1 of 27 7/21/2015 3:33 PM

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1 of 27 7/21/2015 3:33 PM WM 489819 Removing and installing

1 1 of 27 7/21/2015 3:33 PM WM Removing and installing hydraulic pump - as of model year 2009 Tools Technical values Information

2 2 of 27 7/21/2015 3:33 PM Overview of hydraulic pump Preliminary work DANGER Vehicle raised incorrectly. - Danger of fatal injury or material damage should the vehicle fall down. ->Raise the vehicle at the prescribed jacking points.

3 3 of 27 7/21/2015 3:33 PM 1. Raise the vehicle. -> 4X00IN01 Lifting the vehicle See: Vehicle Lifting > Procedures > 4X00IN01 Lifting the Vehicle 2. Place protective covers on the vehicle to avoid damaging the body and passenger compartment. 3. Disconnect the battery. => 2706IN Work instructions after disconnecting the battery. 4. Remove rear wall cover. Rear wall cover -> Removing and installing rear wall cover See: Trim Panel > Removal and Replacement > Removing and Installing Rear Wall Cover 5. Remove engine compartment cover. Engine compartment cover -> Removing and installing engine cover 6. Remove resonance tube. -> Removing and installing resonance tube - section on "Removing" See: Intake Air Plenum > Removal and Replacement >

4 4 of 27 7/21/2015 3:33 PM Removing and installing tuning pipe 7. Remove right intake-air distributor. -> Removing and installing intake-air distributor - section on "Removing" See: Intake Manifold > Overhaul > Removing and installing intake-air distributor Removing hydraulic pump WARNING Danger of injury and material damage when using Pentosin. - Risk of skin irritation and damage to skin. - Damage to hoses and wiring. ->Wear protective gloves and goggles. ->In the event of contact (eyes or skin), wash immediately with water. ->Collect emerging Pentosin. ->Use caps to protect the wiring against soiling and damage. ->Clean hoses and wiring immediately. Information Cover engine openings (e.g. intake openings, crankcase, lines, open containers, etc.) with a cloth to prevent dirt and foreign bodies from getting into the openings. The air-conditioning lines on the compressor do not need to be opened in order to remove the hydraulic pump. After removal, place the air-conditioning compressor on a suitable protective support (e.g. foam or neoprene). Overview of hydraulic pump

5 5 of 27 7/21/2015 3:33 PM 1. Remove drive belt and pulley. Loosen the M8 screws on the pulley before removing the drive belt. -> Removing and installing drive belt See: Drive Belt > Removal and Replacement > Removing and installing drive belt Loosen screws -2- on the pulley -1-. Pulley 1.2. Turn the tensioner -3- clockwise at the hexagon (a/f 30) using a ring wrench -2- and take off the drive belt -1-.

6 6 of 27 7/21/2015 3:33 PM Relieving drive belt 1.3. Allow the tensioner to slide back to its initial position. 2. Remove the engine vent hose Release the engine vent hose -1- on the engine vent pipe -2- and pull it off. Engine vent hose 2.2. Remove the engine vent hose -1- from the clip holder.

7 7 of 27 7/21/2015 3:33 PM 2.3. Unscrew screw -3- and pull the engine vent hose -1- out of the oil separator housing Release the engine vent hose -1- at the oil filler neck -4- and on cylinder bank and pull it off. Engine vent hose 3. Disconnect and remove air conditioning compressor Partially detach hydraulic pump. Hydraulic pump Unscrew M8 x 30 screws -1- and detach the holder and fuel hose -2- at the hydraulic pump Remove B+ box on the air conditioning compressor.

8 8 of 27 7/21/2015 3:33 PM B+ box Open lid -1- of B+ box. Loosen and unscrew M8 nut -2- and remove B+ cable Loosen and unscrew nuts -3- on the B+ box. Remove B+ box and set it aside Disconnect electric cable plug on the air conditioning compressor. Cable plug on air conditioning compressor Pull off electric cable plug -1- and pull connector housing out of the holder -arrow Disconnect air conditioning compressor.

9 9 of 27 7/21/2015 3:33 PM Air conditioning compressor Unscrew screws -2, 3- and remove the holder Remove air conditioning compressor.

10 of 27 7/21/2015 3:33 PM Air conditioning compressor Guide the air-conditioning lines -2- towards the cut-out on the right -arrow- in such a way that the air-conditioning lines -2- are not strained.

10 10 of 27 7/21/2015 3:33 PM Air conditioning compressor Guide the air-conditioning lines -2- towards the cut-out on the right -arrow- in such a way that the air-conditioning lines -2- are not strained. Swivel air conditioning compressor -1- out backwards and set it down. 4. Drain hydraulic fluid at underbody connection point Remove rear underbody panelling. Cover for rear underbody Replace fastening nuts -2- following removal Remove underbody panel at the left side.

11 11 of 27 7/21/2015 3:33 PM Side cover Replace fastening nuts -3- following removal Open the plug-in couplings for the steering hydraulic system on the underbody. Collect emerging Pentosin in a suitable container. Pressure and return lines

12 of 27 7/21/2015 3:33 PM 4.3.1.Follow the instructions for disconnecting lines: -> 4X00IN Plug-in couplings for hydraulic lines - as of model year 2009 See: Power

12 12 of 27 7/21/2015 3:33 PM Follow the instructions for disconnecting lines: -> 4X00IN Plug-in couplings for hydraulic lines - as of model year 2009 See: Power Steering Line/Hose > Procedures > 4X00IN Plug-in couplings for hydraulic lines - as of model year Special tool Open hydraulic lines using release tool 9780.

13 13 of 27 7/21/2015 3:33 PM Releasing plug-in coupling (as of model year 2009) Re-connect the hydraulic lines -1, 2- immediately after draining them. Make sure that the supply and return hydraulic lines are not confused and that the connecting couplings lock with an audible click when you connect them Drain remaining fluid from the reservoir.

14 of 27 7/21/2015 3:33 PM Collecting Pentosin Extract Pentosin fluid from the supply tank with a pump. Dispose of extracted Pentosin according to the relevant regulations.

14 14 of 27 7/21/2015 3:33 PM Collecting Pentosin Extract Pentosin fluid from the supply tank with a pump. Dispose of extracted Pentosin according to the relevant regulations. Lay a cloth under the tank to collect any emerging Pentosin. 5. Remove hydraulic pump Disconnect return line to the reservoir for the hydraulic pump (release and pull it out at the same time).

15 15 of 27 7/21/2015 3:33 PM Return line and holder on pump Disassembly tool, universal NR.21 If you do not have a special tool to hand, press the circlip -centre arrow- forward using two plastic spatulas or an open-ended wrench (a/f 12) and pull the return line -right arrow- out at the same time Close off the return bore on the reservoir -2- with a stopper -1-.

16 16 of 27 7/21/2015 3:33 PM Closing off return bore 5.3. Unscrew screw -1- on holder for hydraulic pump. Holder for compressor 5.4. Remove hydraulic pump.

17 17 of 27 7/21/2015 3:33 PM Hydraulic pump Loosen and unscrew pressure line -1- on the hydraulic pump -3-. Counter at the connection piece (a/f 27) when detaching the pressure line -1- (a/f 16) Unscrew M8 x 30 screw -2- on the hydraulic pump -3- and remove hydraulic pump -3- and reservoir. Installing hydraulic pump 1. Install hydraulic pump Install hydraulic pump. Hydraulic pump Fit the hydraulic pump -3- and reservoir assembly and screw in and tighten M8 x 30 screw -2- on the hydraulic pump Screw in and tighten pressure line -1- on the hydraulic pump -3-. Counter at the connection piece (a/f 27) when tightening the pressure line -1- (a/f 16). => Tightening torque: 35 Nm (26 ftlb.) 1.2. Screw in and tighten screw -1- on holder for hydraulic pump.

18 18 of 27 7/21/2015 3:33 PM Holder for hydraulic pump => Tightening torque: 10 Nm (7.5 ftlb.) 1.3. Remove stopper -1-. Removing stopper 1.4. Connect return line to the reservoir for the hydraulic pump.

19 19 of 27 7/21/2015 3:33 PM Hydraulic pump return line Fit and press in return line on the hydraulic pump reservoir -arrow-. 2. Guide in and fit air conditioning compressor Fit air conditioning compressor. Air conditioning compressor

20 20 of 27 7/21/2015 3:33 PM Guide the air-conditioning lines -2- towards the cut-out on the right -arrow- in such a way that the air-conditioning lines -2- are not strained. Swivel air conditioning compressor -1- forward and position it correctly Fit air conditioning compressor. Air conditioning compressor Fit holder -4- and screw in and tighten screws -2, 3-. => Tightening torque: 23 Nm (17 ftlb.) 2.3. Fit B+ box on the air conditioning compressor.

21 of 27 7/21/2015 3:33 PM B+ box 2.3.1.Remove B+ box and fit it on the air-conditioning compressor holder. Screw on and tighten nuts -3- on the B+ box. 2.3.2.Connect B+ cable and screw on and tighten M8 nut -2-.

21 21 of 27 7/21/2015 3:33 PM B+ box Remove B+ box and fit it on the air-conditioning compressor holder. Screw on and tighten nuts -3- on the B+ box Connect B+ cable and screw on and tighten M8 nut -2-. Close lid -1- of B+ box Connect electric cable plug to the air conditioning compressor. Electric cable plug for compressor Press connector housing into the holder -arrow- and connect electric cable plug Secure hydraulic pump.

22 22 of 27 7/21/2015 3:33 PM Hydraulic pump Fit holder with fuel hoses -2- to the hydraulic pump -3- and screw in two M8 x 30 screws -1-. Tighten the screws -1- and the three lower fastening screws (M8 x 30). => Tightening torque: 23 Nm (17 ftlb.) 3. Connect plug-in couplings for the steering hydraulic system Connect the plug-in couplings for the steering hydraulic system (pressure and return lines) on the underbody if necessary (if you have not already done so after draining the fluid.

23 of 27 7/21/2015 3:33 PM Pressure and return lines Make sure that the hydraulic line connections are not confused and are engaged correctly. 3.2. Install underbody panelling at the left side.

23 23 of 27 7/21/2015 3:33 PM Pressure and return lines Make sure that the hydraulic line connections are not confused and are engaged correctly Install underbody panelling at the left side. Side cover Replace nuts and screws -2, 3-. Tighten nuts and screws -2, 3-. Nuts => Tightening torque: 5 Nm (3.5 ftlb.)+/-1 Nm (+/-0.5 ftlb.) Screws => Tightening torque: 2 Nm (1.5 ftlb.)+/-1 Nm (+/-0.5 ftlb.) 3.3. Install rear underbody panelling.

24 24 of 27 7/21/2015 3:33 PM Cover for underbody Replace screws -1-. Replace nuts -2-. Tighten screws. => Tightening torque: 2 Nm (1.5 ftlb.)+/-1 Nm (+/-0.5 ftlb.) Tighten nuts. => Tightening torque: 5 Nm (3.5 ftlb.)+/-1 Nm (+/-0.5 ftlb.) 4. Install pulley and tighten the drive belt. -> Removing and installing drive belt See: Drive Belt > Removal and Replacement > Removing and installing drive belt Insert pulley and fit M8 screws on the pulley.

Allow the tensioner to slide back to its initial position. 4.4. Tighten screws -4- on the pulley.

25 25 of 27 7/21/2015 3:33 PM Pulley 4.2. Turn the tensioner -3- clockwise at the hexagon (a/f 30) using a ring wrench -2- and fit the belt Allow the tensioner to slide back to its initial position Tighten screws -4- on the pulley. => Tightening torque: 23 Nm (17 ftlb.) 5. Install engine vent hose Connect the engine vent hose -1- at the oil filler neck -4- and on cylinder bank

26 26 of 27 7/21/2015 3:33 PM Engine vent hose 5.2. Fit and engage the engine vent hose -1- on the engine vent pipe -2-. Engine vent hose 5.3. Insert engine vent hose -1- into the clip holder Insert engine vent hose -1- into the oil separator housing and screw in and tighten the screw -3-. => Tightening torque: 10 Nm (7.5 ftlb.) Subsequent work 1. Install right intake-air distributor. -> Removing and installing intake-air distributor - section on "Installing" See: Intake Manifold > Overhaul > Removing and installing intake-air distributor 2. Install resonance tube. Tighten screw-type clamps at the correct position. -> Removing and installing resonance tube - section on "Installing" See: Intake Air Plenum > Removal and Replacement > Removing and installing tuning pipe 3. Connect the battery. -> 2706IN00 Work instructions after disconnecting the battery. 4. Fill in hydraulic fluid, bleed the power steering and check for leaks. Then check the power-steering fluid level again. -> Checking power-steering fluid level See: Power Steering Fluid > Component Tests and General Diagnostics > Checking the fluid level for power steering. 5. Install engine compartment cover.

27 of 27 7/21/2015 3:33 PM Cayman engine compartment cover -> 108319 Removing and installing engine cover 6. Install rear wall cover.

27 27 of 27 7/21/2015 3:33 PM Cayman engine compartment cover -> Removing and installing engine cover 6. Install rear wall cover. Rear wall cover -> Removing and installing rear wall cover See: Trim Panel > Removal and Replacement > Removing and Installing Rear Wall Cover 2015 ALLDATA, LLC. All Rights Reserved. (Version )

1 of 8 10/22/2015 3:08 PM

1 of 8 10/22/2015 3:08 PM WM 105519 Removing and installing oil mist separator on 4.8-liter DFI engines Preliminary work Preliminary work 1. Remove design cover of bar ignition modules and throttle valve.