Disassembling Engine

WARNING: This page is about a different variant/trim than selected.

CAUTION: Heavy components

Risk of squashing
→ Wear personal protective gear.

→ Get someone to help if necessary.

WARNING: Danger of objects or loads falling down

Risk of squashing or crushing
→ Secure components to prevent them from falling down.

NOTIFICATION

Interchanged or dirty bucket tappets

Scoring on cylinder head
→ Since the bucket tappets have been run in the fitting bores, do not interchange them.

→ Absolute cleanliness is essential.

Information

Have a collection pan and some cloths ready before starting work on the engine block. Close off open hoses immediately after opening them using suitable stoppers. Residual fluid can leak out.

Information

Support the engine at the oil pan or engine carrier using suitable lifting equipment and a wide wooden block.

Information

For many components, it is only necessary to partially disassemble the engine. The extent of disassembly depends on the damage and scope of repairs to be carried out.

When replacing the cylinder-head gasket, some add-on parts, such as the vacuum pump, injectors and exhaust manifolds, remain on the cylinder head. In this case, the cylinder head can be lifted off the crankcase with all add-on parts intact.

Remove drive belt.
> 137819 REMOVING AND INSTALLING DRIVE BELT
Remove power-steering pump and air-conditioning compressor if necessary.
Remove front-axle final drive and cross-shaft engine carrier. For a detailed description, see
> WM 398819 REMOVING AND INSTALLING FOUR-WHEEL FINAL DRIVE (PANAMERA 4, PANAMERA 4S, PANAMERA TURBO, PANAMERA 4 S EXECUTIVE, PANAMERA TURBO EXECUTIVE, PANAMERA TURBO S, PANAMERA TURBO S EXECUTIVE, PANAMERA GTS)

First remove the cross-shaft engine carrier and cross shaft and carefully pull them out of the crankcase.

Remove front-axle final drive.
Remove spark plugs.
> 287020 REMOVING AND INSTALLING SPARK PLUGS

Remove tank vent line and engine ventilation lines. The engine ventilation system on turbo engines is designed with one-way plug connections. For details, see

1052IN INFORMATION ON POSITIVE CRANKCASE VENTILATION (FULL-THROTTLE VENTILATION) - TURBO

Fig 1: Ventilation On Turbo Engines Components Location

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Ventilation on turbo engines

1	Engine ventilation line
2	Check valve for full-throttle ventilation with lines secured
3	Tank ventilation
4	Aluminium holder
5	Aluminium screw (holder); see Chain housing cover
6	Belt tensioner
7	Holder
8	Fastening screw; see Belt drive

Remove oil mist separator.
> 105519 REMOVING AND INSTALLING OIL MIST SEPARATOR
Remove intake-air distributor.
> 244619 REMOVING AND INSTALLING INTAKE-AIR DISTRIBUTOR
Remove fuel distributor pipe.
> 243019 REMOVING AND INSTALLING FUEL DISTRIBUTOR PIPE
Remove high-pressure pump at cylinder 8.
> 246319 REMOVING AND INSTALLING HIGH-PRESSURE PUMP

Remove vacuum pump at cylinder 4. To do this, loosen the three screws. >

Fig 2: Vacuum Pump Components Location

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Vacuum pump

1	Vacuum pump
2	Screw, M6 x 25; vacuum pump to cylinder head
3	Sealing ring
4	Sealing ring

Remove low-pressure line -4- at the cylinder head.

Fig 3: High-Pressure Pump Components Location (Turbo Engine)

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High-pressure pump, turbo engine

1	High-pressure pump
2	High-pressure line
3	M6 screw on low-pressure line
4	Low-pressure line; counter at the hexagon on the high-pressure pump
5	Screw socket, M8
6	Screw socket, M6
7	Protective plate
8	Screw, M6 x 20
inset	Required line distance (5 to 8 mm) between components

Detach and remove coolant hose assembly -5- . Remove coolant pipe -4- .

Fig 4: Coolant Return Components Location (Turbo Engine)

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Coolant return on turbo engine

1	Connection piece on generator
2	Connection piece screw
3	Screw, M6 x 20
4	Coolant return line
5	Coolant return hose assembly
6	Holder
7	Screw, M6
8	Clip

Remove water pump.
> 195019 REMOVING AND INSTALLING COOLANT PUMP

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Coolant pump
Remove vent line.
Unscrew and remove fastening screws -1-

Unclip vent line -2- from the cable duct and remove it -arrow- .

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Removing vent line
Remove the generator. Expose peripheral equipment and unscrew the generator.
Remove support bracket (crash support) -10- from the generator (two screws) -9- .

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Auxiliary units

Remove fastening screws on the generator -2 and 3- .

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Generator

Carefully remove generator and disconnect B+ cable. To do this, remove nut in he rear of the generator.

Remove ambient air lines and boost-pressure control lines. Mark lines and place aside in order.

Fig 5: Boost Pressure And Ambient Air Components Location

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Boost pressure and ambient air

1	Pressure line, boost pressure line
2	Hose clamp
3	Cycle valve
4	Holder to chain housing cover
5	Combination holder
6	Control line
7	Control line
8	Hose holder
9	Screw on chain housing cover; see Chain housing cover

Fig 6: Boost Pressure And Ambient Air 2 Components Location

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Boost pressure and ambient air 2

1	Pressure line
2	Vacuum line
3	Hose clamp
4	Screw, M6 x 12
5	Holder
6	Rubber element
7	Electric change-over valve
8	Control line

Remove engine wire harness. Disconnect cable plug for the engine wire harness at the coolant regulator (thermostat insert) using pointed-nose pliers. For details, see
> WM 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE (EXCEPT PANAMERA S E-HYBRID, PANAMERA S HYBRID)

Unscrew and remove fastening screws.

Lift engine wire harness up and out -arrow-

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Loosening engine wire harness at the engine housing

Disconnect coolant pipe at the collection pipe. To do this, remove screws -2- .

Fig 7: Coolant Guide Components Location

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Coolant guide

2	Screw, M6
3	Sealing ring
4	Screw plug, M16 x 1.5
5	Screw, M6
6	Coolant guide tube (collection pipe)
7	Metal seal
8	Stopper

Remove thermostat housing.

Pull out thermostat insert (coolant regulator) -5- . Pull out thermostat insert using a strong cable. For a detailed description of how to remove the coolant regulator, see

> 195819 REMOVING AND INSTALLING COOLANT REGULATOR

Detach thermostat housing and remove with the coolant pipe fitted.

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Thermostat housing and coolant regulator

1	Thermostat housing
2	Screw, M6 x 25
3	Screw, M6 x 25; screwed to fuel high-pressure distributor pipe => see relevant service information
4	Seal for thermostat housing; replace
5	Thermostat insert; including electric heating element

Remove high-pressure line -2- . To do this, remove union nut -5- .

Fig 8: High-Pressure Pump Components Location (Turbo Engine)

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High-pressure pump, turbo engine

1	High-pressure pump
2	High-pressure line
3	M6 screw on low-pressure line
4	Low-pressure line; counter at the hexagon on the high-pressure pump
5	Screw socket, M8
6	Screw socket, M6
7	Protective plate
8	Screw, M6 x 20
inset	Required line distance (5 to 8 mm) between components

Remove starter -1-. To do this, remove screws -2- .

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Starter

Remove the two turbochargers with lines connected.

Disconnect lines at the engine (the lines remain fitted on the turbocharger).

Fig 9: Turbocharger, Cylinders 1 To 4 - Cooling Components Location

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Turbocharger, cylinders 1 to 4 - cooling

1	Coolant return line for turbocharger
2	Coolant supply line for turbocharger
3	Clip
4	Coolant supply hose for turbocharger
5	Turbocharger; exhaust manifold/turbocharger module

Fig 10: Turbocharger, Cylinders 5 To 8 - Cooling Components Location

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Turbocharger, cylinders 5 to 8 - cooling

1	Coolant return line for turbocharger
2	Coolant supply line for turbocharger
3	Bracket for coolant supply line on oil guide housing

Fig 11: Oil Circuit For Turbocharger, Cylinders 1 To 4 Components Location

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Oil circuit for turbocharger, cylinders 1 to 4

1	Vent line for turbocharger, cylinders 1 to 4; vent line to oil extraction line for turbocharger and holding clamp for vent line to collection pipe
2	Oil feed line for turbocharger, cylinders 1 to 4; oil feed line for turbocharger to connection piece; oil feed line for turbocharger to cylinder head
not shown	Connection piece for check valve to turbocharger
3	Holder
4	Seal
5	Oil extraction line
6	Screw, M6 x 12; oil extraction line for turbocharger to oil guide housing
7	Screw, M6 x 16

Fig 12: Oil Circuit For Turbocharger, Cylinders 5 To 8 Components Location

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Oil circuit for turbocharger, cylinders 5 to 8

1	Oil feed line for turbocharger, cylinders 5 to 8; oil feed line for turbocharger to connection piece; oil feed line for turbocharger to cylinder head
2	Vent line for turbocharger, cylinders 5 to 8; vent line to oil extraction line for turbocharger
3	M6 screw; oil extraction line for turbocharger to oil guide housing and holding clamp
4	Holding clamp
5	Oil extraction line
6	Screw, M6 x 16
7	Seal

Fig 13: Turbocharger Exhaust Manifold, Cylinders 1 To 4 Components Location

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Turbocharger exhaust manifold, cylinders 1 to 4

1	Turbocharger exhaust manifold, cylinders 1 to 4
2	Seal; install so that marking on seal is legible
3	Lower tab washer
4	Upper tab washer
5	M8 nut, turbocharger/exhaust manifold to cylinder head

Fig 14: Turbocharger Exhaust Manifold, Cylinders 5 To 8 Components Location

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Turbocharger exhaust manifold, cylinders 5 to 8

1	Turbocharger exhaust manifold, cylinders 5 to 8
2	Seal; install so that marking on seal is legible
3	M8 nut, turbocharger/exhaust manifold to cylinder head
4	Upper tab washer
5	Lower tab washer

Remove metal pipe for coolant supply -2- . Remove coolant hoses and metal pipe.

Fig 15: Cooling System On Turbo Engines Components Location

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Cooling system on turbo engines

1	M6 screw; securing coolant line to collection pipe
2	Coolant pipe
3	Connection piece screw
4	Connection piece on generator
5	Coolant supply hose for oil/coolant heat exchanger
6	Coolant supply hose to generator

Remove belt tensioner and deflection rollers. To do this, carefully lever off the covers on the rollers and unscrew the components. -1,-2,-3,-4-

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Belt drive
Unscrew oil pressure sensor -3- with adapter -1- from the crankcase. To do this, remove screws -4- .

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Oil pressure sensor and oil pressure measuring point
Remove both cylinder head covers (valve covers). > >

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Bar ignition modules and valve covers, cylinder bank 1 to 4

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Bar ignition modules and valve cover, cylinder bank 5 to 8
Loosen screw on vibration balancer by two turns -4 and 3- . To do this, hold a counter-hold tool > 9679/1 - counter-hold tool at the vibration balancer with the help of a second worker. Support the counter - hold tool on the floor if necessary. A very high torque is required to loosen the screw (more than 800 Nm/592 ftlb.). A long 3/4-inch tool is the best tool to use for this. The engine should be supported to prevent it from tipping over.

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Supporting engine (illustration shows V8 4.5-litre engine supported on assembly support)

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Pulleys
Turn the crankshaft at the vibration balancer so that the staking bore of the vibration balancer is located approx. 45° degrees in front of the lower staking point on the chain housing cover. >

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Staking bore 45 degrees before TDC
Remove chain tensioner for timing chain from the chain housing cover. -5-

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Chain tensioner
Loosen camshaft controller and sprockets on the four camshafts by 2 turns. Always counter at the hexagon on the components when doing this. > >

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Sprocket

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Camshaft controller
Remove vibration balancer.
Turn the engine around. The oil pan must be facing upwards.

Unscrew oil pan -1- To do this, remove all screws -5- . The seal must be replaced.

Fig 16: Oil Pan Components Location

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Oil pan

1	Oil pan
2	Seal
3	Seal
4	Oil drain plug, M18; aluminium screw; re-usable
5	Screw, M6 x 20

Detach and remove joint flange on the oil pressure control valve -2- . Disconnect oil level sensor and remove by turning -5- .

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Oil guide housing with accessories

Remove all oil lines between the oil guide housing and oil pump. > >

Fig 17: Oil Lines On Turbo Engine Components Location

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Oil lines on turbo engine

1	Suction pipe between oil pump and turbocharger (fitted in oil guide housing)
2	Suction pipe between oil pump and turbocharger (fitted in oil guide housing)
3	Intake pipe on oil pump
4	Sealing ring
5	Oil pressure pipe
6	Sealing ring
7	Sealing ring; oil before fitting
8	Oil regulating line
9	Sealing ring
10	Sealing ring; oil before fitting
11	Oil pipes to oil pump and oil guide housing
12	Oil pipes to oil pump and oil guide housing

Fig 18: Oil Lines On Turbo Engine Components Location

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Oil lines on turbo engine, view with oil pan removed

1	Mounting for oil pressure pipe
2	Mounting for oil extraction line for turbocharger, cylinders 5 to 8
3	Mounting for oil extraction line for turbocharger, cylinders 1 to 4
4	Mounting for auxiliary sump intake pipe
5	Mounting for oil pump intake pipe
6	Mounting for oil regulating line

Remove cross shaft cover -1- on both sides.

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Cross shaft cover

Unscrew and remove fastening screws -arrows- on both sides.

Remove one cross shaft cover -1- .

The second cross shaft cover will be removed with the cross shaft pipe -1- .

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Cross shaft pipe with cover.

It does not matter whether the cross shaft pipe -1- is removed with the left or right cover.

Remove housing sealant -2- under both cross shaft covers.

Remove all screws between the oil guide housing and crankcase/chain housing cover -4- . Don't forget the screws at the front -7- .

Fig 19: Oil Guide Housing With Accessories Components Location

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Oil guide housing with accessories

1	Screw, M6 x 20
2	Joint flange
3	Sealing ring
4	Oil guide housing to lower part of crankcase - aluminium screw
5	Oil level sensor
6	Oil level sensor to oil guide housing (steel screw)
7	Timing-case cover to oil guide housing - aluminium screw

The oil guide housing is sealed with glue. To make it easier to remove, carefully lever off the oil guide housing between the outer flanges on the crankcase and the oil guide housing. > Loosen by tapping carefully with a plastic hammer if necessary. Remove the entire oil guide housing. Remove old sealing ring.

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Removing oil guide housing
Remove joint flange on vibration balancer -1- at the chain housing cover. To do this, remove screws -2 and 3- .

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Chain tensioner, joint flange

Remove all M6 and M8 screws on the chain housing cover > and lift off chain housing cover. Also remove all the metal seals. >

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Chain housing cover

Fig 20: Chain Housing Cover Seals Components Location

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Chain housing cover seals

1	Chain housing cover
2	Chain housing cover seal, outer right (fill openings with sealant, see 6)
3	Inner chain housing cover seal
4	Chain housing cover rib seal
5	Chain housing cover seal, outer left (fill openings with sealant, see 6)
6	Sealant application on timing chain housing; Loctite 5900 (000.043.204.35 status 10/08)

Remove timing chain -1- (mark rolling direction for reinstallation using a felt-tip pen) from all the sprockets and place on a clean surface.

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Timing chain and sprockets
Remove tensioning rail -4- . Remove threaded peg -1- if necessary.

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Tensioning rail
Remove U-rail (guide rail) -4- . To do this, remove four M8 screws -5- .

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Timing chain and sprockets
Carefully slacken the lower tensioning rail for the oil pump chain. Press the tensioning rail back with a small screwdriver until both staking holes between the tensioning rail and guide rail are aligned. >

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Oil pump tensioning rail
Stake tensioning rail for oil pump chain through the hole in the guide rail using a suitable drill bit, drift punch or nail. This slackens the oil pump chain. >

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Staking tensioning rail for oil pump chain
Remove guide rail -3- . Guide rail is locked with -6- .

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Guide rail

If the sprockets and camshaft controllers are to be separated from the camshafts, now unscrew the loosened camshaft controllers and sprockets.

Fig 21: Camshaft Control Components Location

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Camshaft control

1	Screw, M12 Tighten fully after setting valve timing.
2	Camshaft controller with integrated hexagon for countering
3	Hydraulic valve for camshaft control
4	Screw, M5 x 12

Slowly and uniformly loosen and then unscrew all M6 screws -3 and 5- in the camshaft housings -2, 4 and 6- . The housings are marked E for intake camshaft and A for outlet camshaft. The housings are numbered consecutively by cylinder. The housings are seated very securely in the cylinder head because of a dowel sleeve -1- Jiggle free using a pliers if necessary. Place on a marked, clean surface.

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Camshaft mount, cylinders 5 to 8
Remove camshafts -3 and 6- and place on a marked, clean surface.

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Camshafts, cylinders 5 to 8
Remove valve lifters -1 and 2- and place on a marked, clean surface in such a way that they cannot be mixed up.

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Diagram showing how to set down lifters
Remove mounting saddle at the front -8- . This hides the cylinder head screws underneath.
Remove front M8 screw securing the cylinder head of cylinders 1 to 4 to the crankcase. -3-

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Cylinder head 1 to 4
Turn the engine so that the cylinder head you want to remove is pointing straight upwards.
The injectors can now be removed easily if necessary. For details, see
> 244019 REMOVING AND INSTALLING FUEL INJECTOR
Remove cylinder head screws in the opposite order to the tightening sequence shown > Remove cylinder head.

Fig 22: Cylinder Head Screws Tightening Sequence
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Tightening sequence for cylinder head
Remove cylinder-head gasket.
Remove cylinder head for cylinders 5 to 8 in the same way.
Turn the engine around. The oil pump must be facing upwards.

Remove suction tube -1- To do this, unscrew screws -3- and remove suction tube.

Fig 23: Auxiliary Sump Suction Tube Components Location

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Suction tube for auxiliary sump

1	Suction tube for auxiliary sump
2	Sealing ring
3	Screw, M6
3 inset	View of click position

Remove chain cover for oil pump -9- . To do this, remove screws -10- .

Fig 24: Oil Pump Components Location (Turbo Engine)

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Oil pump, turbo engine

1	Oil pump with extraction stage
2	Screw, M8 x 22; replace
3	Oil pump sprocket
4	Cap screw, M36
5	Solenoid valve
6	Sealing rings (grease before fitting)
7	Dowel sleeve
8	Screw, M6 x 45
9	Sprocket cover
10	Screw, M6 x 16
11	Drive chain

Remove drive pinion for oil pump. Screw is tightened beyond the elastic limit. Use a screwdriver to counter at the oil pump through the bore in the drive pinion. >

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Countering oil pump pinion
Remove oil pump pinion with chain and crankshaft pinion. >

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Oil pump chain
Unscrew oil pump -1- To do this, remove screws -8- . Pull oil pump out at the point where the pipe engages at the rear with the oil plate. When doing so, make sure that the locking lug does not break off. Swivel oil pump up and out.

Unscrew oil plate/oil guide.

Fig 25: Oil Return (Oil Plate) Components Location (4WD)

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Oil return (oil plate), 4WD

1	Oil guide (oil plate)
2	Oil return seal
3	Screw, M6 x 20

Remove lower part of crankcase. First unscrew and remove the four M8 screws on the output side -7 and 8- . The bearing screws for the 4WD shaft are shorter (keep these separate).

Fig 26: Lower Part Of Crankcase Components Location (V8 4WD)

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Lower part of crankcase, V8 4WD

1	Lower part of crankcase
2	Straight pin, 6 x 18
3	Dowel sleeve
4	Seal
5	Joint flange
6	Screw, M6 x 20
7	Screw, M8 x 35
8	Screw, M8 x 50
9	Sealing rings for joint flange/cross tube
10	Cross tube for all-wheel drive cross shaft
11	Aluminium screw, M8 x 70; (cross bolt connection); always use new aluminium screws
12	Thrust-bearing screw, M10
13	Thrust-bearing screw, M11
14	Sealing ring
-	Sealant application - Doboseal 224N (999.915.573.43, status 09/08)

Unscrew and remove outer M8 cross bolt connection in reverse order to the tightening sequence. Always use new aluminium screws.

Fig 27: Lower Part Of Crankcase To Upper Part Of Crankcase Screws Tightening Sequence

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Tightening sequence for securing lower part of crankcase to upper part of crankcase (cross bolt connection)

Unscrew M10 and M11 thrust-bearing screws in the opposite order to the tightening sequence. Start with the outer M10 screws first.

Fig 28: Thrust-Bearing Screws Tightening Sequence

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Tightening sequence for thrust-bearing screws

Lift off lower part of crankcase. Get a second person to help if necessary. Remove old sealing ring. Remove bearing shells if necessary and mark them.

Secure crankshaft at the centre using a holding bridge > 9677/1 - holding bridge . Tighten screws slightly. -1-

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Crankshaft secured
Loosen connecting rod bolts -6- and take off connecting rod caps -5- . Push piston in question out of the crankcase using a wooden rod. Hold it in your other hand or get another person to help. Fit connecting rod cap hand-tight to the connecting rod again using the old screws and set down after marking according to the relevant cylinder. The connecting rod bolts must be replaced with new ones during reinstallation. The connecting rods are cracked and the connecting rod code; is facing the exhaust side. The combustion chamber recess on the piston is facing the injector.

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Piston, connecting rod
Remove all pistons in the same way.
(If you have not already done so) turn the engine so that the crankshaft is at the top.
After removing all the pistons, remove the crankshaft -1- (remove holding bridge) and place on a clean surface.

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Crankshaft
Remove all bearing shells -5 and 6- and thrust washers -4- if necessary. Mark the bearing shells and set them down.
Remove oil spray jets -6- . To do this, loosen screws -7- .

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Upper part of crankcase

Remove coolant guide -6- . Remove seals -7- .

Fig 29: Coolant Guide Components Location

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Coolant guide

2	Screw, M6
3	Sealing ring
4	Screw plug, M16 x 1.5
5	Screw, M6
6	Coolant guide tube (collection pipe)
7	Metal seal
8	Stopper