Crankcase Suspension

2003-2008 ENGINE

Crankcase, Suspension

10 01 21 REMOVING ENGINE - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN)

TOOLS

TOOLS AND MATERIALS

Required tools

The following tools are described in the Workshop Equipment Manual, Chapter 3.0.13 "WE 1206" (exceptions

Designation Type Number Explanation Suspending device VW-tool 3033

Porsche System Tester ll special tool 9588

Circlip pliers for spring band clamps, Cayenne hose connections

commercially available tool

NR.72-1

Flexible screwdriver a/f 7 commercially available tool

NR.73-1

Filling device special tool P 9696

Transport eyebolt special tool P 9700

2006 Porsche Cayenne

2003-2008 ENGINE Crankcase, Suspension



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Wednesday, September 16, 2009 4:52:05 PM Page 1 © 2005 Mitchell Repair Information Company, LLC.

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are noted).

Fig. 1: Lifting platform Courtesy of PORSCHE OF NORTH AMERICA, INC.

Item Designation Source Explanation

-A- See Fig. 1.

Assembly mandrel

Height can be adjusted; used for mounting in the engine cross member; equipped with a locking screw to prevent engine from tipping.

-B- See Fig. 1.

Wheel hub holder Secures the axles against falling out

-C- See Fig. 1.

Assembly mandrel 1/11 Height can be adjusted; for mounting at the front of the front-axle carrier.

-D- See Fig. 1.

Oil pan support

Secures the engine against tipping after the transmission has been disconnected. Do not mount at the beginning of removal

-E- See Fig. 1. Steering knuckle bracket

In conjunction with -B- it protects the axles and spring struts from damage. See Fig. 1.

-F- See Fig. 1. Assembly mandrel

For mounting on the rear front-axle carrier

-G- See Fig. 1.

Assembly mandrel Positioning guide of the elevating platform into the body

-H- See Fig. 1.

Assembly mandrel For mounting on the transmission cross member



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Fig. 2: Tools overview Courtesy of PORSCHE OF NORTH AMERICA, INC.


-A- See Fig. 2.

Oil pan support

Prevents the engine tipping backwards. The support is mounted in the direction of travel towards the rear.

-B- See Fig. 2.

Wheel hub support Prevents the spring struts from tipping to the side, thereby damaging the axles.

-1/11- See Fig. 2.

Front mounting on front-axle carrier

Mounted on the base carrier at position 1.

-1a- See Fig. 2.

Mounting with height adjustment

Screwed into part 1/11.

-2- See Fig. 2.

Lateral mounting mandrel for engine carrier

-2a- See Fig. 2.


Screwed into part 2.

-2b- See Fig. 2.

Protection against tipping Screwed into part 2a. Prevents the engine from tipping forward.

-3- See Fig. 2.

Rear front-axle carrier mounting


-4- See Fig. 2.

Mounting in body Mounted on the base carrier at position 4.

-5- See Fig. 2.

Mounting for transmission cross member

Mounted on the base carrier at position 5



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Item Designation Source Explanation-A- See Fig. 3.

Suspending device 3033 See Workshop Equipment Manual 2.2.3

-B- See Fig. 3. Transport eyebolt P 9700

See Workshop Equipment Manual 2.2.2

-C- See Fig. 3.

Flexible screwdriver a/f 7 NR.73-1

See Workshop Equipment Manual 2.4

-D- See Fig. 3. Antifreeze testing device See Workshop

Equipment Manual,

Combined tool for testing antifreeze and electrolytes



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PRELIMINARY WORK

Preliminary work

Special equipment-specific features are described in the notes.

If the engine is to be replaced by a new one, make sure the air conditioner is evacuated and the existing air-conditioning compressor removed during removal of the engine as the replacement engine is delivered with the new compressor mounted. Refer to 87 34 19 Removing and installing air-conditioning compressor - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

Fix steering wheel with wheels in straight-ahead position (engage steering column lock or clamp steering wheel in center position with steering wheel holder)! If this is not done, the airbag contact unit will have to be put in center position after installation of the steering gear! Refer to 94 50 19 Removing and installing steering-column switch - as of MY 2003 (All Models) .

Position the vehicle at the take-up points provided on a lifting platform. Refer to 40 V0 Lifting the vehicle - as of MY 2003 (Cayenne Turbo S, Cayenne S TIO Titan) . Refer to 40 V0 Lifting the vehicle - as of MY 2003 (Cayenne TIP, Cayenne MAN, Cayenne S TIP, Cayenne S MAN, Cayenne Turbo) .

Put on the protective covers.

Produce the OBD II log.

Move the Tiptronic's selector lever to position N.

Remove ignition key.

Disconnect battery. Refer to 90 IN Work instructions after disconnecting the battery - as of MY 2003 (All Models Except Cayenne S TIO Titan) .

Remove front wheels. Refer to 44 05 19 Removing and installing wheel - as of MY 2003 (All Models) .

Remove the front wheel-housing liners. Refer to 50 56 19 Removing and installing front wheel housing liner - as of MY 2003 (All Models) .

Remove engine compartment covers. Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .

Allow engine to cool down.

Chapter 3.0.6 "WE 1036"

-E- See Fig. 3.

Circlip pliers for spring band clamps, Cayenne hose connections NR.72-1


-F- See Fig. 3.

Filling device P 9696 See Workshop Equipment Manual 2.2.2

Used for vacuum filling of the cooling system

-G- See Fig. 3.

Porsche System Tester ll 9588


-H- See Fig. 3. Lifting platform

Can be found in Workshop Equipment Manual, 3.0.13 "WE 1206"



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REMOVING ENGINE

Removing engine

Special features that are required for the equipment or relate to the Cayenne Turbo (M48/50) are described in the notes.

Fig. 4: V8 engine Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Remove engine guard with transverse strut. --> 108019 Removing and installing engine guard - "Removing".



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Fig. 5: Coolant drain plug Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Drain coolant. Refer to 19 38 17 Draining and filling in coolant (includes bleeding) - as of MY 2003 (All Models) .

3. Remove both wiper arms. Refer to 92 25 19 Removing and installing wiper arm - as of MY 2003 (All Models) .

NOTE: The air quality sensor is located on the cover of the radiator tank. This must be unclipped.



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Fig. 6: Plenum chamber cover Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Loosen the 4 bayonet screws -A- on the plenum panel cover. Then lift the cover in the middle, release left and right and remove from the vehicle. See Fig. 6.



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Fig. 7: Engine wire harness Courtesy of PORSCHE OF NORTH AMERICA, INC.

5. Disconnect the engine wire harness on the right-hand side of the vehicle. To do this, unplug the control unit and disconnect the ground point.



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Fig. 8: Torx screws for cover of central electrical system Courtesy of PORSCHE OF NORTH AMERICA, INC.

6. Open the cover of the central electrical system on the left side of the vehicle. To do this, loosen the four Torx screws.

7. Disconnect the connectors from the engine wire harness (white, red, black and brown). Remove the wiring harness from the retaining clips and lay it down on the engine.



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Fig. 9: B+ transfer point Courtesy of PORSCHE OF NORTH AMERICA, INC.

8. Disconnect B+ transfer point at the left of the engine compartment.



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Fig. 10: Throttle body cover Courtesy of PORSCHE OF NORTH AMERICA, INC.

9. Pull the cover of the throttle body up and off.

Fig. 11: Throttle adjuster electric connection Courtesy of PORSCHE OF NORTH AMERICA, INC.

10. Separate the electric connection from the throttle adjuster. To do this, press on the plug at the top and bottom and, at the same time, pull it off. Unclip the cable from the sheetmetal holder.



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Fig. 12: Fastening bolts on the throttle body Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig. 13: Boost-pressure sensor Courtesy of PORSCHE OF NORTH AMERICA, INC.



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11. Release the fastening bolts on the throttle body. To do this, twist both bolts through 45° in an anti-clockwise direction. The dot on the bolt must appear as illustrated in the figure.

Fig. 14: Pull out fastening bolt with pliers Courtesy of PORSCHE OF NORTH AMERICA, INC.

12. Remove the fastening bolts. To do this, take hold of the bolt by the rubber ring with pliers and pull it out.

13. Pull off the Y-shaped pipe from the throttle body.

NOTE: In the Cayenne Turbo (M48/50), the boost pressure sensor must also be disconnected.



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Fig. 15: Mass air flow connections Courtesy of PORSCHE OF NORTH AMERICA, INC.

14. Disconnect the mass air flow connections. To do this, loosen the hose clamps to the left and right on the bellows and pull the bellows off the mass air flow (in the Cayenne Turbo, pull them off the pressure pipes).

NOTE: If the engine is to be subsequently transported by crane, the right-hand design cover on cylinder row 5 - 8 should be removed at this point. --> 108319 Removing and installing engine cover - "Removing" .



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Fig. 16: Design cover of cylinder row 5 - 8 Courtesy of PORSCHE OF NORTH AMERICA, INC.

To do this, loosen the 4 fastening screws. Unclip the design cover from the intake system and slide out at an angle towards the front.



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Fig. 17: Air cleaner housing clamps Courtesy of PORSCHE OF NORTH AMERICA, INC.

15. Loosen the clamps on the air cleaner housing.



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Fig. 18: Circlip and adapter Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig. 19: Air cleaner cover Courtesy of PORSCHE OF NORTH AMERICA, INC.

16. Remove the air cleaner covers on the right and left. Refer to 24 25 19 Removing and installing air cleaner housing - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne S TIO Titan) . Refer to 24 25 19 Removing and installing air cleaner housing - as of MY 2003 (Cayenne Turbo, Cayenne Turbo S) .

NOTE: In vehicles with air suspension, the suction line of the compressor must also be removed on the right air cleaner cover. To do this, unclip the green cap, press circlip -1- inwards and pull off adapter -2- . See Fig. 18.



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Fig. 20: Filter elements Courtesy of PORSCHE OF NORTH AMERICA, INC.

17. Remove the filter elements.



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Fig. 21: Oxygen sensor connector Courtesy of PORSCHE OF NORTH AMERICA, INC.

18. Disconnect the 2 respective oxygen sensor connectors (brown, black) at the left and right of the water splash panel and unclip the cable from the supports.

Fig. 22: Fastening screws for vacuum pump Courtesy of PORSCHE OF NORTH AMERICA, INC.

NOTE: In the Cayenne Turbo (M48/50), the support for the vacuum pump must also be undone. To do this, unscrew the two fastening screws and press the pump forward slightly.



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Fig. 23: Coolant lines and vacuum line Courtesy of PORSCHE OF NORTH AMERICA, INC.

19. Disconnect the 2 coolant lines and vacuum line on the right side of the engine compartment.

--> Before lines are opened, place a cloth underneath them!

--> Components that come into contact with servo oil must be cleaned IMMEDIATELY with water!

--> Take suitable protective measures (e. g. gloves, safety goggles, oil binding material)

WARNING: Servo oil is aggressive!

Possible danger of injury or damage (swollen hoses, skin irritation, danger of slipping, etc.)



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Fig. 24: Servo oil reservoir Courtesy of PORSCHE OF NORTH AMERICA, INC.

20. Empty the servo oil reservoir with a syringe. Next, remove the hose from the reservoir. Close the open connections with plugs.



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Fig. 25: Torque converter support Courtesy of PORSCHE OF NORTH AMERICA, INC.

21. Loosen the torque support. To do this, remove the screw on the engine and loosen the screw on the body. Then pivot up the torque support.



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Fig. 26: Fuel line and carbon canister line Courtesy of PORSCHE OF NORTH AMERICA, INC.

--> Do not work on fuel system if engine is hot!

--> Do not smoke, avoid fire and naked flames!

--> Wear fuel-resistant protective gloves and goggles.

--> Attach warning sign to vehicle in a clearly visible position.

22. Disconnect fuel line -1- and line -2- from the carbon canister on the plenum panel splash panel. See Fig. 26.

WARNING: Fuel can escape when fuel line is disconnected.

Risk of fatal injury!

Damage to skin



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Fig. 27: Fastening screws for spring struts Courtesy of PORSCHE OF NORTH AMERICA, INC.

23. Loosen the 3 fastening screws on the left and right spring struts. The screws are loosened from inside the engine compartment. Of the 3 screws per spring strut, one is in the plenum panel. Replace screws.



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Fig. 28: Securing clip on connection for coolant feed and return lines Courtesy of PORSCHE OF NORTH AMERICA, INC.

24. Disconnect the coolant feed and return lines from the radiator. To do this, pull out the securing clip and pull off the connection. The clips should be mounted again immediately so that they are not confused.

NOTE: The drive belt must be slackened so that the air-conditioning compressor can be removed later.

If at all possible, the air-conditioning system should not be opened.




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Fig. 29: Drive belt tensioning pulley Courtesy of PORSCHE OF NORTH AMERICA, INC.

25. Slacken the drive belt (a/f 30) and remove from the tensioning roller.



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Fig. 30: Control lines of the ambient air valvesCourtesy of PORSCHE OF NORTH AMERICA, INC.

Fig. 31: Compressed air line on spring strut Courtesy of PORSCHE OF NORTH AMERICA, INC.

NOTE: In the Cayenne Turbo (M48/50), the control lines of the ambient air valves on the T-piece should be pulled off.

NOTE: In the case of vehicles with air suspension, the compressed air line on the spring strut must also be disconnected. Loosen the line carefully and allow the remaining pressure to escape. Loosen the threaded joint completely only when the line is fully depressurized.



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Fig. 32: Electric plug connection for height sensor Courtesy of PORSCHE OF NORTH AMERICA, INC.

The electric plug connection of the height sensor must be disconnected in vehicles with air suspension or automatic headlight levelling system.



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Fig. 33: Electric plug on the spring struts in the wheel housing Courtesy of PORSCHE OF NORTH AMERICA, INC.

26. Disconnect electric plug -1- on the spring struts in the wheel housing. Then unclip the support -2 and 3- . Tie the cable on the spring strut. See Fig. 33.



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Fig. 34: Brake lines in the wheel housing Courtesy of PORSCHE OF NORTH AMERICA, INC.

27. Disconnect the brake lines in the wheel well to the left and right.



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Fig. 35: Ground point of right side member Courtesy of PORSCHE OF NORTH AMERICA, INC.

28. Disconnect the ground point on the right side member.


--> Components that come into contact with ATF must be cleaned IMMEDIATELY with water!


--> Collect emerging ATF!

WARNING: ATF!




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Fig. 36: ATF lines on cooler Courtesy of PORSCHE OF NORTH AMERICA, INC.

29. Disconnect the ATF lines on the cooler. To do this, loosen the fastening screw and pull off the line. Seal open lines with a plug.



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Fig. 37: Heat protection shield on steering gear connection Courtesy of PORSCHE OF NORTH AMERICA, INC.

30. Remove the heat protection shield on the steering gear connection. To do this, loosen the 2 fastening screws.

NOTE: In the case of vehicles with Servotronic, an electric plug must also be removed from the steering gear.



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Fig. 38: Clamping screw on steering column Courtesy of PORSCHE OF NORTH AMERICA, INC.

31. Loosen the clamping screw from the steering column on the steering gear and remove it. The screw must not be re-used. Force the steering column up and off the steering gear.

32. Disconnect the electric plug on the steering gear (Servotronic only).



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Fig. 39: Heat exchanger coolant lines in the left wheel housing Courtesy of PORSCHE OF NORTH AMERICA, INC.

33. Disconnect the heat exchanger coolant lines in the left wheel housing below. Approx. 2 liters of coolant will flow out when you do this.

34. Remove the complete exhaust system from the connection point on the catalytic converter to the tailpipes. Refer to 26 01 19 Removing and installing exhaust system - as of MY 2003 (All Models) .

35. Remove rear cardan shaft. Refer to 39 35 19 Removing and installing rear cardan shaft - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S) . Refer to 39 35 19 Removing and installing rear cardan shaft - as of MY 2003 (Cayenne S TIO Titan) .



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Fig. 40: Electric connections on the transmission Courtesy of PORSCHE OF NORTH AMERICA, INC.

36. Disconnect electrical connections -1,2 and 3- on the transmission and unclip the wiring harness. See Fig. 40.



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Fig. 41: Connections on transfer box Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig. 42: Fastening screws for heat protection shield



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Courtesy of PORSCHE OF NORTH AMERICA, INC.

37. Remove the heat shield on the left transmission side. To do so, loosen the 3 fastening screws and take out the heat protection shield.

Fig. 43: Selector lever cable on the transmission Courtesy of PORSCHE OF NORTH AMERICA, INC.

38. Detach the selector lever cable on the transmission. To do this, press the ball socket away from the transmission. Then pull out top sheetmetal clip -A- and remove the cable in an upward direction. See Fig. 43.


NOTE: Do not loosen nut.

NOTE: If the transmission is to be separated from the engine after removal, the two lower fastening screws on the transmission housing and front cardan shaft should be removed at this point, since access to the lifting platform will be impaired.





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Fig. 44: Lower line on servo oil cooler Courtesy of PORSCHE OF NORTH AMERICA, INC.

39. Disconnect the lower line on the servo oil cooler.



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Fig. 45: Locking spring on turbocharger adapter and hose clamp of turbocharger pressure pipe Courtesy of PORSCHE OF NORTH AMERICA, INC.

NOTE: On the Cayenne Turbo (M48/50), the hose connections on the turbochargers must also be loosened. To do this, pull out locking spring -1- on the turbocharger adapter. Then loosen hose clamp -2- of the pressure pipe on the turbocharger. See Fig. 45.



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Fig. 46: Locking clip and line of ambient air valve Courtesy of PORSCHE OF NORTH AMERICA, INC.

Disconnect the connection on the charge air cooler. To do this, remove locking clip -1- and pull off the line. Line -2- of the ambient air valve must also be disconnected on the right-hand side of the vehicle. To do this, remove the spring band clamp and pull off the line. See Fig. 46.

NOTE: It is easier to remove the air-conditioning compressor from its installation position when the engine has already been lowered a little.

The air-conditioning compressor lines must not be kinked or twisted.

The lines of the air-conditioning compressor remain mounted, so the refrigerant does not need to be evacuated.




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Fig. 47: Fastening screws and electric connector of air-conditioning compressor Courtesy of PORSCHE OF NORTH AMERICA, INC.

40. Loosen the 3 fastening screws and disconnect the electric plug from the air-conditioning compressor. Set the air-conditioning compressor aside.



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Fig. 48: Air-conditioning compressor Courtesy of PORSCHE OF NORTH AMERICA, INC.

41. The air-conditioning compressor must be secured with a piece of wire.

NOTE: For installation, it is a good idea to mark the installation position of the front axle carrier diagonally at at least two places on the body. To do this, place the marks vertically with respect to the floor of the body using a felt-tip pen (e. g. mark along the front-axle carrier mount with the pen).



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Fig. 49: Mark installation position of the front-axle carrier Courtesy of PORSCHE OF NORTH AMERICA, INC.

42. Mark the installation position of the front axle carrier diagonally at at least two places on the body.

NOTE: Because of the high loosening torque, the 6 fastening screws on the front-axle carrier can now be loosened. Loosen the screws by a maximum of one turn.



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Fig. 50: Elevating platform Courtesy of PORSCHE OF NORTH AMERICA, INC.

43. Place the elevating platform under the engine and raise it. When you do this, ensure that the positioning guides of the elevating platform are inserted into the body.



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Fig. 51: Securing the spring struts Courtesy of PORSCHE OF NORTH AMERICA, INC.

44. Secure the spring struts. To do this, turn the rubber discs upwards until they are set under the steering knuckle. Then tighten the retaining brackets on the wheel hub and elevating platform.



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Fig. 52: Fastening screws for transmission cross member Courtesy of PORSCHE OF NORTH AMERICA, INC.

45. Loosen the transmission cross member. To do this, loosen the 4 fastening screws -A- . See Fig. 52.

46. Secure the engine/transmission combination. Then secure the mounting mandrels on the engine transverse bar with locking screws.



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Fig. 53: Fastening screws for front-axle carrier and fastening screws for engine transverse bar Courtesy of PORSCHE OF NORTH AMERICA, INC.

47. Loosen the 4 fastening screws on the front-axle carrier and the 2 fastening screws on the engine transverse bar.

48. Lower the lifting platform slowly. When this is done, a second person should ensure that there is sufficient clearance around the engine compartment and wheel housings.

10 01 21 REMOVING ENGINE - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN)

TOOLS

NOTE: When lowering the engine, make sure that cables or lines do not get mounted accidentally between engine and body. Thus a second person should make sure that the cables and lines do not get caught.




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TOOLS AND MATERIALS

Required tools

The following tools can be found in the Workshop Equipment Manual 3.0.13 "WE 1206" (exceptions are noted).




NR.72-1

Flexible screw driver a/f 7 commercially available tool

NR.73-1


Transport eyebolt special tool P 9700/1



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-A- See Fig. 54.

Assembly mandrel


-B- See Fig. 54. Wheel hub holder Secures the axles against falling out

-C- See Fig. 54. Assembly mandrel 1/11

Height can be adjusted; for mounting at the front of the front-axle carrier.

-D- See Fig. 54.

Oil pan support




-F- See Fig. 54.

Assembly mandrel For mounting on the rear front-axle carrier

-G- See Fig. 54.


-D- See Fig. 54.




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-A- See Fig. 55.

Oil pan support


-B- See Fig. 55.


-1/11- See Fig. 55.



-1a- See Fig. 55.


Is screwed into part 1/11.

-2- See Fig. 55.


-2a- See Fig. 55.



-2b- See Fig. 55.


-3- See Fig. 55.



-4- See Fig. 55.

Mounting in body Mounted on the base carrier at position 4

-5- See Fig. 55.





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-B- See Fig. 56.

Transport eyebolt P 9700/1See Workshop Equipment Manual 2.2.2

Illustration deviates from the appearance of the "hook" (illustration shows V8 tool) -B- See Fig. 56.

-C- See Fig. 56.

Flexible screw driver a/f 7 NR.73-1




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PRELIMINARY WORK

Preliminary work



Position the vehicle at the take-up points provided on a lifting platform. Refer to 40 V0 Lifting the vehicle - as of MY 2003 (Cayenne TIP, Cayenne MAN, Cayenne S TIP, Cayenne S MAN, Cayenne Turbo) .










REMOVING ENGINE

Removing engine

-D- See Fig. 56. Antifreeze testing device

See Workshop Equipment Manual, Chapter 3.0.6 "WE 1036"


-E- See Fig. 56.



-F- See Fig. 56.



-G- See Fig. 56.







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WARNING: ATF!




Damage to skin



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Fig. 59: Bayonet screws for plenum chamber cover Courtesy of PORSCHE OF NORTH AMERICA, INC.





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8. Disconnect B+ transfer point at the left of the engine compartment. To do this, disconnect the 2 connecting cables -A and B- for the engine. See Fig. 62.



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Fig. 63: Engine cover Courtesy of PORSCHE OF NORTH AMERICA, INC.

9. Pull engine cover vertically upwards and off.



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Fig. 64: Connecting tube from air cleaner to engine Courtesy of PORSCHE OF NORTH AMERICA, INC.

10. Remove connecting tube from air cleaner to engine. To do this, loosen the tube clamp on the engine, unplug the electric connector on the mass air-flow meter and remove the 2 fastening bolts on the air cleaner cover.



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Fig. 65: Vacuum line Courtesy of PORSCHE OF NORTH AMERICA, INC.

11. Remove the vacuum line on the throttle body from the connecting tube. Then take the pressure pipe out of the engine compartment.

NOTE: The air tube is only present in vehicles with air suspension.



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Fig. 66: Air tube cap Courtesy of PORSCHE OF NORTH AMERICA, INC.

12. Remove air tube on air cleaner cover. To do this, unclip the green cap. Insert a screwdriver into the cut-out of the cap and lever the cap off.



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Fig. 67: Circlip Courtesy of PORSCHE OF NORTH AMERICA, INC.

13. Push the circlip into the adapter -1- and then pull it off together with the adapter -2- . See Fig. 67.



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Fig. 68: Cap Courtesy of PORSCHE OF NORTH AMERICA, INC.

14. Clip the green cap on again after disassembly.

Fig. 69: Clamps on the air cleaner housings Courtesy of PORSCHE OF NORTH AMERICA, INC.


16. Remove the air cleaner cover. Refer to 24 25 19 Removing and installing air cleaner housing - as of MY 2004 (Cayenne TIP, Cayenne MAN) .



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



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Fig. 71: Oxygen sensor connector on the water splash panel Courtesy of PORSCHE OF NORTH AMERICA, INC.

18. Disconnect the 4 oxygen sensor connectors (brown, black) at the right of the water splash panel and unclip the cable from the supports.



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21. Disconnect fuel line -1- and line -2- from the carbon canister on the plenum panel splash panel. Then pull off the vacuum line -3- . See Fig. 74.



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22. Loosen the 3 fastening screws on the left and right spring struts. The screws are loosened from inside the engine compartment. Of the 3 screws per spring strut, one is in the plenum panel. The screws must not be re-used.



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Fig. 77: Drive belt Courtesy of PORSCHE OF NORTH AMERICA, INC.

24. Slacken the drive belt. To do this, screw a screw (M 8 x 50) into the tensioner until the belt can be removed from the tensioning roller.



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25. Disconnect electric connector -1- on the spring struts in the wheel housing. Then unclip the support -2 and 3- . Tie the cable on the spring strut. See Fig. 80.



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28. Disconnect the ATF lines on the radiator. To do this, loosen the fastening screw (a/f 10) and pull the lines off. Seal open lines with a plug.



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Fig. 84: Secondary air pump hose Courtesy of PORSCHE OF NORTH AMERICA, INC.

29. Detach secondary air pump hose. To do this, pull off the plug on the pump in the right wheel housing.



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NOTE: For vehicles with Servotronic, an electric connector must also be removed from the steering gear.



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32. Disconnect the electric connector on the steering gear (Servotronic only).



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Fig. 88: Hydraulic lines under steering gear Courtesy of PORSCHE OF NORTH AMERICA, INC.


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

NOTE: In vehicles with an offroad stabilizer, the two hydraulic lines under the steering gear must be disconnected. Counter with an open-ended wrench when doing this.



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36. Disconnect electric connections -1, 2 and 3- on the transmission. See Fig. 89.



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Fig. 90: Loosening the connections on the transfer box Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig. 91: Loosening the connections on the transfer box



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NOTE: Do not loosen screw -B- .

NOTE: If the transmission is to be separated from the engine after removal, the 2 lower fastening screws on the transmission housing and front cardan shaft should be removed at this point, since access to the lifting platform will be impaired.



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38. Loosen the lower line on the servo oil cooler.



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Fig. 94: Electric connector on the offroad stabilizerCourtesy of PORSCHE OF NORTH AMERICA, INC.

39. Disconnect the electric connector on the offroad stabilizer at the front left.

Fig. 95: Elevating platform under engine Courtesy of PORSCHE OF NORTH AMERICA, INC.


NOTE: Because of the high loosening torque, the 6 fastening screws on the suspension subframe can now be loosened. Loosen the screws by a maximum of 1 turn.



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43. Secure the engine/transmission combination. Then secure the mounting mandrels on the engine transverse bar with the locking screws.



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Fig. 98: Fastening screws for suspension subframe and fastening screws for engine transverse bar Courtesy of PORSCHE OF NORTH AMERICA, INC.

44. Loosen the 4 fastening screws on the suspension subframe and the 2 fastening screws on the engine transverse bar.

45. Lower the lifting platform slowly by approx. 20 to 30 cm. When this is done, a second person should ensure that there is sufficient clearance around the engine compartment and wheel housings.

46. Loosen power steering pump. To do so, loosen the two front fastening screws and turn the pulley as required. Then loosen the rear fastening screw.





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Fig. 99: Fastening screws and electric connector for the air-conditioning compressor Courtesy of PORSCHE OF NORTH AMERICA, INC.

47. Loosen the 3 fastening screws and disconnect the electric connector from the air-conditioning compressor. Set the air-conditioning compressor aside.



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49. Lower the lifting platform fully. When doing this, a second person should ensure that there is sufficient clearance around the engine compartment and wheel housings.

NOTE: 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.




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Fig. 101: Engine removed Courtesy of PORSCHE OF NORTH AMERICA, INC.

10 01 AW THE MOST IMPORTANT WORKING REGULATIONS AND WARNING NOTES - AS OF MY 2003 (ALL MODELS EXCEPT CAYENNE S TIO TITAN)

FOLDER 1

Group 1 - Engine

--> Do not work at or under a suspended load.

--> Never reach in between the engine and components during installation or removal.

--> Wear protective safety gear.

WARNING: Suspended load!

Risk of serious crushing and injury

CAUTION: Leaks due to components being at too low a temperature or at different temperatures!

If components that are cold or at different temperatures are sealed together by the application of sealant, adhesion problems and leaks can arise due to the build-up of condensation water or component distortion.



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--> Components must have reached at least 17°C throughout.

--> Components must not be too hot (distortion).

--> Spare parts that are stored in the cold or heat (strong sunlight), must be brought to room temperature or the same temperature as other parts before installation.

Group 10 - Crankcase - suspension

--> When working on the engine suspension, the engine must be appropriately secured against falling or lowering.

--> Never use defective lifting equipment (bent or damaged tools must not be used or repaired. Always replace these tools). Check tools for signs of damage before use.

--> Only use lifting equipment tested and approved by Porsche. Home-made and auxiliary constructions result in improper use and are dangerous.

--> The transport eyebolt can only bear vertical traction with no side or transverse forces. Side loads (e. g. from chains or cables) will damage the transport eyebolt, which must then be replaced. Extreme cases of improper use can break the transport eyebolt.

--> Tools and lifting equipment must always be used properly. Improper use or dangerous home-made constructions can break tools and result in falling loads.

--> Wear protective gloves.

--> Do not consume food or drink while working (danger of mixing).

--> Silicones, greases and oils are toxic and must not be swallowed or handled without protection.

--> Observe the specifications on the containers. If swallowed, seek medical advice and show the information on the containers.

--> Wear gloves.

WARNING: Danger of injury from incorrect use of tools and from falling loads!

Danger of crushing from heavy loads!

WARNING: Danger of poisoning from silicone, grease and oil!

Danger of poisoning and damage to skin

NOTE: When working on the crank mechanism, absolute cleanliness is essential.



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Group 13 - Crank drive, pistons




--> Wear gloves.

--> Never reach into running belt drives or rotating components.

--> Switch off engine.

--> Drive belts should only be removed when they have cooled down.

--> The vehicle fans can continue running or start up when the ignition is switched off.

--> The power supply to the fans must be disconnected before starting work on the radiator or radiator fans.

Any seals which have been removed must always be replaced.

Only the auxiliary and assembly equipment recommended for the repair job may be used for the particular assembly work.

Only the auxiliary materials recommended by Porsche (such as lubricants or sealants) may be used.

All screw fittings must be tightened according to the prescribed torque or torque angle.



WARNING: Danger of injury from rotating components and belt drive!

Risk of severe hand injuries.

WARNING: Do not remove the drive belt when the engine is warm!

Risk of damage or deformation!

WARNING: Danger of injury from running radiator fans (electric fans)!

Risk of severe hand injuries.



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(Remove fuse, refer to 97 84 IN Fuse carrier - as of MY 2003 (All Models) ).

Group 15 - Cylinder head, valve drive




--> Wear gloves.

NOTE: Work on the crank mechanism/pistons must be carried out very carefully and in clean conditions.

A dirty engine should be cleaned before opening.

No dirt may enter the engine when opened.

During work interruptions, the open engine or components must be covered to protect them from dirt.


Only processing materials (silicones, oils, greases, etc.) approved by Porsche may be used.


NOTE: Only processing materials (silicones, oils, greases, etc.) approved by Porsche may be used.


Never remove the drive belt when it is hot.



NOTE: Work on the valve drive must be carried out very carefully and in clean conditions.

A dirty engine should be cleaned before opening.

No dirt may enter the engine when opened.

During work interruptions, the open engine or components must be covered to protect them from dirt.




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Group 17 - Lubrication


--> If swallowed, observe the warning information on the containers, contact a doctor if necessary and show the information on the containers.

--> Engine oil and components of the oil circuit can become very hot!

--> Allow engine and components to cool down.

--> Avoid contact with the skin and eyes.

--> Wear suitable protective clothing.

--> Do not pour engine oil over very hot components (e. g. turbocharger).

--> Never place cloths soaked with oil on hot engine components.

--> In case of fire, use CO2 or dry powder fire extinguishers.

Only the auxiliary materials recommended by Porsche (such as lubricants or sealants) may be used.


WARNING: Engine oil is toxic.

Danger of poisoning!

WARNING: Danger of scalding from hot oil!

WARNING: Oil is combustible!

Risk of fire due to oil and hot components (exhaust manifold, etc.)

NOTE: Only oils with the appropriate viscosity and approved by Porsche may be used.

A mixture of different oils is not permitted.

During an oil change, the old oil must be drained from the engine via the drain plugs provided. Extraction by suction is not recommended.

Engine oil and oil filters must be disposed of according to the respective,



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Group 19 - Cooling

--> Swallowing coolant additives and cleaning liquids must be urgently avoided.

--> Do not consume any food or drink while working (danger of accidental mixing).

--> If swallowed, observe the warning information on the containers and contact a doctor. If necessary, show the doctor the warning information on the packaging.

--> Never open the cooling system when it is hot. Emerging coolant may be very hot and can cause scalding.

--> The cooling system must be depressurized before being opened.

--> Allow engine to cool down.

--> The power supply to the fans must be disconnected before starting work on the radiator, radiator fans, or the belt drive. Refer to 97 84 IN Fuse carrier - as of MY 2003 (All Models) or battery. Refer to 90 IN Work instructions after disconnecting the battery - as of MY 2003 (All Models Except Cayenne S TIO Titan) .

--> Do not relieve the system pressure of the cooling system and then run the engine.

--> Relieving the system pressure and subsequently starting the engine can cause severe damage to components in the cooling system. If the cooling system must be opened when it is hot, allow the cooling system to cool down before starting the engine again.

applicable national laws.

Seals in the oil circuit must be replaced by new ones following disassembly.

Observe the specified torques.

CAUTION: Danger of poisoning!

Coolant additives and cleaning liquids are toxic.

CAUTION: Danger of scalding with hot coolant!

WARNING: The vehicle fans can continue running or start up automatically.

Injuries which can lead to the loss of body parts.

CAUTION: Risk of damaging the cooling system!



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INFORMATION

Group 20 - Fuel supply, control

--> Gasoline is toxic.

--> Inhaling vapors can cause irritation of the mucous membranes and eyes.

--> It can be carcinogenic. It represents a serious risk to health when inhaled, touched or swallowed over longer periods.

--> Only work on the fuel system in well-ventilated rooms.

--> Wear protective gloves that are fuel-resistant.

--> Wear a breathing mask with active charcoal filter; do not breathe in any fuel vapors.

--> Ensure that there is adequate ventilation and extract all fuel vapors.

--> Before opening the fuel lines or fuel hoses, relieve the fuel pressure.

--> Collect escaping fuel, absorb it if necessary with a suitable binding material and dispose of properly.

--> Pay attention to cleanliness when working on the fuel system.

NOTE: The coolant filled in at the factory is intended to suffice for the entire service life. As long as the coolant is not contaminated by foreign bodies or other fluids it need not be changed.

Different coolant additives must not be mixed and doing so may damage the cooling system. Only use original Porsche coolant additives.

The coolant must be set to antifreeze protection of -37 °C. This corresponds to a mixing ratio of 50 : 50 (coolant additive : water). This mixing ratio provides optimum corrosion and antifreeze protection.

Coolant additives, coolants and cleaning agents must be disposed of according to the respective, applicable national laws.

Seals in the cooling system must be replaced by new ones following disassembly.

WARNING: Danger of poisoning from fuels!

WARNING: Danger of fire from fuel!



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--> Keep clear of ignition sources.

--> Do not smoke.

--> Disconnect battery.

--> Danger of fire due to naked flames and sparks, e. g. during welding or grinding work.

--> Danger of fire due to escaping fuel, e. g. on hot engine components or due to electrostatic charge. Allow engine to cool down.

--> Secure the vehicle, e. g. with a warning sign.

--> Change any clothing soaked with fuel immediately.


Group 21 - Exhaust system, turbocharging

--> Components of the exhaust system can be extremely hot.

--> Allow the parts to cool down first and wear protective gloves.

Group 24 - Fuel system, electronic injection

NOTE: The ignition must be switched off when working on the fuel system.

Absorb any escaping fuel using a suitable binding material or a cloth.

Cloths which have absorbed fuel must be disposed of according to the applicable national laws.

The fuel system must be depressurized before starting work on it.

Only work on the fuel system in well-ventilated rooms.


CAUTION: Danger of burns from very hot components (turbocharger, exhaust manifold)!

NOTE: After the connecting clamps in the exhaust system have been released, they must always be replaced.

During assembly work on the exhaust system, ensure that the components are aligned and installed correctly.

Seals must be replaced by new ones following removal.

Observe the correct tightening sequence and tightening torques.



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--> Gasoline is toxic.

--> Inhaling vapors can cause irritation of the mucous membranes and eyes.

--> It can be carcinogenic. It represents a serious risk to health when inhaled, touched or swallowed over longer periods.

--> Only work on the fuel system in well-ventilated rooms.

--> Wear protective gloves that are fuel-resistant.

--> Wear a breathing mask with active charcoal filter; do not breathe in any fuel vapors.

--> Ensure that there is adequate ventilation and extract all fuel vapors.

--> Before opening the fuel lines or fuel hoses, relieve the fuel pressure.

--> Collect escaping fuel, absorb it if necessary with a suitable binding material and dispose of properly.

--> Pay attention to cleanliness when working on the fuel system.

--> Keep clear of ignition sources.

--> Do not smoke.

--> Disconnect battery.

--> Danger of fire due to naked flames and sparks, e. g. during welding or grinding work.

--> Danger of fire due to escaping fuel, e. g. on hot engine components or due to electrostatic charge. Allow engine to cool down.

--> Secure the vehicle, e. g. with a warning sign.

--> Change any clothing soaked with fuel immediately.


WARNING: Danger of poisoning from fuels!

WARNING: Danger of fire from fuel!



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Precautionary measures when handling oxygen sensors

--> Do not remove the plastic cap on the thread until just prior to fitting the oxygen sensor. The thread grease must never come into contact with the connector.

--> Protect sensors - before and after fitting - against mechanical shocks.

--> Sensors that were dropped on the floor must not be used owing to the risk of a broken ceramic insulator.

--> The cables must not be twisted or kinked when the sensors are screwed in. Avoid pulling on the cable and connector.

--> Cleanliness in the housing of the plug connections is of utmost importance for the oxygen sensor to function properly. Particles of dirt can impair the function of the oxygen sensor. The connector must therefore be protected against any and all types of soiling.

--> Sensors with a soiled or damaged connector must no longer be used.

--> Protect the cables and plugs when carrying or moving the exhaust system with the sensors already fitted.

--> High-pressure cleaning equipment must not be used in the area of the sensors and plug connections.

--> Contact and corrosion agents, e. g. Stabilant, must not be applied to the plug contacts of the oxygen sensors.

Group 26 - Exhaust system

NOTE: The ignition must be switched off when working on the fuel system.

Absorb any escaping fuel using a suitable binding material or a cloth.

Cloths which have absorbed fuel must be disposed of according to the applicable national laws.

The fuel system must be depressurized before starting work on it.

Only work on the fuel system in well-ventilated rooms.


CAUTION: The oxygen sensor may be damaged if handled incorrectly.

Change in engine emissions.

Damage to the environment.

Check Engine lamp may come on.

CAUTION: Danger of injury from heavy loads!



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--> When working on the exhaust system, it must be appropriately secured against falling or lowering.

--> Never use defective lifting equipment.

--> Only use lifting equipment tested and approved by Porsche.

--> Only operate the engine with an appropriate exhaust gas extraction system.

--> Components of the exhaust system can be extremely hot.

--> Allow the parts to cool down first and wear protective gloves.

Group 28 - Ignition system

--> When working on the ignition system, the ignition key must be removed from the ignition lock.

--> The ignition system must be disconnected from the power supply before starting work on it.

--> Only connect/disconnect lines or plugs when the ignition is switched off.

--> Only connect measuring devices when the ignition is switched off.

CAUTION: Engine exhaust gas!

Danger of poisoning!

CAUTION: Danger of burns from very hot components (turbocharger, exhaust manifold)!

NOTE: After the connecting clamps in the exhaust system have been released, they must always be replaced.

During assembly work on the exhaust system, ensure that the components are aligned and installed correctly.

Seals must be replaced by new ones following removal.

Observe the correct tightening sequence and tightening torques.

CAUTION: High-voltage ignition system!

Danger of electric shocks!

This can cause cardiac irregularities.

NOTE: The ignition system must be disconnected from the power supply before starting work on it.



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10 01 19 REMOVING AND INSTALLING V6 3.2 L ENGINE - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN)

TOOLS

TOOLS AND MATERIALS

Required tools

The following tools can be found in the Workshop Equipment Manual 3.0.13 "WE 1206" (exceptions are

Observe the specified torques.

Spark plug threads must not be greased.





NR.72-1


NR.73-1





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noted).



-A- See Fig. 102.

Assembly mandrel


-B- See Fig. 102.

Wheel hub holder Secures the axles against falling out

-C- See Fig. 102.

Assembly mandrel 1/11 Height can be adjusted; for mounting at the front of the front-axle carrier.

-D- See Fig. 102.

Oil pan support




-F- See Fig. 102. Assembly mandrel

For mounting on the rear front-axle carrier

-G- See Fig. 102.


-D- See Fig. 102.




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-A- See Fig. 103.

Oil pan support


-B- See Fig. 103.


-1/11- See Fig. 103.



-1a- See Fig. 103.



-2- See Fig. 103.


-2a- See Fig. 103.



-2b- See Fig. 103.


-3- See Fig. 103.



-4- See Fig. 103.


-5- See Fig. 103.





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-B- See Fig. 104.



-C- See Fig. 104.





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PRELIMINARY WORK

Preliminary work



Position the vehicle at the take-up points provided on a lifting platform. Refer to 40 V0 Lifting the vehicle - as of MY 2003 (Cayenne TIP, Cayenne MAN, Cayenne S TIP, Cayenne S MAN, Cayenne Turbo) .










REMOVING V6 3.2 L ENGINE

Removing engine




-E- See Fig. 104.



-F- See Fig. 104.



-G- See Fig. 104.







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WARNING: ATF!




Damage to skin



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8. Disconnect B+ transfer point at the left of the engine compartment. To do this, disconnect the 2 connecting cables -A and B- for the engine. See Fig. 110.



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Fig. 111: Engine cover Courtesy of PORSCHE OF NORTH AMERICA, INC.

9. Pull engine cover vertically upwards and off.



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Fig. 112: Connecting tube from air cleaner to engine Courtesy of PORSCHE OF NORTH AMERICA, INC.

10. Remove connecting tube from air cleaner to engine. To do this, loosen the tube clamp on the engine, unplug the electric connector on the mass air-flow meter and remove the 2 fastening bolts on the air cleaner cover.



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11. Remove the vacuum line on the throttle body from the connecting tube. Then take the pressure pipe out of the engine compartment.

NOTE: The air tube is only present in vehicles with air suspension.



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Fig. 114: Air tube cap Courtesy of PORSCHE OF NORTH AMERICA, INC.

12. Remove air tube on air cleaner cover. To do this, unclip the green cap. Insert a screwdriver into the cut-out of the cap and lever the cap off.



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Fig. 115: Circlip Courtesy of PORSCHE OF NORTH AMERICA, INC.

13. Push the circlip into the adapter -1- and then pull it off together with the adapter -2- . See Fig. 115.



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Fig. 116: Cap Courtesy of PORSCHE OF NORTH AMERICA, INC.

14. Clip the green cap on again after disassembly.

Fig. 117: Clamps on the air cleaner housings Courtesy of PORSCHE OF NORTH AMERICA, INC.


16. Remove the air cleaner cover. Refer to 24 25 19 Removing and installing air cleaner housing - as of MY 2004 (Cayenne TIP, Cayenne MAN) .



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Fig. 119: Oxygen sensor connector on the water splash panel Courtesy of PORSCHE OF NORTH AMERICA, INC.

18. Disconnect the 4 oxygen sensor connectors (brown, black) at the right of the water splash panel and unclip the cable from the supports.



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21. Disconnect fuel line -1- and line -2- from the carbon canister on the plenum panel splash panel. Then pull off the vacuum line -3- . See Fig. 122.



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22. Loosen the 3 fastening screws on the left and right spring struts. The screws are loosened from inside the engine compartment. Of the 3 screws per spring strut, one is in the plenum panel. The screws must not be re-used.



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24. Slacken the drive belt. To do this, screw a screw (M 8 x 50) into the tensioner until the belt can be removed from the tensioning roller.



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25. Disconnect electric connector -1- on the spring struts in the wheel housing. Then unclip the support -2 and 3- . Tie the cable on the spring strut. See Fig. 128.



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28. Disconnect the ATF lines on the radiator. To do this, loosen the fastening screw (a/f 10) and pull the lines off. Seal open lines with a plug.



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Fig. 132: Secondary air pump hose Courtesy of PORSCHE OF NORTH AMERICA, INC.

29. Detach secondary air pump hose. To do this, pull off the plug on the pump in the right wheel housing.



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NOTE: For vehicles with Servotronic, an electric connector must also be removed from the steering gear.



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32. Disconnect the electric connector on the steering gear (Servotronic only).



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Fig. 136: Hydraulic lines under steering gear Courtesy of PORSCHE OF NORTH AMERICA, INC.


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

NOTE: In vehicles with an offroad stabilizer, the two hydraulic lines under the steering gear must be disconnected. Counter with an open-ended wrench when doing this.



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36. Disconnect electric connections -1, 2 and 3- on the transmission. See Fig. 137.



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Fig. 138: Loosening the connections on the transfer box Courtesy of PORSCHE OF NORTH AMERICA, INC.

NOTE: Do not loosen screw -B- (see Fig. 139).



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NOTE: If the transmission is to be separated from the engine after removal, the 2 lower fastening screws on the transmission housing and front cardan shaft should be removed at this point, since access to the lifting platform will be impaired.



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38. Loosen the lower line on the servo oil cooler.



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Fig. 141: Electric connector on the offroad stabilizerCourtesy of PORSCHE OF NORTH AMERICA, INC.

39. Disconnect the electric connector on the offroad stabilizer at the front left.

Fig. 142: Elevating platform under engine Courtesy of PORSCHE OF NORTH AMERICA, INC.


NOTE: Because of the high loosening torque, the 6 fastening screws on the suspension subframe can now be loosened. Loosen the screws by a maximum of 1 turn.



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43. Secure the engine/transmission combination. Then secure the mounting mandrels on the engine transverse bar with the locking screws.



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Fig. 145: Fastening screws for suspension subframe and fastening screws for engine transverse bar Courtesy of PORSCHE OF NORTH AMERICA, INC.

44. Loosen the 4 fastening screws on the suspension subframe and the 2 fastening screws on the engine transverse bar.

45. Lower the lifting platform slowly by approx. 20 to 30 cm. When this is done, a second person should ensure that there is sufficient clearance around the engine compartment and wheel housings.

46. Loosen power steering pump. To do so, loosen the two front fastening screws and turn the pulley as required. Then loosen the rear fastening screw.





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Fig. 146: Fastening screws and electric connector for the air-conditioning compressor Courtesy of PORSCHE OF NORTH AMERICA, INC.

47. Loosen the 3 fastening screws and disconnect the electric connector from the air-conditioning compressor. Set the air-conditioning compressor aside.



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49. Lower the lifting platform fully. When doing this, a second person should ensure that there is sufficient clearance around the engine compartment and wheel housings.

NOTE: 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.




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Fig. 148: Engine removed Courtesy of PORSCHE OF NORTH AMERICA, INC.

INSTALLING V6 3.2 L ENGINE

Installing engine




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Fig. 149: Overview of V6 engine Courtesy of PORSCHE OF NORTH AMERICA, INC.



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Fig. 150: Lifting the engine with a workshop crane Courtesy of PORSCHE OF NORTH AMERICA, INC.

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.



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


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

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.



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Fig. 152: Air conditioning compressor fastening screws Courtesy of PORSCHE OF NORTH AMERICA, INC.

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) .



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Fig. 153: Inserting the engine completely Courtesy of PORSCHE OF NORTH AMERICA, INC.

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



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Fig. 154: Fastening screws for front-axle carrier and engine carrier Courtesy of PORSCHE OF NORTH AMERICA, INC.

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 °



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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. 155.



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Fig. 156: Support on wheel hub Courtesy of PORSCHE OF NORTH AMERICA, INC.

15. Release the lateral supports on the wheel hubs.

16. Lower the lifting platform slowly and remove.



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Fig. 157: Electric connector to transmission Courtesy of PORSCHE OF NORTH AMERICA, INC.

17. Connect electric connector -1, 2 and 3- to transmission. See Fig. 157.



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Fig. 158: Connector to transfer box Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig. 159: 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. 160: Hydraulic lines Courtesy of PORSCHE OF NORTH AMERICA, INC.



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Fig. 161: Electric lead on anti-roll bar Courtesy of PORSCHE OF NORTH AMERICA, INC.

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.



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Fig. 162: Spring band clamp, servo oil cooler to oil cooler Courtesy of PORSCHE OF NORTH AMERICA, INC.

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.




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Fig. 163: Steering column to steering gear Courtesy of PORSCHE OF NORTH AMERICA, INC.

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) .



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Fig. 164: Heat protection shield to steering gear Courtesy of PORSCHE OF NORTH AMERICA, INC.

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



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Fig. 165: Heater coolant lines on the left side member Courtesy of PORSCHE OF NORTH AMERICA, INC.

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



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Fig. 166: Coolant connection piece on the lower left on the radiatorCourtesy of PORSCHE OF NORTH AMERICA, INC.

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

Fig. 167: Secondary air line to secondary air pump Courtesy of PORSCHE OF NORTH AMERICA, INC.

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



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Fig. 168: ATF lines to cooler Courtesy of PORSCHE OF NORTH AMERICA, INC.

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) .



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Fig. 169: Ground point of the generator to the right side member Courtesy of PORSCHE OF NORTH AMERICA, INC.

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




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Fig. 170: Catalytic converter to body Courtesy of PORSCHE OF NORTH AMERICA, INC.

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. 170.



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Fig. 171: Installing cardan shaft Courtesy of PORSCHE OF NORTH AMERICA, INC.

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.



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Fig. 172: Exhaust system on transmission jack Courtesy of PORSCHE OF NORTH AMERICA, INC.

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) .



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Fig. 173: Transverse strut Courtesy of PORSCHE OF NORTH AMERICA, INC.

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



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Fig. 174: Front apron fastening screws on transverse strut Courtesy of PORSCHE OF NORTH AMERICA, INC.

32. Screw the front apron onto the transverse strut.

33. Lower the vehicle halfway.

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



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Fig. 175: Compressed air line Courtesy of PORSCHE OF NORTH AMERICA, INC.

Then connect the headlight levelling system sensor.



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Fig. 177: Brake lines in the wheel housings

Fig. 176: Sensor for headlight levelling system Courtesy of PORSCHE OF NORTH AMERICA, INC.



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

Fig. 178: Electrical connections of the spring struts Courtesy of PORSCHE OF NORTH AMERICA, INC.

35. Mount the electrical connections of the spring struts. To do this, connect cable -1- and then fasten supports -2 and 3- . See Fig. 178.

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.



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Fig. 179: Mounting the fastening screws of the spring struts Courtesy of PORSCHE OF NORTH AMERICA, INC.

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. 180.



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Fig. 180: Spring strut view from the wheel housing Courtesy of PORSCHE OF NORTH AMERICA, INC.



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Fig. 181: Oxygen sensor connector on the plenum panel splash panel Courtesy of PORSCHE OF NORTH AMERICA, INC.

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



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Fig. 182: B+ transfer point on left spring dome Courtesy of PORSCHE OF NORTH AMERICA, INC.

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.



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Fig. 183: Servo line to reservoir Courtesy of PORSCHE OF NORTH AMERICA, INC.

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



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Fig. 184: Line from carbon canister and fuel line to plenum panel splash panel Courtesy of PORSCHE OF NORTH AMERICA, INC.

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. 184.



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Fig. 185: Right spring dome Courtesy of PORSCHE OF NORTH AMERICA, INC.

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.



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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.



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Fig. 187: Fastening screws for the central electrical system box cover Courtesy of PORSCHE OF NORTH AMERICA, INC.

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.



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46. Mount the plenum chamber cover. Do not forget the electric connector. Mount the 4 bayonet screws -A- . See Fig. 188.

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.



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Fig. 189: Air-cleaner element Courtesy of PORSCHE OF NORTH AMERICA, INC.

49. Insert the air-cleaner element.




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Fig. 190: Sheetmetal clips Courtesy of PORSCHE OF NORTH AMERICA, INC.

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



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Fig. 191: Air tube on air cleaner cover Courtesy of PORSCHE OF NORTH AMERICA, INC.

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



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Fig. 192: Intake manifold to throttle body and vacuum lineCourtesy of PORSCHE OF NORTH AMERICA, INC.

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. 193: Air cleaner housing Courtesy of PORSCHE OF NORTH AMERICA, INC.

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



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Fig. 194: Pressing rubber elements onto the ball head supports in the cover Courtesy of PORSCHE OF NORTH AMERICA, INC.

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

SUBSEQUENT WORK

Reworking

1. Fill and bleed the cooling system. Refer to 19 38 17 Draining and filling in coolant (includes bleeding) - as of MY 2003 (All Models) .

2. Bleed brake system. Refer to 47 01 07 Bleeding the brake system - as of MY 2003 (All Models Except Cayenne S TIO Titan) .

3. Connect battery. Refer to 90 IN Work instructions after disconnecting the battery - as of MY 2003 (All Models Except Cayenne S TIO Titan) .

4. Mount the wiper arms. Refer to 92 25 19 Removing and installing wiper arm - as of MY 2003 (All Models) .

5. Mount engine compartment covers. Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .

6. Check ATF level. Refer to 48 IN Test and assembly work on power steering - as of MY 2003 (All Models Except Cayenne S TIO Titan) .



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7. Bleed power-assisted steering. Refer to 48 IN Test and assembly work on power steering - as of MY 2003 (All Models Except Cayenne S TIO Titan) .

8. Bleed offroad stabilizer if necessary. Refer to 40 26 07 Bleeding the Off-Road stabilizer System (ORS) - as of MY 2003 (All Models Except Cayenne Turbo S) .

9. Mount front wheels. Refer to 44 05 19 Removing and installing wheel - as of MY 2003 (All Models) .

10. Perform suspension alignment. Refer to 44 IN Suspension alignment, complete - as of MY 2003 (All Models) .

Fig. 195: Engine guard Courtesy of PORSCHE OF NORTH AMERICA, INC.

11. Fit engine guard. --> 108019 Removing and installing engine guard - "Installing"

12. 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.

13. Check engine oil level.

10 01 19 REMOVING AND INSTALLING V8 4.5 L ENGINE - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN)



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TOOLS

TOOLS AND MATERIALS

Required tools

The following tools are described in the Workshop Equipment Manual, Chapter 3.0.13 "WE 1206" (exceptions are noted).





NR.72-1


NR.73-1





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-A- See Fig. 196.

Assembly mandrel





-D- See Fig. 196.

Oil pan support




-F- See Fig. 196.


-G- See Fig. 196.


-H- See Fig. 196.




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-A- See Fig. 197.

Oil pan support


-B- See Fig. 197.


-1/11- See Fig. 197.



-1a- See Fig. 197.



-2- See Fig. 197.


-2a- See Fig. 197.



-2b- See Fig. 197.


-3- See Fig. 197.



-4- See Fig. 197.


-5- See Fig. 197.





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-C- See Fig. 198.




Equipment Manual,




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PRELIMINARY WORK

Preliminary work




Position the vehicle at the take-up points provided on a lifting platform. Refer to 40 V0 Lifting the vehicle - as of MY 2003 (Cayenne Turbo S, Cayenne S TIO Titan) . Refer to 40 V0 Lifting the vehicle - as of MY 2003 (Cayenne TIP, Cayenne MAN, Cayenne S TIP, Cayenne S MAN, Cayenne Turbo) .










Chapter 3.0.6 "WE 1036"

-E- See Fig. 198.



-F- See Fig. 198.



-G- See Fig. 198.







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REMOVING V8 4.5 L ENGINE

Removing engine






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Fig. 201: Plenum chamber cover Courtesy of PORSCHE OF NORTH AMERICA, INC.




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8. Disconnect B+ transfer point at the left of the engine compartment.



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Fig. 206: Throttle adjuster electric connection Courtesy of PORSCHE OF NORTH AMERICA, INC.

10. Separate the electric connection from the throttle adjuster. To do this, press on the plug at the top and bottom and, at the same time, pull it off. Unclip the cable from the sheetmetal holder.



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Fig. 207: Fastening bolts on the throttle body Courtesy of PORSCHE OF NORTH AMERICA, INC.

NOTE: In the Cayenne Turbo (M48/50), the boost pressure sensor must also be disconnected.



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11. Release the fastening bolts on the throttle body. To do this, twist both bolts through 45° in an anti-clockwise direction. The dot on the bolt must appear as illustrated in the figure.




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Fig. 209: Pull out fastening bolt with pliers Courtesy of PORSCHE OF NORTH AMERICA, INC.

12. Remove the fastening bolts. To do this, take hold of the bolt by the rubber ring with pliers and pull it out.

13. Pull off the Y-shaped pipe from the throttle body.



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Fig. 210: Mass air flow connections Courtesy of PORSCHE OF NORTH AMERICA, INC.

14. Disconnect the mass air flow connections. To do this, loosen the hose clamps to the left and right on the bellows and pull the bellows off the mass air flow (in the Cayenne Turbo, pull them off the pressure pipes).

NOTE: If the engine is to be subsequently transported by crane, the right-hand design cover on cylinder row 5 - 8 should be removed at this point. --> 108319 Removing and installing engine cover - "Removing"



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Fig. 211: Design cover of cylinder row 5 - 8 Courtesy of PORSCHE OF NORTH AMERICA, INC.

To do this, loosen the 4 fastening screws. Unclip the design cover from the intake system and slide out at an angle towards the front.



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Fig. 212: Air cleaner housing clamps Courtesy of PORSCHE OF NORTH AMERICA, INC.




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Fig. 213: Circlip and adapter Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig. 214: Air cleaner cover Courtesy of PORSCHE OF NORTH AMERICA, INC.

16. Remove the air cleaner covers on the right and left. Refer to 24 25 19 Removing and installing air cleaner housing - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne S TIO Titan) . Refer to 24 25 19 Removing and installing air cleaner housing - as of MY 2003 (Cayenne Turbo, Cayenne Turbo S) .

NOTE: In vehicles with air suspension, the suction line of the compressor must also be removed on the right air cleaner cover. To do this, unclip the green cap, press circlip -1- inwards and pull off adapter -2- . See Fig. 213.



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Fig. 216: Oxygen sensor connector Courtesy of PORSCHE OF NORTH AMERICA, INC.

18. Disconnect the 2 respective oxygen sensor connectors (brown, black) at the left and right of the water splash panel and unclip the cable from the supports.

Fig. 217: Fastening screws for vacuum pump Courtesy of PORSCHE OF NORTH AMERICA, INC.

NOTE: In the Cayenne Turbo (M48/50), the support for the vacuum pump must also be undone. To do this, unscrew the two fastening screws and press the pump forward slightly.



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21. Loosen the torque support. To do this, remove the screw on the engine and loosen the screw on the body. Then pivot up the torque support.



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22. Disconnect fuel line -1- and line -2- from the carbon canister on the plenum panel splash panel. See Fig. 221.



Damage to skin



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23. Loosen the 3 fastening screws on the left and right spring struts. The screws are loosened from inside the engine compartment. Of the 3 screws per spring strut, one is in the plenum panel. Replace screws.



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Fig. 224: Drive belt tensioning pulley Courtesy of PORSCHE OF NORTH AMERICA, INC.

25. Slacken the drive belt (a/f 30) and remove from the tensioning roller.



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Fig. 225: Control lines of the ambient air valvesCourtesy of PORSCHE OF NORTH AMERICA, INC.


NOTE: In the Cayenne Turbo (M48/50), the control lines of the ambient air valves on the T-piece should be pulled off.




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26. Disconnect electric plug -1- on the spring struts in the wheel housing. Then unclip the support -2 and 3- . Tie the cable on the spring strut. See Fig. 228.



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WARNING: ATF!




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29. Disconnect the ATF lines on the cooler. To do this, loosen the fastening screw and pull off the line. Seal open lines with a plug.



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NOTE: In the case of vehicles with Servotronic, an electric plug must also be removed from the steering gear.



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32. Disconnect the electric plug on the steering gear (Servotronic only).



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35. Remove rear cardan shaft. Refer to 39 35 19 Removing and installing rear cardan shaft - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S) . Refer to 39 35 19 Removing and installing rear cardan shaft - as of MY 2003 (Cayenne S TIO Titan) .



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36. Disconnect electrical connections -1,2 and 3- on the transmission and unclip the wiring harness. See Fig. 235.



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Fig. 236: Connections on transfer box Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig. 237: Fastening screws for heat protection shield



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37. Remove the heat shield on the left transmission side. To do so, loosen the 3 fastening screws and take out the heat protection shield.




NOTE: Do not loosen nut.

NOTE: If the transmission is to be separated from the engine after removal, the two lower fastening screws on the transmission housing and front cardan shaft should be removed at this point, since access to the lifting platform will be impaired.





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39. Disconnect the lower line on the servo oil cooler.



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Fig. 240: Locking spring on turbocharger adapter and hose clamp of turbocharger pressure pipe Courtesy of PORSCHE OF NORTH AMERICA, INC.

NOTE: On the Cayenne Turbo (M48/50), the hose connections on the turbochargers must also be loosened. To do this, pull out locking spring -1- on the turbocharger adapter. Then loosen hose clamp -2- of the pressure pipe on the turbocharger. See Fig. 240.



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Fig. 241: Locking clip and line of ambient air valve Courtesy of PORSCHE OF NORTH AMERICA, INC.

Disconnect the connection on the charge air cooler. To do this, remove locking clip -1- and pull off the line. Line -2- of the ambient air valve must also be disconnected on the right-hand side of the vehicle. To do this, remove the spring band clamp and pull off the line. See Fig. 241.



The lines of the air-conditioning compressor remain mounted, so the refrigerant does not need to be evacuated.




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Fig. 242: Fastening screws and electric connector of air-conditioning compressor Courtesy of PORSCHE OF NORTH AMERICA, INC.

40. Loosen the 3 fastening screws and disconnect the electric plug from the air-conditioning compressor. Set the air-conditioning compressor aside.



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NOTE: For installation, it is a good idea to mark the installation position of the front axle carrier diagonally at at least two places on the body. To do this, place the marks vertically with respect to the floor of the body using a felt-tip pen (e. g. mark along the front-axle carrier mount with the pen).



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Fig. 244: Mark installation position of the front-axle carrier Courtesy of PORSCHE OF NORTH AMERICA, INC.

42. Mark the installation position of the front axle carrier diagonally at at least two places on the body.

NOTE: Because of the high loosening torque, the 6 fastening screws on the front-axle carrier can now be loosened. Loosen the screws by a maximum of one turn.



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46. Secure the engine/transmission combination. Then secure the mounting mandrels on the engine transverse bar with locking screws.



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Fig. 248: Fastening screws for front-axle carrier and fastening screws for engine transverse bar Courtesy of PORSCHE OF NORTH AMERICA, INC.

47. Loosen the 4 fastening screws on the front-axle carrier and the 2 fastening screws on the engine transverse bar.

48. Lower the lifting platform slowly. When this is done, a second person should ensure that there is sufficient clearance around the engine compartment and wheel housings.

INSTALLING V8 4.5 L ENGINE

Installing engine





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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.

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. Refer to 37 35 27 Removing and refitting transmission - as of MY 2003 (Cayenne S TIP, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) or refer to 34 35 27 Removing and refitting transmission - as of MY 2003 (Cayenne S MAN) .

4. Install pre- and main catalytic converters. Refer to 26 76 19 Removing and installing primary catalytic converter - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne S TIO Titan) . Refer to 26 76 19 Removing and installing primary catalytic converter - Cayenne Turbo - as of MY 2003 (Cayenne Turbo, Cayenne Turbo S) .



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Fig. 251: Catalytic converter support Courtesy of PORSCHE OF NORTH AMERICA, INC.

5. Tighten the fastening screw on the catalytic converter support. --> Tightening torque: 23 (17 ftlb.) Nm

6. Bolt the main catalytic converter supports onto the transmission cross member. For details, refer to 26 73 19 Removing and installing (main) catalytic converter - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .




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Fig. 252: Oxygen sensor cable for the rear oxygen sensors Courtesy of PORSCHE OF NORTH AMERICA, INC.


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.


When moving the unit into the body, put the air-conditioning compressor into installation position.

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



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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. Refer to 87 34 19 Removing and installing air-conditioning compressor - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

NOTE: Position the front-axle carrier back in the original, marked installation position and be careful not to damage adjacent parts.



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Fig. 254: Guiding the engine/transmission combination into the body with the lifting platform Courtesy of PORSCHE OF NORTH AMERICA, INC.

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.



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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 S TIP, Cayenne S MAN, Cayenne Turbo) . Refer to 40 06 19 Removing and installing front-axle carrier - as of MY 2003 (Cayenne Turbo S, Cayenne S TIO Titan) . --> Initial tightening: 120 (89 ftlb.) Nm --> Final tightening - torque angle: 180 °



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Fig. 257: Support of wheel hub Courtesy of PORSCHE OF NORTH AMERICA, INC.

15. Loosen the lateral supports on the wheel hubs.




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Fig. 258: Connector to transmission Courtesy of PORSCHE OF NORTH AMERICA, INC.

17. Connect electric connector -1, 2 and 3- on the transmission and clip in the wiring harness. See Fig. 258.



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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 S TIO Titan) . Refer to 37 15 19 Removing and installing selector lever cable - as of MY 2003 (Cayenne S TIP, Cayenne Turbo, Cayenne Turbo S) .



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Fig. 260: Hose clamp and sheetmetal clip Courtesy of PORSCHE OF NORTH AMERICA, INC.

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. See Fig. 260.



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Fig. 261: Locking clip and line to ambient air valve Courtesy of PORSCHE OF NORTH AMERICA, INC.

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. See Fig. 261.



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Fig. 262: Spring band clamp on servo line Courtesy of PORSCHE OF NORTH AMERICA, INC.


NOTE: For vehicles with Servotronic, the electric connector on the steering gear must also be connected.



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Fig. 263: Steering column on steering gear Courtesy of PORSCHE OF NORTH AMERICA, INC.

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) . Refer to 48 90 19 Removing and installing steering gear - as of MY 2003 (Cayenne S TIO Titan) .



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Fig. 264: Fastening screws for heat protection shield to steering gear Courtesy of PORSCHE OF NORTH AMERICA, INC.

21. Fit the heat protection shield on the steering gear by means of 2 fastening screws. --> Tightening torque: 10 (7.5 ftlb.) Nm



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22. Slide the heater coolant lines on the left side member and mount the clips.



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Fig. 266: Coolant connection piece Courtesy of PORSCHE OF NORTH AMERICA, INC.


Fig. 267: ATF lines Courtesy of PORSCHE OF NORTH AMERICA, INC.

24. Connect the ATF lines to the radiator. 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 S TIP, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .



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Fig. 268: Generator ground point Courtesy of PORSCHE OF NORTH AMERICA, INC.

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



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Fig. 269: Catalytic converter on elbow Courtesy of PORSCHE OF NORTH AMERICA, INC.

26. Tighten the catalytic converter fastening on the body. For details, refer to 26 73 19 Removing and installing (main) catalytic converter - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .



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27. Install cardan shaft. Refer to 39 35 19 Removing and installing rear cardan shaft - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S) . Refer to 39 35 19 Removing and installing rear cardan shaft - as of MY 2003 (Cayenne S TIO Titan) .



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Fig. 272: Fastening screws of front transverse strut Courtesy of PORSCHE OF NORTH AMERICA, INC.

29. Install the front transverse strut under the radiators. To do this, tighten the four fastening screws. --> Tightening torque: 23 (7.5 ftlb.) Nm



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Fig. 273: Front apron fastening screw on transverse strut Courtesy of PORSCHE OF NORTH AMERICA, INC.

30. Screw the front apron onto the transverse strut. --> Tightening torque: 5 (3.5 ftlb.) Nm




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Fig. 276: Brake lines in the wheel housingsCourtesy of PORSCHE OF NORTH AMERICA, INC.


Fig. 277: Electric connections of the spring struts Courtesy of PORSCHE OF NORTH AMERICA, INC.

33. Fit the electric connections of the spring struts. To do this, connect cable -1- and then fasten supports -2 and 3- . See Fig. 277.




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35. Mount the three 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. 279.



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36. Mount B+ transfer point on left spring dome. --> Tightening torque: 23 (17 ftlb.) Nm



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Fig. 281: Spring band clamp on servo line to reservoirCourtesy of PORSCHE OF NORTH AMERICA, INC.


Fig. 282: Line from carbon canister and fuel line Courtesy of PORSCHE OF NORTH AMERICA, INC.

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 ftlb.) Nm See Fig. 282.



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Fig. 283: Plug connections for oxygen sensors Courtesy of PORSCHE OF NORTH AMERICA, INC.

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.



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Fig. 284: Fastening screws for vacuum pump support Courtesy of PORSCHE OF NORTH AMERICA, INC.

--> Tightening torque: 7.5 ftlb.

NOTE: In the Cayenne Turbo, the support for the vacuum pump must also be screwed into position.



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Fig. 285: Vacuum line and lines on coolant reservoir Courtesy of PORSCHE OF NORTH AMERICA, INC.




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Fig. 286: Control unit, connector, and ground point Courtesy of PORSCHE OF NORTH AMERICA, INC.

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 ftlb.) Nm



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Fig. 287: Fastening screws for the central electrical system box Courtesy of PORSCHE OF NORTH AMERICA, INC.

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.




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44. Mount the plenum chamber cover. Do not forget the electric connector for the air-quality sensor. Mount the 4 bayonet screws -A- . See Fig. 288.



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45. Position and tighten drive belt on all pulleys. Refer to 13 78 19 Removing and installing drive belt - as of MY 2003 (Cayenne S TIP, Cayenne S MAN) . Refer to 13 78 19 Removing and installing drive belt - as of MY 2003 (Cayenne S TIO Titan) . Refer to 13 78 19 Removing and installing drive belt - as of MY 2003 (Cayenne Turbo, Cayenne Turbo S) .



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Fig. 290: Upper left coolant connection piece Courtesy of PORSCHE OF NORTH AMERICA, INC.

46. Connect the upper left coolant connection piece to the radiator. The connection piece must engage audibly.



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47. Mount the torque support with new lock nuts. --> Tightening torque: 60 (44 ftlb.) Nm --> Tightening torque: 60 (44 ftlb.) Nm



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.



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Fig. 293: Air cleaner with cover Courtesy of PORSCHE OF NORTH AMERICA, INC.

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.



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Fig. 294: Control lines of the ambient air valves on T-piece Courtesy of PORSCHE OF NORTH AMERICA, INC.

NOTE: In the Cayenne Turbo (M48/50), the control lines of the ambient air valve on the T-piece must also be connected.



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Fig. 295: Clipping in lines Courtesy of PORSCHE OF NORTH AMERICA, INC.

NOTE: Clip on the leads when mounting the Y-shaped pipe on the bottom.



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50. Attach the vacuum line to the underside of the Y-shaped pipe.



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Fig. 297: Hose clamps on the Y-shaped pipeCourtesy of PORSCHE OF NORTH AMERICA, INC.

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. See Fig. 298.



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Fig. 299: Fastening bolt Y-shaped pipe on throttle adjuster Courtesy of PORSCHE OF NORTH AMERICA, INC.

52. Slide the Y-shaped pipe onto the throttle adjuster. Then insert the left and right fastening bolts. Turn both bolts 45° clockwise.



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Fig. 300: Connecting cable to throttle adjuster Courtesy of PORSCHE OF NORTH AMERICA, INC.

53. Connect the throttle adjuster. The connector must engage audibly. Clip the connecting cable into the sheetmetal holder.



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Fig. 301: Rubber elements in cover on ball head support Courtesy of PORSCHE OF NORTH AMERICA, INC.


SUBSEQUENT WORK

Subsequent work









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8. Bleed offroad stabilizer if necessary. Refer to 40 26 07 Bleeding the Off-Road stabilizer System (ORS) - as of MY 2003 (All Models) . Refer to 40 26 07 Bleeding the Off-Road stabilizer System (ORS) - as of MY 2003 (All Models Except Cayenne Turbo S) .


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. Refer to 87 34 19 Removing and installing air-conditioning compressor - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) and refer to 87 03 17 Adding refrigerant and removing by suction - as of MY 2003 (All Models) .



12. Fit engine guard. --> 108019 Removing and installing engine guard - "installing"




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10 01 23 INSTALLING ENGINE. - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN)

TOOLS

TOOLS AND MATERIALS

Required tools

The following tools can be found in the Workshop Equipment Manual 3.0.13 "WE 1206" (exceptions are noted).





NR.72-1


NR.73-1





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-A- See Fig. 303.

Assembly mandrel





-D- See Fig. 303.

Oil pan support




-F- See Fig. 303.


-G- See Fig. 303.


-D- See Fig. 303.




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-A- See Fig. 304.

Oil pan support


-B- See Fig. 304.


-1/11- See Fig. 304.



-1a- See Fig. 304.



-2- See Fig. 304.


-2a- See Fig. 304.



-2b- See Fig. 304.


-3- See Fig. 304.



-4- See Fig. 304.


-5- See Fig. 304.





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-B- See Fig. 305.



-C- See Fig. 305.





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INSTALLING ENGINE.

Installing engine





-E- See Fig. 305.



-F- See Fig. 305.



-G- See Fig. 305.







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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.



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.



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


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

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



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Fig. 309: Air conditioning compressor fastening screws Courtesy of PORSCHE OF NORTH AMERICA, INC.

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) .



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Fig. 310: Inserting the engine completely Courtesy of PORSCHE OF NORTH AMERICA, INC.

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



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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 °



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Fig. 313: Support on wheel hub Courtesy of PORSCHE OF NORTH AMERICA, INC.

15. Release the lateral supports on the wheel hubs.




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Fig. 314: Electric connector to transmission Courtesy of PORSCHE OF NORTH AMERICA, INC.

17. Connect electric connector -1, 2 and 3- to transmission. See Fig. 314.



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Fig. 316: 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. 317: Hydraulic lines Courtesy of PORSCHE OF NORTH AMERICA, INC.



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Fig. 318: Electric lead on anti-roll bar Courtesy of PORSCHE OF NORTH AMERICA, INC.

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

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



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Fig. 319: Spring band clamp, servo oil cooler to oil cooler Courtesy of PORSCHE OF NORTH AMERICA, INC.


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




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Fig. 320: Steering column to steering gear Courtesy of PORSCHE OF NORTH AMERICA, INC.

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) .



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Fig. 321: Heat protection shield to steering gear Courtesy of PORSCHE OF NORTH AMERICA, INC.

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



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



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Fig. 323: Coolant connection piece on the lower left on the radiatorCourtesy of PORSCHE OF NORTH AMERICA, INC.


Fig. 324: Secondary air line to secondary air pump Courtesy of PORSCHE OF NORTH AMERICA, INC.

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



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Fig. 325: ATF lines to cooler Courtesy of PORSCHE OF NORTH AMERICA, INC.

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) .



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Fig. 326: Ground point of the generator to the right side member Courtesy of PORSCHE OF NORTH AMERICA, INC.

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




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Fig. 327: Catalytic converter to body Courtesy of PORSCHE OF NORTH AMERICA, INC.

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. 327.



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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.



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Fig. 330: Transverse strut Courtesy of PORSCHE OF NORTH AMERICA, INC.

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



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Fig. 331: Front apron fastening screws on transverse strut Courtesy of PORSCHE OF NORTH AMERICA, INC.

32. Screw the front apron onto the transverse strut.




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Fig. 335: Electrical connections of the spring struts Courtesy of PORSCHE OF NORTH AMERICA, INC.

35. Mount the electrical connections of the spring struts. To do this, connect cable -1- and then fasten supports -2 and 3- . See Fig. 335.


NOTE: If the fastening screws for the spring strut cannot be positioned, the



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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. 337.

spring strut can be pushed up slightly using a garage jack.



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Fig. 338: Oxygen sensor connector on the plenum panel splash panel Courtesy of PORSCHE OF NORTH AMERICA, INC.

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



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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.



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Fig. 340: Servo line to reservoir Courtesy of PORSCHE OF NORTH AMERICA, INC.




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Fig. 341: Line from carbon canister and fuel line to plenum panel splash panel Courtesy of PORSCHE OF NORTH AMERICA, INC.

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. 341.



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Fig. 342: Right spring dome Courtesy of PORSCHE OF NORTH AMERICA, INC.




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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.



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Fig. 344: Fastening screws for the central electrical system box cover Courtesy of PORSCHE OF NORTH AMERICA, INC.

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.




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46. Mount the plenum chamber cover. Do not forget the electric connector. Mount the 4 bayonet screws -A- . See Fig. 345.

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.



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Fig. 347: Sheetmetal clips Courtesy of PORSCHE OF NORTH AMERICA, INC.

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



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Fig. 348: Air tube on air cleaner cover Courtesy of PORSCHE OF NORTH AMERICA, INC.

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



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Fig. 349: Intake manifold to throttle body and vacuum lineCourtesy of PORSCHE OF NORTH AMERICA, INC.

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. 350: Air cleaner housing Courtesy of PORSCHE OF NORTH AMERICA, INC.

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



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Fig. 351: Pressing rubber elements onto the ball head supports in the cover Courtesy of PORSCHE OF NORTH AMERICA, INC.


SUBSEQUENT WORK

Reworking









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8. Bleed offroad stabilizer if necessary. Refer to 40 26 07 Bleeding the Off-Road stabilizer System (ORS) - as of MY 2003 (All Models Except Cayenne Turbo S) .




11. Fit engine guard. --> 108019 Removing and installing engine guard - "Installing"



10 01 23 INSTALLING ENGINE. - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN)



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TOOLS

TOOLS AND MATERIALS

Required tools

The following tools are described in the Workshop Equipment Manual, Chapter 3.0.13 "WE 1206" (exceptions are noted).





NR.72-1


NR.73-1





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-A- See Fig. 353.

Assembly mandrel





-D- See Fig. 353.

Oil pan support




-F- See Fig. 353.


-G- See Fig. 353.


-H- See Fig. 353.




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-A- See Fig. 354.

Oil pan support


-B- See Fig. 354.


-1/11- See Fig. 354.



-1a- See Fig. 354.



-2- See Fig. 354.


-2a- See Fig. 354.



-2b- See Fig. 354.


-3- See Fig. 354.



-4- See Fig. 354.


-5- See Fig. 354.





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-C- See Fig. 355.




Equipment Manual,




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INSTALLING ENGINE

Installing engine


Chapter 3.0.6 "WE 1036"

-E- See Fig. 355.



-F- See Fig. 355.



-G- See Fig. 355.







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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.

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. Refer to 37 35 27 Removing and refitting transmission - as of MY 2003 (Cayenne S TIP, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) or refer to 34 35 27 Removing and refitting transmission - as of MY 2003 (Cayenne S MAN) .

4. Install pre- and main catalytic converters. Refer to 26 76 19 Removing and installing primary catalytic converter - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne S TIO Titan) . Refer to 26 76 19 Removing and installing primary catalytic converter - Cayenne Turbo - as of MY 2003 (Cayenne Turbo, Cayenne Turbo S) .



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Fig. 358: Catalytic converter support Courtesy of PORSCHE OF NORTH AMERICA, INC.

5. Tighten the fastening screw on the catalytic converter support. --> Tightening torque: 23 (17 ftlb.) Nm

6. Bolt the main catalytic converter supports onto the transmission cross member. For details, refer to 26 73 19 Removing and installing (main) catalytic converter - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .




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Fig. 359: Oxygen sensor cable for the rear oxygen sensors Courtesy of PORSCHE OF NORTH AMERICA, INC.


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.


When moving the unit into the body, put the air-conditioning compressor into installation position.

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



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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. Refer to 87 34 19 Removing and installing air-conditioning compressor - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

NOTE: Position the front-axle carrier back in the original, marked installation position and be careful not to damage adjacent parts.



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Fig. 361: Guiding the engine/transmission combination into the body with the lifting platform Courtesy of PORSCHE OF NORTH AMERICA, INC.

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.



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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 S TIP, Cayenne S MAN, Cayenne Turbo) . Refer to 40 06 19 Removing and installing front-axle carrier - as of MY 2003 (Cayenne Turbo S, Cayenne S TIO Titan) . --> Initial tightening: 120 (89 ftlb.) Nm --> Final tightening - torque angle: 180 °



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Fig. 364: Support of wheel hub Courtesy of PORSCHE OF NORTH AMERICA, INC.

15. Loosen the lateral supports on the wheel hubs.




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Fig. 365: Connector to transmission Courtesy of PORSCHE OF NORTH AMERICA, INC.

17. Connect electric connector -1, 2 and 3- on the transmission and clip in the wiring harness. See Fig. 365.



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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 S TIO Titan) . Refer to 37 15 19 Removing and installing selector lever cable - as of MY 2003 (Cayenne S TIP, Cayenne Turbo, Cayenne Turbo S) .



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Fig. 367: Hose clamp and sheetmetal clip Courtesy of PORSCHE OF NORTH AMERICA, INC.

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. See Fig. 367.



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Fig. 368: Locking clip and line to ambient air valve Courtesy of PORSCHE OF NORTH AMERICA, INC.

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. See Fig. 368.



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Fig. 369: Spring band clamp on servo line Courtesy of PORSCHE OF NORTH AMERICA, INC.


NOTE: For vehicles with Servotronic, the electric connector on the steering gear must also be connected.



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Fig. 370: Steering column on steering gear Courtesy of PORSCHE OF NORTH AMERICA, INC.

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) . Refer to 48 90 19 Removing and installing steering gear - as of MY 2003 (Cayenne S TIO Titan) .



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Fig. 371: Fastening screws for heat protection shield to steering gear Courtesy of PORSCHE OF NORTH AMERICA, INC.

21. Fit the heat protection shield on the steering gear by means of 2 fastening screws. --> Tightening torque: 10 (7.5 ftlb.) Nm



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22. Slide the heater coolant lines on the left side member and mount the clips.



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Fig. 373: Coolant connection piece Courtesy of PORSCHE OF NORTH AMERICA, INC.


Fig. 374: ATF lines Courtesy of PORSCHE OF NORTH AMERICA, INC.

24. Connect the ATF lines to the radiator. 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 S TIP, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .



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Fig. 375: Generator ground point Courtesy of PORSCHE OF NORTH AMERICA, INC.

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



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Fig. 376: Catalytic converter on elbow Courtesy of PORSCHE OF NORTH AMERICA, INC.

26. Tighten the catalytic converter fastening on the body. For details, refer to 26 73 19 Removing and installing (main) catalytic converter - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .



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27. Install cardan shaft. Refer to 39 35 19 Removing and installing rear cardan shaft - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S) . Refer to 39 35 19 Removing and installing rear cardan shaft - as of MY 2003 (Cayenne S TIO Titan) .



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Fig. 379: Fastening screws of front transverse strut Courtesy of PORSCHE OF NORTH AMERICA, INC.

29. Install the front transverse strut under the radiators. To do this, tighten the four fastening screws. --> Tightening torque: 23 (7.5 ftlb.) Nm



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Fig. 380: Front apron fastening screw on transverse strut Courtesy of PORSCHE OF NORTH AMERICA, INC.

30. Screw the front apron onto the transverse strut. --> Tightening torque: 5 (3.5 ftlb.) Nm




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Fig. 384: Electric connections of the spring struts Courtesy of PORSCHE OF NORTH AMERICA, INC.

33. Fit the electric connections of the spring struts. To do this, connect cable -1- and then fasten supports -2 and 3- . See Fig. 384.




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35. Mount the three 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. 386.



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36. Mount B+ transfer point on left spring dome. --> Tightening torque: 23 (17 ftlb.) Nm



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Fig. 388: Spring band clamp on servo line to reservoirCourtesy of PORSCHE OF NORTH AMERICA, INC.


Fig. 389: Line from carbon canister and fuel line Courtesy of PORSCHE OF NORTH AMERICA, INC.

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 ftlb.) Nm See Fig. 389.



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Fig. 390: Plug connections for oxygen sensors Courtesy of PORSCHE OF NORTH AMERICA, INC.

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.



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Fig. 391: Fastening screws for vacuum pump support Courtesy of PORSCHE OF NORTH AMERICA, INC.

--> Tightening torque: 7.5 ftlb.

NOTE: In the Cayenne Turbo, the support for the vacuum pump must also be screwed into position.



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Fig. 392: Vacuum line and lines on coolant reservoir Courtesy of PORSCHE OF NORTH AMERICA, INC.




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Fig. 393: Control unit, connector, and ground point Courtesy of PORSCHE OF NORTH AMERICA, INC.

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 ftlb.) Nm



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Fig. 394: Fastening screws for the central electrical system box Courtesy of PORSCHE OF NORTH AMERICA, INC.

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.




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44. Mount the plenum chamber cover. Do not forget the electric connector for the air-quality sensor. Mount the 4 bayonet screws -A- . See Fig. 395.



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45. Position and tighten drive belt on all pulleys. Refer to 13 78 19 Removing and installing drive belt - as of MY 2003 (Cayenne S TIP, Cayenne S MAN) . Refer to 13 78 19 Removing and installing drive belt - as of MY 2003 (Cayenne S TIO Titan) . Refer to 13 78 19 Removing and installing drive belt - as of MY 2003 (Cayenne Turbo, Cayenne Turbo S) .



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Fig. 397: Upper left coolant connection piece Courtesy of PORSCHE OF NORTH AMERICA, INC.

46. Connect the upper left coolant connection piece to the radiator. The connection piece must engage audibly.



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47. Mount the torque support with new lock nuts. --> Tightening torque: 60 (44 ftlb.) Nm --> Tightening torque: 60 (44 ftlb.) Nm



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.



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Fig. 400: Air cleaner with cover Courtesy of PORSCHE OF NORTH AMERICA, INC.

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.



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Fig. 401: Control lines of the ambient air valves on T-piece Courtesy of PORSCHE OF NORTH AMERICA, INC.

NOTE: In the Cayenne Turbo (M48/50), the control lines of the ambient air valve on the T-piece must also be connected.



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Fig. 402: Clipping in lines Courtesy of PORSCHE OF NORTH AMERICA, INC.

NOTE: Clip on the leads when mounting the Y-shaped pipe on the bottom.



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50. Attach the vacuum line to the underside of the Y-shaped pipe.



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Fig. 404: Hose clamps on the Y-shaped pipeCourtesy of PORSCHE OF NORTH AMERICA, INC.

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. See Fig. 405.



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Fig. 406: Fastening bolt Y-shaped pipe on throttle adjuster Courtesy of PORSCHE OF NORTH AMERICA, INC.

52. Slide the Y-shaped pipe onto the throttle adjuster. Then insert the left and right fastening bolts. Turn both bolts 45° clockwise.



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Fig. 407: Connecting cable to throttle adjuster Courtesy of PORSCHE OF NORTH AMERICA, INC.

53. Connect the throttle adjuster. The connector must engage audibly. Clip the connecting cable into the sheetmetal holder.



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Fig. 408: Rubber elements in cover on ball head support Courtesy of PORSCHE OF NORTH AMERICA, INC.


SUBSEQUENT WORK

Subsequent work









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8. Bleed offroad stabilizer if necessary. Refer to 40 26 07 Bleeding the Off-Road stabilizer System (ORS) - as of MY 2003 (All Models) . Refer to 40 26 07 Bleeding the Off-Road stabilizer System (ORS) - as of MY 2003 (All Models Except Cayenne Turbo S) .


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. Refer to 87 34 19 Removing and installing air-conditioning compressor - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) and refer to 87 03 17 Adding refrigerant and removing by suction - as of MY 2003 (All Models) .



12. Fit engine guard. --> 108019 Removing and installing engine guard - "installing".




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10 01 29 CLEANING THE ENGINE (WASHING THE ENGINE) - AS OF MY 2003 (ALL MODELS)

NOTES ON WASHING THE ENGINE

Notes on washing the engine

--> Only wash the engine when it is cold.

--> Only wash the engine when engine is switched off (electric shock through the ignition system).

--> Protect the oxygen sensor connectors from moisture.

--> Maintain a minimum clearance of 50 cm between the cleaning lance and engine component.

--> Protect the brake fluid reservoir from moisture.

1. Open the bonnet.

2. Protect components sensitive to moisture, possibly by covering them with plastic sheeting. Oxygen sensor connectors must not get wet.

3. Remove any maintenance labels (e. g. oil change schedule tag) and replace after the work is completed.

4. Pre-clean very dirty engines with pure water.

WARNING: Hot water under high pressure!

Risk of damage for engine components.

Incoming washer-fluid in electric components.

NOTE: The engine should be washed only if this is absolutely essential for repair work.

Components sensitive to moisture must be adequately protected. Cover them, if necessary.

Cleaning agents or water should never be applied directly to components that are sensitive to moisture, such as electric connectors.

When using high-pressure cleaning apparatus, maintain a minimum clearance of 50 cm between the cleaning lance and the engine component.

Never wash the engine when the engine is warm.

For environmental reasons, the engine may only be washed in workshops in which oils are separated from waste water.



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5. Spray engine components to be cleaned with an appropriate engine cleaning agent and allow it to work in.

6. Clean the engine. Ensure that a minimum clearance of 50 cm is maintained between the cleaning lance and engine component. The water temperature must not exceed 80 °C. Remove persistent dirt with a non-abrasive sponge.

7. Moving components in the engine compartment, such as the hook for the bonnet, must be re-greased.

8. Carry out a test drive after washing the engine.

10 01 37 DISASSEMBLING AND ASSEMBLING V6 (BFD) ENGINE - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN)

TOOLS

PRELIMINARY WORK

Preliminary work

1. Remove engine. --> 100119 Removing and installing V6 3.2 l engine - "Removing"

2. Support engine on engine support. 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).

3. Drain engine oil, hydraulic oil and coolant. Turn engine in engine support, if necessary. Dispose of fluid in accordance with legal requirements.

TOOLS AND MATERIALS

Designation Type Number Explanation camshaft guide VW-tool T10068

arm bracket VW-tool T10069

funnel VW-tool T10147



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Special tools

DISASSEMBLING V6 (BFD) ENGINE

Disassembling V6 (BFD) engine

--> Wear suitable protective clothing (e. g. gloves).

NOTE: For special tools that are required for repairing engines, refer to 10 01 WM (Special) tools required for repairing engines - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

WARNING: Danger of cutting oneself on sharp metal edges!

NOTE: Various different types of fluid will emerge while you are working on the engine. Have sufficient cloths and collecting containers to hand. Dispose of fluid in accordance with country-specific regulations.

More detailed work instructions can be found in the individual repair descriptions in the article. Only the necessary information for disassembly and assembly is provided in the articles linked by cross-references.

References to tightening torques are given separately. --> 10 Tightening torques for Cayenne (engine type BFD).



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1. Remove drive belt. Refer to 13 78 19 Removing and installing drive belt - as of MY 2004 (Cayenne TIP, Cayenne MAN) .



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Fig. 411: Belt tensioner Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Remove belt tensioner. To do this, remove three M8 x 30 fastening screws.

3. Remove deflection roller. Lever off the lid and remove deflection roller by loosening the fastening screw.

4. Remove generator. Refer to 27 22 19 Removing and installing three-phase generator - as of MY 2004 (Cayenne TIP, Cayenne MAN) . Disconnect cable plug. Then unscrew two M8 x 90 fastening screws and carefully press generator out of the support using a mounting lever. Get an assistant to hold the generator while you remove water hoses.

5. Remove hydraulic pump. Refer to 48 98 19 Removing and installing hydraulic pump (Cayenne V6) - as of MY 2004 (Cayenne TIP, Cayenne MAN) . To do this, unscrew three fastening screws (two at the front through the pulley and one from behind).

6. Screw off unit holder (three M8 x 40 and two M8 x 28 fit bolts).



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Fig. 412: Water pump Courtesy of PORSCHE OF NORTH AMERICA, INC.

7. Remove water pump. To do this, remove three internal-serration screws through the pulley from the front and remove the water pump. Collect emerging coolant. Replace sealing ring.



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Fig. 413: Additional coolant pump Courtesy of PORSCHE OF NORTH AMERICA, INC.

8. Remove coolant run-on pump at top chain case lid -2- . To do this, pull off cable plug and remove together with coolant hoses. Press pump out of the bracket at the rubber mounts. Refer to 19 45 19 Removing and installing additional coolant pump - as of MY 2004 (Cayenne TIP, Cayenne MAN) . See Fig. 413.

9. Screw the sheet-metal holder for the vacuum valves -7- sideways off the intake-air distributor (two M6 studs with a hexagon in the middle -8- ). Press support for switch-over pipe control valves out of the bracket. Disconnect cable plugs and lines. See Fig. 414.



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Fig. 414: Vacuum and secondary air Courtesy of PORSCHE OF NORTH AMERICA, INC.

10. Remove oil/water heat exchanger -4- by loosening the coolant hoses and unscrewing the banjo bolt -5- . Unscrew drain plug -9- and drain oil filter. Remove oil-filter housing/engine support arm by loosening five fastening screws -10- . Replace seal. See Fig. 415.



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Fig. 415: Oil/water heat exchanger and support arm Courtesy of PORSCHE OF NORTH AMERICA, INC.

11. Remove engine wire harness. Refer to 97 52 21 Removing wiring harness for engine (V6) - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

12. Loosen and remove the intake-air distributor. Remove vacuum lines and hoses. Remove the sheet-metal holder between the exhaust manifold and intake-air distributor (three hexagon socket head bolts). Unscrew two hexagon socket head bolts at the front and rear sideways at the exhaust side -7 and 12- . Unscrew nine M7 x 40 hexagon socket head bolts at the inlet side using a long socket. Raise the intake-air distributor starting at the exhaust side and tip it off. Remove at the inlet side. See Fig. 416.



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Fig. 416: Intake-air distributor and accessories Courtesy of PORSCHE OF NORTH AMERICA, INC.

13. Unscrew the secondary air valve (combination valve) -1 to 5- . To do this, unscrew three M6 x 23 fastening screws. Replace seal. See Fig. 417.



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Fig. 417: Vacuum and secondary air Courtesy of PORSCHE OF NORTH AMERICA, INC.



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Fig. 418: Heat protection shield on exhaust manifold Courtesy of PORSCHE OF NORTH AMERICA, INC.

14. Unscrew heat protection shield on exhaust manifold (two M6 hexagon socket head bolts).



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Fig. 419: Exhaust manifold Courtesy of PORSCHE OF NORTH AMERICA, INC.

15. Unscrew the two exhaust manifolds. To do this, unscrew seven M8 copper nuts (x 2) from the studs on the cylinder head.

16. Remove aluminum water tube -1- under the exhaust manifolds. To do this, unscrew two fastening screws -17- from the holders and pull the spring band clamp and water hose off the flange. See Fig. 420.

Fig. 420: Water tubes Courtesy of PORSCHE OF NORTH AMERICA, INC.



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Fig. 421: Distributor pipe Courtesy of PORSCHE OF NORTH AMERICA, INC.

17. Remove fuel distributor pipe. To do this, unscrew four M6 x 26 hexagon socket head bolts -arrows- . Carefully pull the distributor pipe along with the fuel injectors out of the cylinder head. See Fig. 421.

18. Remove engine support fasteners at the front and rear (M8 hexagon socket).

19. Unscrew the thermostat housing -3- by loosening two M6 x 120 and one M6 x 26 fastening screws. Remove water hoses. Pull off water tube -6- (replace seals). See Fig. 422.



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20. Remove double-mass flywheel (DMF) or drive plate. Remove ten M10 internal-serration fastening screws. The DMF cannot be mixed up. Refer to 13 63 19 Removing and installing drive plate for torque converter - as of MY 2004 (Cayenne TIP) .



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Fig. 423: Spark plugs Courtesy of PORSCHE OF NORTH AMERICA, INC.

21. Remove ignition coils and spark plugs. Refer to 28 70 55 Replacing spark plugs - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

22. Unscrew all nine fastening screws and two fastening nuts on the cylinder head cover. Lift off cylinder head cover and set it down on a clean surface. See Fig. 424.



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Fig. 424: Cylinder head cover Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig. 425: TDC marking on pulley and housing cover Courtesy of PORSCHE OF NORTH AMERICA, INC.

23. Turn engine to the ignition TDC of cylinder 1. To do this, turn the crankshaft so that the notch on the crankshaft pulley is aligned with the marking on the housing cover. It must be possible to insert the camshaft guide T10068 into the rear slits on the camshafts. If this is not the case, turn the crankshaft a further 360° and insert the camshaft guide again.



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Fig. 426: Camshaft guide inserted in camshafts Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig. 427: Installation location of chain tensioner Courtesy of PORSCHE OF NORTH AMERICA, INC.



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24. Remove chain tensioner. To do this, remove the chain tensioner to the side on the top chain case lid -arrow-. See Fig. 427.

Fig. 428: Sheetmetal holder for additional coolant pump Courtesy of PORSCHE OF NORTH AMERICA, INC.

25. Remove sheet-metal holder for additional coolant pump -1- . See Fig. 428.



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Fig. 429: Top chain case lid Courtesy of PORSCHE OF NORTH AMERICA, INC.

26. Unscrew both chain case lids (top and bottom). Hall senders can remain fitted on the top chain case lid. See Fig. 429 and Fig. 430.



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Fig. 430: Bottom chain case lid Courtesy of PORSCHE OF NORTH AMERICA, INC.



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Fig. 431: Arm bracket Courtesy of PORSCHE OF NORTH AMERICA, INC.

27. Secure the crankshaft at the pulley using the special arm bracket T10069. See Fig. 431.

28. Loosen fastening screw on intermediate shaft gear wheel -14- . See Fig. 432.



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Fig. 432: Timing drive mechanism Courtesy of PORSCHE OF NORTH AMERICA, INC.



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Fig. 433: Hexagon on camshafts Courtesy of PORSCHE OF NORTH AMERICA, INC.

29. Loosen camshaft adjuster -4 and 22- . To do this, counter camshafts at the hexagon and loosen the fastening screws on the camshaft adjusters -23- . See Fig. 432, Fig. 434.

30. Remove top tensioning rail -8- and guide rail -24- . Remove two fastening screws for the guide rail -21- . See Fig. 434, Fig. 432, Fig. 436.



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31. Remove timing chain for camshafts -3- . Remove camshaft adjusters -4 and 22- . See Fig. 434.

32. Remove fastening screw on intermediate shaft -14- and take off gear wheel -13- . See Fig. 436.

33. Loosen bottom chain tensioner -15- . Hold the chain tensioner in tensioned state and secure with a tie-wrap. Loosen two fastening screws -2 below- and remove tensioned chain tensioner. See Fig. 436.

NOTE: Press the bottom chain tensioner together during removal because otherwise it will push out due to spring tensioning. Secure chain tensioner with a tie-wrap in tensioned state.



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34. Remove bottom timing chain -17- . Remove guide rail -18- . See Fig. 436.

Fig. 435: Oil strainer and timing chain housing Courtesy of PORSCHE OF NORTH AMERICA, INC.

The oil strainer -2- must be checked and cleaned if necessary. See Fig. 435.

35. Unscrew camshaft adjuster timing chain housing -1- . Do this carefully because the screws -2 above- are micro-encapsulated and can snap easily. Pull off camshaft adjuster timing chain housing. Loosen it if necessary by tapping carefully with a plastic hammer. See Fig. 436.

NOTE: The screws for the camshaft adjuster timing chain housing -1- are micro-encapsulated and can snap during removal. Screws must be replaced. See Fig. 435.



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NOTE: Camshaft bearing caps are marked as follows:

Even numbers on bearing cap = outlet; uneven numbers on bearing cap = inlet; numbering sequence starting from timing chain side (output), legible from inlet side, housing edges pointed outward, no. 7 and 8 are thrust or guide bearings!



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Fig. 437: Camshafts and bearing covers Courtesy of PORSCHE OF NORTH AMERICA, INC.

36. Unscrew camshaft bearing covers. Proceed step-by-step from the outside in. Mark the exact position of the bearing covers and place on a clean surface according to installation position.

Fig. 438: Marking camshafts Courtesy of PORSCHE OF NORTH AMERICA, INC.

NOTE: Grooves and numbers are located in the middle of the camshafts: No. 102 inlet, two grooves -B- , No. 101outlet, one groove -A- !



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37. Remove camshafts carefully and place on a clean surface.

38. Unscrew cylinder head. Remove twenty internal-serration screws (thirteen M10 x 110 and seven M10 x 140) in reverse order to the sequence shown (middle screws are longer). Remove cylinder head with the help of an assistant and place it on a clean surface.

Fig. 439: Tightening sequence for cylinder head Courtesy of PORSCHE OF NORTH AMERICA, INC.

39. Take hydro-tappets and roller-type cam followers -14 to 16- out of the cylinder head and lay them on a clean surface in such a way that they cannot get mixed up. See Fig. 440.



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Fig. 440: Cylinder head Courtesy of PORSCHE OF NORTH AMERICA, INC.

40. Remove cylinder-head gasket.



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Fig. 441: Component arrangement for oil pump drive Courtesy of PORSCHE OF NORTH AMERICA, INC.

41. Disassemble oil pump drive.



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Fig. 442: Oil retaining valve Courtesy of PORSCHE OF NORTH AMERICA, INC.

42. Pull oil retaining valve with an M8 screw -arrow- . See Fig. 442.

43. Turn engine in engine support.

44. Remove oil pump. For details, refer to 17 20 19 Removing and installing oil pump - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

45. Unscrew connecting-rod bearing cap -6- and pull out pistons -2- in sequence. Turn the crankshaft back and forth to make room for removing the connecting-rod bearing cap. Join connecting-rod bearing cap and connecting-rod big end together again, mark each one and lay to one side. Connecting-rod bearing caps are legible on alternate sides for each cylinder bank. See Fig. 443.

NOTE: Connecting-rod bearing caps must be marked and numbered during removal. Retaining lugs of bearing shells are pressed together. The cast lugs of connecting-rod bearings and connecting-rod big end are identical!

NOTE: The flat side of the piston crown always points to the middle of the cylinder block.



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Fig. 443: Pistons and connecting rods Courtesy of PORSCHE OF NORTH AMERICA, INC.



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Fig. 444: Piston/connecting rod installation position (cast lugs -1- piston crown -2-) Courtesy of PORSCHE OF NORTH AMERICA, INC.




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46. Remove the crankshaft belt pulley with a helper. To do this, block the pulley using an arm bracket T10069and loosen the M18 x 40 fastening screw. Replace the fastening screw.

Fig. 446: Loosening the central screw Courtesy of PORSCHE OF NORTH AMERICA, INC.



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Fig. 447: Sealing flange Courtesy of PORSCHE OF NORTH AMERICA, INC.

47. Remove the sealing flange behind the crankshaft belt pulley. To do this, remove the fastening screws -A and B- and lever the flange off with a screwdriver. See Fig. 447.



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Fig. 448: Levering off sealing flange Courtesy of PORSCHE OF NORTH AMERICA, INC.

48. Unscrew crankshaft bearing caps -1- (legible from exhaust side and from opposite the output), mark each one and lay to one side according to cylinders (no. 5 is the thrust and guide bearing). Store the thrust washers -4- and bearing shells -3- along with the corresponding bearing caps. See Fig. 449.



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Fig. 449: Crankshaft and mount Courtesy of PORSCHE OF NORTH AMERICA, INC.

--> Conscientious and precise work

--> Use suitable storage places.

CAUTION: Damage to sensitive engine components (e. g. speed sensor wheel)

WARNING: Risk of crushing your hands when lifting the crankshaft!



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--> Hold the very outside of the crankshaft.

--> Wear gloves.

--> Get an assistant to help lift the crankshaft.

49. Prepare a space for the crankshaft that does not impede the speed sensor wheel. Lever out the crankshaft and set it down on a clean surface.

ASSEMBLING V6 (BFD) ENGINE

Assembling V6 (BFD) engine

--> Wear suitable protective clothing (e. g. gloves).

--> Conscientious and precise work

--> Use suitable storage places.


--> Wear gloves.

--> Get an assistant to help lift the crankshaft.


WARNING: Danger of cutting oneself on sharp metal edges!

CAUTION: Damage to sensitive engine components (e. g. speed sensor wheel)

WARNING: Risk of crushing your hands when lifting the crankshaft!





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Fig. 450: Bearing shell Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Replace crankshaft bearing shells (color markings must match). Insert and oil crankshaft bearing shells (on crankcase side). Make sure the twist lock is positioned in the corresponding cut-out --> Bearing shell . For details, refer to 13 48 19 Removing and installing crankshaft - as of MY 2004 (Cayenne TIP, Cayenne MAN) . See Fig. 450.

2. Insert crankshaft into the oiled bearing.

3. Fit thrust bearing no. 5 with thrust washers -4- (insert with grease, lubricating groove facing outwards), then

NOTE: Bearing covers for the crankshaft are numbered 1 to 7 and the numbers can be read on the side facing the exhaust.

Bearing no. 5 is a guide or thrust bearing with two thrust washers at the side.

The twist locks or retaining lugs are on the same side.

Bearing screws must be replaced.

Bearing shells must be replaced. Use only identical color markings



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fit the remaining bearing covers -1- (from exhaust side no. 1, numbering legible opposite output). See Fig. 451.

Fig. 451: Crankshaft and mount Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Position bearing covers by tapping with a rubber hammer.

5. Replace bearing screws -2- and tighten to the specified tightening torque in stages from the middle outwards. --> 10 01 IN Tightening torques for Cayenne (engine type BFD) - as of MY 2004 (Cayenne TIP, Cayenne MAN) , see Fig. 451.

6. Turn crankshaft to try it out.



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Fig. 452: Funnel Courtesy of PORSCHE OF NORTH AMERICA, INC.

NOTE: Piston installation instructions must be followed at all times. Refer to 13 10 19 Removing and installing pistons - as of MY 2004 (Cayenne TIP, Cayenne MAN) .



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Fig. 453: Arrangement of pistons and connecting rods Courtesy of PORSCHE OF NORTH AMERICA, INC.

The cast lugs, twist locks (retaining lugs) -1- and the flat side of the piston crown -2- are on the same side. See Fig. 453.

7. Insert oiled pistons and connecting rods using a funnel T10147. Turn the crankshaft back and forth as required so that there is sufficient room for installation. Align flat side of piston crown to the middle of the cylinder block. Always align the pins -arrow- on the funnel T10147 to the middle of the cylinder block.

NOTE: Always replace the connecting-rod bearing shells and oil them before inserting them into the bearing covers.



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Fig. 454: Twist lock Courtesy of PORSCHE OF NORTH AMERICA, INC.

The connecting-rod big end and connecting-rod bearing caps must be aligned according to the cast lugs -B and C- . The retaining lugs of the connecting-rod bearing shells are on one side. Connecting-rod bearing caps are legible on alternate sides. See Fig. 454.

Install connecting rod and connecting-rod bearing caps unrestrained. If necessary, remove them again, position the bearing caps by tapping lightly with a plastic hammer and then refit them.

8. Align the connecting rods of the pistons to the crank pins. Oil the bearings. Position connecting-rod bearing covers in the correct sequence and screw bolts into the connecting-rod big end by hand. Retaining lugs of bearing shells must be pressed together.

9. Position the connecting-rod bearings by tapping with a plastic hammer. Tighten all connecting-rod screws to the prescribed tightening torque. --> 10 01 IN Tightening torques for Cayenne (engine type BFD) - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

10. Turn the crankshaft provisionally with belt pulley and fastening screw to check for smooth operation.



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Fig. 455: Sender gap on speed sender ring gear Courtesy of PORSCHE OF NORTH AMERICA, INC.

11. Turn the crankshaft so that the sender gap on the speed sender ring gear is pointing downwards to the middle (rough TDC presetting).



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Fig. 456: Sealing flange Courtesy of PORSCHE OF NORTH AMERICA, INC.

12. Fit the sealing flange behind the crankshaft belt pulley. For details, refer to 13 48 19 Removing and installing crankshaft - as of MY 2004 (Cayenne TIP, Cayenne MAN) .



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13. Fit the crankshaft belt pulley with a helper. To do this, block the pulley using an arm bracket T10069 and fit the M18 x 40 fastening screw. Use a new fastening screw. --> 10 01 IN Tightening torques for Cayenne (engine type BFD) - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

14. Install oil pump. Refer to 17 20 19 Removing and installing oil pump - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

15. Turn engine in engine support.



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Fig. 458: Component arrangement for oil pump drive Courtesy of PORSCHE OF NORTH AMERICA, INC.

16. Install oil pump drive. Refer to 17 22 19 REMOVING AND INSTALLING OIL PUMP DRIVE - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN) LUBRICATION .



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Fig. 459: Oil retaining valve Courtesy of PORSCHE OF NORTH AMERICA, INC.

17. Insert oil retaining valve with sealing ring in crankcase -arrow- . See Fig. 459.



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Fig. 460: TDC marking on pulley and housing coverCourtesy of PORSCHE OF NORTH AMERICA, INC.

18. Turn engine to the ignition TDC of cylinder 1. To do this, turn the crankshaft so that the notch on the pulley is aligned with the marking on the housing cover.

19. Position cylinder-head gasket correctly on the dowel sleeves (inscription pointing upwards) and install the cylinder head. For details, refer to 15 70 23 Installing cylinder head - as of MY 2004 (Cayenne TIP, Cayenne MAN) .




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Fig. 462: Roller-type cam follower and support element connection Courtesy of PORSCHE OF NORTH AMERICA, INC.

20. Assemble support element, roller-type cam followers and safety clips or check that they are assembled correctly. Make sure the support elements and roller-type cam followers are joined correctly by the safety clips -1 and 2- . See Fig. 462.



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Fig. 463: Installation position of roller-type cam follower -1- and support element -2- Courtesy of PORSCHE OF NORTH AMERICA, INC.

21. Oil the components. Install support element/roller-type cam follower. Make sure that the safety clip does not slip out of place during installation. The pressure face of the roller-type cam follower -3- must rest on the valve pressure face. This can slip out of place when the camshaft is installed later. See Fig. 463.



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22. Install camshafts. Refer to 15 05 23 Installing camshafts - as of MY 2004 (Cayenne TIP, Cayenne MAN) .



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Fig. 465: TDC of cylinder 1 Courtesy of PORSCHE OF NORTH AMERICA, INC.

23. Check that the crankshaft is positioned at the TDC of cylinder 1.



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Fig. 466: Sealing rings Courtesy of PORSCHE OF NORTH AMERICA, INC.

24. Fit timing chain housing. To do this, slide the timing chain housing on to the oiled sealing rings of the camshafts. If necessary, press the sealing rings together in the ring stacks -arrows- . Push the timing chain housing up as far as the centering pins. See Fig. 466.



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Fig. 467: Securing timing chain housing Courtesy of PORSCHE OF NORTH AMERICA, INC.

25. Fit the four M6 x 30 fastening screws with securing liquid -arrows- . --> Tightening torque: 8 (6 ftlb.) Nm . See Fig. 467.



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26. Install camshaft adjusters. Refer to 15 84 23 Installing camshaft adjusters - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

27. Set the timing. Refer to 15 05 16 Setting the timing - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

28. Install bottom chain case lid. Refer to 15 33 23 INSTALLING CHAIN CASE LID - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN) or 15 33 23 INSTALLING CHAIN CASE LID - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN) .



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29. Install top chain case lid. Refer to 15 33 23 INSTALLING CHAIN CASE LID - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN) or 15 33 23 INSTALLING CHAIN CASE LID - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN) .

30. Fit water tube -6- in water pump housing (tap pointing downwards). See Fig. 469.


31. Turn engine through two turns at the crankshaft and check the timing again. Refer to 15 05 02 Checking the timing - as of MY 2004 (Cayenne TIP, Cayenne MAN) .



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32. Install cylinder head cover. Refer to 15 91 23 INSTALLING COVER FOR CAMSHAFT HOUSING -AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN) .

33. Fit oil/water heat exchanger -3 to 5- . Fit oil filter housing/engine support arm -10- . Replace seals -2 and 3-. --> Tightening torque: 23 (17 ftlb.) Nm , see Fig. 470.

Fig. 470: Oil/water heat exchanger Courtesy of PORSCHE OF NORTH AMERICA, INC.

34. Install fuel distribution pipe and fuel injectors. Refer to 24 30 19 Removing and installing fuel distributor pipe - as of MY 2004 (Cayenne TIP, Cayenne MAN) .



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35. Insert water pump with new seal and secure from the front through the belt pulley with three internal-serration screws. Refer to 19 50 19 Removing and installing coolant pump - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

36. Place aluminum water tube in installation position. Secure water hoses. --> Tightening torque: 8 (6 ftlb.) Nm

37. Fit exhaust manifolds. Refer to 26 10 19 Removing and installing exhaust manifold - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

38. Fit intake-air distributor. Refer to 24 46 19 Removing and installing intake-air distributor - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

39. Fit oil dip stick with a new sealing ring and insert into guide tube. Refer to 17 17 19 Removing and installing guide tube for oil dip stick - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

40. Fit unit holder. To do this, insert two fit bolts and three fastening screws and tighten holder. --> Tightening torque: 23 (17 ftlb.) Nm

41. Install generator. Refer to 27 22 19 Removing and installing three-phase generator - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

42. Install servo pump. Refer to 48 98 19 Removing and installing hydraulic pump (Cayenne V6) - as of



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MY 2004 (Cayenne TIP, Cayenne MAN) .

43. Fit engine wire harness. Refer to 97 52 23 Installing wiring harness for engine (V6) - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

44. Fit the deflection roller in front of the generator. Press on plastic lid.

45. Fit belt tensioner with bracket using three fastening screws. Refer to 13 73 19 Removing and installing belt tensioner - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

46. Fit and tension the drive belt. Refer to 13 78 19 Removing and installing drive belt - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

SUBSEQUENT WORK

Subsequent work

1. Install engine. --> 100119 Removing and installing V6 3.2 l engine - "Installing".

10 01 37 DISASSEMBLING AND ASSEMBLING ENGINE - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN)

TOOLS

Designation Type Number Explanation piston ring restraining strap for 944 - S2 and Boxster and 911 Carrera (996)

special tool 57

centering pins special tool P 9321

mounting elements special tool P 9590

engine support special tool P 9676



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TOOLS AND MATERIALS

Required special tools

TECHNICAL VALUES

Technical values

PRELIMINARY WORK

Preliminary work for disassembling engine


2. Remove engine from transmission. Refer to 34 35 27 Removing and refitting transmission - as of MY 2003 (Cayenne S MAN) or refer to 37 35 27 Removing and refitting transmission - as of MY 2003 (Cayenne S TIP, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

holding bridges special tool P 9677

NOTE: For special tools that are required for repairing engines, refer to 10 01 WM (Special) tools required for repairing the M48/00 and M48/50 engines - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

NOTE: For information on all tightening torques, see --> Tightening torques for Cayenne S (M48/00) and Cayenne Turbo (M48/50) [9PAAF1 9PAAJ1 9PAAK1] or --> Tightening torques for Cayenne S (M48/00) and Cayenne Turbo (M48/50) [9PAAE1 9PAAE7] or the corresponding individual articles.

NOTE: The engine must be disassembled in accordance with the detailed descriptions in the article!

This article does not provide details or further information. Further details can be found in the relevant individual descriptions.



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3. Secure engine support P 9676 on engine --> Crankcase on engine support (shown with lower part of crankcase) . To do this, use the four screws for mounting elements P 9590 and tighten them slightly. Secure engine on engine support. To do this, carefully guide the engine support axle into the take-up bore on the engine support and secure it. See Fig. 472.

4. Remove wire harness for engine. Refer to 97 52 19 Removing and installing wiring harness for engine - as of MY 2003 (Cayenne S TIP, Cayenne S MAN) . Refer to 97 52 19 Removing and installing wiring harness for engine - Cayenne Turbo (Type M48/50) - as of MY 2003 (Cayenne Turbo, Cayenne Turbo S) .

5. Remove the generator. Refer to 27 22 19 Removing and installing three-phase generator - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne S TIO Titan) . Refer to 27 22 19 Removing and installing the generator - as of MY 2006 (Cayenne S TIP, Cayenne S MAN) . Refer to 27 22 19 Removing and installing the generator - as of MY 2006 (Cayenne Turbo, Cayenne Turbo S) .

6. Remove power-steering pump. Refer to 48 98 19 Removing and installing hydraulic pump (Cayenne Turbo/Cayenne S) - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S) .

7. Remove left additional assembly bracket -2- and right engine carrier -8- . There are also two dowel sleeves (not shown) on the additional assembly bracket. See Fig. 473.

Fig. 472: Crankcase on engine support (shown with lower part of crankcase) Courtesy of PORSCHE OF NORTH AMERICA, INC.



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Fig. 473: Removing and installing engine support Courtesy of PORSCHE OF NORTH AMERICA, INC.

1 - Nut --> Tightening torque: 75 (56 ftlb.) Nm

2 - Additional assembly bracket, left

3 - Screw x 10 --> Tightening torque: 65 (48 ftlb.) Nm

4 - Hydraulic mount, left

5 - Engine carrier



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7 - Hydraulic mount, right

8 - Engine carrier


DISASSEMBLING ENGINE

Disassembling engine

1. Remove starter. Refer to 27 60 19 Removing and installing starter - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo) .

2. Remove knock sensors. Refer to 28 72 19 Removing and installing knock sensor - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

3. Remove cylinder heads. Refer to 15 70 21 Removing cylinder head - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

4. Remove water pump. Refer to 19 50 19 Removing and installing coolant pump - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S) .

5. Remove coolant regulator. Refer to 19 58 19 Removing and installing coolant regulator (thermostat) - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

6. Remove guide and tensioning rails. Refer to 15 47 19 REMOVING AND INSTALLING GUIDE AND TENSIONING RAILS - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN) or 15 47 19 REMOVING AND INSTALLING GUIDE AND TENSIONING RAILS - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN) .

7. Remove crankshaft. Refer to 13 48 19 Removing and installing crankshaft - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

8. Remove oil spray jets on turbo engine and cap on naturally aspirated engine. --> 101321 Removing oil spray jets for piston cooling [9PAAF1 9PAAJ1].

PRELIMINARY WORK

Preliminary work for engine assembly

1. The crankcase must be prepared for installation (dowel sleeves, caps and pins screwed in).



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Fig. 474: Crankcase on engine support Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Attach top section of crankcase to engine support. To do this, use the four screws for mounting elements P 9590 and tighten them slightly.

ASSEMBLING ENGINE

Assembling engine








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Fig. 475: Caps and oil spray nozzles Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Fit caps on crankcase. When doing so, make sure that new O-rings are fitted. Tighten the --> Tightening torque: 10 (7.5 ftlb.) Nm .



NOTE: Four oil spray nozzle are installed in the M48/50 engine instead of the caps used in the M48/00 engine.



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Fig. 476: Inserting bearing shells Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig. 477: color marking on bearing shell



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2. Insert the bearing shells with the lubricating groove into the upper part of the crankcase --> Inserting bearing shells . Make sure the twist locks are positioned correctly. Then lightly oil the bearing locations. See Fig. 476.

Fig. 478: Inserting sickle-shaped washers Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Insert the sickle-shaped washers (make sure of axial bearing play). To do this, insert the two sickle-shaped washers to the left and right on crankshaft bearing no. 3. Apply some grease (000.043.204.17) between the crankshaft bearing and the sickle washers so that the sickle washers do not fall down. Each of the lubricating grooves of the sickle-shaped washers must face outwards. See Fig. 478.

NOTE: The bearing shells are available in various tolerance classes. The classes are indicated by the color marking on the outside. The color marking must match the corresponding color dot on the crankshaft. Further details: Refer to 13 48 19 Removing and installing crankshaft - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .



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Fig. 479: Crankshaft holding bridges Courtesy of PORSCHE OF NORTH AMERICA, INC.


--> Wear gloves.

4. Insert crankshaft. The connecting flange must point towards the back of the engine. Then secure the crankshaft from falling down using holding bridges P 9677. Attach the holding bridges at bearing locations 3 and 5 --> Crankshaft holding bridges . Then screw the fastening screw of the front pulley into the crankshaft until they just make contact. See Fig. 479.

5. Turn crankcase by 180° on the assembly support.

WARNING: The crankshaft is heavy!

There is a danger of hands being crushed when inserting the crankshaft.



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Fig. 480: Turning the crankshaft Courtesy of PORSCHE OF NORTH AMERICA, INC.

The connecting rod is symmetrical and can be fitted either on the piston so that the number on the connecting rod is facing outwards or inwards, or the tolerance class designation of the piston does not have to be on the same side as the connecting rod code. The direction of travel arrow is on the same side as the connecting rod code -A- as is evident on the piston shown. This can be installed as standard on one cylinder bank side on the same side as shown here, and on the other cylinder bank side, the connecting rod code is on the opposite side. The connecting rod code is installed to the exhaust side as standard. See Fig. 481.

NOTE: The pistons must already be pre-fitted (pistons, piston rings, connecting rods and fastening material) before performing the next step.

The required bearing shells must be inserted in the connecting rods.



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Fig. 481: Connecting rod code and direction of travel arrow Courtesy of PORSCHE OF NORTH AMERICA, INC.

When installing the piston in the crankcase, the direction of travel arrow must point in the direction of travel.

For further information, refer to 13 10 19 Removing and installing pistons - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .



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Fig. 482: Connecting rod code "A" Courtesy of PORSCHE OF NORTH AMERICA, INC.

The code on the connecting-rod big end and connecting-rod bearing cap must be on the same side and at the exhaust side.

6. Install piston. To do this, turn the crankshaft with a wrench (a/f 27) until the corresponding lift pin is pointing straight downwards.

7. Lightly oil cylinder and piston.



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Fig. 483: Tensioning the piston rings Courtesy of PORSCHE OF NORTH AMERICA, INC.

8. Align piston-ring set (offset by 120°) and compress piston rings using piston ring restraining strap for 944 - S2 and Boxster and 911 Carrera (996) 57.



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Fig. 484: Direction of travel arrow Courtesy of PORSCHE OF NORTH AMERICA, INC.

9. Place piston onto cylinder from above and push into cylinder. When doing so, make sure that the direction of travel arrow is pointing forwards (in direction of travel). -Arrow- See Fig. 484.



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Fig. 485: Push piston in using the handle of a hammer, if necessary. Courtesy of PORSCHE OF NORTH AMERICA, INC.

Sliding in the piston



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Fig. 486: Twist lock on bearing shells Courtesy of PORSCHE OF NORTH AMERICA, INC.

10. Push the piston downwards until the connecting-rod bearing is sitting on the lift pin. Then fit connecting-rod bearing cap with bearing shell. The connecting rod numbers must face each other. Screw in con-rod bolts by hand. Make sure the twist locks and connecting rod code are positioned correctly during assembly.

Fig. 487: View of connecting rod numbers Courtesy of PORSCHE OF NORTH AMERICA, INC.

11. Fit the opposite piston (e. g. 1 and 4).

12. Fit other pistons in accordance with the step above.

13. Turn crankcase on the assembly support until the crankshaft is on top.

14. Tighten con-rod bolts that have been replaced., refer to 13 10 19 Removing and installing pistons - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

15. Holding bridges P 9677 must be removed from the crankshaft.

NOTE: Con-rod bolts must always be replaced.



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Fig. 488: Centering pin Courtesy of PORSCHE OF NORTH AMERICA, INC.

16. Screw the two thin centering pins P 9321 into the outer fastening bores on the upper part of the crankcase -Arrows- (crankshaft not fitted in illustration). See Fig. 488.



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Fig. 489: Inserting the bearing shells Courtesy of PORSCHE OF NORTH AMERICA, INC.

17. Insert the bottom bearing shells into the lower part of the crankcase (bed plate) and lightly oil running surfaces. Pay attention to the twist locks when doing so.

18. Make sure the crankcase is ready to be screwed in. Check that the sickle-shaped washers are positioned correctly. Degrease parting surfaces between upper and lower parts of the crankcase. A totally grease-free product (e. g. brake cleaner) must be used for this. Then insert a new O-ring at the front of the parting surface.



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Fig. 490: Lower part of crankcase (bed plate) Courtesy of PORSCHE OF NORTH AMERICA, INC.

1 - Crankcase, lower part

2 - Cylindrical pin used to center the lower part of the crankcase on the crankcase

3 - Sealing ring; replace

4 - Application of sealant; liquid sealant 000.043.204.58 (status 02/06) must be applied and the screws screwed in within five minutes and without interruption

5 - Thrust-bearing screw, M12 x 1.5 x 132



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6 - Thrust-bearing screw, M10 x 117

7 - Fastening screw, M8 x 70



10 - Dowel sleeve

19. Apply liquid sealant 000.043.204.58 (status 02/06, for details of current sealant, see Parts Catalogue) to the lower part of the crankcase as shown. The surfaces marked -A- must be cleaned after fitting. See Fig. 491.

Fig. 491: Applying sealant to lower part of crankcase Courtesy of PORSCHE OF NORTH AMERICA, INC.

20. Place lower part of crankcase into position. When doing so, make sure that the sealing bead is not destroyed.

21. For details of the tightening sequence for the lower part of the crankcase and tightening torques, refer to 13 48 19 Removing and installing crankshaft - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

NOTE: Liquid sealant must be applied and screws tightened immediately and without interruption.

The threads and head contact surface of the bearing seat screws (M10 x 1.5 and M12 x 1.5) must be oiled.



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Fig. 492: Lower part of crankcase (clutch side) Courtesy of PORSCHE OF NORTH AMERICA, INC.

22. Then tighten the four fastening screws on the clutch side --> Tightening torque: 23 (17 ftlb.) Nm -Arrows- . See Fig. 492.



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Fig. 493: Chain drive sprocket Courtesy of PORSCHE OF NORTH AMERICA, INC.

23. Fit chain drive sprocket on the crankshaft. Unscrew fastening screw on belt pulley. Check that the feather keys are fitted correctly and push on the chain sprocket with the oil pump drive chain. The double-tooth row must be facing forwards.



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Fig. 494: Oil pump Courtesy of PORSCHE OF NORTH AMERICA, INC.

24. Install oil pump. Refer to 17 20 19 Removing and installing oil pump - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

25. Fit guide rail -9- and tensioning rail -6- for the oil pump drive. Push the tensioning rail over the fastening pin and engage the guide rail in the lower part of the crankcase as shown in the illustration. See Fig. 495.



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Fig. 495: Oil pump components Courtesy of PORSCHE OF NORTH AMERICA, INC.



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Fig. 496: Timing chain cover on oil pump Courtesy of PORSCHE OF NORTH AMERICA, INC.

26. Fit timing chain cover on oil pump. Tighten --> Tightening torque: 10 (7.5 ftlb.) Nm .

27. Turn engine 180° on the assembly support.



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Fig. 497: Installing starter Courtesy of PORSCHE OF NORTH AMERICA, INC.

28. Install starter Refer to 27 60 19 Removing and installing starter - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo) or 27 60 19 REMOVING AND INSTALLING STARTER - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN) .



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Fig. 498: Knock sensor on bank 1 - 4 Courtesy of PORSCHE OF NORTH AMERICA, INC.

29. Fit knock sensors. Align the knock sensors as shown in the illustration and tighten the --> Tightening torque: 23 (17 ftlb.) Nm .



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Fig. 499: Knock sensor on bank 5 - 8 Courtesy of PORSCHE OF NORTH AMERICA, INC.

30. Install thermostat housing. Fit a new O-ring at the water pump inlet and then insert the thermostat housing. Tighten the two --> Tightening torque: 10 (7.5 ftlb.) Nm .

31. Mount cylinder heads. To do this, turn the engine on the assembly support so that the required cylinder row is pointing vertically upwards.



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Fig. 500: Cylinder row 1 - 4 Courtesy of PORSCHE OF NORTH AMERICA, INC.

32. Fit new cylinder-head gasket. The gasket designation is shown on the back and is legible from above when fitted correctly.



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Fig. 501: Cylinder row 5 - 8 Courtesy of PORSCHE OF NORTH AMERICA, INC.

33. Fit cylinder head. The fastening screws must be tightened in the sequence shown below. The tightening sequences and step-by-step tightening torques must be observed! For details, refer to 15 70 23 Installing cylinder head - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

Fig. 502: Cylinderhead fasteners installation sequence



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34. Fit camshaft housing. Apply a bead of liquid sealant 000.043.204.58 (status 02/06, for details of current sealant, see Parts Catalogue) -A- as shown. Then screw two thin centering pins P 9321 into two opposing blind holes in the cylinder head. Insert the O-ring -B- into the oil duct. Wipe off any sealant -C- that emerges as a result of screwing. See Fig. 503.

Fig. 503: Applying sealant Courtesy of PORSCHE OF NORTH AMERICA, INC.

35. Position camshaft housing and then unscrew the two centering pins.

36. Tighten the camshaft housing screws in the sequence shown. Don't forget the two hexagon socket head bolts at the front of the camshaft housing. For details, refer to 15 03 23 Installing camshaft housing - as of MY 2005 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .



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Fig. 504: Tightening sequence for camshaft housing Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig. 505: Screws at the front Courtesy of PORSCHE OF NORTH AMERICA, INC.

NOTE: The bearing locations of the camshafts must be lightly oiled.

Place the camshafts in such a way that the cams are positioned as shown



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37. Install camshafts. Refer to 15 05 23 Installing camshafts - as of MY 2005 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

Fig. 506: Positioning camshafts Courtesy of PORSCHE OF NORTH AMERICA, INC.

1 - Cam position cylinder 6

2 - Cam position cylinder 2 (A) and cylinder 3 (B)

D - Cam position cylinder row 5 - 8 exhaust side

C - Cam position cylinder row 5 - 8 inlet side

B - Cam position cylinder row 1 - 4 inlet side

A - Cam position cylinder row 1 - 4 exhaust side

38. Fit oil return line to camshaft housing 5 - 8. Fit oil return line -1- with a new O-ring -2- . Tighten the four --> Tightening torque: 10 (7.5 ftlb.) Nm -3 and 4- (camshaft housing, cylinder head, crankcase and oil pan). See Fig. 507.

below!



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Fig. 507: Oil return line Courtesy of PORSCHE OF NORTH AMERICA, INC.

39. Position oil feed housing of inlet camshaft and tighten --> Tightening torque: 10 (7.5 ftlb.) Nm .



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Fig. 508: Diamond washer Courtesy of PORSCHE OF NORTH AMERICA, INC.

40. Replace the diamond washer and fastening screw located underneath the camshaft adjuster and camshaft timing gear.

41. Fit deflection rail -4- . Refer to 15 47 19 REMOVING AND INSTALLING GUIDE AND TENSIONING RAILS - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN) or 15 47 19 REMOVING AND INSTALLING GUIDE AND TENSIONING RAILS - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN) . See Fig. 509.

NOTE: If the camshaft timing gears and camshaft adjusters are removed completely, the diamond washers and fastening screws must be replaced!



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Fig. 509: Deflection rail Courtesy of PORSCHE OF NORTH AMERICA, INC.



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Fig. 510: Fastening screw for camshaft switch-over valve Courtesy of PORSCHE OF NORTH AMERICA, INC.

--> Do not turn camshaft switch-over valve.

42. Install camshaft switch-over valves --> Tightening torque: 10 (7.5 ftlb.) Nm . --> Fastening screw for camshaft switch-over valve shows procedure with timing-case cover fitted. See Fig. 510.

43. Fit timing drive mechanism. Fit guide rail of cylinder bank 5 - 8. Tighten the leaf spring of the oil pump tensioning rail at the same time. Refer to 15 47 19 REMOVING AND INSTALLING GUIDE AND TENSIONING RAILS - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN) or 15 47 19 REMOVING AND INSTALLING GUIDE AND TENSIONING RAILS - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN) .

44. Fit tensioning rail to cylinder bank 1 - 4.

CAUTION: Damage to the camshaft switch-over valve!

Malfunction.



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Fig. 511: Installing timing chain Courtesy of PORSCHE OF NORTH AMERICA, INC.

45. Install timing chain. Position the chain on the crankshaft gear wheel and then fit it over all four camshaft timing gears. To do this, use both hands to carefully insert the camshaft adjuster and camshaft timing gear into the timing chain. Screw in fastening screws on the timing gears loosely to half a turn. --> Installing timing chainshows procedure with timing-case cover fitted. Screw in fastening screws on the timing gears loosely to half a turn. Refer to 15 35 23 Fitting timing chain - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) . See Fig. 511.

46. Fit U-rail. Insert the U-rail into the timing drive mechanism from above. Tighten the four fastening screws.



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Fig. 512: Guide rails Courtesy of PORSCHE OF NORTH AMERICA, INC.

47. Fit the short guide rails between the camshaft timing gears. --> Guide rails shows assembly with timing-case cover fitted. See Fig. 512.

48. Fit timing-case cover. Refer to 15 33 23 INSTALLING CHAIN CASE LID - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN) or 15 33 23 INSTALLING CHAIN CASE LID - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN) .



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Fig. 513: Sealing ring with assembly sleeve Courtesy of PORSCHE OF NORTH AMERICA, INC.

49. Place sealing ring over crankshaft using assembly sleeve.



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Fig. 514: Crankshaft sealing ring Courtesy of PORSCHE OF NORTH AMERICA, INC.

50. Tighten the two upper fastening screws (M6 x 50) and the lower fastening screws (M6 x 12) by hand.

Fig. 515: Crankshaft sealing ring Courtesy of PORSCHE OF NORTH AMERICA, INC.

51. Tighten the two upper fastening screws (M6 x 50) and the lower fastening screws (M6 x 12) by hand. Then tighten the screws crosswise. --> Tightening torque: 10 (7.5 ftlb.) Nm



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Fig. 516: Assembly sleeve Courtesy of PORSCHE OF NORTH AMERICA, INC.

52. Pull assembly sleeve evenly off the sealing ring.



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Fig. 517: Crankshaft belt pulley Courtesy of PORSCHE OF NORTH AMERICA, INC.

53. Fit crankshaft belt pulley. Refer to 13 76 19 Removing and installing crankshaft belt pulley - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

Fig. 518: Measurement on the oil pan Courtesy of PORSCHE OF NORTH AMERICA, INC.

54. Fit oil pan. Refer to 17 50 23 Installing oil pan (includes sealing) - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

55. Fit drive plate or flywheel.

NOTE: If the sealing flange on the pulley is slightly rusted, polish the rust off with a special polishing pad (e. g. Never Dull).

If the sealing flange is badly corroded or contains deep grooves, replace it.

NOTE: A feather key is inserted into the crankshaft. When fitting the pulley, ensure that the feather key slots into the groove in the pulley.

The key must not fall into the engine.



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Fig. 519: Installation position of chain tensioner Courtesy of PORSCHE OF NORTH AMERICA, INC.

56. Install chain tensioner with new sealing ring. --> Tightening torque: 60 (44 ftlb.) Nm

57. Set the timing. Refer to 15 05 16 Adjusting the timings for the camshafts - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

58. Install the camshaft housing cover on both cylinder rows Refer to 15 91 23 Installing cover for camshaft housing - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

59. Fit water pump. Refer to 19 50 19 Removing and installing coolant pump - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S) .

SUBSEQUENT WORK

Subsequent work

1. Fit left additional assembly bracket -2- and right engine carrier -8- . There are still two dowel sleeves (not shown) on the additional assembly bracket. See Fig. 520.

NOTE: To remove the play from the timing chain for the setting process, the crankshaft must be positioned approx. 45° in front of the TDC of cylinder 1 before turning!



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5 - Engine carrier



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8 - Engine carrier


2. Fit power-steering pump. Refer to 48 98 19 Removing and installing hydraulic pump (Cayenne Turbo/Cayenne S) - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S) .

3. Fit generator. Refer to 27 22 19 Removing and installing three-phase generator - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne S TIO Titan) . Refer to 27 22 19 Removing and installing the generator - as of MY 2006 (Cayenne S TIP, Cayenne S MAN) . Refer to 27 22 19 Removing and installing the generator - as of MY 2006 (Cayenne Turbo, Cayenne Turbo S) .

4. Fit wire harness for engine. Refer to 97 52 19 Removing and installing wiring harness for engine - as of MY 2003 (Cayenne S TIP, Cayenne S MAN) . Refer to 97 52 19 Removing and installing wiring harness for engine - Cayenne Turbo (Type M48/50) - as of MY 2003 (Cayenne Turbo, Cayenne Turbo S) .

5. Refit engine on transmission. Refer to 34 35 27 Removing and refitting transmission - as of MY 2003 (Cayenne S MAN) or refer to 37 35 27 Removing and refitting transmission - as of MY 2003 (Cayenne S TIP, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

6. Install engine. --> 100119 Removing and installing V8 4.5 l engine - "Installing".

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)

TOOLS

TOOLS AND MATERIALS





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Special tools

Fig. 521: Suspending device Courtesy of PORSCHE OF NORTH AMERICA, INC.

REMOVING DESIGN COVER ON CYLINDER BANK 5-8


-A- See Fig. 521. Suspending device 3033See Workshop Equipment Manual, Chapter 2.2.3

Only this tool is tested and approved by Porsche. It guarantees only vertical traction of the transport eyebolt with no side or transverse forces.

-B- See Fig. 521. Transport eyebolt P 9700 See Workshop Equipment Manual, Chapter 2.2.2

The transport eyebolt can only bear vertical traction with no side or transverse forces. Side loads (e. g. from chains or cables) will damage the transport eyebolt, which must then be replaced. The transport eyebolt can be broken in extreme cases.



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Removing design cover on cylinder bank 5-8

Fig. 522: Fastening screws Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Remove design cover from cylinder bank 5-8. To do this, loosen the four fastening screws -arrows- on the design cover. See Fig. 522.



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Fig. 523: Unclipping cover Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Lift the cover slightly with both hands at the side pointing towards the intake system until it is released from its holder.



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Fig. 524: Removing the cover Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Lift the front of the design cover and remove it.

LIFTING THE ENGINE

Lifting the engine

The engine must be detached from the transmission. Refer to 34 35 27 Removing and refitting transmission - as of MY 2003 (Cayenne S MAN) or refer to 37 35 27 Removing and refitting transmission - as of MY 2003 (Cayenne S TIP, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .









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NOTE: Place a cloth between the secondary air pump bracket and design cover to avoid scratching the cover.

NOTE: Never use defective lifting equipment (bent or damaged tools must not be used or repaired -3- . Always replace these tools). Check tools for signs of damage before use. See Fig. 525.



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Fig. 525: Damaged transport eyebolt Courtesy of PORSCHE OF NORTH AMERICA, INC.

The transport eyebolt must only be pulled straight -1- . Never use side or transverse force on the transport eyebolt -2- because this can damage the transport eyebolt. See Fig. 525.



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Fig. 526: Bore for transport eyebolt Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Screw transport eyebolt P 9700 hand-tight as far as you can into the opening on cylinder head 5 - 8 -arrow-. See Fig. 526.



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Fig. 527: Engaging torque support bracket Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Insert an M10 screw through the torque support bracket and secure it with a nut. Then attach the hooks of the suspending device 3033 on both sides --> Engaging torque support bracket --> Engaging transport eyebolt after screwing it in . Align the suspending device so that it only pulls the transport eyebolt. To do this, adjust the spindles of the hooks in such a way that the suspending device 3033 is suspended as horizontally as possible above the engine. Move the spindles on the suspending device into positions 4 and 9 . Side forces, e. g. from cables or chains attached at an angle, will bend and break the transport eyebolt. See Fig. 527, Fig. 528.



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Fig. 528: Engaging transport eyebolt after screwing it in Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig. 529: Lifting the engine Courtesy of PORSCHE OF NORTH AMERICA, INC.



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3. Engage spindles into positions 4 and 9 -A and B- of the suspending device 3033 and tension spindles slightly. Lift the engine carefully and balance it out. Raise the engine as shown. --> Lifting the engine See Fig. 530 and Fig. 529.

Fig. 530: Suspending device Courtesy of PORSCHE OF NORTH AMERICA, INC.

Position 4 and 9 -A and B- , See Fig. 530.

10 01 IN SUPPORTING ENGINE ON MOUNTING BRACKET - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN)

INFORMATION

Information

10 01 IN SUPPORTING THE ENGINE ON THE BODY - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN)

NOTE: 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).



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TOOLS

TOOLS AND MATERIALS

Special tools required

Fig. 531: Overview of safety device Courtesy of PORSCHE OF NORTH AMERICA, INC.

Designation Type Number Explanation Safety device VW-tool 10-222 A



Safety device 10-222 A Only this tool is tested and approved by Porsche.

-B- See Fig. 531. Spring hook or chain For lengthening

The transport eyebolt can only bear vertical traction with no side or transverse forces. Side loads (e.



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SUPPORTING THE ENGINE ON THE BODY

Supporting the engine on the body

--> Before starting work, check the body for structural damage (accident, corrosion, etc.). The load capacity of the wing mounting points must not be restricted.

--> Do not apply excessive force (e. g. a high screw torque) to supported units.

--> Units must not be supported on the body over an extended period of time.







-C- See Fig. 531.

Transport eyebolt P 9700

g. from chains or cables) will damage the transport eyebolt, which must then be replaced. The transport eyebolt can weaken and break if this instruction is not observed.

WARNING: Danger of injury from falling loads!

Drive line components (engine, transmission, etc.) can fall down.



NOTE: Never use defective lifting equipment (bent or damaged tools must not be



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Fig. 532: Damaged transport eyebolt Courtesy of PORSCHE OF NORTH AMERICA, INC.

The transport eyebolt must only be pulled straight -1- . Never use side or transverse force on the transport eyebolt -2- because this can damage the transport eyebolt. See Fig. 532.

used or repaired -3- . Always replace these tools). Check tools for signs of damage before use. See Fig. 532.

NOTE: The engine must be supported on the body for some repair work on the front axle and engine bearings.

NOTE: When setting up the suspending device, make sure not to scratch or



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Fig. 533: Design cover of cylinder bank 5-8 Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Remove design cover of cylinder bank 5-8. Unscrew the four fastening screws on the design cover.

damage adjacent components.



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Fig. 534: Supporting the design cover Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. To do this, lift the cover slightly with both hands at the side pointing towards the intake system until it is released from its bracket.



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Fig. 535: Design cover of cylinder bank 5-8 Courtesy of PORSCHE OF NORTH AMERICA, INC.




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Fig. 536: Bore for transport eyebolt Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Screw transport eyebolt P 9700 hand-tight as far as you can into the opening on cylinder head 5 - 8 --> Bore for transport eyebolt . See Fig. 536.

5. Position the suspending device on the inner side of the wing, near the radiator tank, and align it. Then tighten the two wing nuts.

Fig. 537: Hook in transport eyebolt Courtesy of PORSCHE OF NORTH AMERICA, INC.

6. Engage the hook of the suspending device in the transport eyebolt and tighten the wing nut.



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Fig. 538: Fastening to torque support bracket Courtesy of PORSCHE OF NORTH AMERICA, INC.

7. Insert an M10 screw through the torque support bracket and secure it with a nut. Then attach the hook of the safety device 10-222 A. If the hook is too short, lengthen it with a suitable spring hook or chain --> Fastening to torque support bracket . Tighten wing nut. Pull the engine slightly and make sure that the force is distributed evenly on both spindles --> Complete view of engine support on body . See Fig. 538, Fig. 539.

NOTE: Place a cloth between secondary air pump bracket and design cover to avoid scratching the cover.



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Fig. 539: Complete view of engine support on body Courtesy of PORSCHE OF NORTH AMERICA, INC.

10 01 IN SUPPORTING THE ENGINE ON THE BODY - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN)

TOOLS


Suspending device VW-tool 3033

Adapter special tool P 9591/2




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TOOLS AND MATERIALS

Special tools required

Fig. 540: Special tool Courtesy of PORSCHE OF NORTH AMERICA, INC.

Bonnet stay special tool P 9704


-A- See Fig. 540.

Safety device 10-222 A--> "See Workshop Equipment Manual, Chapter 2.2.3"

Only this tool is tested and approved by Porsche. It ensures good support at the wing edge.

-B- See Fig. 540.

Suspending device 3033

--> "Commercially available, see Workshop Equipment Manual, Chapter 2.2.3 "

Only this tool is tested and approved by Porsche.

-C- See Fig. 540.

Bonnet stay P 9704--> "See Workshop Equipment Manual, Chapter 2.2.2 "

-D- See Fig. 540.

Transport eyebolt P 9700/1--> "See Workshop Equipment Manual, Chapter 2.2.2 "

Check the transport eyebolt for signs of damage before use. Do not use damaged



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SUPPORTING THE ENGINE ON THE BODY

Supporting the engine on the body

--> Before starting work, check the body for structural damage (accident, corrosion, etc.). The load capacity of the wing mounting points must not be restricted.

--> Do not apply excessive force (e. g. a high screw torque) to supported units.

--> Units must not be supported on the body over an extended period of time.




--> Improper use can damage the transport eyebolt, which must then be replaced. Extreme cases of improper use can break the transport eyebolt.



transport eyebolts.

-E- See Fig. 540.

Adapter P 9591/2--> "See Workshop Equipment Manual, Chapter 2.2.2 "

WARNING: Danger of injury from falling loads!

Drive line components (engine, transmission, etc.) can fall down.



NOTE: The engine must be supported on the body for some repair work on the front axle and engine bearings.



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Fig. 541: Design cover Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Pull design cover up and off.

2. Remove engine cover at the back on plenum panel. Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .



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Fig. 542: Spacers and safety device Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Extend safety device 10-222 A using spacers with adapter P 9591/2. Position the safety device on the inner side of the wing, near the radiator tank, and align it. Tighten the two wing nuts.



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Fig. 543: Engine suspending device Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Engage suspending device 3033 in one hook --> Engine suspending device . See Fig. 543.



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Fig. 544: Rear suspension Courtesy of PORSCHE OF NORTH AMERICA, INC.

5. Engage rear hook of rear left engine suspension to the radiator tank on the engine --> Rear suspension . See Fig. 544.

Fig. 545: Engine transport eyebolt Courtesy of PORSCHE OF NORTH AMERICA, INC.

6. Engage front right transport eyebolt to engine and then engage into engine suspension. --> Engine transport eyebolt See Fig. 545.

NOTE: When setting up the suspending device, make sure not to scratch or damage adjacent components.



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Fig. 546: Adjusting the suspension Courtesy of PORSCHE OF NORTH AMERICA, INC.

7. Adjust engine suspension at the spindles --> Adjusting the suspension and align as horizontally as possible --> View shows supported engine . Pull the engine slightly and make sure that the force is distributed evenly on both spindles. Do not apply force at the sides of the spindles and position them as vertically as possible. Complete assembly as shown in illustrations --> View shows supported engine . See Fig. 546 and Fig. 547.



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Fig. 547: View shows supported engine Courtesy of PORSCHE OF NORTH AMERICA, INC.

10 01 IN SECURING ENGINE ON ASSEMBLY SUPPORT - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN)

TOOLS

PRELIMINARY WORK

Preliminary work

Designation Type Number Explanation mounting elements special tool P 9590

engine support special tool P 9676



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1. Lift the engine with a workshop crane. 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).

SECURING ENGINE ON ASSEMBLY SUPPORT

Securing engine on assembly support














NOTE: Some repair jobs involve suspending the engine on a suitable assembly support.



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Fig. 548: Crankcase on engine support (shown with lower part of crankcase) Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Secure engine support P 9676 on engine --> Crankcase on engine support (shown with lower part of crankcase) . To do this, use the four screws for mounting elements P 9590 and tighten them slightly. Secure engine on engine support. To do this, carefully guide the engine support axle into the take-up bore on the engine support and secure it. See Fig. 548.

10 01 IN TECHNICAL DATA FOR BFD ENGINE (CAYENNE) - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN)

INFORMATION

Engine design

Engine designType 6-cylinder, four-stroke Otto engine, 15 ° V-engineCrankcase Grey cast iron, single-partCrankshaft Forged steelCrankshaft bearings 7 binary bearings, dia. 60 mmConnecting rods Forged, l = 164 mmCon-rod bearings Binary bearings, dia. 54 mmPistons Cast aluminumPiston pins Floating



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Engine

* including double-mass flywheel

Engine cooling

Piston rings 2 compression rings, 1 oil scraper ringCylinders Grey cast iron running surfaceCylinder head Single-part light alloy head

Arrangement of valves per cylinder 2 parallel overhead intake valves 2 parallel overhead exhaust valves

Valve diameter Intake 33.2 Exhaust 30.2Valve lift Intake Exhaust 10 mm 10 mmValve control Intake Exhaust Roller-type cam follower Roller-type cam followerCamshaft Built with steel camsIntake camshaft adjustment Rotary-vane adjuster, 26° camshaftExhaust camshaft adjustment Rotary-vane adjuster, 11° camshaftValve clearance Hydraulic valve-clearance compensation

Timing at 1-mm valve lift and zero clearance, early/late limit

Intake opens at 26° before OT/26° after OT Intake closes at 184° after OT/236° after OT Exhaust opens at 236° before OT/214° before OT Exhaust closes at 26° before OT/4° before OT

EngineEngine type BFD No. of cylinders 6 Bore 84 (3.31) mm (in.)Stroke 95.9 (3.78) mm (in.)

Cubic capacity 3189 (194.6) cm3 (cu. in.)Compression ratio 11.5 (-0.5) : 1 Max. engine power as per 80/1269/EEC 184 (250) kW (HP)Net power as per SAE J1349 247 HPAt engine speed 6000 rpmMax. torque as per 80/1269/EEC 310 Nm (ftlb.)Net torque as per SAE J1349 229 ftlb.At engine speed 2500 - 5500 rpmMax. output per liter 57.7 (78.5) 77.5 kW/l (HP/l) HP/lRpm limitation by fuel cut-off and E-gas at 6700 rpmIdle speed 700 rpm without air conditioning

Engine weight as per DIN 70020 A kg Manual transmission* 192 Automatic transmission 180

Engine cooling



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Engine lubrication

Engine control

Electric system

Exhaust system

Water cooling; 1 radiator ahead of the engine. Two electric fans, continuous control

Cooling in cylinder head Longitudinal flowCooling in crankcase Cross flow cooling

Engine lubrication Type Forced-feed lubrication with gear pumpOil cooling Via oil-water heat exchangerOil filter On pressure side behind oil pumpOil pressure at n = 5000 rpm Approx. 4.5 bar at 90 °COil pressure indicator Displayed on instrument clusterOil level check Via instrument cluster and oil dipstickOil consumption Max. 1.5 l/1000 kmOil change quantity Oil change quantity with change of filter

5.7 l 6.3 l

Engine control Engine control module Bosch ME 7.11Ignition DME, individual spark coils, knock controlFiring order 1 - 5 - 3 - 6 - 2 - 4Ignition timing control Via DME (ECM)Spark plugs NKG IZKR 7BElectrode gap mm (in) 0.9 - 0.1Electronic throttle Electronic throttle actuator control via DMEEuropean version Euro-IV On Board Diagnosis (EOBD)USA version On-Board Diagnosis II (OBDII)

Electric system Radio interference suppression ECE-R 10 and 95 / 54 / ECNominal voltage V 12Battery capacity Ah/A 70Starter W 1700Rated generator output W 2100



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Position and coding of the engine number

Fig. 549: Engine number Courtesy of PORSCHE OF NORTH AMERICA, INC.

Exhaust system/emission control

Exhaust system 2-pipe, 3-way catalytic converter exhaust system 1 rear muffler

EURO IVOxygen sensor closed-loop control + post-catalytic converter control (4 sensors) 3-way catalytic converter with 2 pre-catalytic converters and 2 main catalytic converters. Additional secondary air system and EOBD.

USA LEV I (LDT) Differs from EURO IV OBD II and ORVR



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The engine number can be found on the front right of the crankcase next to the crankshaft pulley.

Fig. 550: Engine number coding Courtesy of PORSCHE OF NORTH AMERICA, INC.

Cylinder arrangement

Item Position in engine number Explanation-A- See Fig. 550. Information on engine type BFD = 3.2 liter, 176 kW

-B- See Fig. 550. Engine series number

< 500 = special vehicle or pre-production engine; deviations from the Workshop Manual can occur. = 500 series engine



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Fig. 551: Cylinder arrangement Courtesy of PORSCHE OF NORTH AMERICA, INC.

10 01 IN DETERMINING THE OPERATING CYCLE OF CYLINDER 1 - AS OF MY 2003 (CAYENNE TIP, CAYENNE MAN)

INFORMATION

Determining the operating cycle of cylinder 1 with the "cylinder pipe" dead center finder.

--> Forces from the valve drive can cause the timing chain to jump over or tilt.

CAUTION: Risk of damage to timing drive mechanism!

Never twist the crankshaft against the direction of rotation.

Remove and install the chain tensioner only in overlapping TDC.

Never twist the crankshaft when the chain tensioner is removed.

Never twist the camshafts when the chain tensioner is removed.

Never apply forces across the camshafts in the timing drive mechanism.

Always counter the sprocket wheels when performing assembly work on them.

NOTE: An alternative method for determining the overlapping TDC is the "cylinder pipe" (dead center finder). This tool is part of the pressure-loss tester WE 1066, Workshop Installation Manual 3.1.4.



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For some tasks, it is necessary to be familiar with the position of the piston in the cylinder (ignition TDC, overlapping TDC).

Ignition is off, ignition key is removed.

Fig. 552: V8 spark plugs Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Remove spark plugs for the relevant cylinder 3. Refer to 28 70 55 Replacing spark plugs - as of MY 2004 (Cayenne TIP, Cayenne MAN) .



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Fig. 553: Undoing spark plugs using spark plug wrench - V6 Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig. 554: Dead center finder - "cylinder pipe"



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2. The dead center finder or "cylinder pipe" consists of glass tubes (inspection glass) with pistons -1- , a hose and a rubber taper -2- . See Fig. 554.

Fig. 555: Tool setup - dead center finder Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. The rubber taper is pressed onto the spark plug hole. The inspection glass is either held by an assistant --> Tool setup - dead center finder or secured vertically using a magnet so that it is clearly visible. See Fig. 555.



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Fig. 556: Top piston Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. If the engine is then turned in the direction of rotation on the crankshaft, the piston in the inspection glass is pressed upward in the compression cycle --> Top piston , and moves back down again immediately once the TDC has been reached. The piston remains down in the inspection glass in the overlapping TDC --> Bottom piston . See Fig. 556 and Fig. 557.



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Fig. 557: Bottom piston Courtesy of PORSCHE OF NORTH AMERICA, INC.

10 01 IN DETERMINING THE OPERATING CYCLE OF CYLINDER 1 - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN)

INFORMATION

Determining the operating cycle of cylinder 1 with the "cylinder pipe" dead center finder.

CAUTION: Risk of damage to timing drive mechanism!



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--> Forces from the valve drive can cause the timing chain to jump over or tilt.

For some tasks, it is necessary to be familiar with the position of the piston in the cylinder (ignition TDC, overlapping TDC).

Ignition is off, ignition key is removed.


Never twist the crankshaft against the direction of rotation.

Remove and install the chain tensioner only in overlapping TDC.

Never twist the crankshaft when the chain tensioner is removed.

Never twist the camshafts when the chain tensioner is removed.

Never apply forces across the camshafts in the timing drive mechanism.

Always counter the sprocket wheels when performing assembly work on them.

NOTE: An alternative method for determining the overlapping TDC is the "cylinder pipe" (dead center finder). This tool is part of the pressure-loss tester WE 1066, Workshop Installation Manual 3.1.4.



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1. Remove spark plugs for the relevant cylinder 3. Refer to 28 70 55 Replacing spark plugs - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

Fig. 559: Undoing spark plugs using spark plug wrench - V6 Courtesy of PORSCHE OF NORTH AMERICA, INC.



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Fig. 560: Dead center finder - "cylinder pipe" Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. The dead center finder or "cylinder pipe" consists of glass tubes (inspection glass) with pistons -1- , a hose and a rubber taper -2- . See Fig. 560.



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Fig. 561: Tool setup - dead center finder Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. The rubber taper is pressed onto the spark plug hole. The inspection glass is either held by an assistant --> Tool setup - dead center finder or secured vertically using a magnet so that it is clearly visible. See Fig. 561.



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Fig. 562: Top piston Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. If the engine is then turned in the direction of rotation on the crankshaft, the piston in the inspection glass is pressed upward in the compression cycle --> Top piston , and moves back down again immediately once the TDC has been reached. The piston remains down in the inspection glass in the overlapping TDC --> Bottom piston . See Fig. 562, Fig. 563.



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Fig. 563: Bottom piston Courtesy of PORSCHE OF NORTH AMERICA, INC.

Compression cycle for cylinder 1 (ignition TDC)

NOTE: This method only works in ignition rod modules that have rubber seals facing the spark-plug recess.



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Fig. 565: Ignition rod module of cylinder 1 Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Find ignition TDC of cylinder 1. To do this, insert the ignition rod module of the first cylinder into the corresponding opening in the valve cover and press in firmly.



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Fig. 566: Ignition rod module of cylinder 1 pops out Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Twist the crankshaft in the direction of motion until the ignition rod module comes out again with an audible plop.



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Fig. 567: TDC marking of cylinder 1 Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Then twist the crankshaft until the fixing bore on the crankshaft belt pulley is aligned with the bore in the timing case cover. The engine is now located in the ignition TDC of cylinder 1.

Intake cycle (overlapping TDC)

NOTE: If the crankshaft is then turned through 180°, the piston in cylinder 1 will be located in the bottom dead center (BDC). The emission cycle then follows.

NOTE: This method only works in ignition rod modules that have rubber seals facing the spark-plug recess.



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Fig. 569: Ignition rod module of cylinder 1 Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Find overlapping TDC of cylinder 1. To do this, insert the ignition rod module of the first cylinder into the corresponding opening in the valve cover and press in firmly.



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Fig. 570: Ignition rod module of cylinder 1 pops out Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Twist the crankshaft in the direction of rotation until the ignition rod module comes out again with an audible plop.



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4. Then twist the crankshaft until the fixing bore on the crankshaft belt pulley is aligned with the bore in the timing case cover. The engine is now located in the ignition TDC of cylinder 1.



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5. Remove the marking mandrel if necessary and twist the crankshaft through 360° in the direction of motion. The engine is now located in the overlapping TDC of cylinder 1.

10 01 IN TIGHTENING TORQUES FOR CAYENNE (ENGINE TYPE BFD) - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN)

INFORMATION

Information

NOTE: If the crankshaft is then turned through 180°, the piston in cylinder 1 will be located in the bottom dead center (BDC). The compression cycle then follows.



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The torques in the table below generally apply to screws which are not specifically listed.

Group 10 - Crankcase, suspension

NOTE: This torque list is organized according to component groups in the same way as service numbering.

The torque for the coolant pump is provided in the COOLING article.

Screws which are tightened with a torque angle must always be replaced with new ones.

The tightening sequences are indicated in the figures in the corresponding articles, and it is essential to observe them.

The most important torques are specified at the end of the respective articles.

Bolt quality 8.8 Bolt quality 10.9Thread ftlb. Thread ftlb.

M4 3 M4 4M5 6 M5 8M6 10 M6 13M8 25 M8 33M10 40 M10 65M10 x 1.25 50 M10 x 1.25 70M12 80 M12 115



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Group 15 - Cylinder head, pistons

Location Thread Tightening torque [Nm] (ftlb.)Rear sealing flange on crankcase M6 x 58 10Rear sealing flange on crankcase M6 x 16 10Guide ring on crankcase M6 x 10 7.5 With screw locking agentGuide rail on crankcase M8 x 11.5 10Pulse sender on crankcase M6 x 15 10Knock sensor M8 x 26 20Secondary unit carrier M8 x 40 25Engine support arm M10 x 35 40...45Tensioning rail on crankcase M8 x 10 10

Location Thread Tightening torque [Nm] (ftlb.)Sensor wheel to crankshaft M6 x 13 7.5+ 90°Generator to secondary unit carrier M8 x 90 25Air-conditioning compressor M8 x 95 25Air-conditioning compressor M10 x 100 x 45 45Crankshaft bearing cap M10 x 78 22 + 180°Drive plate to crankshaft M10 x 1 x 41 44 + 180°Connecting rod cap M9 x 1 x 50 22 + 90°Coolant pump pulley M8 x 11 20Belt pulley on crankshaft M18 x 1.5 x 40 74 + 90°Servo pump pulley M8 x 14 25...30Belt tensioner on cylinder head M8 x 30 25Servo pump M8 x 40 25Deflection roller to secondary unit carrier M10 x 50 45DMF to crankshaft M10 x 1 x 29 44 + 90° + 30°

Location Thread Tightening torque [Nm] (ftlb.)Cover on crankcase M5 x 15 2Cover on cylinder head M6 x 20 8Cover on cylinder head M6 x 70 8Cylinder head cover M6 x 62 6Vent on cylinder head cover M4 x 12 2...3Guide rail on crankcase M8 x 11.5 10Guide rail on cylinder head M8 x 45 23Hall sensor unit M6 x 18 8Holder on cylinder head cover M6 x 10 8



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Group 19 - Cooling


Chain tensioner on crankcase M6 x 24 8Chain tensioner in cover M22 x 1.5 x 19 40Positive crankcase ventilation M6 x 25 8Bearing cap on cylinder head M7 x 45 10Bearing cap on cylinder head M7 3.5 + 45°Camshaft adjuster M12 x 1.5 x 85 44 + 90°Timing case cover on cylinder head M6 x 30 8Transport eyebolts M8 x 25 25Intermediate shaft cover M6 x 16 8Cylinder head on crankcase M10 x 141 22, then 37 + 180°Cylinder head cover M6 x 33 8...10Cylinder head cover M6 8

Location Thread Tightening torque [Nm] (ftlb.)Oil drain plug M14 x 1.5 x 22 30Oil filter on crankcase M8 x 105 23Oil cooler on oil filter housing 25Oil filter cover 25Oil pump on crankcase M8 x 30 23Oil pump cover on oil pump M6 x 32 8Oil pipe on crankcase M6 x 20 6 Use screw locking agentOil pipe to oil pump M6 x 20 6 Use screw locking agentOil level sensor M6 x 28 10Oil pan on crankcase M6 x 20 12Watertight sheetmetal panel to oil pan M6 x 16 10

Location Thread Tightening torque [Nm] (ftlb.)Coolant pump to crankcase M6 x 18 8Coolant regulator M6 x 25 8Coolant regulator cap M6 x 20 8Coolant regulator M6 x 120 x 80 8Plug for coolant pipe M10 x 6.9 1.5 (hand-tight)

Location Thread Tightening torque [Nm] (ftlb.)Fuel tank restraining strap M8 x 25 23Carbon canister and degassing tank M6 10



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Group 27 - Starter, power supply


10 01 IN TIGHTENING TORQUES FOR CAYENNE S (M48/00) AND CAYENNE

Filler neck fastening screws M6 x 20 10Connection unit ring fastener 140Cover plate under rear seat M6 10

Location Thread Tightening torque [Nm] (ftlb.)Knock sensor on crankcase M8 x 26 20Intake distributor M8 x 20 20Throttle adjuster M6 x 45 8Fuel distribution pipe on intake distributor M6 x 16 8Intake distributor to support M8 x 20 20Intake distributor support on cylinder head M8 x 16 20Shift mechanism on intake pipe M6 x 20 5Bearing cap on intake pipe M6 x 20 5Vacuum reservoir on intake pipe M6 x 15 8

Location Thread Tightening torque [Nm] (ftlb.)Exhaust manifold on cylinder head M8 24Exhaust clamps M10 60 (44) (replace)Fastening screw for catalytic converter holder M8 23

Location Thread Tightening torque [Nm] (ftlb.)Generator on crankcase M8 20B+ wire on generator M8 15Water connection on generator M6 9Starter on transmission M12 75B+ wire on starter M8 15Terminal 50 on starter M6 8

Location Thread Tightening torque [Nm] (ftlb.)

New spark plug M12 x 1.25 x 16.4

20



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TURBO (M48/50) - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN)

INFORMATION

Information






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Tightening sequences




M4 3 M4 4M5 6 M5 8M6 10 M6 13M8 23 M8 33M10 45 M10 65M10 x 1.25 50 M10 x 1.25 70M12 80 M12 115M12 x 1.25 90 M12 x 1.25 125M12 x 1.5 85 M12 x 1.5 120M14 130 M14 180M16 200 M16 280

Location Thread Tightening torque [Nm] (ftlb.)Thrust block screw fitting M12 x 1.5 x 132 40 (30) + 75° (observe sequence!)Thrust block screw fitting M10 x 117 22 (16) + 60° (observe sequence!)Oil spray valve on crankcase M6 x 16 10Top section of crankcase with bottom section of crankcase - cross bolt connection

M8 23

Bracket for auxiliary units M10 x 45 65Design cover M5 x 16 5Engine carrier, cylinder row 1 - 4 M10 x 45 65Bracket for torque support M6 x 40 13Bracket for torque support M8 x 45 23



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Fig. 575: Tightening sequence, inner bearing seat Courtesy of PORSCHE OF NORTH AMERICA, INC.



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Fig. 576: Tightening sequence, outer bearing seat Courtesy of PORSCHE OF NORTH AMERICA, INC.



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Fig. 577: Tightening sequence, outer cross bolt connection Courtesy of PORSCHE OF NORTH AMERICA, INC.


Location Thread Tightening torque [Nm] (ftlb.)Sealing flange on timing case cover M6 10Belt pulley (vibration balancer) on crankshaft

M16 x 1.5 x 7720, 50, 250, then 90° (always replace

screw!)Deflection roller, left M10 x 41 35Deflection roller, right M10 x 85 35Belt tensioner on bracket M8 x 33 35



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Belt tensioner on timing case cover M8 x 100 35Tensioner roller on belt tensioner M10 35

Connecting rod cap on connecting rod M9 x 56 8 (6), then 40 (30), then 90° (always replace screws with new ones!)

Air-conditioning compressor on engine M8 x 95 23Air-conditioning compressor on engine M10 x 90 46Servo pump on engine M8 x 35 23Belt pulley on servo pump M8 x 16 23

Drive plate to crankshaft M10 x 2260 (44) + 90° (always replace screws with

new ones!)

Location Thread Tightening torque [Nm] (ftlb.)Timing case cover M6 See NoteTiming case cover M8 x 50 23Tensioning rail bearing M10/12 x 25 35Chain tensioner M24 x 1.5 60Guide rail bearing on camshaft housing M8 x 25 20Guide rail M8 x 25 20Deflector rail M8 x 35 32

Chain sprocket on exhaust camshaftM12 x 1.5 x

14010 (7.5), then 50 (37), then 90°

Camshaft adjuster on inlet camshaft M12 x 1.5 x 140

10 (7.5), then 50 (37), then 135°

Camshaft housing cover (valve cover) M6 x 30 13 (9.5) (observe sequence!)Camshaft bearing saddles M6 x 35 10 (7.5) (observe sequence!)Thrust bearing cover on camshaft housing M6 x 35 10Hall sender on camshaft housing M6 x 16 10Camshaft housing on cylinder head M8 23Hydraulic valve for camshaft adjuster M6 x 16 10Adapter for torque support M10 x 24 20

Cylinder head M12 x 1.5 x 140

30 (22), then 50 (37), then loosen 30 (22), then 30 (22), then 90°

Ground point on camshaft housing M6 x 12 10Cable duct on timing case cover M6 x 18 10Cable duct on cylinder head 5 - 8 M6 x 12 10

NOTE: The exterior fastening screws must have a quality of 10.9.

If the quality is 8.8, the screws must be replaced.



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Fig. 578: Timing cover fasteners installation sequence Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig. 579: Right side cylinderhead cover fasteners installation sequence Courtesy of PORSCHE OF NORTH AMERICA, INC.

Tighten screws 1 to 4 (M6 / 8.8) to 7.5 ftlb.

Tighten screws 5 to 6 (M8 / 8.8) to 17 ftlb.

Tighten screws 7 to 32 (M6/10.9) to 13 Nm (9.5 ftlb.).



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Fig. 580: Left side cylinderhead cover fasteners installation sequence Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig. 581: Cylinderhead fasteners installation sequence Courtesy of PORSCHE OF NORTH AMERICA, INC.


Location Thread Tightening torque [Nm] (ftlb.)Chain sprocket on oil pump M10 x 1 45Oil pump on crankcase M8 x 50 23Chain cover on oil pump M5 x 20 6



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Group 19 - Cooling


Tensioning rail bearing for oil pump M8 x 25 20Short oil extraction pipe M6 x 25 13Oil extraction pipe M6 x 25 13Oil drain plug M18 x 1.5 50Oil return line into oil pan M6 x 20 10Oil pan on crankcase M6 x 25 10Oil level sender on oil pan M6 x 25 10Guide tube for oil dipstick M6 x 16 10Cover on oil filter bracket M6 x 20 10Oil filter bracket on oil pan M8 x 70 23Spacer sleeve for oil filter bracket M16 x 1.5 2 (1.5) to 5 (3.5)Oil filter bracket on connection piece M8 x 50 23Oil/water heat exchanger M6 x 20 10Oil filter housing S80 x 3 25 (19) (sealing ring oiled)Oil pressure switch on oil filter bracket M10 x 1 20

Location Thread Tightening torque [Nm] (ftlb.)Belt pulley on coolant pump M8 x 16 23Water pump on crankcase M6 x 25 10 (7.5) (observe sequence!)Thermostat housing cover M6 x 25 10 (7.5) (observe sequence!)Coolant distribution pipe M6 x 25 10Thermostat housing trough M6 x 16 10Coolant pipe on crankcase M6 x 16 10Coolant drain plug on distribution pipe M16 x 1.5 x 6 30T-piece on generator M6 x 16 10Supply connection fitting on generator M6 x 16 10Coolant pipe on thermostat housing M6 x 12 10Temperature sensor on coolant distribution pipe

M14 x 1.5 30



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Fig. 582: Thermostat housing Courtesy of PORSCHE OF NORTH AMERICA, INC.






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Fig. 584: Suction module Courtesy of PORSCHE OF NORTH AMERICA, INC.


Fuel tank restraining strap M8 x 25 23Carbon canister and degassing tank M6 10Filler neck fastening screws M6 10Connection unit ring fastener 140Filler neck fastening screws M6 x 20 10Cover plate under rear seat M6 10

Location Thread Tightening torque [Nm] (ftlb.)Knock sensor on crankcase M8 x 35 23Intake distributor M7 x 52 10 (7.5), then 15 (11) (observe sequence!)Throttle adjuster M6 x 45 8Fuel distribution pipe on intake distributor M6 x 10 8T-piece on intake distributor 2,2


Exhaust manifold on cylinder head M8 25, then 33 (observe sequence); replacing fastening nuts

Oxygen sensors in exhaust manifold M18 x 1.5 45



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Oxygen sensor holder on engine M6 x 12 10Secondary air pump on holder M6 x 50 10Secondary air pump holder M6 x 50 10Exhaust system fastening screws M8 x 25 23Exhaust clamps M10 60 (44) (replace)Fastening screw for catalytic converter holder

M8 23

Location Thread Tightening torque [Nm] (ftlb.)Generator on crankcase M8 23B+ wire on generator M8 plastic 18Heat shield on generator M6 x 12 10Starter M10 x 45 45 (33) to 53 (39)B+ wire on starter M8 18Terminal 50 on starter M6 9

Location Thread Tightening torque [Nm] (ftlb.)New spark plug M14 x 1.25 30



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10 01 IN TIGHTENING TORQUES FOR CAYENNE S (M48/00) AND CAYENNE TURBO (M48/50) - AS OF MY 2003 (CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN)

INFORMATION

Information

Spark plug reinstallation M14 x 1.25 25

Ignition coilsM6 x 16.5/M5 x

9 10

Knock sensor M8 x 35 23



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M4 3 M4 4M5 6 M5 8M6 10 M6 13M8 23 M8 33M10 45 M10 65M10 x 1.25 50 M10 x 1.25 70M12 80 M12 115M12 x 1.25 90 M12 x 1.25 125M12 x 1.5 85 M12 x 1.5 120M14 130 M14 180M16 200 M16 280

Location Thread Tightening torque [Nm] (ftlb.)Thrust block screw fitting M12 x 1.5 x 132 40 (30) + 75° (observe sequence!)Thrust block screw fitting M10 x 117 22 (16) + 60° (observe sequence!)Oil spray valve on crankcase M6 x 16 10Top section of crankcase with bottom section of crankcase - cross bolt connection M8 23

Bracket for auxiliary units M10 x 45 65Design cover M5 x 16 5Engine carrier, cylinder row 1 - 4 M10 x 45 65Bracket for torque support M6 x 40 13Bracket for torque support M8 x 45 23



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Fig. 587: Tightening sequence, inner bearing seat Courtesy of PORSCHE OF NORTH AMERICA, INC.



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Fig. 588: Tightening sequence, outer bearing seat Courtesy of PORSCHE OF NORTH AMERICA, INC.



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Fig. 589: Tightening sequence, outer cross bolt connection Courtesy of PORSCHE OF NORTH AMERICA, INC.


Location Thread Tightening torque [Nm] (ftlb.)Sealing flange on timing case cover M6 10Belt pulley (vibration balancer) on crankshaft

M16 x 1.5 x 7720, 50, 250, then 90° (always replace

screw!)Deflection roller, left M10 x 41 35Deflection roller, right M10 x 85 35Belt tensioner on bracket M8 x 33 35



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Belt tensioner on timing case cover M8 x 100 35Tensioner roller on belt tensioner M10 35

Connecting rod cap on connecting rod M9 x 56 8 (6), then 40 (30), then 90° (always replace screws with new ones!)

Air-conditioning compressor on engine M8 x 95 23Air-conditioning compressor on engine M10 x 90 46Servo pump on engine M8 x 35 23Belt pulley on servo pump M8 x 16 23

Drive plate to crankshaft M10 x 2260 (44) + 90° (always replace screws with

new ones!)

Location Thread Tightening torque [Nm] (ftlb.)Timing case cover M6 See NoteTiming case cover M8 x 50 23Tensioning rail bearing M10/12 x 25 35Chain tensioner M24 x 1.5 60Guide rail bearing on camshaft housing M8 x 25 20Guide rail M8 x 25 20Deflector rail M8 x 35 32

Chain sprocket on exhaust camshaftM12 x 1.5 x

14010 (7.5), then 50 (37), then 90°

Camshaft adjuster on inlet camshaft M12 x 1.5 x 140

10 (7.5), then 50 (37), then 135°

Camshaft housing cover (valve cover) M6 x 30 13 (9.5) (observe sequence!)Camshaft bearing saddles M6 x 35 10 (7.5) (observe sequence!)Thrust bearing cover on camshaft housing M6 x 35 10Hall sender on camshaft housing M6 x 16 10Camshaft housing on cylinder head M8 23Hydraulic valve for camshaft adjuster M6 x 16 10Adapter for torque support M10 x 24 20

Cylinder head M12 x 1.5 x 140

30 (22), then 50 (37), then loosen 30 (22), then 30 (22), then 90°

Ground point on camshaft housing M6 x 12 10Cable duct on timing case cover M6 x 18 10Cable duct on cylinder head 5 - 8 M6 x 12 10

NOTE: The exterior fastening screws must have a quality of 10.9.



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If the quality is 8.8, the screws must be replaced.

Tighten screws 1 to 4 (M6 / 8.8) to 7.5 ftlb.

Tighten screws 5 to 6 (M8 / 8.8) to 17 ftlb.

Tighten screws 7 to 32 (M6/10.9) to 13 Nm (9.5 ftlb.).

Fig. 590: Timing cover fasteners installation sequence Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig. 591: Right side cylinderhead cover fasteners installation sequence Courtesy of PORSCHE OF NORTH AMERICA, INC.



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Fig. 592: Left side cylinderhead cover fasteners installation sequence Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig. 593: Cylinderhead fasteners installation sequence Courtesy of PORSCHE OF NORTH AMERICA, INC.


Location Thread Tightening torque [Nm] (ftlb.)Chain sprocket on oil pump M10 x 1 45Oil pump on crankcase M8 x 50 23Chain cover on oil pump M5 x 20 6



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Group 19 - Cooling


Tensioning rail bearing for oil pump M8 x 25 20Short oil extraction pipe M6 x 25 13Oil extraction pipe M6 x 25 13Oil drain plug M18 x 1.5 50Oil return line into oil pan M6 x 20 10Oil pan on crankcase M6 x 25 10Oil level sender on oil pan M6 x 25 10Guide tube for oil dipstick M6 x 16 10Cover on oil filter bracket M6 x 20 10Oil filter bracket on oil pan M8 x 70 23Spacer sleeve for oil filter bracket M16 x 1.5 2 (1.5) to 5 (3.5)Oil filter bracket on connection piece M8 x 50 23Oil/water heat exchanger M6 x 20 10Oil filter housing S80 x 3 25 (19) (sealing ring oiled)Oil pressure switch on oil filter bracket M10 x 1 20

Location Thread Tightening torque [Nm] (ftlb.)Belt pulley on coolant pump M8 x 16 23Water pump on crankcase M6 x 25 10 (7.5) (observe sequence!)Thermostat housing cover M6 x 25 10 (7.5) (observe sequence!)Coolant distribution pipe M6 x 25 10Thermostat housing trough M6 x 16 10Coolant pipe on crankcase M6 x 16 10Coolant drain plug on distribution pipe M16 x 1.5 x 6 30T-piece on generator M6 x 16 10Supply connection fitting on generator M6 x 16 10Coolant pipe on thermostat housing M6 x 12 10Temperature sensor on coolant distribution pipe

M14 x 1.5 30



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Fig. 594: Thermostat housing Courtesy of PORSCHE OF NORTH AMERICA, INC.






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Group 21 - Exhaust system, turbocharging



Fuel tank restraining strap M8 x 25 23Carbon canister and degassing tank M6 10Filler neck fastening screws M6 10Connection unit ring fastener 140Filler neck fastening screws M6 x 20 10Cover plate under rear seat M6 10

Location Thread Tightening torque [Nm] (ftlb.)Turbocharger on manifold M8 x 75 23 (17); then 30 (22)Turbocharger support on camshaft housing M8 x 20 23Turbocharger support on charger M8 x 40 30 (22); replace nutOil return line on oil filter bracket 35Oil supply line on camshaft housing 35Clip for oil supply line M6 x 12 10Coolant line on turbocharger 40 (30); replace sealsLower coolant line on turbocharger 40 (30); replace sealsCoolant line on coolant distribution pipe 35Vent line on turbocharger 35Sheetmetal holder M6 10

Location Thread Tightening torque [Nm] (ftlb.)Knock sensor on crankcase M8 x 35 23Intake distributor M7 x 52 10 (7.5), then 15 (11) (observe sequence!)Throttle adjuster M6 x 45 8Fuel distribution pipe on intake distributor M6 x 10 8T-piece on intake distributor 2,2



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Fig. 596: Suction module Courtesy of PORSCHE OF NORTH AMERICA, INC.




Exhaust manifold on cylinder head M825, then 33 (observe sequence); replacing

fastening nutsOxygen sensors in exhaust manifold M18 x 1.5 45Oxygen sensor holder on engine M6 x 12 10Secondary air pump on holder M6 x 50 10Secondary air pump holder M6 x 50 10Exhaust system fastening screws M8 x 25 23Exhaust clamps M10 60 (44) (replace)Fastening screw for catalytic converter holder

M8 23



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10 01 WM (SPECIAL) TOOLS REQUIRED FOR REPAIRING THE M48/00 AND M48/50 ENGINES - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN)

TOOLS

Location Thread Tightening torque [Nm] (ftlb.)Generator on crankcase M8 23B+ wire on generator M8 plastic 18Heat shield on generator M6 x 12 10Starter M10 x 45 45 (33) to 53 (39)B+ wire on starter M8 18Terminal 50 on starter M6 9

Location Thread Tightening torque [Nm] (ftlb.)New spark plug M14 x 1.25 30Spark plug reinstallation M14 x 1.25 25

Ignition coilsM6 x 16.5/M5 x

910

Knock sensor M8 x 35 23



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Spark plug wrench VW-tool 3122 B


Chain pipe cutters special tool NR.166

Drift punch, 1 mm tip, special tool NR.167

Slide hammer kit special tool NR.168

Multiple-tooth socket wrench insert M12

special tool NR.31

56-piece Torx screw tool set

special tool NR.49-1

Circlip pliers for spring special tool NR.72-1



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band clamps, Cayenne hose connections

Flexible screwdriver a/f 7 special tool NR.73-1

Torque angle torque key special tool NR.88

Mechanical angle disc for torque angle threaded joint

special tool NR.88-1

Oil filter spanner special tool P 9204

Relay puller special tool P 9235

Plug special tool P 9264/7

Toothed segment special tool P 9538/1

Locating pin special tool P 9595

Spacer special tool P 9609/2



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Engine support special tool P 9676

Camshaft guide special tool P 9678

Arm bracket special tool P 9679



Assembly sleeve special tool P 9701



Socket-wrench insert special tool P 9714



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TOOLS AND MATERIALS

(Special) tools required for repairing the M48/00 and M48/50 engines

Fig. 598: Tools overview 1 Courtesy of PORSCHE OF NORTH AMERICA, INC.



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Item Designation Source Explanation-1- See Fig. 598. Tester for cooling system

See Workshop Equipment Manual 3

Required for leak test of cooling system

-2- See Fig. 598.

Socket-wrench insert P 9714See Workshop Equipment Manual 2.2.2

Very low height, for turning the engine

-3- See Fig. 598.

Plug P 9264/7 See Workshop Equipment Manual 2.2.2

For intake system leak test. Use with compressed-air reducer

-4- See Fig. 598.

Torque angle torque key NR.88


For torque-angle-controlled tightening of screws.

-5- See Fig. 598.

Suspending device 3033See Workshop Equipment Manual 2.2.3

Required to transport the engine

-6- See Fig. 598.

Transport eyebolt P 9700 See Workshop Equipment Manual 2.2.2

Required to transport the engine or to support the body

-7- See Fig. 598. Safety device 10-222 A

See Workshop Equipment Manual 2.2.3 For supporting the body

-8- See Fig. 598.

Spacer P 9609/2See Workshop Equipment Manual 2.2.2

Required to fit the radial shaft seal on the flywheel

-9- See Fig. 598.

Assembly sleeve P 9701See Workshop Equipment Manual 2.2.2

For positioning the sealing lip on the camshaft switch-over valve

-10- See Fig. 598. Camshaft guide P 9678

See Workshop Equipment Manual 2.2.2 For adjusting the timing

-11- See Fig. 598.

Locating pin P 9595See Workshop Equipment Manual 2.2.2

For fixing the pulley. The piston is then in the TDC

-12- See Fig. 598.

Relay puller P 9235See Workshop Equipment Manual 2.2.2

For removing the camshaft switch-over valve

-13- See Fig. 598.

Arm bracket P 9679 See Workshop Equipment Manual 2.2.2

Required to loosen the pulley fastening.

-14- See Fig. 598.

Bonnet stay P 9704See Workshop Equipment Manual 2.2.2

Facilitates the vertical raising of the bonnet

-15- See Fig. 598.

Chain pipe cutters NR.166See Workshop Equipment Manual 2.4

For disconnecting the exhaust system

-16- See Fig. 598.



For loosening and tightening hose clamps

-17- See Fig. 598.

Antifreeze protection and battery acid tester

See Workshop Equipment Manual 3

For checking antifreeze contents, acid density and windscreen cleaner

-18- See Fig. 598.



For opening and loosening spring-band clamps

-19- See Fig. 598.

56-piece Torx screw tool set NR.49-1


Required for all assembly work on the vehicle



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Fig. 599: Tools overview 2 Courtesy of PORSCHE OF NORTH AMERICA, INC.


-20- See Fig. 599.

Mechanical angle disc for torque angle threaded joint NR.88-1


For torque-angle-controlled tightening of large screws (pulley, suspension subframe)

-21- See Fig. 599.

Spark plug wrench 3122 BSee Workshop Equipment Manual 2.2.3

For installing and removing spark plugs.

-22- See See Workshop For filling the



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10 01 WM (SPECIAL) TOOLS REQUIRED FOR REPAIRING ENGINES - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN)

TOOLS

Fig. 599. Filling device P 9696 Equipment Manual 2.2.2 cooling system

-23- See Fig. 599.

Porsche System Tester ll 9588 See Workshop Equipment Manual 2.2.2

For reading out the fault memory or for activating drive links

-24- See Fig. 599.

Oil filter spanner P 9204See Workshop Equipment Manual 2.2.2

For unscrewing and tightening the oil filter

-25- See Fig. 599. Slide hammer kit NR.168


For pulling out the crankshaft sealing ring on the flywheel side

-26- See Fig. 599. Toothed segment P 9538/1


For fixing the flywheel

-27- See Fig. 599.

Multiple-tooth socket wrench insert M12 NR.31


For loosening the flywheel

-28- See Fig. 599. Drift punch, 1 mm tip, NR.167


For perforating the crankshaft sealing ring on the flywheel side

-29- See Fig. 599.

Socket-wrench insert with recommended size Refer to 15 91 21 Removing cover for camshaft housing - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .


For removing and installing the camshaft housing cover

-30- See Fig. 599.

Plug P 9710/3 See Workshop Equipment Manual 2.4

For checking the exhaust system for leaks

-31- See Fig. 599.

Engine support P 9676 See Workshop Equipment Manual 2.4

For attaching the engine to the assembly support.

-32- See Fig. 599.

Engine unit elevating platform WE 1206 See Workshop Equipment Manual 3.0.13




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Lever tool VW-tool 2036


Spark plug wrench VW-tool 3122 B

Sealing ring extractor VW-tool 3203

Engine support VW-tool 3269

Puller VW-tool 3364

Press-on tool VW-tool 3365

56-piece Torx screw tool set


49-1

System tester special tool 9288



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Chain pipe cutters commercially available tool

NR.166

Drift punch, 1 mm tip, commercially available tool

NR.167

Slide hammer kit commercially available tool

NR.168



NR.72-1


NR.73-1

Torque angle torque key commercially available tool

NR.88

Mechanical angle disc for torque angle threaded joint


NR.88-1

Relay puller special tool P 9235




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Puller hook special tool P 9328/1

Toothed segment special tool P 9538/1





Camshaft guide VW-tool T10068

Arm bracket VW-tool T10069

Puller VW-tool T10095 A



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Insertion tool VW-tool T10122

Pressure sleeve VW-tool T10174

Assembly fixture VW-tool T10215

Adapter VW-tool T40012

Additional tool VW-tool VW 541/1A



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Fig. 600: Special tools 1 Courtesy of PORSCHE OF NORTH AMERICA, INC.


-1- See Fig. 600.

Adapter T40012

See Workshop Equipment Manual, Chapter 2.2.3

For applying compressed air to cylinders (e. g. cylinder head repairs).

-2- See Fig. 600.

Sealing ring extractor 3203


Crankshaft sealing ring belt pulley

See Workshop



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-3- See Fig. 600. Drift punch, 1 mm tip, NR.167

Equipment Manual, Chapter 2.2.3

For removing the crankshaft sealing ring on the flywheel side.

-4- See Fig. 600.

Assembly fixture T10215


For fitting the crankshaft sealing ring at the front.

-5- See Fig. 600.

Assembly fixture T10215


For fitting the crankshaft sealing ring at the front.

-6- See Fig. 600. Puller T10095 A


For removing the ignition rod modules.

-7- See Fig. 600.

Insertion tool T10122


For fitting the crankshaft sealing ring on the flywheel side.

-8- See Fig. 600.

Insertion tool T10122



-9- See Fig. 600. Insertion tool T10122



-10- See Fig. 600.

Slide hammer kit NR.168

See Workshop Equipment Manual, Chapter 2.4

For removing sealing rings.

-11- See Fig. 600.

Spark plug wrench 3122 B


For fitting the spark plugs.

-12- See Fig. 600.

Filling device P 9696


For filling and bleeding the cooler circuit.

-13- See Fig. 600. Plug P 9264/7


For checking the intake system for leaks.

-14- See Fig. 600.

Filling device P 9696See Workshop Equipment Manual, Chapter

For filling and bleeding the cooler circuit.



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2.2.2

-15- See Fig. 600.

Tester for cooling systemSee Workshop Equipment Manual, Chapter 3

Hose extension for pressure pump

-16- See Fig. 600.

Tester for cooling systemSee Workshop Equipment Manual, Chapter 3

Pressure pump for checking the cooling system for leaks.

-17- See Fig. 600.

Tester for cooling systemSee the Workshop Equipment Manual 3 "WE 1069"

Cap adapter for Cayenne

-18- See Fig. 600. Puller hook P 9328/1


For loosening electric plugs (e. g. on the ignition rod module).

-19- See Fig. 600.

Pressure sleeve T10174


For pressing in the seal for the camshaft switch-over valve.

-a20- See Fig. 600.

Mechanical angle disc for torque angle threaded joint NR.88-1


For torque-angle-controlled tightening of screws.

-21- See Fig. 600.

System tester 9288


-22- See Fig. 600. Flexible screw driver a/f 7 NR.73-1


For loosening and tightening hose clamps

-23- See Fig. 600.

Antifreeze protection and battery acid testerSee Workshop Equipment Manual 3 "WE 1036"

For measuring the consistency of fluids.

-24- See Fig. 600.



For fitting spring band clamps.

-25- See Fig. 600.

Additional tool VW 541/1A


For removing valve keys.

-26- See Fig. 600.

Press-on tool 3365


Assembly tool for valve stem seals.



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-27- See Fig. 600.

Lever tool 2036


Required for fitting or removing parts on the valve drive.

-28- See Fig. 600. Puller 3364


For pulling out valve seals.

-29- See Fig. 600.

56-piece Torx screw tool set 49-1




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Fig. 601: Special tools 2 Courtesy of PORSCHE OF NORTH AMERICA, INC.


-30- See Fig. 601. Suspending device 3033


Required for transporting the engine.

-31- See Fig. 601.

Safety device 10-222 A--> "See Workshop Equipment Manual, Chapter 2.2.3 "

For supporting the engine/transmission on the body.

-32- See Fig. 601.

Multiple-tooth socket wrench insert M6 and M12


M12 for removing the flywheel. M6 for removing the coolant pump.

-33- See Fig. 601.

Engine support 3269See Workshop Equipment Manual, Chapter 2.2.3

For assembly work on the engine. Fastened at the threaded joints of the left engine support arm

-34- See Fig. 601.

Torque angle torque key NR.88See Workshop Equipment Manual, Chapter 2.4

For torque-angle-controlled tightening of bolts.

-35- See Fig. 601.

Plug P 9710/3See Workshop Equipment Manual, Chapter 2.2.3

For checking the exhaust system for leaks

-36- See Fig. 601.

Toothed segment P 9538/1See Workshop Equipment Manual, Chapter 2.2.3

For blocking the crankshaft.

-37- See Fig. 601. Lifting platform


For removing and installing the engine.

-38- See Fig. 601. Bonnet stay P 9704


Allows the bonnet to be opened fully.

-39- See Fig. 601. Transport eyebolt P 9700/1

-40- See Fig. 601. Arm bracket T10069


For countering the crankshaft belt pulley.

-41- See Fig. 601.

Relay puller P 9235See Workshop Equipment Manual, Chapter 2.2.3

For fitting the camshaft switch-over valves.

-42- See Fig. 601.

Camshaft guide T10068See Workshop Equipment Manual, Chapter 2.2.3

For setting the timing.

-43- See Chain pipe cutters NR.166 See Workshop

Equipment Manual, For repair work on the



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10 04 33 COMPLETING RECONDITIONED ENGINE - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN)

COMPLETING RECONDITIONED ENGINE

Completing reconditioned engine

Starting point for re-fitting work: old engine is secured to assembly support and the new one is in the transport cradle.

At higher mileages, components (cooling hoses, clips etc.) must be checked for damage and, if necessary, replaced.

1. Remove numerous transport plugs for water and vacuum connection pieces from the new engine.

Fig. 602: Coolant hose Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Convert coolant hose between thermostat housing and radiator. To do this, convert a spring band clamp and

Fig. 601. Chapter 2.2.3 exhaust system.

NOTE: In order to replace the old, removed engine with a new one, some re-fitting work must be done.



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clip. -arrows- See Fig. 602.

Fig. 603: Tensioning roller Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Remove tensioning roller by undoing three M8 fastening screws -1- . Convert generator. To do this, remove two M8 fastening screws -2- , remove cable plug. Convert generator on new engine and fit fastening screws by hand. Connect cable plug. Fit tensioning roller with three M8 fastening screws. For details and tightening torques, refer to 27 22 19 Removing and installing three-phase generator - as of MY 2004 (Cayenne TIP, Cayenne MAN) . See Fig. 603.



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4. Convert coolant hose from water tube under exhaust manifolds to radiator. To do this, convert a spring band clamp. -arrow- See Fig. 604.



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Fig. 605: Pressure pipe Courtesy of PORSCHE OF NORTH AMERICA, INC.

5. Convert pressure pipe between combination valve and secondary air pump. To do this, undo cable connection on combination valve and undo clip for pressure pipe on exhaust manifold heat protection shield -arrow- . Convert pressure pipe and fit connections. See Fig. 605.



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6. Convert vacuum line between intake-air distributor and vacuum line in plenum panel (to brake booster). To do this, convert a spring band clamp. -arrow- See Fig. 606.



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7. Convert coolant hose to coolant reservoir. To do this, convert a spring band clamp. -arrow- See Fig. 607.

10 04 33 COMPLETING RECONDITIONED ENGINE - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN)

COMPLETING RECONDITIONED ENGINE

Starting point for re-fitting work: old engine is secured to assembly support and the new one is in the transport cradle.

At higher mileages, components (cooling hoses, clips etc.) must be checked for damage and, if necessary, replaced.

1. Remove numerous transport plugs for water and vacuum connection pieces of the new engine.

2. Check that all leads and hoses between the engines have been re-fitted and no component has been forgotten.

NOTE: In order to replace the old, removed engine with a new one, some re-fitting work must be done.



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3. Depending on the transmission version, the drive plate or flywheel must be re-fitted. Refer to 13 63 19 Removing and installing drive plate for torque converter - as of MY 2003 (Cayenne S TIP, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) or 13 60 19 Removing and installing flywheel - as of MY 2004 (Cayenne S MAN) .

10 10 55 REPLACING CRANKCASE - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN)

PRELIMINARY WORK

Preliminary work


2. Remove wire harness for engine. Refer to 97 52 19 Removing and installing wiring harness for engine - as of MY 2003 (Cayenne S TIP, Cayenne S MAN) . Refer to 97 52 19 Removing and installing wiring harness for engine - Cayenne Turbo (Type M48/50) - as of MY 2003 (Cayenne Turbo, Cayenne Turbo S) .

3. Remove the generator. Refer to 27 22 19 Removing and installing three-phase generator - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne S TIO Titan) . Refer to 27 22 19 Removing and installing the generator - as of MY 2006 (Cayenne S TIP, Cayenne S MAN) . Refer to 27 22 19 Removing and installing the generator - as of MY 2006 (Cayenne Turbo, Cayenne Turbo S) .

4. Remove power-steering pump. Refer to 48 98 19 Removing and installing hydraulic pump (Cayenne Turbo/Cayenne S) - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S) .

5. Remove left additional assembly bracket -2- and right engine carrier -8- . There are still two dowel sleeves (not shown) on the additional assembly bracket. See Fig. 608.



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5 - Engine carrier



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8 - Engine carrier


6. Remove starter. Refer to 27 60 19 Removing and installing starter - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo) .

7. Remove knock sensors. Refer to 28 72 19 Removing and installing knock sensor - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

8. Remove cylinder heads. Refer to 15 70 21 Removing cylinder head - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

9. Remove water pump. Refer to 19 50 19 Removing and installing coolant pump - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S) .

10. Remove coolant regulator. Refer to 19 58 19 Removing and installing coolant regulator (thermostat) - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

11. Remove guide and tensioning rails. Refer to 15 47 19 REMOVING AND INSTALLING GUIDE AND TENSIONING RAILS - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN) or 15 47 19 REMOVING AND INSTALLING GUIDE AND TENSIONING RAILS - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN) .


13. Remove oil spray jets on turbo engine and cap on naturally aspirated engine. --> 101321 Removing oil spray jets for piston cooling [9PAAF1 9PAAJ1].

INFORMATION

Component overview



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Fig. 609: Upper crankcase section assembly Courtesy of PORSCHE OF NORTH AMERICA, INC.

1 - Crankcase, top

2 - Closure cap

3 - Seal

4 - Closure cap

5 - Screw --> Tightening torque: 10 (7.5 ftlb.) Nm



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6 - Screw plug --> Tightening torque: 10 (7.5 ftlb.) Nm

7 - Sealing ring

8 - Sealing ring (not marked in illustration)

9 - Screw plug --> Tightening torque: 75 (56 ftlb.) Nm

10 - Oil spray jets on turbo engine and cap on naturally aspirated engine

11 - Dowel sleeves

REPLACING CRANKCASE

Replacing crankcase

--> The piston rings on the pistons must always be replaced when replacing the crankcase.




1. Remove coolant guide. To do this, remove 10 screws -arrows- . See Fig. 610.

CAUTION: Risk of damage to cylinder liners on new crankcase if the old pistons are used.

Piston separation could cause the dimensions of the old piston to be unacceptably large compared with the new cylinder bore.

Risk of piston and cylinder-liner scoring if old, worn pistons are used.



NOTE: The bearing shells of the main and connecting-rod bearings must be replaced on vehicles with high mileage.



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Fig. 610: Coolant pipe Courtesy of PORSCHE OF NORTH AMERICA, INC.

Component overview for coolant guide



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Fig. 611: Coolant guide Courtesy of PORSCHE OF NORTH AMERICA, INC.

1 - Distributor pipe

2 - Temperature sensor

3 - Sealing ring

4 - Screw plug --> Tightening torque: 30 (22 ftlb.) Nm

5 - Fastening screws on distributor pipe --> Tightening torque: 10 (7.5 ftlb) Nm



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6 - Gasket; replace

7 - Sealing ring; check and replace if necessary

8 - Coolant pipe

2. Remove coolant guide and remove seals. Clean sealing surfaces.

3. Re-fit crankcase. When doing so, watch out for dowel sleeves and studs.

4. Fit coolant guide with new seals.

SUBSEQUENT WORK

Subsequent work

1. Assemble engine. --> 100137 Disassembling and assembling engine - "Assembling"

2. Install engine. --> 100119 Removing and installing V8 4.5 l engine - "Installing"

10 13 21 REMOVING OIL SPRAY JETS FOR PISTON COOLING - AS OF MY 2003 (CAYENNE TURBO, CAYENNE TURBO S)

PRELIMINARY WORK

Preliminary work


INFORMATION

Component overview



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Fig. 612: Component overview Courtesy of PORSCHE OF NORTH AMERICA, INC.

1 - Crankcase (upper part)

2 - Closure cap

3 - Seal

4 - Closure cap

5 - Fastening screw M6 x 16



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9 - M22 screw plug

10 - Oil spray jet; replacing the sealing ring

11 - Dowel sleeve

REMOVING OIL SPRAY JETS FOR PISTON COOLING

Removing oil spray jets for piston cooling

Fig. 613: Engine block in engine support Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Turn engine block in engine support so that the oil spray jets are visible from above.



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Fig. 614: Oil spray jets Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Unscrew fastening screws on the oil spray jets --> Oil spray jets . See Fig. 614.

3. Carefully remove the oil spray jets using a water-pump pliers.

4. Always replace the sealing ring on the oil spray jets.

10 13 23 INSTALLING OIL SPRAY JETS FOR PISTON COOLING - AS OF MY 2003 (CAYENNE TURBO, CAYENNE TURBO S)

INFORMATION

Component overview



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1 - Crankcase (upper part)

2 - Closure cap

3 - Seal

4 - Closure cap




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9 - M22 screw plug

10 - Oil spray jet; replacing the sealing ring

11 - Dowel sleeve

INSTALLING OIL SPRAY JETS FOR PISTON COOLING

Installing oil spray jets for piston cooling

Fig. 616: Engine block in engine support Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Turn engine block in engine support so that the oil spray jets can be installed from above.



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Fig. 617: Oil spray jet fastening screws Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Position the oil spray jets -arrows- and tighten the fastening screws. --> Tightening torque: 7.5 ftlb. See Fig. 617.

SUBSEQUENT WORK

Subsequent work

1. Install crankshaft. Refer to 13 48 19 Removing and installing crankshaft - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

10 18 02 TESTING PRESSURE LOSS FROM THE ENGINE - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN)

PRELIMINARY WORK

Preliminary work

NOTE: The sealing rings for the oil spray jets must be replaced.



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1. Unscrew all spark plugs. Refer to 28 70 55 Replacing spark plugs - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .



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Fig. 619: Ignition rod module comes out at TDC Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Position cylinder to be tested to ignition TDC and remove tool. There are two ways of ascertaining the compression cycle in V8 engines with sealed-off ignition rod modules. --> Determining the operating cycle of cylinder 1

TOOLS AND MATERIALS

Tool kit for testing pressure loss



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Fig. 620: Tool kit for testing pressure loss Courtesy of PORSCHE OF NORTH AMERICA, INC.

INFORMATION

Test evaluation

The test does not show any meaningful result on a new engine (i. e. one that hasn't been run in).

A difference in pressure loss between the individual cylinders of approx. 5% is not significant.

If the test shows an excessive loss of pressure (> 30%), a few drops of oil can be sprayed into the combustion chamber. Repeat the test. If the loss in pressure is now significantly less, the seal between the piston and cylinder is damaged.

The air that is escaping causes hissing noises, which provide information about the component that is causing the damage.

If the limit values are exceeded, the engine must be started and the test repeated.


-A- See Fig. 620.

Testing hose with spark plug thread WE1066 pressure loss tester Bosch EFAW 210 A

see Workshop Equipment Manual, Chapter 3.1.4

-B- See Fig. 620.

Test nozzle WE1066 pressure loss tester Bosch EFAW 210 A


Test nozzle for adjusting display scale. This must be done before every test.

-C- See Fig. 620.

Pressure loss tester WE1066 pressure loss tester Bosch EFAW 210 A




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TESTING PRESSURE LOSS FROM THE ENGINE

Testing pressure loss from the engine

--> Ensure that operational steps and tips from the tool instruction manual for the Bosch tester are observed at all times.

--> The piston must be located accurately in the upper reversing point.

--> Do not touch any belt drive components during the test.

--> Do not insert any tool on the belt pulley of the crankshaft.

The percentage leakage quantity can be used to establish whether the leaks in the combustion chamber in question are so large that the combustion chamber must be repaired.

The worn components (e. g. piston rings) can be identified by the compressed air that is escaping.

Potentially faulty component Location of noisePistons, piston rings, cylinder line Oil filler neck, positive crankcase ventilationCylinder head gasket, cylinder head Coolant expansion tankExhaust valve Exhaust systemInlet valve Intake system

CAUTION: Danger of damage or injury if pressure loss tester is operated incorrectly

WARNING: Danger of injury!

The crankshaft can turn because of the pressure in the cylinder.

NOTE: The check for loss of pressure can be used to assess the mechanical condition of a combustion engine.



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Fig. 621: Test hose Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Screw in the test hose by hand into the spark plug thread and tighten it by hand.

2. Connect the pressure loss tester to the compressed air system.



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Fig. 622: Adjusting the scale Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Adjust the scale. To do this, insert the test nozzle at the front into the device.



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Fig. 623: Adjusting wheel Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Turn the adjusting wheel until the scale pointer is at the "cal." marking or "23%". The pressure is then equal in the two test chambers of the tool.



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Fig. 624: Check for loss of pressure Courtesy of PORSCHE OF NORTH AMERICA, INC.

5. Remove test hose and check that the pointer falls back. Connect the test hose. The value that is displayed should not be greater than 30%. If the loss in pressure is greater, it can be assumed that the engine needs an overhaul.

6. Interrupt the compressed air supply and unscrew the test hose.

7. Check the next cylinder by turning the crankshaft through another 90° and check the next cylinder in the firing order following the instructions provided.

Firing order: 1 - 3 - 7 - 2 - 6 - 5 - 4 - 8

SUBSEQUENT WORK

Subsequent work



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1. Remove the test hose once the test is complete and install the spark plugs. For tightening torques, refer to 28 70 55 Replacing spark plugs - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

10 18 02 CHECKING FOR LOSS OF PRESSURE - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN)

TOOLS AND MATERIALS

Tool kit for testing pressure loss



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Fig. 626: Tool kit for testing pressure loss Courtesy of PORSCHE OF NORTH AMERICA, INC.

INFORMATION

Test evaluation

The test does not show any meaningful result on a new engine (i. e. one that hasn't been run).

A difference in pressure loss between the individual cylinders of approx. 5% is not significant.

If the test shows an excessive loss of pressure (> 30%), a few drops of oil can be sprayed into the combustion chamber. Repeat the test. If the loss in pressure is now significantly less, the seal between the piston and cylinder is damaged.


-A- See Fig. 626.

Testing hose with spark plug thread WE1066 pressure loss tester Bosch EFAW 210 A


-B- See Fig. 626.

Test nozzle WE1066 pressure loss tester Bosch EFAW 210 A


Test nozzle for adjusting display scale. This must be done before every test.

-C- See Fig. 626.

Pressure loss tester WE1066 pressure loss tester Bosch EFAW 210 A


NOTE: Some of the illustrations are not based on the BFD (V6) engine. They simply display the principles involved and are used to make the workflow more comprehensible.



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The air that is escaping causes hissing noises, which provide information about the component that is causing the damage.

If the limit values are exceeded, the engine must be started and the test repeated.

CHECKING FOR LOSS OF PRESSURE

Checking for loss of pressure

--> Ensure that operational steps and tips from the tool instruction manual for the Bosch tester are observed at all times.

--> The piston must be located accurately in the upper reversing point.

--> Do not touch any belt drive components during the test.

--> Do not insert any tool on the belt pulley of the crankshaft.

The percentage leakage quantity can be used to establish whether the leaks in the combustion chamber in question are so large that the combustion chamber must be repaired.

The worn components (e. g. piston rings) can be identified by the compressed air that is escaping.

Potentially faulty component Location of noisePistons, piston rings, cylinder line Oil filler neck, positive crankcase ventilationCylinder head gasket, cylinder head Coolant expansion tankExhaust valve Exhaust systemInlet valve Intake system

CAUTION: Danger of damage or injury if pressure loss tester is operated incorrectly


The crankshaft can turn because of the pressure in the cylinder.

NOTE: The check for loss of pressure can be used to assess the mechanical condition of a combustion engine.



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1. Unscrew all spark plugs. Refer to 28 70 55 Replacing spark plugs - as of MY 2004 (Cayenne TIP, Cayenne MAN) .



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Fig. 628: TDC for cylinder 1 Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Position cylinder to be tested to ignition TDC and remove tool. The ignition TDC for cylinder 1 (and the remaining cylinders) can be tested using the "dead center finder" contained in the WE1066 Bosch EFAW 210 A pressure loss tester. Refer to 10 01 IN Determining the operating cycle of cylinder 1 - as of MY 2003 (Cayenne TIP, Cayenne MAN).



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Fig. 629: Test hose Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Screw in the test hose by hand into the spark plug thread and tighten it by hand.

4. Connect the pressure loss tester to the compressed air system.



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Fig. 630: Test nozzle Courtesy of PORSCHE OF NORTH AMERICA, INC.

5. Adjust the scale. To do this, insert the test nozzle at the front into the device.



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Fig. 631: Adjusting the scale Courtesy of PORSCHE OF NORTH AMERICA, INC.

6. Turn the adjusting wheel until the scale pointer is at the "cal." marking or "23%".



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Fig. 632: Pressure loss test Courtesy of PORSCHE OF NORTH AMERICA, INC.

7. Remove test hose and check that the pointer falls back. Connect the test hose. The value that is displayed should not be greater than 30%. If the loss in pressure is greater, it can be assumed that the engine needs an overhaul.

8. Interrupt the compressed air supply and unscrew the test hose.

9. Check the next cylinder by turning the crankshaft through another 120° and check the next cylinder in the firing order.

Firing order: 1 - 5 - 3 - 6 - 2 - 4



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10. Remove the test hose once the test is complete and install the spark plugs. Refer to 28 70 55 Replacing spark plugs - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

10 19 02 CHECKING COMPRESSION OF CYLINDERS - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN)

TOOLS

PRELIMINARY WORK

Preliminary work

1. Open the bonnet.

Designation Type Number Explanation Spark plug wrench VW-tool 3122 B



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Fig. 634: Central electrical box Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Open lid of central electrical box. To do this, loosen the four fastening screws.

--> Always remove the ignition rod module fuse.

--> Always disconnect ignition rod module electrical connections.

--> Prevent the fuel from injecting by removing the fuse.

3. Remove the fuses -7- for the ignition rod modules -8- and injection system. See Fig. 634.

WARNING: Risk of electric shocks from high-voltage ignition system and danger of damage to ignition rod modules!

Connected ignition rod modules can be damaged.

CAUTION: Risk of damage to components that affect the exhaust system!

Unburnt injected fuel enters the exhaust system.



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Fig. 635: Fuses for ignition rod modules and fuel injectors Courtesy of PORSCHE OF NORTH AMERICA, INC.


4. Remove spark plugs.

TOOLS AND MATERIALS



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Tools and materials

Fig. 637: Tools for testing pressure loss Courtesy of PORSCHE OF NORTH AMERICA, INC.

INFORMATION

Evaluating test results and prerequisites for testing


-A- See Fig. 637. Spark plug wrench 3122 B


-B- See Fig. 637.

Compression tester WE1065 Moto-Meter compression tester


Tester range: between 3.5 and 17 bar Number of cylinders: max. 8

-C- See Fig. 637.

Flexible extension WE1065 Moto-Meter compression tester


-D- See Fig. 637.

Extension with spark plug thread WE1065 Moto-Meter compression tester


NOTE: A test document is created when a compression test is performed.

In order to prevent misuse, vehicle ID, date and current mileage must be entered.



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Fig. 638: Test sheet Courtesy of PORSCHE OF NORTH AMERICA, INC.

The throttle must remain open during the test.

The vehicle voltage must remain more or less constant during the test (connect a charger).

The vehicle voltage must not drop below 12 V.

The fuses for the injection system and the ignition system must be removed during the test.

The engine must be at operating temperature.

TESTING ENGINE COMPRESSION

Testing engine compression

No. Designation Instructions

-A- See Fig. 638. Vehicle ID

This is used to assign the test diagram to the vehicle that is being tested. The engine number or the chassis number can be entered here instead of the vehicle ID.

-B- See Fig. 638. Date

Provides information about when the test was performed.

-C- See Fig. 638.

MileageProvides information about when the test was performed.

-I- See Fig. 638.

Compression pressure in the cylinder that is tested

The pressure is measured in bars. 1 bar = 14.5 psi. There are various diagram charts. The charts for petrol engines are used.

-II- See Fig. 638.

Difference in pressure between the individual cylinders

The pressure difference between two cylinders must not be greater than 1.5 bars.

NOTE: The compression test can only provide an indication as to whether the tested



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Fig. 639: Pressure tester Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Press pressure tester onto the relevant cylinder.

2. Have the starter actuated by a second person. Testing of this cylinder is complete when the needle of the test device ceases to rise. Keep the accelerator pedal fully depressed.

3. Deflate the pressure on the tester.

cylinder is working or not working properly. The cause of any loss can be further isolated by a pressure loss test. --> 101802 Testing pressure loss

NOTE: Once the starter is activated, it switches on the engine for approx. seven seconds.

This process should not be interrupted.

The vehicle voltage must not drop below 12 V during the test.

The throttle must always remain in the same position throughout the test. A mechanical pressing-on tool is not permitted.

The accelerator pedal must be fully depressed during the test.



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Fig. 640: Moving the test device on by one cylinder Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Move the scale on to another cylinder. To do this, pull the pin once under the handle on the back --> Moving the test device on by one cylinder . See Fig. 640.

5. Then check the next cylinder according to number sequence (not according to firing order).

SUBSEQUENT WORK

Subsequent work



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1. Fit spark plugs. For tightening torques, refer to 28 70 55 Replacing spark plugs - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

2. Fit the ignition rod module fuses and the injection system.

Fig. 642: Fuses for ignition rod modules and injection valves



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3. Fit lid of central electrical box.

10 19 02 CHECKING COMPRESSION OF CYLINDERS - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN)

TOOLS

PRELIMINARY WORK

Preliminary work

1. Open the bonnet.

Designation Type Number Explanation Spark plug wrench VW-tool 3122 B



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2. Open lid of central electrical box. To do this, loosen the four fastening screws.

--> Always remove the ignition rod module fuse.

--> Always disconnect ignition rod module electrical connections.

--> Prevent the fuel from injecting by removing the fuse.

3. Remove fuses -7- for ignition rod modules -8- and injection system. See Fig. 644.

WARNING: Risk of electric shocks from high-voltage ignition system and danger of damage to ignition rod modules!

Connected ignition rod modules can be damaged.

CAUTION: Risk of damage to components that affect the exhaust system!

Unburnt injected fuel enters the exhaust system.



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Fig. 645: Fuses for ignition rod modules and fuel injectors Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig. 646: Loosening spark plugs using spark plug wrench Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Remove spark plugs. Refer to 28 70 55 Replacing spark plugs - as of MY 2004 (Cayenne TIP, Cayenne MAN) .



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TOOLS AND MATERIALS

Tools and materials

Fig. 647: Tools for testing pressure loss Courtesy of PORSCHE OF NORTH AMERICA, INC.

INFORMATION

Test conditions and evaluation


-A- See Fig. 647.

Spark plug wrench 3122 BSee Workshop Equipment Manual, Chapter 2.2.3

-B- See Fig. 647.

Compression tester WE1065 Moto-Meter compression tester


Tester range: between 3.5 and 17 bar Number of cylinders: max. 8

-C- See Fig. 647.

Flexible extension WE1065 Moto-Meter compression tester


-D- See Fig. 647.

Extension with spark plug thread WE1065 Moto-Meter compression tester


If necessary, the supplied extensions and rubber taper must be used. The process requires two fitters (one for the tool and one to press the starter).

NOTE: A test document is created when a compression test is performed.



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To prevent misuse, the information indicated by -A, B and C- must be recorded. See Fig. 648.

Fig. 648: Diagram Courtesy of PORSCHE OF NORTH AMERICA, INC.

The throttle must remain open during the test.

The vehicle voltage must remain more or less constant during the test (connect a charger).

The vehicle voltage must not drop below 12 V.

The fuses for the injection system and the ignition system must be removed during the test.

The engine must be at operating temperature.

PERFORMING THE TEST

Performing the test

No. Designation Instructions

-A- See Fig. 648.

Vehicle IDThis is used to assign the test diagram to the vehicle that is being tested. The engine number or the chassis number can be entered here instead of the vehicle ID.

-B- See Fig. 648.

Date Indicates when the test was performed.

-C- See Fig. 648.

Mileage Indicates when the test was performed

-I- See Fig. 648.

Compression pressure in the cylinder that is tested

Pressure is measured in bars. 1 bar = 14.5 psi. There are various diagram charts. The charts for petrol engines are used. Wear limit: 7.5 bar

-II- See Fig. 648.

Difference in pressure between the individual cylinders

The pressure difference between two cylinders should not be greater than 3 bar.



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Fig. 649: Compression tester Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Press pressure tester onto the relevant cylinder.

2. Get a second person to press the starter. Testing of the cylinder is complete when the needle of the test device ceases to rise. Keep the accelerator pedal fully depressed during the test.

3. Deflate the pressure on the tester.

NOTE: Some of the illustrations are not based on the BFD (V6) engine. They simply display the principles involved and are used to make the workflow more comprehensible.

NOTE: Once the starter is activated, it switches on the engine for approx. seven seconds.

This process should not be interrupted.

The vehicle voltage must not drop below 12 V during the test.

The throttle must always remain in the same position throughout the test. A mechanical pressing-on tool is not permitted.

The accelerator pedal must be fully depressed during the test.



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Fig. 650: Moving between cylinders Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Move the scale on to another cylinder. To do this, pull the pin under the handle on the back once.

5. Then check the next cylinder according to number sequence (not according to firing order).

SUBSEQUENT WORK

Subsequent work



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1. Fit spark plugs. For tightening torques, refer to 28 70 55 Replacing spark plugs - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

2. Fit the ignition rod module fuses and the injection system.

Fig. 652: Fuses for ignition rod modules and injection valves



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3. Fit lid of central electrical box.

10 30 19 REMOVING AND INSTALLING ENGINE CARRIER - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN)

PRELIMINARY WORK

Preliminary work

1. Support engine on the body. --> Supporting engine on the body.

2. Remove engine guard. --> 108019 Removing and installing engine guard - "Removing".

3. Remove front axle until the engine carrier can be removed. Refer to 40 06 19 Removing and installing front-axle carrier - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo) . Refer to 40 06 19 Removing and installing front-axle carrier - as of MY 2003 (Cayenne Turbo S, Cayenne S TIO Titan) .

INFORMATION



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Component overview


1 - Fastening nut, M12 X 1.5

2 - Bracket for auxiliary units


4 - Align left-hand hydraulic mount with the aid of the engine carrier -5- then tighten the fastening nuts -1- . See Fig. 654.



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5 - Engine carrier

6 - Fastening screw

7 - Align right-hand hydraulic mount with the aid of the engine carrier -5- then tighten the fastening nuts -1- . See Fig. 654.

8 - Engine carrier, right


REMOVING ENGINE CARRIER

Removing engine carrier




--> The components are very heavy. There is a danger of crushing.


--> Please observe general warning notes.


NOTE: This task can only be performed if the engine has been removed or suspended on the body.

Do not undo the engine mounts on the engine.

If the engine mounts have been undone on the engine, they must be aligned using the engine carrier. --> 103519 Removing and installing engine mount .



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Fig. 655: Engine carrier Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig. 656: Fastening screws for engine mounting Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Undo the two fastening screws to the left and right on the hydraulic mounts. See Fig. 656.

2. Undo the two fastening screws from the engine carrier to the body and remove the engine carrier.



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INSTALLING ENGINE CARRIER

Installing engine carrier

Fig. 657: Fastening screws for engine mounting Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Install engine carrier. To do this, first position the fastening screws (M10 x 45) on the hydraulic mounts and tighten them. --> 103519 Removing and installing engine mounting - "Installing"

SUBSEQUENT WORK

Subsequent work

1. Screw in new fastening screws for securing the engine carrier to the body. --> Initial tightening: 89 ftlb. --> Torque angle: 180 °

2. Install front axle. Refer to 40 06 19 Removing and installing front-axle carrier - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo) . Refer to 40 06 19 Removing and installing front-axle carrier - as of MY 2003 (Cayenne Turbo S, Cayenne S TIO Titan) .

3. Install engine guard. --> 108019 Removing and installing engine guard - "Installing".

10 30 19 REMOVING AND INSTALLING ENGINE CARRIER - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN)



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PRELIMINARY WORK

Preliminary work

Fig. 658: Engine supported on body Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Support engine on the body --> Supporting engine on the body.



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2. Remove engine guard. --> 108019 Removing and installing engine guard - "Removing"

3. Remove the front-axle carrier. Refer to 40 06 19 Removing and installing front-axle carrier - as of MY 2003 (Cayenne TIP, Cayenne MAN) .

INFORMATION

Component overview



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Fig. 660: Engine carrier removed Courtesy of PORSCHE OF NORTH AMERICA, INC.



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Fig. 661: Accessories Courtesy of PORSCHE OF NORTH AMERICA, INC.

1 - Engine carrier

2 - Fastening screws

3 - Fastening screw for engine carrier M14 x 1.5 x 115, replace

4 - Left engine support arm with integrated oil circuit

5 - Fastening nut M12



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6 - Left engine mount

7 - Dowel sleeves

8 - Right engine mount

9 - Right engine support arm


REMOVING ENGINE CARRIER

Removing engine carrier

Fig. 662: Engine mount Courtesy of PORSCHE OF NORTH AMERICA, INC.

If the engine mounts have been undone on the engine -A- , they must be aligned using the engine carrier. See Fig. 662.

NOTE: This task can only be performed if the engine has been removed or suspended on the body.

Do not undo the engine mounts on the engine.



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Fig. 663: Fastening screws Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Undo the two fastening screws to the left and right -arrows- from above on the hydraulic mounts. See Fig. 663.



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Fig. 664: Fastening screws for engine carrier Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Undo the two fastening screws from the engine carrier -center arrow- to the body and remove the engine carrier. See Fig. 664.

INSTALLING ENGINE CARRIER

Installing engine carrier



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Fig. 665: Mount for hydraulic mount Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Install engine carrier. To do this, first position the fastening screws (M10 x 45) -arrows- on the hydraulic mounts and tighten them. Tighten the fastening nuts -A- . --> Tightening torque: 44 ftlb. --> Tightening torque: 44 ftlb. See Fig. 665.



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Fig. 666: Fastening screws for engine carrier Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Tighten the new fastening screws on the engine carrier -center arrow- . --> Tightening torque: 74 ftlb. --> Torque angle: 180 ° See Fig. 666.

SUBSEQUENT WORK

Subsequent work

1. Install the front-axle carrier. Refer to 40 06 19 Removing and installing front-axle carrier - as of MY 2003 (Cayenne TIP, Cayenne MAN) .



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2. Mount engine guard. --> 108019 Removing and installing engine guard - "Installing"

10 35 19 REMOVING AND INSTALLING ENGINE MOUNTING - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN)

PRELIMINARY WORK

Preliminary work

1. Support engine on the body. --> Supporting engine on the body.

2. Remove engine guard. --> 108019 Removing and installing engine guard - "Removing"

3. Remove front axle until the engine carrier can be removed. Refer to 40 06 19 Removing and installing front-axle carrier - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo) . Refer to 40 06 19 Removing and installing front-axle carrier - as of MY 2003 (Cayenne Turbo S, Cayenne S TIO Titan) .

INFORMATION

Component overview



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1 - Fastening nut, M12 X 1.5

2 - Bracket for auxiliary units


4 - Align left-hand hydraulic mount with the aid of the engine carrier -5- then tighten the fastening nuts -1- . See Fig. 668.

5 - Engine carrier



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6 - Fastening screw

7 - Align right-hand hydraulic mount with the aid of the engine carrier -5- then tighten the fastening nuts -1- . See Fig. 668.

8 - Engine carrier, right


REMOVING ENGINE MOUNTING

Removing engine mounting




--> The components are very heavy. There is a danger of crushing.


--> Please observe general warning notes.


NOTE: This task can only be performed in the Cayenne S (M48/00) if the engine has been removed or suspended on the body. This description covers suspension on the body.

The engine must be removed on the Cayenne Turbo (M48/50) --> 100119 Removing and installing V8 4.5 l engine - "Removing". The turbochargers are removed next. Refer to 21 30 21 Removing turbocharger - as of MY 2003 (Cayenne Turbo, Cayenne Turbo S) .



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Fig. 669: Hydraulic mount Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Undo the two fastening screws -Arrows- to the left and right on the hydraulic mounts. See Fig. 669.



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Fig. 670: Engine carrier Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Undo the two fastening screws from the engine carrier to the body and remove the engine carrier. -center arrow- See Fig. 669.

3. Undo engine mounts. To do this, undo the fastening nuts on the support arms and remove the engine mounts.

INSTALLING ENGINE MOUNTING

Installing engine mounts

1. Position engine mounts on the support arm. When doing so, note the positioning pin on the mount. It must engage in the recess on the support arm.

2. Position new fastening nuts and screw them on so that the positioning pin cannot pop out. Do not tighten the fastening nuts.

Fig. 671: Fastening screws for hydraulic mount Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Fit the engine carrier. Position the fastening screws (M10 x 45) for the hydraulic mounts and tighten them. --

NOTE: The engine mounts must be aligned using the engine carrier.

The engine mounts differ (left/right) and must not be interchanged.



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> Tightening torque: 44 ftlb. See Fig. 671.

4. Tighten engine mounts on the engine. Tighten the fastening nuts. --> Tightening torque : 56 ftlb.

SUBSEQUENT WORK

Subsequent work

1. Screw in new fastening screws for securing the engine carrier to the body. --> Initial tightening: 89 ftlb. --> Torque angle: 180 °

2. Install front axle. Refer to 40 06 19 Removing and installing front-axle carrier - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo) . Refer to 40 06 19 Removing and installing front-axle carrier - as of MY 2003 (Cayenne Turbo S, Cayenne S TIO Titan) .

3. Install engine guard. --> 108019 Removing and installing engine guard - "Installing"

10 35 19 REMOVING AND INSTALLING ENGINE MOUNTING - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN)

PRELIMINARY WORK

Preliminary work

1. Remove engine carrier. --> 103019 Removing and installing engine carrier - "Removing".

INFORMATION

Component overview



Microsoft


Fig. 672: Engine carrier removed Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig. 673: Accessories Courtesy of PORSCHE OF NORTH AMERICA, INC.

1 - Engine carrier


3 - Fastening screw for engine carrier M14 x 1.5 x 115, replace

4 - Left engine support arm with integrated oil circuit



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6 - Left engine mount

7 - Dowel sleeves

8 - Right engine mount

9 - Right engine support arm


REMOVING ENGINE MOUNTING

Removing engine mounting

Fig. 674: Fastening nuts Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Undo engine mounts. To do this, undo the fastening nuts -A- on the support arms and remove the engine mounts. See Fig. 674.

NOTE: On the Cayenne (BFD), this task can only be performed if the engine has been removed or suspended on the body. This description covers suspension on the body.



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INSTALLING ENGINE MOUNTING

Installing engine mounts

1. Position engine mounts on the support arm. When doing so, note the positioning pin on the mount. It must engage in the recess on the support arm.

2. Position new fastening nuts -A- and screw them on so that the positioning pin cannot pop out. Do not tighten the fastening nuts. See Fig. 675.

Fig. 675: Engine mount Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Fit the engine carrier. To do this, position the fastening screws of the hydraulic mount -arrows- and tighten. --> Tightening torque: 44 ftlb. See Fig. 675.

4. Tighten engine mounts on the engine. Tighten the fastening nut -A- . --> Tightening torque: 56 ftlb.

SUBSEQUENT WORK

Subsequent work

NOTE: The engine mounts must be aligned using the engine carrier.

The engine mounts differ (left/right) and must not be interchanged.



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1. Install engine carrier. --> 103019 Removing and installing engine carrier - "Installing".

10 80 19 REMOVING AND INSTALLING ENGINE GUARD - AS OF MY 2003 (ALL MODELS)

INFORMATION

Overview

Fig. 676: Engine cover, complete Courtesy of PORSCHE OF NORTH AMERICA, INC.



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Fig. 677: Engine cover screws Courtesy of PORSCHE OF NORTH AMERICA, INC.

1 - Engine guard, front

2 - Engine guard

3 - Fastening screw M6

4 - Transverse strut


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REMOVING ENGINE GUARD

Removing engine guard

Fig. 678: Front screws Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Remove front engine guard. To do this, loosen the screws -1- at the front and side. Then loosen the rear -2- and front screws -3- . See Fig. 678.



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Fig. 679: Rear screws Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Remove rear engine guard. To do this, loosen the fastening screws on the transmission cross member -1- and the screws on the traverse strut -2- . See Fig. 679.

INSTALLING ENGINE GUARD

Installing engine guard



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Fig. 680: Rear screws Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Install the rear engine guard. To do this, screw in the front fastening screws -2- and rear fastening screws -1- . See Fig. 680, Fig. 681.



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Fig. 681: Front screws Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Tighten front fastening screws -3- and rear fastening screws -2- and -1- --> Tightening torque: 6.5 ftlb. . See Fig. 681.

10 83 19 REMOVING AND INSTALLING DESIGN COVER. - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN)

INFORMATION

Overview



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Fig. 682: Overview of design cover Courtesy of PORSCHE OF NORTH AMERICA, INC.

NOTE: A special paint is applied to the covers for reasons of appearance.

When the engine is washed, a minimum clearance of 50 cm must be maintained between the cleaning apparatus lance and the covers.

The covers are sensitive to scratching.

Small scratches on the paintwork can be touched up with a special touch-up applicator.



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Fig. 683: Individual parts of design cover Courtesy of PORSCHE OF NORTH AMERICA, INC.

1 - Design cover, cylinder row 5-8

2 - Countersunk screw, M5 x 16

3 - Sleeve

4 - Rubber sleeve

5 - M6 screw with M5 internal thread; for securing ignition coil



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6 - Rubber ball socket

7 - Sheetmetal holder; fastening on valve cover; screw fastening points 4 and 5


9 - Throttle body cover


11 - Design cover, cylinder row 1-4

REMOVING DESIGN COVER

Removing throttle body cover



Removing design cover of cylinder row 1 - 4




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1. Remove engine compartment cover on the right and rear. Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .


2. Detach the torque support. To do this, unscrew the fastening screw on the torque support bracket and pull it out.



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Fig. 686: Swivelling the torque support Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Detach the torque support from the body and swivel upwards.



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Fig. 687: Secondary air pump Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Detach the secondary air pump from cylinder row 1-4. To do this, unscrew the 3 fastening screws, pull the pump out of the support and lay it aside.

Fig. 688: Fastening screws of design cover Courtesy of PORSCHE OF NORTH AMERICA, INC.

5. Unscrew the four fastening screws on the design cover (picture shows side 5 - 8).



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Fig. 689: Lifting the design cover Courtesy of PORSCHE OF NORTH AMERICA, INC.

6. Remove design cover from cylinder bank 1 - 4. Lift the cover slightly with both hands on the edge pointing towards the intake system until it snaps out of the fastening points.



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Fig. 690: Removing the design cover Courtesy of PORSCHE OF NORTH AMERICA, INC.

7. Lift the cover at the front edge and slide the ignition coil cover of the second cylinder out of the torque support bracket. Pull out cover to the front.

Removing design cover of cylinder bank 5 - 8

NOTE: Place a cloth between secondary air pump and design cover to avoid scratching the cover.



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Fig. 691: Fastening screws on design cover Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Unscrew the four fastening screws on the design cover.



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Fig. 692: Pulling off the design cover Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Remove design cover of cylinder bank 5 - 8. To do this, lift the cover slightly with both hands at the edge pointing towards the intake system until it is released from its holder.

Fig. 693: Removing the design cover Courtesy of PORSCHE OF NORTH AMERICA, INC.


INSTALLING DESIGN COVER

Installing design cover of cylinder bank 1 - 4




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Fig. 694: Sliding on the design cover Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Slide the design cover of cylinder bank 1 - 4 under the secondary air pump bracket as shown in the illustration and then slide the cover of the second ignition coil through underneath the torque support bracket.



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Fig. 695: Pressing the design cover on Courtesy of PORSCHE OF NORTH AMERICA, INC.

2. Press down the two rubber mounts on the bracket. The rubber mounts must be felt to engage.



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Fig. 696: Fastening screws on the ignition coilsCourtesy of PORSCHE OF NORTH AMERICA, INC.

3. Tighten the four fastening screws on the ignition coils (illustration shows side 5-8). --> Tightening torque: 3.5 ftlb.

Fig. 697: Secondary air pump Courtesy of PORSCHE OF NORTH AMERICA, INC.

4. Reinstall secondary air pump. Tighten the three fastening screws. Refer to 26 65 19 Removing and installing secondary air pump - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .



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Fig. 698: Torque support on bracket Courtesy of PORSCHE OF NORTH AMERICA, INC.

5. Reinstall torque support. Fit the fastening screw (M10 x 85) with a new fastening nut on the bracket. --> Tightening torque: 44 ftlb.

6. Screw in the fastening screw securing the torque support to the body (M10 x 70). --> Tightening torque: 44 ftlb.

7. Install engine compartment cover on the right and rear. Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .

Installing design cover of cylinder bank 5 - 8

NOTE: Place a cloth between secondary air pump and design cover to avoid scratching the cover.



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Fig. 699: Design cover under secondary air pump Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. Slide the design cover under the secondary air pump as illustrated.



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2. Then press in the two rubber mountings on the bracket. The rubber mounts must be felt to engage.

Fig. 701: Fastening screws securing design cover over ignition coils Courtesy of PORSCHE OF NORTH AMERICA, INC.

3. Screw in the four fastening screws at the ignition coils --> Tightening torque: 3.5 ftlb.

Installing throttle body cover



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10 83 19 REMOVING AND INSTALLING ENGINE COVER (DESIGN COVER). -AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN)

REMOVING AND INSTALLING ENGINE COVER

Removing and installing engine cover

NOTE: A special paint is applied to the covers for reasons of appearance.

When the engine is washed, a minimum clearance of 50 cm must be maintained between the cleaning apparatus lance and the covers.

The covers are sensitive to scratching.



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Fig. 703: Pulling off the design cover Courtesy of PORSCHE OF NORTH AMERICA, INC.

1. To remove the engine cover, detach it at the left and right and pull it straight up.



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2. To re-attach the engine cover, place it on the engine and press the four rubber sleeves on firmly. Now check that the cover is seated securely.



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Crankcase Suspension

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