Starters: Removal & Installation Porsche Cayenne I

REMOVAL & INSTALLATION

Scheme 1

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

1. Remove throttle body cover. (Scheme 1) Disconnect Throttle Position Sensor (TPS) harness connector. Unclip TPS wire harness from retaining clip.
2. Unlock retaining bolts for throttle body. Turn right bolt 45° counterclockwise, and left bolt 45° clockwise. (Scheme 2) Using pliers, gently pull retaining bolts out, by rubber ring. Remove "Y" pipe from throttle body.
3. Separate air bellows for air flow sensors. (Scheme 3)
4. Remove vacuum hose for "Y" pipe by pressing button at vacuum connection. (Scheme 4) Disconnect vacuum hose, on rear of intake system. (Scheme 5)
5. Remove right side (passenger) engine cover. Remove bolt securing engine torque support. (Scheme 6) Loosen torque support on body and pull engine torque support upward from body bracket. (Scheme 7)
6. Remove bolts securing secondary air pump. Remove secondary air pump from holder, and place aside. (Scheme 8)
7. Remove bolts securing engine design covers. (Scheme 9) Gently remove engine design cover from cylinder Nos. 1-4 bank (passenger side). Lift design cover on side point towards intake manifold until it snaps out of mounting bosses. (Scheme 10) Lift design cover on the front edge and slide the ignition coil cover of the second cylinder out of the torque support bracket. Pull off the cover to the front. Repeat this procedure for cylinder Nos. 5-8 bank (driver side).
8. Disconnect PCV hoses from both valve covers. To do this, press the plastic ring and pull the connections. (Scheme 11) Remove the PCV hose from the retaining clip. Remove vent line between intake distributor and oil separator.
9. Disassemble line between oil mist collector and the intake manifold. (Scheme 12) Separate fuel line on plenum panel. (Scheme 13)
10. Disconnect harness connectors from fuel injectors. Remove bolts securing intake manifold, in sequence as shown. (Scheme 14) Remove intake manifold.

Scheme 12

1. Replace intake manifold gaskets.
2. Place intake manifold on engine. Install and tighten screws in 2 stages. See «TORQUE SPECIFICATIONS»(ref-165712-S07385483052004090200000). (Scheme 15) Continue installation in reverse of removal procedure.

Scheme 13

Scheme 14

Scheme 15

1. Disconnect and isolate battery cables. See «SERVICE PRECAUTIONS»(ref-165712-S07000369442004090200000). Battery is located below driver's front seat. Remove front and rear engine guards. (Scheme 16) Open press studs (arrows) and remove heat insulation cover, for starter solenoid switch. see scheme 17
2. Pull off protective cap for battery cable terminal, on starter solenoid. Disconnect battery cable and wiring terminals from starter solenoid.
3. Remove screw securing harness holder. Turn holder slightly, and remove. Remove starter bolt from transmission side. see scheme 18 Remove bolt securing transmission oil cooler lines retainer. Gently pull retainer in a downward motion. Remove starter bolt, from engine side. Rotate starter, if necessary and remove.
4. To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-165712-S07385483052004090200000).

Removal & Installation (4.5L V8)

Note. Starter motor for 4.5L V8 is located on top of engine, under intake manifold.

Scheme 16

1. Disconnect and isolate battery cables. See «SERVICE PRECAUTIONS»(ref-165712-S07000369442004090200000). Battery is located below driver's front seat.
2. Remove intake manifold. See «INTAKE MANIFOLD»(ref-165712-S28864416962004090300000).
3. Remove nuts from starter solenoid switch terminals. Remove wires, and set aside. Remove starter mounting bolts. Remove starter. see scheme 19
4. To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-165712-S07385483052004090200000).