Disassembling Engine

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

Information 

• Guide the timing chains with your hand when turning the crankshaft so that they do not get stuck in the crankcase. 

1. Remove cylinder head cover.

   → 158219 REMOVING AND INSTALLING CYLINDER HEAD COVER - TURBO .

   1. 1.1. Unscrew one external Torx screw (E12, M8 x 20) for the engine ground strap on cylinder bank 4-6 and remove the ground strap.
2. Check visually to see which cylinder bank is at overlapping position. Remove this cylinder bank first.
   1. 2.1. Cam positions: 
      • Overlapping position of cylinder bank 1-3: Cams on cylinder 1 are facing outward at a slant -arrows-  .
        Fig 1: Locating Cylinder (1) Cam Position

        Courtesy of PORSCHE CARS NORTH AMERICA, INC.
      • Overlapping position of cylinder bank 4-6: Cams on cylinder 4 are facing inward at a slant to the spark-plug recess -arrows-  .
        Fig 2: Locating Cylinder (4) Cam Position

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   2. 2.2. If the camshafts are at overlapping position, square markings can be seen on the outlet and intake camshaft. These markings are facing the observer (data matrix code) -inset-  .
      Fig 3: Identifying Camshafts Marking (4-6)

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Remove camshafts.

   → 150520 REMOVING AND INSTALLING CAMSHAFTS (INCLUDES SETTING TIMING) .

   Information 

   • Position hydraulic tappets on a surface you have prepared and labelled yourself in accordance with their installation position in the cylinder head. 
   • Components have been run in fitted bores and must not be confused. 
   • Do not use magnets for removal or installation. This can cause the components to malfunction. 
4. Remove hydraulic tappets.
   1. 4.1. Pull six bucket tappets -1-  and six switching tappets -2-  out of the fitted bores in the cylinder head with your thumb and index finger.

      Do not use a magnet! 

      Fig 4: Identifying Hydraulic Tappets Valve Control

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   2. 4.2. Lay components on clean, labelled cardboard →
      Fig 5: Example Of Laying Aside Bucket Tappets

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5. Remove tensioning and guide rails.
   1. 5.1. Cylinder 1-3:  Unscrew one bearing pin -2-  for the tensioning rail and two bearing pins -1-  for the guide rail.
      Fig 6: Identifying Cylinder Bank Bearing Pins (1-3)

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   2. 5.2. Pull out the guide and tensioning rails -1-  using a pair of flat-nosed pliers.
      Fig 7: Pulling Guide And Tensioning Rails

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   3. 5.3. Lay the timing chain in the chain slot.
   4. 5.4. Pull oil supply valve on the vacuum pump -1-  out of the cylinder head using a pair of flat-nosed pliers -arrow-  . Replace O-ring.
      Fig 8: Identifying Vacuum Pump Oil Supply Valve (Brake Booster)

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      Fig 9: Locating Oil Supply Valve

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   5. 5.5. Cylinder 4-6:  Unscrew two bearing pins -2-  for the guide rail and one bearing pin -3-  for the tensioning rail.
      Fig 10: Identifying Bearing Pins (Cylinder Bank 4-6)

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   6. 5.6. The bearing pin for the tensioning rail 4-6 -1-  is longer than the five other pins -2-  for the timing chain rails.
      Fig 11: Identifying Difference Between Bearing Pins

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   7. 5.7. Replace O-rings on the bearing pins.
6. Remove cylinder head and cylinder head gasket.

   → 157019 REMOVING AND INSTALLING CYLINDER HEAD .

7. Pull out twelve displacement bodies -1-  on cylinder bank 1-3 using a pair of flat-nosed pliers.
   Fig 12: Identifying Piston Marking And Displacement Bodies (Cylinder Bank 1-3)

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
8. Turn the engine at the engine assembly support so that the oil pan is at the top.
9. Remove lower part of oil pan.

   → 175019 REMOVING AND INSTALLING OIL PAN .

   1. 9.1.
10. Remove oil lines in the oil pan.
    1. 10.1. Remove return lines -1 and 3-  for the turbocharger by unscrewing two external Torx screws (E10) M6 x 16 -2-  and one (E10) M6 x 12 on each -4-  .
    2. 10.2. Remove supply line -5-  by unscrewing three external Torx screws (E10, M6 x 16) -2-  .
       Fig 13: Identifying Oil Pan Lines

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11. Remove upper part of oil pan.

    → 175019 REMOVING AND INSTALLING OIL PAN .

12. Remove coolant pipe -1-  for the coolant pump.
    1. 12.1. Unscrew two external Torx screws (E10, M6 x 12) -2-  and remove the pipe.
       Fig 14: Identifying Coolant Pipe

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13. Remove oil pump and oil guide.

    → 172019 REMOVING AND INSTALLING OIL PUMP .

14. Turn the engine at the engine assembly support so that cylinder bank 1-3 is facing upwards.
15. Remove pistons for cylinders 1-3.

    → 131020 REMOVING AND INSTALLING PISTONS - TURBO .

16. Remove crankcase half 1-3.
    1. 16.1. Unscrew 19 external Torx screws for the outer cross bolt connection. The threaded bolt must be removed for the screw -17-  .
       Fig 15: Outer Cross Bolt Connection Loosening Sequence

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       15, 16 and 17  - External Torx screw, M8 x 35

       18  - External Torx screw, M6 x 40

       19-32  - External Torx screw, M6 x 25

       33  - External Torx screw, M8 x 120

    2. 16.2. Loosen and unscrew through-bolt screws (E14) M10 x 195 in the opposite sequence to the tightening sequence.
       Fig 16: Crankcase Through-Bolt Screws Tightening Sequence

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.

       1-14  - External Torx screw M10 x 1.5 x 195 with sealing washer

    3. 16.3. Check screws for damage and replace them if necessary or only replace the sealing washers.
17. Unscrew two mounting parts 9590  for bolting crankcase half 1-3 to the engine support.
18. Lift off crankcase 1-3.
    1. 18.1. To do this, put on heat-resistant gloves and heat the sealant at the joint slightly with a hot-air gun.
    2. 18.2. Carefully lift up crankcase half 1-3 at the positions shown using a large slotted screwdriver.
       Fig 17: Locating Lever Positions On Crankcase

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    3. 18.3. Slide in two pieces of wood above the oil-pump pressure channels and lift up the crankcase half using a mounting lever.
       Fig 18: Locating Mounting Lever Position On Crankcase

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
19. Remove pistons and connecting rods on cylinders 4-6.

    → 131020 REMOVING AND INSTALLING PISTONS - TURBO .

    1. 19.1. Remove connecting rods 1-3 on the crankshaft.
20. Remove and dispose of crankshaft sealing rings.
21. Lift crankshaft and timing chains out of crankcase half 4-6.

    Get another person to help if necessary. 

    Fig 19: Identifying Crankshaft And Timing Chains

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    1. 21.1. Remove bearing shells from the crankcase halves and dispose of them.
    2. 21.2. The deviation sample catalogue for the Cayenne can be used to assess the cylinder linings.

       → WM 101001 ASSESSMENT OF CYLINDER LINERS (CHECKING CRANKCASE) .

22. Carefully clean the crankcase and sealing surfaces.