vapours.
-> Attach warning sign in a clearly visible position.
NOTICE
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.
2. Disconnect fuel low-pressure line.
2.1. Put a cloth under the connection for the fuel low-pressure line to absorb emerging fluid.
2.2. Release and disconnect tank ventilation and vacuum line -arrows- at the connection point.
Tank ventilation and vacuum line
2.3. Release the fuel low-pressure line -arrow- by countering with a wrench and disconnect it. Counter at the centre piece and loosen the union nut at the engine side.
Fuel low-pressure line
3. Remove upper torque support.
-> 103719 Removing and installing torque support Service and Repair
4. Disconnect plug connections for oxygen sensors at the left and right.
4.1. Release and disconnect oxygen sensor plug connection -1- ( -arrow- ) at both sides.
Oxygen sensor plug connection
4.2. Place connecting cable for oxygen sensors on the engine.
5. Remove secondary-air pump.
5.1. Unscrew secondary-air pump and pull off hose. => Removing secondary-air pump -> 266519 Removing and installing secondary-air pump with bracket Service and Repair
Removing secondary-air pump
5.2. Place the secondary-air pump on the engine and secure it with tie-wraps to prevent it from falling down.
6. Pull vacuum line off the vacuum pump at the connection piece -arrow-.
Vacuum line
7. Release clip on coolant hoses at the plenum panel and remove them from the connection point at the plenum panel (cross panel).
Removing coolant hoses
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.
8. Pull breather hose off the bleeder valve -arrow- and set it down on the engine.
Breather hose
9. Remove positive cable at the jump-lead starting point.
9.1. Release flap on jump-lead starting point -arrow-.
Jump-lead starting point
9.2. Unscrew positive cable for battery at the jump-lead starting point and set it down on the engine. => Jump-lead starting point
10. Disconnect hose for coolant reservoir underneath the valve cover (cylinders 5 to 8) -arrow-.
Hose for coolant reservoir
11. Drain hydraulic oil tank until empty.
-> 430955 Replacing reservoir (PDCC) 430955 Replacing reservoir (PDCC)
-> 489755 Replacing reservoir Service and Repair
12. Release and disconnect hose for hydraulic oil tank => Hose for hydraulic oil tank.
Hose for hydraulic oil tank
13. Remove air box on throttle valve.
13.1. Remove design cover.
-> 108319 Removing and installing engine cover (design cover) Service and Repair
13.2. Release both locking pins -arrows- on the air box and pull them out.
Locking pins
13.3. Release and unplug connector for boost pressure sensor -arrow-.
Connector for boost pressure sensor
13.4. Release hose clamps -arrows- on the air box at both sides.
Hose clamps
13.5. Pull the air box out of the retaining clip, but leave the ventilation line (underneath the air box) for the crankcase fitted.
13.6. Set the air box down on the engine.
14. Disconnect wastegate control lines on both sides at the T-piece -arrow-.
Wastegate control line
15. Release and disconnect the clamp on the coolant hoses -arrows- on the aluminium pipes for the thermostat housing at both sides. => Coolant hoses
Coolant hoses
16. Secure coolant hoses -arrows- together with the pressure hoses for the charge-air cooler at the lock carrier with tie-wraps.
Securing hoses
17. To relieve the control arms, fit the safety hooks -arrow- for the upper control arm at both sides.
Spring compressor VW 552
Safety hooks
18. Raise the vehicle halfway.
-> 4X00IN Lifting the vehicle Service and Repair
19. Release and disconnect plug connection for rpm sensor -arrow- at the wheel carrier on both sides.
Connector for rpm sensor
20. Remove chassis components.
20.1. Remove fastening nuts -1- on the upper control arms at both sides.
Fastening nuts on upper control arms
20.2. Remove fastening nut -arrow- on the connecting link at the spring strut on both sides.
Fastening nut on connecting link
20.3. Loosen fastening nut -1- on the lower control arm at both sides, but do not remove the bolt yet.
Fastening nuts on lower control arms
21. Left wheel housing: Remove fastening nut on power-steering pressure line holder and detach the retaining eyelet -arrow-.
Fastening nut on holder
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.
22. Left wheel housing: Disconnect steel flexi-pipes on the PDCC valve block at the front.
22.1. Mark the installation position of the steel flexi-pipes -2- on the steel flexi-pipes and on the valve block -3- using a suitable paint marker.
22.2. Unscrew cap screws on steel flexi-pipes -1-.
Steel flexi-pipes
23. Right wheel housing: Remove fastening screw on the ground cable for the engine -arrow- at the front right frame carrier.
Ground cable
24. Raise the vehicle fully.
-> 4X00IN Lifting the vehicle Service and Repair
25. Disconnect the pressure hose by carefully releasing the tension lock on the charge-air cooler -arrow- and leave the pressure hose hanging freely.
Pressure hose on charge-air cooler
26. Press the pressure hose aside at both sides, loosen the hose clamp -arrow- on the suction hose and pull off the hose.
Suction hose
27. Remove ambient air valves at both sides.
Ambient air valve
27.1. Disconnect ambient air valve at the suction hose -1- on both sides.
27.2. Disconnect ambient air valve at the pressure hose -2- on both sides.
27.3. Disconnect the vacuum line on the ambient air valve -3- on both sides and remove ambient air valve.
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.
28. Left side: Loosen steel flexi-pipe to the expansion hose => Steel flexi-pipe to expansion hose.
28.1. Mark the installation position of the steel flexi-pipes on the steel flexi-pipes themselves and on the valve block using a suitable paint marker.
28.2. Loosen steel flexi-pipe to the expansion hose -arrow- and disconnect it.
Steel flexi-pipe to expansion hose
29. Left side: Remove return hose for hydraulic oil cooler.
29.1. Unscrew fastening screw -1- between the hose clamps.
29.2. Disconnect return hose -2- at the hydraulic oil cooler.
Return hose for hydraulic oil cooler
30. Remove reinforcement plate -1-.
Reinforcement plate
30.1. Unscrew fastening screws -2-.
30.2. Remove reinforcement plate -1-.
NOTICE
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
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.
31. Remove air-conditioning compressor accessories.
Tool recommendation:
Flexible-head socket wrench, a/f 10 9824/1
Torx Micro Bit T45 9824/3
31.1. Remove intake pipe and pressure line from the air-conditioning compressor. => Air-conditioning compressor lines
Air-conditioning compressor lines
31.2. Loosen fastening screw -1- on air-conditioning line holder -2-.
Air-conditioning line holder (at the front of the supporting frame)
31.3. Remove air-conditioning line holder from the guide -2-.
32. Remove PDK wire harness.
32.1. Remove fastening screws -arrows- on heat protection panel for PDK wire harness on the transmission.
Heat protection panel for PDK wire harness
32.1.1. Remove heat protection panel for PDK wire harness.
32.2. Release and unplug the connectors on the end of the PDK wire harness -1- at the transmission -2- and loosen the retaining clip -3-.
Connectors on PDK wire harness
32.3. Loosen retaining clips on the PDK wire harness and remove the PDK wire harness from the clips -arrows-.
Retaining clips on PDK wire harness
33. Remove parking lock cable.
33.1. Disconnect parking lock cable from the lever using disassembly tool Nr.21. => Removing parking lock cable
Removing parking lock cable
33.2. Press fastening part on the parking lock cable -arrows- up and pull it backwards out of the support.
Parking lock cable support
34. Remove heat protection panel -1- between the universal joint for the steering gear and the primary catalytic converter.
Heat protection panel
34.1. Remove fastening screws -2-.
34.2. Remove heat protection panel -1-.
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 centre position with a steering-wheel holder. If this is not done, the airbag contact unit will have to be moved to centre position after installation of the steering gear. -> 945019 Removing and installing steering-column switch Service and Repair
35. Remove universal joint -1-.
Removing universal joint
35.1. Vehicles with Servotronic:
Pull off connector -3-.
35.2. Detach holder on cable for the Servotronic connector and set the cable aside.
35.3. Loosen clamping screw -2-.
35.4. Slide universal joint -1- and lower part of steering column upwards. -arrow-
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!
36. Loosen supply and return hose for the ATF transmission fluid cooler -arrows- and drain the fluid.
Supply and return hose for transmission fluid cooler
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
37. Place lifting platform Master Gear unit elevating platform WE 1206 under the vehicle and move all assembly mandrels -1 to 6- to the same height at the correct position.
Overview of assembly mandrels
Legend for assembly mandrels and supports
38. 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 mandrels and supports and ensure solid contact.
39. Remove bolts on lower control arms.
39.1. Raise the lifting platform slightly in order to relieve the pressure on the bolts on the lower control arm.
39.2. Pull out bolt on the lower control arm -arrow- on both sides.
Bolts on lower control arm
40. Remove the safety hooks -arrow- for the upper control arm on both sides.
Safety hooks
41. Detach front-axle carrier.
Marking and fastening screws on front-axle carrier
41.1. Mark the position of the contact points of the front-axle carrier on the longitudinal members -arrow- on both sides.
41.2. Remove fastening screws securing front-axle carrier to the longitudinal member on both sides.
42. Remove fastening screws -arrows- securing the anti-roll bar mount to the supporting plate on both sides.
Fastening screws on supporting plate
43. Remove transverse struts.
Removing struts (right side shown here)
43.1. Right side: Press down rear wheel housing cover -1- ( -arrow- ). Remove the transverse strut -2- between the supporting plate and door sill.
43.2. Left side: Remove transverse strut between the supporting plate and door sill.
44. Fit wheel hub holder -1- at both sides using assembly pins -2- on the wheel hub.
Wheel hub holder (shown here on steel brake disc)
45. Remove fastening screws -arrows- on the rear transmission mount.
Fastening screws on transmission mount
Information
- When lowering the engine, make sure that cables or lines are not trapped accidentally between the engine and body. To prevent this, a second person must make sure that the cables 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.
46. Remove the engine.
46.1. Gradually lower the lifting platform Master Gear unit elevating platform WE 1206 and engine/transmission unit.
46.2. Gradually guide the air-conditioning lines => Air-conditioning lines along with your hand.
Air-conditioning lines
46.3. Move engine out from under the vehicle using the lifting platform.