Completing reconditioned engine
Note. In order to replace the old, removed engine with a new one, some re-fitting work must be done.
- 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.
Scheme 242
2. Convert coolant hose between thermostat housing and radiator. To do this, convert a spring band clamp and clip. -arrows- see scheme 602
Scheme 243
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 scheme 603
Scheme 244
4. Convert coolant hose from water tube under exhaust manifolds to radiator. To do this, convert a spring band clamp. -arrow- see scheme 604
Scheme 245
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 scheme 605
Scheme 246
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 scheme 606
Scheme 247
7. Convert coolant hose to coolant reservoir. To do this, convert a spring band clamp. -arrow- see scheme 607
Note. In order to replace the old, removed engine with a new one, some re-fitting work must be done.
- 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.
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) .
1. Remove engine. > 100119 Removing and installing V8 4.5 l engine - "Removing"
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 scheme 608
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
6 - Screw x 4 --> Tightening torque: 60 (44 ftlb.) Nm
7 - Hydraulic mount, right
8 - Engine carrier
9 - Screw x 6 --> Tightening torque: 65 (48 ftlb.) Nm
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) .
12. 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) .
13. Remove oil spray jets on turbo engine and cap on naturally aspirated engine. > 101321 Removing oil spray jets for piston cooling [9PAAF1 9PAAJ1] .
Scheme 248
1 - Crankcase, top
2 - Closure cap
3 - Seal
4 - Closure cap
5 - Screw --> Tightening torque: 10 (7.5 ftlb.) Nm
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