Wednesday, 31 October 2018

2010 Porsche Cayenne Turbo (9PA) V8-4.8L Turbo Page 1 Engine: Removal and Replacement Part 2

2010 Porsche Cayenne Turbo (9PA) V8-4.8L Turbo Page 1
Engine: Removal and Replacement
Part 2
WM 100119 Removing and installing V8 4.8-litre DFI engine
Information
  • 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). This makes it easier to correctly position the front-axle carrier on the body during re-installation.
  1. Mark the installation position of the front-axle carrier diagonally on at least two places on the body using a felt-tip pen. => Marking installation position of front-axle carrier



































Marking installation position of front-axle carrier
  1. Set up the lifting platform according to instructions -> 100119 Removing and installing V8 4.8-litre DFI engine - section on "Tools and materials"
Position the lifting platform under the engine and raise it. When you do this, make sure that the positioning guides on the lifting platform are inserted into the body. => Lifting platform under engine

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Lifting platform under engine
44.  The -arrows- show the take-up points for the mounting frame in the front-axle carrier (view from below shown here).





























Take-up points for front-axle carrier
45.  Position lifting platform in the front-axle carrier in the take-up points provided -arrows- ( -1, 3 and 4 into the body- ).

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Lifting platform
  1. 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 -arrow- on the wheel hub and lifting platform.





























Securing spring struts
47.  Loosen the transmission cross member. To do this, loosen the four fastening screws -1-.

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Fastening screws on transmission cross member
  1. Secure the engine/transmission unit. Then secure the mounting mandrels on the engine transverse bar with the locking screws.
  1. Loosen four fastening screws -arrows- on the front-axle carrier.





























Threaded joint on chassis subframe
50.  Loosen two fastening screws -arrow- on the engine transverse bar.

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Engine carrier mounting
Information
  • When lowering the engine, make sure that cables or lines are not trapped accidentally between the engine and body. To prevent this, a second person must make sure that the cables and lines do not get caught.
  1. Slowly lower the lifting platform by about 20 to 30 cm. When doing this, a second person must ensure that there is sufficient clearance around the engine compartment and spring struts in the wheel housings.
Installing 4.8-litre DFI engine
The following tools are described in Tools and Equipment, Section 3.0.13 "WE 1206" (exceptions are noted).
Special equipment-specific features are described in the notes.
























Lifting platform

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  1. Lift the engine at the take-up points provided on a workshop crane and set it down on the front-axle carrier.
  2. Position the lifting platform with the engine/transmission unit under the body.
  3. Raise the body to a comfortable working height using the lifting platform.
Information
  • Position the front-axle carrier back in its original, marked installation position and be careful not to damage adjacent parts.
  1. Raise the engine/transmission unit into the body using the lifting platform => Guiding engine/transmission unit into the body with the lifting platform and make sure there is sufficient clearance.





























Guiding engine/transmission unit into the body with the lifting platform
Information
  • Make sure that the lines are not trapped.
4.1. Freely-suspended lines (e.g. PDCC) must be routed in such a way that they go back into installation position.
4.2. The insertion guides -1, 3 and 4- on the lifting platform must fit into the holes in the body. When doing so, use the markings used for removal as a positioning guide.

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Lifting platform
  1. Tighten four fastening screws -arrows- on the front-axle carrier. -> 400619 Removing and installing front-axle carrier - section on "Installing" See: Body and Frame/Frame/Subframe/Front Subframe/Service and Repair





























Threaded joint on chassis subframe
  1. Tighten two fastening screws -arrow- on the engine transverse bar.=> Initial tightening: 120 Nm (89 ftlb.) => Final tightening - torque
angle: 180°

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Engine carrier mounting
  1. Tighten four fastening screws -1- on the transmission support. => Initial tightening: 50 Nm (37 ftlb.) => Final tightening - torque angle: 90°





























Fastening screws on transmission cross member
8.  Loosen lateral supports on the wheel hubs. => Support for wheel hub

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Support for wheel hub
  1. Slowly lower the lifting platform and remove it.
  2. Connect electric connectors -1, 2 and 3- to the transmission and clip in the wire harness.





























Connectors on transmission
11.  Secure the heat shield above the right electric connections -1, 2 and 3-.

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Connectors on transfer gear
  1. Fit refrigerant lines. -> 873419 Removing and installing air-conditioning compressor - section on "Installing" See: Heating and Air Conditioning/Compressor HVAC/Service and Repair.






























Securing refrigerant lines on air-conditioning compressor
  1. Connect cable plug to the air-conditioning compressor.
  1. Fit connections for the PDCC lines around the front axle. Counter screw torque. For tightening torques, see -> 4300TW Tightening torques
14.1.  Fit the two lines -arrows- on the front right side member.

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Front right PDCC lines
14.2. Position lines in the valve block -arrows- in the right wheel housing and tighten.





























PDCC line in right wheel housing
14.3. Fit and tighten line -arrow- on the distributor under the front-axle final drive.

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PDCC line on distributor under front-axle final drive
14.4. Fit and tighten PDCC line -arrow- on the front axle. => PDCC line on front axle





























PDCC line on front axle
  1. Turbo engine:
Fit hose -3- between the ambient air valve and intake pipe -1- on both sides by fastening the hose clamp -2-.

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Connection between ambient air valve hose and intake pipe
  1. Fit selector lever cable to transmission. To do this, press the ball socket -arrow- onto the ball. Then slide the upper sheetmetal clip -1- into position.





























Selector lever cable on transmission
17.  Push the power-steering fluid line onto the cooler -arrow- and fit the spring band clamp.

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Spring band clamp on power-steering fluid line
  1. Fit the steering column onto the steering gear. => Steering column on steering gear -> 489019 Removing and installing steering gear - section on "Installing" See: Steering and Suspension/Steering/Steering Gear/Service and Repair





























Steering column on steering gear
  1. Fit the heat shield on the steering gear using two fastening screws -arrows-. => Fastening screws securing heat shield to steering gear => Tightening torque: 10 Nm (7.5 ftlb.)

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Fastening screws securing heat shield to steering gear
Information
  • For vehicles with Servotronic, the electric connector on the steering gear must also be connected.
20.  Fit electric connector -arrow- on the steering gear (Servotronic only). Figure shows right-hand drive vehicle.































Servotronic cable plug
21.  Slide the heater coolant lines -arrows- onto the left side member and fit the clips.

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Heater coolant lines on left side member
22.  Attach coolant connection piece -arrow- at the top left of the radiator. The connection piece must engage audibly.





























Coolant connection piece
  1. Connect ATF lines to the radiator. Remove stoppers -arrow- and fit the lines. -> 386219 Removing and installing line for ATF cooling - section on "Installing". => ATF lines

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ATF lines
24.  Fit the ground point of the generator -arrow- on the right side member. => Tightening torque: 20 Nm (15 ftlb.)




























Generator ground point
  1. Turbo engine:
Fit the two pressure pipes. Push pressure pipes into connections and fit spring band clamp. The couplings -1- must lock with an audible click. -1-

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Left pressure pipe





























Boost pressure pipe
  1. Install rear cardan shaft. -> 393519 Removing and installing rear cardan shaft See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/393519 Removing and installing rear cardan shaft
  1. Fit exhaust system. Move exhaust system into position using a transmission jack or get a second person to assist you. -> 260119 Removing and installing exhaust system on DFI engines - section on "Installing" See: Exhaust System/Testing and Inspection

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Exhaust system on transmission jack
28.  Secure the catalytic converter holders on the body. => Tightening torque: 23 Nm (17 ftlb.) => Fastening screws on body and cross member




























Fastening screws on body and cross member
  1. Lower the vehicle halfway.
  2. Vehicles with air suspension:
30.1. Fit air suspension hose -arrow-.

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Compressed air line
30.2. Plug in cable plug -arrow- on sensor for headlight levelling system.



























Sensor for headlight levelling system
31.  Tighten brake lines -arrow-.

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Brake lines in wheel housings
  1. Fit electric connector for wear indicator -1-.
32.1.  Press in holders -2 and 3-.





























Cable guide at spring strut 2
  1. Fit ABS sensor cable => Cable guide at spring strut 1 and connect cable plug.
33.1.  Plug in sensor on air spring strut.

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Cable guide at spring strut 1
  1. Lower the vehicle.
  1. Replace and screw in three fastening screws on the spring struts -1- at the left and right. One screw is easily accessible in the plenum panel. -> 4000TW00 Tightening torques for front axle => Spring strut view from wheel housing





























Spring strut screws

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Spring strut view from wheel housing
36.  Mount B+ transfer point on left spring dome. => Tightening torque: 23 Nm (17 ftlb.)































B+ transfer point on left spring dome
37.  Fit upper coolant pipe and both intake pipes (turbo engine) into the air cleaner housing. --

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Pipes
  1. Fit hoses -2 and 3- to the reservoir.
38.1.  Vehicles with PDCC:
Use a clip to fit the PDCC reservoir -1-.
38.2.  Fill reservoir with the specified amount of fluid.





























Reservoir
  1. Clip in engine wire harness -1- and route into the plenum panel.
  1. Fit line from the carbon canister -2- to the plenum panel splash panel. Fit vacuum line -3-. Fit fuel line -4- to the plenum panel splash panel. => Tightening torque: 35 Nm (26 ftlb.)

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Lines on plenum panel
41.  Fit two coolant lines to the reservoir. -1 and 2-






















Coolant hoses
Fit torque support => Torque support. Secure torque support on engine => Tightening torque: 60 Nm (44 ftlb.) and torque support on body
=> Tightening torque: 60 Nm (44 ftlb.).

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Torque support
42.  Connect vacuum line at the vacuum pump connection piece -arrow- on the engine.





















Vacuum line to vacuum pump
  1. Turbo engine:
Connect line to the ambient air valves -1-. Prepare clip -2- for correct installation position.

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Line to ambient air valves
  1. Turbo engine:
Connect the two cable plugs for the MAF sensor -1-. Fit the PCV line -2- on the right pressure pipe (PCV is positive crankcase ventilation).





























PCV and MAF sensor
  1. On V8 naturally aspirated engines, fit the intake pipe between the air cleaner housings. -> 243519 Removing and installing air box for throttle housing on DFI engines (intake pipes upstream of throttle valve) - section on "Installing"
  1. Turbo engine: Fit Y-shaped pipe ahead of the throttle valve. -> 243519 Removing and installing air box for throttle housing on DFI engines (intake pipes upstream of throttle valve) - section on "Installing"
  1. Fit the two oxygen sensor connectors => Oxygen sensor connectors on the plenum panel at the left and right. Fit retaining clip straight on.

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Oxygen sensor connectors
  1. Lay the engine wire harness -2- in the plenum panel. Clip rubber sleeve -3- into the plenum panel. Then guide the control unit connector to the right. Secure the control unit, connector and ground point -1-. => Tightening torque: 10 Nm (7.5 ftlb.)





























Engine wire harness in plenum panel
49.  Plug in connector -1 - on the DME control unit -3- and -arrows A- close the latch -arrows B-.

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Plugging in connector
50.  Secure DME control unit with support.
50.1. Position DME control unit -3- with holder -arrow A- and secure in place with fastening screws -1-.
50.2. Clip in wire harness -2- at the holder -arrow B-.





























Securing DME control unit with holder
  1. Fit the two connectors for the engine wire harness -1 and 2- (white, red) inside the central electrical system. Move the wire harness into installation position and fit into the retaining clips inside the plenum panel.

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Cable plug for engine wire harness
52.  Fit the cover of the central electrical system on the side of the vehicle. To do this, screw in four Torx screws -arrows-.




























Torx screws for cover of central electrical system
Subsequent work
  1. Peripheral work must be carried out in the same way for vehicles with manual transmission. -> 343519 Removing and installing transmission - section on "Installing"
  1. Install cover for plenum panel. -> 664419 Removing and installing cowl panel cover - section on "Installing" See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair
  1. Fit pneumatic spring for bonnet -> 553119 Removing and installing front pneumatic spring See: Body and Frame/Doors, Hood and Trunk/Hood/Hood Shock / Support/Service and Repair. While doing so, fit engine compartment rubber seal -> 553319 Removing and installing front lid seal - section on "Installing" See: Body and Frame/Doors, Hood and Trunk/Hood/Hood Weatherstrip/Service and Repair.
  1. Fill the air conditioning system. -> 870317 Draining and filling refrigerant - section on "Filling" See: Heating and Air Conditioning/Refrigerant/Service and Repair
  2. Fill and bleed the cooling system. -> 193817 Draining and filling coolant (includes bleeding) - section on "Filling"
  1. Bleed the brake system. -> 470107 Bleeding the brake system - section on "Bleeding" See: Brakes and Traction Control/Brake Bleeding/Service and Repair
  1. Fit engine compartment trim panels. -> 700219 Removing and installing front trim (engine compartment) - section on "Installing" See: Access Cover/Service and Repair

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  1. Install front wheel housing liners. -> 505619 Removing and installing front wheel housing liner - section on "Installing" See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair
  2. Connect the battery. -> 9000IN00 Work instructions after disconnecting the battery
  3. Bleed power steering. -> 4800IN00 Test and assembly work on power steering
  4. Bleed ATF and check level. -> 370235 Checking and topping up ATF
  1. Fit engine guard with transverse strut. -> 108019 Removing and installing engine guard (underbody panel) on DFI engines - section on "Installing" See: 108019 Removing and installing engine guard (underbody panelling)
  1. Mount front wheels. -> 440519 Removing and installing wheel - section on "Installing" See: Maintenance/Wheels and Tires/Wheels/Service and Repair/Removal and Replacement
  2. Check engine oil level.
  1. Bleed PDCC. -> 430300 Bleed Porsche Dynamic Chassis Control (PDCC) See: Steering and Suspension/Suspension/Suspension Control ( Automatic - Electronic )/Service and Repair/430307 Bleeding Porsche Dynamic Chassis Control (PDCC)
  2. Perform suspension alignment. -> 4400IN Suspension alignment, complete
Information
  • Following replacement of the high-pressure pump and engine, the values for the high-pressure adaptation must be reset using the PIWIS Tester. Then carry out a test and adaptation drive. Read the information in the section -> 24701900 Removing and installing DME (DFI) control unit See: Powertrain Management/Computers and Control Systems/Engine Control Module/Service and Repair.

  1. The high-pressure adaptation must be reset when replacing the engine.
  2. Read out DME fault memory and compare with the log you printed prior to removal.
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