Installing engine

WARNING: This page is about a different car, the 2006 Porsche Cayenne, 2005 Porsche Cayenne, 2004 Porsche Cayenne, and 2003 Porsche Cayenne. However, it is still accessible from the selected car via links, so may be relevant.

Special equipment-specific features are described in the notes.

Fig 1: Overview of V6 engine

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Fig 2: Lifting the engine with a workshop crane

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1. Suspend the engine at the jacking points provided on a workshop crane and set down on the front-axle carrier. Refer to 10 01 IN Lifting the engine with a workshop crane - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

2. Secure the engine against tipping. To do this, attach the safety locks on the engine cross member and raise the support under the oil pan until it touches the oil pan.

3. Install the transmission and mount it on the engine. Refer to 37 35 27 Removing and refitting transmission - as of MY 2003 (Cayenne TIP) or refer to 34 35 27 Removing and refitting transmission - as of MY 2003 (Cayenne MAN) .

4. Bolt the main catalytic converter holders onto the transmission cross member. → Tightening torque: 17 ftlb.

5. Remove the support from under the oil pan and remove the tipping protection from the engine cross member.

6. Clip the oxygen sensor cable of the rear oxygen sensors into the supports and place the connector on the engine.

7. Pre-fit the drive belt. Mount the drive belt on the pulleys as far as possible. For details, refer to 13 78 19 Removing and installing drive belt - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

8. Position the lifting platform under the engine/transmission combination.

9. Raise the body to a comfortable working height with the platform lift.

NOTE:

Have a helper ensure the engine/transmission combination clearance when moving it into the body.

When moving the unit into the body, ensure that the shift cable is on the transmission.

Fig 3: Air-conditioning compressor

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When moving the unit into the body, fit the air-conditioning compressor at the same time.

Fig 4: Air conditioning compressor fastening screws

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10. 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. Fit the air-conditioning compressor when the engine is at half height. For details, refer to 87 34 19 Removing and installing V6 air-conditioning compressor - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

11. Install power-steering pump (hydraulic pump). Refer to 48 98 19 Removing and installing hydraulic pump (Cayenne V6) - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

Fig 5: Inserting the engine completely

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12. Then insert the engine completely up into the engine compartment.

Fig 6: Fastening screws for front-axle carrier and engine carrier

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13. Tighten the 6 new front-axle carrier engine carrier screws. For details, refer to 40 06 19 Removing and installing front-axle carrier - as of MY 2003 (Cayenne TIP, Cayenne MAN) . → Initial tightening: 89 ftlb. → Final tightening - torque angle: 180 °

Fig 7: Fastening screws for transmission cross member

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14. Install transmission cross member. For details, refer to 39 65 19 Removing and installing transfer box - as of MY 2003 (All Models) . -A- . See Fig 7.

Fig 8: Support on wheel hub

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15. Release the lateral supports on the wheel hubs.

16. Lower the lifting platform slowly and remove.

Fig 9: Electric connector to transmission

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17. Connect electric connector -1, 2 and 3- to transmission. See Fig 9.

Fig 10: Connector to transfer box

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Fig 11: Shift cable

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18. Mount selector lever cable. For details, refer to 37 15 19 Removing and installing selector lever cable - as of MY 2003 (Cayenne TIP) .

Fig 12: Hydraulic lines

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Fig 13: Electric lead on anti-roll bar

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NOTE:

In vehicles with an offroad stabilizer, the electric lead must also be connected to the anti-roll bar.

In addition, the two hydraulic lines (near the steering gear) must be screwed on.

Fig 14: Spring band clamp, servo oil cooler to oil cooler

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19. Push the servo oil line onto the oil cooler and mount the spring band clamp.

NOTE:

For vehicles with Servotronic, the electric connectors on the steering gear must also be connected.

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

Fig 15: Steering column to steering gear

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20. Fit the steering column onto the steering gear. For details, refer to 48 90 19 Removing and installing steering gear - as of MY 2003 (All Models Except Cayenne S TIO Titan) .

Fig 16: Heat protection shield to steering gear

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21. Fit the heat protection shield on the steering gear by means of 2 fastening screws. → Tightening torque: 7.5 ftlb.

Fig 17: Heater coolant lines on the left side member

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22. Slide the heater coolant lines on the left side member and mount the space-saving clamps.

Fig 18: Coolant connection piece on the lower left on the radiator

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23. Push on the coolant connection piece on the lower left on the radiator. The connection piece must engage audibly.

Fig 19: Secondary air line to secondary air pump

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24. Fit secondary air line to the secondary air pump. The connector must engage audibly.

Fig 20: ATF lines to cooler

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25. Connect the ATF lines to the cooler. Remove the plugs and mount the lines. For details, refer to 38 62 19 Removing and installing line for ATF cooling - as of MY 2003 (Cayenne TIP) .

Fig 21: Ground point of the generator to the right side member

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26. Mount the ground point of the generator on the right side member. → Tightening torque: 15 ftlb.

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

Fig 22: Catalytic converter to body

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27. Tighten the catalytic converter fastening on the body (Ill. shows two-train exhaust system for V8) → Catalytic converter to body . For details, refer to 26 73 19 Removing and installing (main) catalytic converter - as of MY 2004 (Cayenne TIP, Cayenne MAN) . See Fig 22.

Fig 23: Installing cardan shaft

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28. Remove and align cardan shaft. Refer to 39 35 19 Removing and installing rear cardan shaft - as of MY 2003 (Cayenne MAN) .

29. Push new exhaust clamps on catalytic converter.

NOTE:

Use a transmission jack to support the exhaust system during installation.

Fig 24: Exhaust system on transmission jack

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30. Install the exhaust system. Move the exhaust system to its installation position using a transmission jack. Refer to 26 01 19 Removing and installing exhaust system - as of MY 2003 (All Models) .

Fig 25: Transverse strut

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31. Install the front cross member under the radiators. To do this, tighten the four fastening screws. → Tightening torque: 17 ftlb.

Fig 26: Front apron fastening screws on transverse strut

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32. Screw the front apron onto the transverse strut.

33. Lower the vehicle halfway.

Fig 27: Compressed air line

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NOTE:

In the case of vehicles with air suspension, the compressed air lines must also be screwed on.

Fig 28: Sensor for headlight levelling system

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Then connect the headlight levelling system sensor.

Fig 29: Brake lines in the wheel housings

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34. Tighten the brake lines on the left and right in the wheel housings.

Fig 30: Electrical connections of the spring struts

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35. Mount the electrical connections of the spring struts. To do this, connect cable -1- and then fasten supports -2 and 3- . See Fig 30.

36. Lower the vehicle.

NOTE:

If the fastening screws for the spring strut cannot be positioned, the spring strut can be pushed up slightly using a garage jack.

Fig 31: Mounting the fastening screws of the spring struts

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37. Mount the 3 fastening screws on the left and right spring struts from above (engine compartment side). -arrows- . Refer to 40 TW Tightening torques for front axle - as of MY 2003 (All Models) . See Fig 32.

Fig 32: Spring strut view from the wheel housing

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Fig 33: Oxygen sensor connector on the plenum panel splash panel

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38. Connect the 4 oxygen sensor connectors at the radiator tank splash panel.

Fig 34: B+ transfer point on left spring dome

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39. Mount B+ transfer point on left spring dome. To do this, connect the two positive cables from the engine over the bolts. → Tightening torque: 17 ftlb.

Fig 35: Servo line to reservoir

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40. Connect the servo line to the reservoir and mount the spring band clamp. Then fill the container with Pentosin.

Fig 36: Line from carbon canister and fuel line to plenum panel splash panel

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41. Tighten the line on the plenum panel splash panel from the carbon canister -2- and the fuel line -1- . → Tightening torque: 26 ftlb. . Then mount the vacuum line. See Fig 36.

Fig 37: Right spring dome

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42. 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.

Fig 38: Engine wire harness

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43. Lay the engine wiring 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: 7.5 ftlb.

Fig 39: Fastening screws for the central electrical system box cover

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44. Plug in the 4 connectors (red, brown, white and black) in the left-hand central electrical system box. Then mount the cover using four Torx screws.

45. Check whether the wiring harness is laid correctly. Close all fixing clips.

Fig 40: Bayonet screws for plenum chamber cover

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46. Mount the plenum chamber cover. Do not forget the electric connector. Mount the 4 bayonet screws -A- . See Fig 40.

47. Fit the drive belt and check that it is positioned correctly. Then remove the locking screw. For details, refer to 13 78 19 Removing and installing drive belt - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

48. Connect the upper right coolant connection piece to the radiator. The connection piece must engage audibly.

Fig 41: Air-cleaner element

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

49. Insert the air-cleaner element.

Fig 42: Sheetmetal clips

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50. Insert the air cleaners into the housing and slide on the cover from the top downwards. Then close the two respective sheetmetal clips.

Fig 43: Air tube on air cleaner cover

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51. Push the air tube on the air cleaner cover.

Fig 44: Intake manifold to throttle body and vacuum line

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52. Mount the intake manifold. To do this, push the intake manifold onto the throttle body and mount the vacuum line at the same time. Then attach the other end to the cover of the air cleaner housing.

Fig 45: Air cleaner housing

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53. Attach the hose clamp, the electric connector on the mass air-flow meter and the 2 fastening bolts on the air cleaner housing.

Fig 46: Pressing rubber elements onto the ball head supports in the cover

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54. Press the 4 rubber elements in the cover onto the 4 ball head supports. The mounts must be felt to engage.