Assembling Engine

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

NOTIFICATION

Ingress of dirt

Danger of material damage due to blocked oil bores/oil ducts
→ Ensure absolute cleanliness when working on the engine.

→ Lay removed engine parts on a clean surface and cover them.

→ Use a cover or PE sheet on the engine assembly support to prevent dirt from getting into the engine during assembly.

CAUTION: Heavy components

Risk of squashing
→ Wear personal protective gear.

→ Get someone to help if necessary.

CAUTION: Leaks due to insufficiently or differently tempered components!

If cold or differently tempered components are sealed to each other by applying a sealant, adhesion problems or leaks can result because of condensed water forming or components becoming distorted.
→ All components must be at least 17°C.

→ Components must not be too hot (distortion).

→ Spare parts stored in cold or heat (strong exposure to sunlight) must be at room temperature, or must have the same temperature as other components, before installation.

CAUTION: Emerging residual fluid can soil the engine!

Residual fluid (fuel, oil, Pentosin, coolant, etc.) will emerge even after a long time when disassembling and assembling the engine.
→ Place a drip tray under the engine at the assembly support.

→ Have a sufficient number of cleaning cloths ready.

→ Close off engine openings using stoppers.

Information

The tightening specifications for the basic engine are stored centrally.

> TECHNICAL VALUES

> WM 2X00IN TECHNICAL VALUES (PANAMERA, PANAMERA S, PANAMERA S EXECUTIVE, PANAMERA 4, PANAMERA 4S, PANAMERA 4 S EXECUTIVE)

> 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES AND ASSEMBLY OVERVIEWS

Tightening torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.

Information

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Colour marking on bearing shell

The bearing shells are available in various classes. The classes are indicated by the colour marking on the outside. For every bearing (main and connecting rod bearings), the colour marking must match the corresponding letter on the flywheel flange of the crankshaft. -arrow- Each letter on the flywheel flange of the crankshaft indicates the correct colour classification of the bearing shell.
Information

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Connecting rod code and direction of travel arrow

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Connecting rod code "A"
The corresponding connecting-rod bearing shells must be selected according to the marking on the crankshaft transmission flange (4-digit) and inserted into the connecting rod.
When removing the pistons with connecting rods, the pistons should be marked with a water-resistant marker on both the piston and connecting rod according to cylinder and cylinder bank.
The removed pistons and connecting rods must be cleaned carefully so as not to remove the markings.
The connecting rod code is installed to the exhaust side as standard. The direction of travel arrow on the DFI piston is always on the same side as the connecting rod code -A- The pistons are assigned to the cylinder bank (1 to 4 and 5 to 8), i.e. because of the DFI combustion chamber recess there are two different pistons for the left and right cylinder bank.
When installing the piston in the crankcase, the direction of travel arrow must point in the direction of travel when installed. It is always on the same side as the connecting rod code. The combustion chamber recess on the piston is always on the intake side. Note the assignment of the pistons to the cylinder bank.
Naturally aspirated engines and turbo engines have different pistons.
The code on the connecting-rod big end and connecting rod cap must be on the same side and at the exhaust side. -A-
NOTE: Select the correct piston for the correct cylinder bank. Install with connecting rod code on the exhaust side with the direction of travel arrow on the piston.

Information

Connecting rod bolts must always be replaced.

Information

Please note the following for the V6 =>

The repair concepts for the V6 are the same as for the V8.
The special features and component deviations are listed and shown in
> 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES AND ASSEMBLY OVERVIEWS
More significant deviations are shown in separate descriptions.
If no special features are specifically highlighted, the assembly and adjustment instructions for the V8 apply.

Information

Particular care and attention must be paid to the combined V6 oil pump balance shaft module during disassembly and assembly work. This is completely different from the V8 oil pump concept.
The V6 oil pump balance shaft module with the balance weight is installed at a defined position with respect to the crankshaft.
The balance shaft in the V6 oil pump balance shaft module is fixed to the crankshaft. Non-observance of this requirement results in strong vibrations in the engine.
For details, see
> 172019 REMOVING AND INSTALLING OIL PUMP

Place crankshaft bearing shells into the lower part of the crankcase.

Select crankshaft bearing shell classification based on the inscription on the crankshaft's flywheel flange -9- . Example: GGGGB GGGG mean 5 main shaft bearings and 4 double connecting rod bearings (8 connecting rods in total). The letters are the abbreviations for the colour code of the bearing shells (G for yellow, B for blue, R for red, N for green). Based on the example above, yellow bearing shells are to be selected for the main shaft bearings 1 to 4 and a blue bearing shell is to be selected for the fifth main shaft bearing. The connecting rod bearing shells must all have a yellow marking in this case.

Fig 1: Crankshaft Components Location

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Crankshaft

1	Crankshaft (stroke: 83 mm)
2	Straight pin, 6x20
3	Spring wedge
4	Thrust washer
5	Main bearing shell, upper
6	Main bearing shell, lower
7	Shaft seal
8	View of crankshaft flange
9	Crankshaft bearing classification (four types) G Yellow; B Blue, R Red; N Green => (example: GGGGG-BBBB; 5 main shaft bearings with yellow marking, 4 double (8) connecting rod bearings with blue marking) => For numbering, see A

Place crankshaft bearing shells with lubricating groove and bore -2- into the upper part of the crankcase -1- . Smooth crankshaft bearing shells -3- belong in the lower part of the crankcase. Insert the thrust washers into the centre with grooves facing outwards (affix using multipurpose grease) or alternatively wait until after the crankshaft has been inserted.

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Inserting bearing shells

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Inserting bearing shells

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Thrust washer

Oil crankshaft bearing shells on the outside and inside with engine oil and insert correctly into the lower part of the crankcase according to the twist lock. Place lower part of crankcase on a clean surface. The retaining lugs (twist lock) prevent it from being installed incorrectly. As the thrust washers fall off without the crankshaft, do not insert until after the crankshaft is fitted.

If you have not already done so, fit knock sensors on the upper part of the crankcase using screws.
Align the knock sensors between cylinder 1 and 2 and cylinder 5 and 6 parallel to the cylinder head and the plug connection parallel to the starter. Fit knock sensors hand-tight.

Insert starter briefly and align concealed knock sensors so that there is no knock sensor near the starter. Remove the starter. Fit plug connection for knock sensor between cylinders 3 and 4 in the direction of the water pump so that it is turned upwards and slightly towards the cylinder head. Fit plug connection for knock sensor between cylinders 7 and 8 in the direction of the flywheel so that it is turned upwards and slightly towards the cylinder head.

Fit knock sensors correctly.

Fig 2: Knock Sensors Components Location
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Knock sensors

1 Knock sensor

2 Screw, M8 x 35

Insert two seals for the thermostat housing into the upper part of the crankcase on both sides. -2- .

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Seals between crankcase and thermostat housing

Check coolant guide (collection pipe) to make sure that the sealing faces are clean and free of burrs. Fit metal seals on left and right, screw in screws securely on metal seals by hand. Move coolant guide at the upper part of the crankcase into installation position and fit it.

Fig 3: Coolant Guide Components Location

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Coolant guide

1	Coolant pipe
2	M6 screw
3	Sealing ring
4	Screw plug, Ml6 x 1.5
5	M6 screw
6	Coolant guide tube (collection pipe)
7	Metal seal
8	Stopper

Fit oil spray jets -6- .

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Upper part of crankcase

Insert oil spray jets into the upper part of the crankcase and screw them on. To do this, grease the sealing ring sparingly with Kuber Syntheso GLEP 1 and fit it. Check that oil spray jets are pointing in the correct direction of spray toward the inside of the piston crown. The oil spray jet must be aimed at the piston crown. > Spray direction > Spray direction from side

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Spray direction

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Spray direction from side
Pre-fit spring wedge of crankshaft into the corresponding groove on the crankshaft using a plastic hammer if necessary.

Pre-fit all pistons with connecting rods and piston rings, number by cylinder and place to one side. For details, see

> 131037 DISASSEMBLING AND ASSEMBLING PISTONS

Fig 4: Piston, Connecting Rod Components Location

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Piston, connecting rod

1	Piston-ring set
2	Pistons
3	Circlip/piston-pin circlip
4	Piston pins
5	Connecting rods
6	Connecting rod bolt; replace as it must be tightened in the plastic area
7	Connecting-rod bearing shells

Check that all the seals are installed in the oil plate (oil return). > Oil return (oil plate), 4WD shown

Fig 5: Oil Return (Oil Plate) Components Location (4WD)

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Oil return (oil plate), 4WD shown

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

If you have not already done so, drive dowel sleeves for the metal seals in the chain housing cover using a copper or plastic hammer.
Insert new metal seals on the chain housing cover and press onto the dowel sleeves.
Oil pump is pre-fitted with the oil pressure control valve.
Cylinder heads fitted with solenoid valves of the valve lift switchover, camshaft housings loosely positioned and removed camshafts prepared. Alternatively, the camshaft housings, which have been marked according to installation position, can be set down on a clean surface together with the corresponding camshafts. Cam followers and injectors are fitted.
If you have not already done so, drive in dowel sleeves on auxiliary unit bracket for power-steering pump or tandem pump using a copper or plastic hammer.
Move starter into installation position and screw down.
> 276019 REMOVING AND INSTALLING STARTER
Insert crankshaft and oil crankshaft bearing pin and connecting-rod bearing pin.
First position timing chain pinion with the ring gear of the oil pump drive onto the crankshaft stub (check that the two diamond washers at the front and rear on the ring gear are clipped in -1- . Then position the drive pinion of the oil pump chain -2- with respect to the crankcase.

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Timing chain pinion on crankshaft stub

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Timing chain pinion with two diamond washers
Fit crankshaft holding bridge > 9677/1 - holding bridge in the centre of the crankshaft.

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Crankshaft secured
Turn upper part of crankcase and oil cylinder liners.
Pre-tension pistons using an assembly funnel > 9784/1 - funnel and press pistons into the cylinder. For details, see
> 131020 REMOVING AND INSTALLING PISTONS

Remove crankshaft holding bridge. Apply Doboseal 224N sealant (999.915.573.43, status 09/09) to the lower part of the crankcase as shown. Insert sealing ring -3- into the upper part of the crankcase and position the lower part of the crankcase onto the upper part of the crankcase. Insert all the fastening screws, fit to the prescribed tightening torque within 5 minutes and wipe off excess sealant.

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Applying sealant

1	Wipe off sealant residues after fitting
A	Direction of travel

Screw down M11 and M10 bearing screws to the prescribed torques. -5 and 6- . The bearing screws for the 4WD shaft are shorter. Do not confuse them.

Fig 6: Thrust-Bearing Screws Tightening Sequence

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Tightening sequence for thrust-bearing screws

1 to 20	Tightening sequence for M11 and M10 screws => Observe different torques!
A	Direction of travel

Fig 7: Lower Part Of Crankcase Components Location (2WD)

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Lower part of crankcase, 2WD

1	Lower part of crankcase
2	Straight pin, 6x18
3	0-ring
4	Sealant application - Doboseal 224N (999.915.573.43, status 09/08)
5	Thrust-bearing screw Mil; tighten screws within 5 minutes; observe tightening sequence.
6	Thrust-bearing screw MIO; tighten screws within 5 minutes; observe tightening sequence.
7	Aluminium screw, M8 x 70; (cross bolt connection); always use new aluminium screws
8	Screw, M8 x 35
9	Screw, M8 x 50
10	Dowel sleeve
A	Direction of travel

Fig 8: 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 four-wheel drive cross shaft
11	Aluminium screw, M8 x 70; (cross bolt connection); always use new aluminium screws
12	Thrust-bearing screw M10; tighten screws within 5 minutes; observe tightening sequence.
13	Thrust-bearing screw Mil; tighten screws within 5 minutes; observe tightening sequence.
14	Sealing ring
-	Sealant application - Doboseal 224N (999.915.573.43, status 09/08)

Fit cross bolt connection.

Fig 9: 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)
Fit M8 screws on the side -8 and 9- , Remove emerging sealant.
Punch in or imprint the engine number if necessary (when replacing engine). Use a 4-mm number embossing tool and counter at the cast-metal part with a hammer.

Move oil plate with all the seals into installation position and secure to the lower part of the crankcase.

Fig 10: Oil Return (Oil Plate) Components Location (2WD)

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Oil return (oil plate), 2WD

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

Fig 11: 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

Fit the oil pump > 0/7 pump on naturally aspirated engine. Fit suction tube for auxiliary sump > Suction tube for auxiliary sump.

Fig 12: Oil Pump On Naturally Aspirated Engine Components Location

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Oil pump on naturally aspirated engine

1	Oil pump
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

Fig 13: 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	M6 screw
3 inset	View of click position

Fit oil pump sprocket with drive chain with respect to the crankshaft chain pinion > Oil pump chain. Counter the oil pump sprocket at the oil pump using a screwdriver and fit a new screw.

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Oil pump chain

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Countering oil pump pinion
Fit cover plate for oil pump drive (drive pinion cover) using three screws.
Turn engine and clean sealing faces. Blow out bores of cylinder head screws. Position both cylinder head seals. Part number/marking facing upward. When doing so, make sure that the cylinder head gasket is positioned on the dowel sleeves.

Unscrew front camshaft mounting saddles (lower parts) of the cylinder heads (if you have not already done so), as the bores in the cylinder head screws are covered -8- .

Fig 14: Camshafts Components Location (Cylinder Bank 1 To 4)

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Camshafts (cylinder bank 1 to 4 shown)

1	Camshaft (outlet)
2	Camshaft (intake)
3	Hydraulic valve for variable valve lift control
4	Screw, M5 x 12
5	Switching tappet (oil with engine oil)
6	Bucket tappet (oil with engine oil)
7	Stopper
8	Mounting saddle 1 to 4
9	Stopper
10	Bearing locations (oil with engine oil)
A	Direction of travel

Position cylinder heads, insert cylinder head screws and fit them. Observe tightening sequence and prescribed tightening torque.

Fig 15: Cylinder Head Components Location

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Cylinder head (1 to 4 shown)

1	Cylinder head 1 to 4
2	Cylinder head gasket 1 to 4
3	M8 screw
4	Cap
5	Stopper
6	Stopper
7	Restrictor for valve lift adjustment
8	Cylinder head screws => For tightening specifications, see Tightening sequence for cylinder head
9	Spark plug

Fig 16: Cylinder Head Screws Tightening Sequence

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Tightening sequence for cylinder head

Fit front M8 screw of cylinder head 1 to 4. -3- .
Coat camshaft bearings with normal multipurpose grease or engine oil.
Insert bucket tappets into the cylinder head if necessary (bucket tappets for intake and outlet side have different diameters). The bucket tappets have a twist lock that fits into a guide groove in the cylinder head. Fit used bucket tappets at the same position.
Position vibration balancer with screw tightened by hand. Turn crankshaft to just before cylinder 1 TDC (prevents the valves from sitting on the piston when directly at TDC). -2- .

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Staking bore 45 degrees before TDC

Information
- A data matrix code is shown on the staking dihedron of the camshafts.
- This is a square black/white dotted marking used for identification purposes during the production process.
- This marking can be used as an aid when inserting the camshafts into the cylinder head. All four camshafts exert the least amount of pressure on the valves when the data matrix code is facing upwards during installation.

Insert camshafts so that the minimum amount of pressure is exerted on the valve springs and coat bearing locations with normal multipurpose grease or engine oil. Position housings correctly and screw down. The housings are numbered and marked with E (intake) or A (outlet). Fit camshaft housings evenly and gradually, and tighten slowly to the specified tightening torque. The camshafts must not be preloaded or tilted. Outlet camshafts and intake camshafts (also bank-specific) cannot be confused because of the bearing locations and length.

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Camshaft identification on V8 naturally aspirated engine

A	Cylinders 1 to 4
B	Cylinders 5 to 8
1	Outlet camshaft identification (green)
2	Intake camshaft identification (white)
3	Intake camshaft identification (white)
4	Outlet camshaft identification (green)

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Camshaft bearing cover identification

All markings can be read from the exhaust side/main diagram applies symmetrically for both cylinder heads

1	Matching number for cylinder head/intake camshaft bearing cover, cylinder 1 (E1)
2	Matching number for cylinder head/intake camshaft bearing cover, cylinder 2 (E2)
3	Matching number for cylinder head/intake camshaft bearing cover, cylinder 3 (E3)
4	Matching number for cylinder head/intake camshaft bearing cover, cylinder 4 (E4)
5	Matching number for cylinder head/outlet camshaft bearing cover, cylinder 1 (A1)
6	Matching number for cylinder head/outlet camshaft bearing cover, cylinder 2 (A2)
7	Matching number for cylinder head/outlet camshaft bearing cover, cylinder 3 (A3)
8	Matching number for cylinder head/outlet camshaft bearing cover, cylinder 4 (A4)
arrow	Direction of travel

Fig 17: Camshaft Mount, Cylinders 5 To 8 Components Location

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Camshaft mount, cylinders 5 to 8

1	Dowel sleeves
2	Bearing cover (intake)
3	Screw, M6 x 70
4	Bearing cover
5	Screw, M6 x 35
6	Bearing cover (outlet)
7	Bearing surfaces (oil with engine oil)
A	Direction of travel

Move both hydraulic valves for camshaft control into installation position and fit them. -3 and 4-.

Fig 18: Camshaft Adjustment Components Location

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Camshaft adjustment

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

Fit threaded peg for tensioning and guide rails if necessary. -1 and 2-

Fig 19: Timing Chain And Chain Guide Components Location

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Timing chain and chain guide

1	Threaded peg
2	Threaded peg
3	Guide rail
4	Tensioning rail
5	Chain tensioner with sealing ring
6	Pin (for locking the oil-pump tensioning rail)
A	Direction of travel

Fit guide rail with tensioning rail for oil pump chain and pull locking pin (tensioning rail will be released).

Fit "U"-shaped deflection rail -4- .

Fig 20: Timing Chain And Sprockets Components Location

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Timing chain and sprockets

1	Double-chain camshaft drive
2	Camshaft sprocket
3	Screw, M12 Tighten fully after setting timing.
4	Deflector rail
5	Screw, M8 x 35
6	Camshaft-to-camshaft guide pad
A	Direction of travel

Fit tensioning rail and let it hang.
Fit both small guide rail pieces between the camshaft controller and sprocket (if removed).
Loosely fit camshaft controller and sprockets using screws.
Position timing chain and guide correctly over guide and tensioning rails.
Fit chain housing cover. Secure sheetmetal holder for the tank vent valve to the upper screw on the chain housing cover at the 1 st cylinder.
> 153319 REMOVING AND INSTALLING CHAIN HOUSING COVER

; chain tensioner is still removed.
Replace and fit joint flange (sealing ring) between the vibration damper and chain housing cover.
> 137419 REMOVING AND INSTALLING CRANKSHAFT SEALING RING FOR PULLEY/VIBRATION BALANCER
Turn the engine around. Oil pump is upright.
Lay sealing ring in the lower part of the crankcase.

Apply sealant to the oil guide housing as specified. Sealant should be applied thinly and evenly. Screw down within 5 minutes.

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Applying sealant to oil guide housing (2WD)

1	Sealant application (geometry, 1 - mm bead of sealant)
2	Sealant application - Doboseal 224N (999.915.573.43, status 09/09)
A	Direction of travel

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Applying sealant to oil guide housing (4WD)

1	Sealant application (geometry, sealing bead = 1 mm); Doboseal 224N (999.915.573.43, status 09/09)

Position oil guide housing and align against transmission or projection of lower part of the crankcase. On the transmission side the oil guide housing must not project further than the crankcase. Make sure that the transmission can later be screwed evenly to the block. The oil guide housing can be adjusted in the same way as the chain housing cover (using a dial gauge, etc.). For details, see
> 175019 REMOVING AND INSTALLING OIL GUIDE HOUSING

Screw down oil guide housing. Tighten all screws uniformly in diagonally opposite sequence -4- Don't forget the screws between the oil guide housing and chain housing cover (five screws behind front vibration balancer, bores are currently overhead). -7- .

Fig 21: Oil Guide Housing With Accessories Components Location (2WD)

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Oil guide housing with accessories (2WD shown)

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

Place sealing ring on intake manifold and fit intake manifold. Tighten all oil pipes. Replace sealing rings.

Fig 22: Oil Lines On Naturally Aspirated Engine Components Location

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Oil lines on naturally aspirated engine

1	Oil pump intake pipe; screw M6 x 20
2	Sealing ring
3	Oil pressure pipe; screw M6 x 16
4	Sealing ring
5	Sealing ring; oil before fitting
6	Oil regulating line; screw M6 x 16
7	Sealing ring
8	Sealing ring; oil before fitting
9	Oil pipes to oil pump and oil guide housing
10	Oil pipes to oil pump and oil guide housing

Fig 23: Oil Lines On Naturally Aspirated Engine Components Location

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Oil lines on naturally aspirated engine, view with oil pan removed

1	Mounting point for oil pressure pipe
2	Mounting point for auxiliary sump intake manifold
3	Mount for oil pump intake manifold
4	Mount for oil regulating line

Push joint flange of the oil pressure control valve through the side opening in the housing via the oil pressure control valve and secure using two screws -1. 2 and 3- .
Fit oil level sensor (turn carefully when inserting sensor). -5 and 6-

Fit oil Pan with a new seal and tighten evenly and in diagonally opposite sequence.

Fig 24: Oil Pan Components Location

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Oil pan

1	Oil pan
2	Seal; replace following removal
3	Seal; replace following removal
4	Oil drain plug, Ml8; aluminium screw; reusable
5	Screw, M6 x 20

Turn the engine around.
Position vibration balancer with screw tightened by hand.
Set the timing. Follow procedure exactly.
> 150516 SETTING TIMING FOR CAMSHAFTS
WARNING:
Risk of damage to the engine and danger of crushing if the engine tips over
- When removing and installing the vibration damper with the engine removed (engine on assembly support), excessive use of force can cause the assembly mounting to become kinked.
  → The engine must be supported at the oil pan or engine carrier using suitable lifting equipment and a wide wooden block. This applies to all engines and assembly mountings.

Tighten vibration balancer -3 and 4- to the specified torque (use a brace > 9679/1 - brace ). Make a mark between the screw and the vibration balancer using a water-resistant marker (continuous line from screw to vibration balancer). Mark a second line on the vibration balancer at 180° from the first marking. Tighten from first marking to the second marking (torque-angle tightening). For details, see

> 137619 REMOVING AND INSTALLING PULLEY (VIBRATION BALANCER)

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Supporting engine (illustration shows V8 engine supported on assembly support)

Fig 25: Pulleys Components Location

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Pulleys

1	Water pump pulley
2	Screw, M8 x 16
3	Vibration damper
4	Screw, M18 x 1.5 x 72;use new screw
5	Power-steering pump pulley
6	Screw, M8 x 16
7	Tandem pump pulley

Fit high-pressure pump at cylinder head for cylinders 5 to 8. For details, see
> WM 477619 REMOVING AND INSTALLING VACUUM PUMP (ALL MODELS)

Move vacuum pump at cylinder head for cylinders 1 to 4 into installation position and fit it.

Fig 26: Vacuum Pump Components Location

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Vacuum pump

1	Vacuum pump
2	Screw, M6 x 25
3	0-ring
4	0-ring

Fit spark plugs if necessary.
> 287020 REMOVING AND FITTING SPARK PLUGS
Fit both cylinder head covers (valve covers). Centre cylinder head cover over the bar ignition modules. For details, see
> 158219 REMOVING AND INSTALLING CYLINDER HEAD COVER
Fit both eyelets.

Move thermostat housing between the two sides of the crankcase into installation position. Tighten three screws (leave one loose for the fuel rail). Grease sealing ring on the small coolant pipe sparingly with Kluber Syntheso GLEP 1 and press it into the thermostat housing from the front. Fit from the rear with a screw. Alternatively, the thermostat housing can be pre-fitted and installed complete with the rear coolant pipe.

Fig 27: Thermostat Housing And Coolant Regulator Components Location

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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

Grease sealing rings on the thermostat housing with Kluberplus S06-100 assembly gel (diluted 50: 50 with water) and press them as far as they will go into the thermostat housing. For details, see
> 195819 REMOVING AND INSTALLING COOLANT REGULATOR (THERMOSTAT INSERT)

Grease both sealing rings on the coolant pipe sparingly with Kluber Syntheso GLEP 1 and press them into the thermostat housing from the rear. Align with screw points on the coolant collection pipe and then screw down!

Fig 28: Coolant Guide Components Location

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Coolant guide

1	Heater coolant pipe
2	M6 screw
3	Sealing ring
4	Screw plug, Ml6 x 1.5
5	M6 screw
6	Coolant guide tube (collection pipe)
7	Metal seal
8	Stopper

Fit water pump. Fit pulley for water pump. For details, see
> 195019 REMOVING AND INSTALLING COOLANT PUMP

Fit oil pressure sensor with adapter. Replace sealing rings.

Fig 29: Oil Pressure Sensor And Oil Pressure Measuring Point Components Location

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Oil pressure sensor and oil pressure measuring point

1	Oil pressure sensor adapter
2	0-ring
3	Oil-pressure sender with temperature sensor
4	Screw, M6 x 40
5	Stopper
6	Sealing ring
A	Direction of travel

On 4WD vehicles, install one cross shaft cover with the cross shaft pipe -1- . Replace sealing rings in the covers.

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Cross shaft pipe with cover

Apply housing seal -2- (Doboseal 224N (999.915.573.43 status 09/09)) to the seating points of the two cross shaft covers close to the edge of the housing.

Position cross shaft cover with cross shaft pipe -1- .

Make sure that the cross shaft pipe is protruding at a centre position from the opposite opening on the oil guide housing.

The -TOP- marking must be facing upwards.

Screw in fastening screws -arrows- .
Install the second cross shaft cover -1- .

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Cross shaft cover

Position the cross shaft cover -1- .

Make sure that the cross shaft pipe is inserted into the centre opening on the cover.

The -TOP- marking must be facing upwards.

Screw in fastening screws.

Fit bracket for auxiliary units for power-steering pump or tandem pump (PDCC) and air conditioning compressor -1- . Fit bearing console -4- .

Fig 30: Left Bracket For Auxiliary Units And 2WD Engine Mounting Components Location

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Left bracket for auxiliary units and 2WD engine mounting

1	Bracket for auxiliary units
2	Screw, Ml Ox 45
3	Dowel sleeve
4	Engine carrier
5	Hydraulic mount, left
6	M12 nut

Fig 31: Left Bracket For Auxiliary Units And 4WD Engine Mounting Components Location

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Left bracket for auxiliary units and 4WD engine mounting

1	Bracket for auxiliary units
2	Screw, Ml Ox 45
3	Dowel sleeve
4	Engine carrier/cross-shaft engine carrier
5	Hydraulic mount, left
6	M12 nut

Fit bearing console on the right on 2WD vehicles.

Fig 32: Engine Mounting Components Location (Right)

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Engine mounting, right

1	Engine carrier
2	Screw, M10 x 45
3	Nut, M 12 x1.5
4	Hydraulic mount, right
5	Installation view of screw-on points for engine carrier on crankcase

Fit front-wheel drive (all-wheel drive) for 4WD vehicles.
> 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)
Fit and secure the engine mountings. When doing so, make sure to fit the mountings at the correct installation position.
> 103519 REMOVING AND INSTALLING ENGINE MOUNTING

Fit coolant pipe between coolant collection pipe and generator. Replace sealing rings.

Fig 33: Coolant Supply On Naturally Aspirated Engine Components Location

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Coolant supply on naturally aspirated engine

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

Fit the generator and crash support. For details, see

> 272219 REMOVING AND INSTALLING GENERATOR

Fig 34: Generator Components Location

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Generator

1	Generator
2	Screw, M8 x 95
3	Screw, M8 x 35
4	Bores for screws, M8 x 95
A	View

Fit deflection rollers and belt tensioner and press on cover.

Fig 35: Belt Drive Components Location

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Belt drive

1	Deflection roller
2	Hydraulic belt tensioner; tensioner at the lever, tensioning roller at the tensioning lever
3	M8 screw; complete lever on timing-case cover and cylinder head; belt tensioner and timing-case cover at the console
4	Deflection roller
5	Dual poly-V-belt

Fit crankshaft sealing ring on flywheel side. See
> 135919 REMOVING AND INSTALLING SEALING RING FOR CRANKSHAFT (ON TRANSMISSION SIDE)

Fit coolant hosing and secure clamps.

Fig 36: Coolant Supply On Naturally Aspirated Engine Components Location

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Coolant supply on naturally aspirated engine

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

Fig 37: Coolant Return On Naturally Aspirated Engine Components Location

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Coolant return on naturally aspirated 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	M6 screw Aluminium screw; always use new aluminium screws
8	Clip

Lay coolant vent line at both cylinder heads (grease sealing rings sparingly with Kluber Syntheso GLEP 1). Pull off injector plug if necessary and fit coolant vent line into the clips at the rear. Screw down coolant vent line with seals at both cylinder heads.

Fig 38: Ventilation Components Location
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Ventilation

1 Vent line

2 Screw, M6 x 16
Roughly position engine wire harness. Fit cable duct onto coolant collection pipe and route both harnesses for the cylinder banks. At the chain housing cover, route them down to the generator. Wire up air-conditioning compressor, insert injectors and wire up bar ignition modules. Screw down ground points. For details, see
> WM 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE (EXCEPT PANAMERA S E-HYBRID, PANAMERA S HYBRID)

Fit high-pressure line and low-pressure line. To do this, fit union nut in the cylinder head. Clip in cable duct at the union nut.

Fig 39: High-Pressure Pump Components Location (Naturally Aspirated Engine)

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High-pressure pump, naturally aspirated engine

1	High-pressure pump
2	High-pressure line; (3 turns: tighten, loosen, tighten)
3	M6 screw on low-pressure line
4	Low-pressure line; (3 turns: tighten, loosen, tighten); counter at hexagon on 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

Fit high-pressure fuel distribution pipe. For details, see
> 243019 REMOVING AND INSTALLING FUEL DISTRIBUTION PIPE
Check the DFI high-pressure system for leaks.
> 243001 CHECKING FUEL DISTRIBUTOR PIPE FOR LEAKS

Fit exhaust manifold. Fit seal correctly. Observe tightening sequence.

Fig 40: Exhaust Manifold On Naturally Aspirated Engine Screws Tightening Sequence

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Tightening sequence for exhaust manifold on naturally aspirated engine, cylinders 1 to 4

1 to 12 applies to both sides, always start at the chain housing cover

Fig 41: Exhaust Manifold Seal And Mount On Naturally Aspirated Engine Components Location

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Exhaust manifold seal and mount on naturally aspirated engine, cylinders 1 to 4

1	Exhaust manifold
2	Exhaust manifold seal
3	Studs M8;
5	M8 hexagon nut; replace; (check nuts by clicking once); observe tightening sequence
A	M6 screw; heat shield to exhaust manifold

Fig 42: Exhaust Manifold Seal And Mount On Naturally Aspirated Engine Components Location

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Exhaust manifold seal and mount on naturally aspirated engine, cylinders 5 to 8

1	Exhaust manifold
2	Seal
3	M8 hexagon nut; replace; (check nuts by clicking once); observe tightening sequence
4	M6 screw; securing heat shield to exhaust manifold;

Lay tank vent with plastic line at cylinder bank 1 to 4 and clip it in at the sheetmetal brackets. -3-.

Fig 43: Ventilation On Naturally Aspirated Engines Components Location

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Ventilation on naturally aspirated engines

1	Engine ventilation line
2	Oil mist separator line to intake-air distributor
3	Tank ventilation
4	Aluminium holder
5	Aluminium screw (holder); see Chain housing cover

Prepare and fit intake-air distributor. Ensure that the seals are seated correctly. Move intake-air distributor into installation position. Check that the switch-over valve is seated and connected properly. For details, see
> 244619 REMOVING AND INSTALLING INTAKE-AIR DISTRIBUTOR
Fit oil mist separator. For details, see
> 105519 REMOVING AND INSTALLING OIL MIST SEPARATOR
Fit power-steering pump. For details, see installation description
> Refer to 489855 Replacing hydraulic pump
Fit air-conditioning compressor.
> WM 873419 REMOVING AND INSTALLING ELECTRIC AIR-CONDITIONING COMPRESSOR (PANAMERA S E-HYBRID, PANAMERA S HYBRID)

Fit pulley for power-steering pump or tandem pump.

Fig 44: Pulleys Components Location

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Pulleys

1	Water pump pulley
2	Screw, M8 x 16
3	Vibration damper
4	Screw, M18; use a new screw
5	Power-steering pump pulley
6	Screw, M8 x 16
7	Tandem pump pulley

Fit drive belt and then tighten it (manipulate belt tensioner using a socket or ring wrench).
> 137819 REMOVING AND INSTALLING DRIVE BELT
Fit heat protection panels on generator and on exhaust manifold.
Check to ensure that all the lines and connections have been routed and tightened correctly. Check that no lines were forgotten.

NOTIFICATION

Ingress of dirt

Danger of material damage due to blocked oil bores/oil ducts
→ Ensure absolute cleanliness when working on the engine.

→ Lay removed engine parts on a clean surface and cover them.

→ Use a cover or PE sheet on the engine assembly support to prevent dirt from getting into the engine during assembly.

CAUTION: Heavy components

Risk of squashing
→ Wear personal protective gear.

→ Get someone to help if necessary.

CAUTION: Leaks due to insufficiently or differently tempered components!

If cold or differently tempered components are sealed to each other by applying a sealant, adhesion problems or leaks can result because of condensed water forming or components becoming distorted.
→ All components must be at least 17°C.

→ Components must not be too hot (distortion).

→ Spare parts stored in cold or heat (strong exposure to sunlight) must be at room temperature, or must have the same temperature as other components, before installation.

CAUTION: Emerging residual fluid can soil the engine!

Residual fluid (fuel, oil, Pentosin, coolant, etc.) will emerge even after a long time when disassembling and assembling the engine.
→ Place a drip tray under the engine at the assembly support.

→ Have a sufficient number of cleaning cloths ready.

→ Close off engine openings using stoppers.

Information

The tightening specifications for the basic engine are stored centrally.

> TECHNICAL VALUES

> WM 2X00IN TECHNICAL VALUES (PANAMERA, PANAMERA S, PANAMERA S EXECUTIVE, PANAMERA 4, PANAMERA 4S, PANAMERA 4 S EXECUTIVE)

> 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES AND ASSEMBLY OVERVIEWS

Tightening torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.

Information

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Colour marking on bearing shell

The bearing shells are available in various classes. The classes are indicated by the colour marking on the outside. For every bearing (main and connecting rod bearings), the colour marking must match the corresponding letter on the flywheel flange of the crankshaft -arrow- Each letter on the flywheel flange of the crankshaft indicates the correct colour classification of the bearing shell.
Information

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Connecting rod code and direction of travel arrow

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Connecting rod code "A"
The corresponding connecting-rod bearing shells must be selected according to the marking on the crankshaft transmission flange (4-digit) and inserted into the connecting rod.
When removing the pistons with connecting rods, the pistons should be marked with a water-resistant marker on both the piston and connecting rod according to cylinder and cylinder bank.
The removed pistons and connecting rods must be cleaned carefully so as not to remove the markings.
The connecting rod code is installed to the exhaust side as standard. The direction of travel arrow on the DFI piston is always on the same side as the connecting rod code -A- The pistons are assigned to the cylinder bank (1 to 4 and 5 to 8), i.e. because of the DFI combustion chamber recess there are two different pistons for the left and right cylinder bank.
When installing the piston in the crankcase, the direction of travel arrow must point in the direction of travel when installed. It is always on the same side as the connecting rod code. The combustion chamber recess on the piston is always on the intake side. Note the assignment of the pistons to the cylinder bank.
Naturally aspirated engines and turbo engines have different pistons.
The code on the connecting-rod big end and connecting rod cap must be on the same side and at the exhaust side. -A-

NOTE: Select the correct piston for the correct cylinder bank. Install with connecting rod code on the exhaust side with the direction of travel arrow on the piston.

Information

Connecting rod bolts must always be replaced.

Place crankshaft bearing shells into the lower part of the crankcase.

Fig 1: Crankshaft Components Location

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Crankshaft

1	Crankshaft (stroke: 83 mm)
2	Straight pin, 6x20
3	Spring wedge
4	Thrust washer
5	Main bearing shell, upper
6	Main bearing shell, lower
7	Shaft seal
8	View of crankshaft flange
9	Crankshaft bearing classification (four types) G Yellow; B Blue, R Red; N Green => (example: GGGGG-BBBB; 5 main shaft bearings with yellow marking, 4 double (8) connecting rod bearings with blue marking) => For numbering, see A

Place crankshaft bearing shells with lubricating groove and bore -2- into the upper part of the crankcase -1-. Smooth crankshaft bearing shells -3- belong in the lower part of the crankcase. Insert the thrust washers into the centre with grooves facing outwards (affix using multipurpose grease) or alternatively wait until after the crankshaft has been inserted.

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Inserting bearing shells

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Inserting bearing shells

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Thrust washer

If you have not already done so, fit knock sensors on the upper part of the crankcase using screws.
Align the knock sensors between cylinder 1 and 2 and cylinder 5 and 6 parallel to the cylinder head and the plug connection parallel to the starter. Fit knock sensors hand-tight.

Insert starter briefly and align concealed knock sensors so that there is no knock sensor near the starter. Remove the starter. Fit plug connection for knock sensor between cylinders 3 and 4 in the direction of the water pump so that it is turned upwards and slightly towards the cylinder head. Fit plug connection for knock sensor between cylinders 7 and 8 in the direction of the flywheel so that it is turned upwards and slightly towards the cylinder head.

Fit knock sensors correctly.

Fig 2: Knock Sensors Components Location
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Knock sensors

1 Knock sensor

2 Screw, M8 x 35

Insert two seals for the thermostat housing into the upper part of the crankcase on both sides. -2- .

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Seals between crankcase and thermostat housing

Fig 3: Coolant Guide Components Location

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Coolant guide

1	Coolant pipe
2	M6 screw
3	Sealing ring
4	Screw plug, Ml6 x 1.5
5	M6 screw
6	Coolant guide tube (collection pipe)
7	Metal seal
8	Stopper

Fit oil spray jets -6- .

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Upper part of crankcase

Insert oil spray jets into the upper part of the crankcase and screw them on. To do this, grease the sealing ring sparingly with Kluber Syntheso GLEP 1 and fit it. Check that oil spray jets are pointing in the correct direction of spray toward the inside of the piston crown. The oil spray jet must be aimed at the piston crown. > Spray direction > Spray direction from side

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Spray direction

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Spray direction from side
Pre-fit spring wedge of crankshaft into the corresponding groove on the crankshaft using a plastic hammer if necessary.

Pre-fit all pistons with connecting rods and piston rings, number by cylinder and place to one side. For details, see

> 131037 DISASSEMBLING AND ASSEMBLING PISTONS

Fig 4: Piston, Connecting Rod Components Location

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Piston, connecting rod

1	Piston-ring set
2	Pistons
3	Circlip/piston-pin circlip
4	Piston pins
5	Connecting rods
6	Connecting rod bolt; replace as it must be tightened in the plastic area
7	Connecting-rod bearing shells

Check that all the seals are installed in the oil plate (oil return). > Oil return (oil plate), 4WD shown

Fig 5: Oil Return (Oil Plate) Components Location (4WD)

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Oil return (oil plate), 4WD shown

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

If you have not already done so, drive dowel sleeves for the metal seals in the chain housing cover using a copper or plastic hammer.
Insert new metal seals on the chain housing cover and press onto the dowel sleeves.
Oil pump is pre-fitted with the oil pressure control valve.
Cylinder heads fitted with solenoid valves of the valve lift switchover, camshaft housings loosely positioned and removed camshafts prepared. Alternatively, the camshaft housings, which have been marked according to installation position, can be set down on a clean surface together with the corresponding camshafts. Cam followers and injectors are fitted.
If you have not already done so, drive in dowel sleeves on auxiliary unit bracket for power-steering pump or tandem pump using a copper or plastic hammer.
Move starter into installation position and screw down.
> 276019 REMOVING AND INSTALLING STARTER
Insert crankshaft and oil crankshaft bearing pin and connecting-rod bearing pin.
First position timing chain pinion with the ring gear of the oil pump drive onto the crankshaft stub (check that the two diamond washers at the front and rear on the ring gear are clipped in -1- ). Then position the drive pinion of the oil pump chain -2- with respect to the crankcase.

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Timing chain pinion on crankshaft stub

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Timing chain pinion with two diamond washers
Fit crankshaft holding bridge > 9677/1 - holding bridge in the centre of the crankshaft.

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Crankshaft secured
Turn upper part of crankcase and oil cylinder liners.
Pre-tension pistons using an assembly funnel > 9784/1 - funnel and press pistons into the cylinder. For details, see
> 131020 REMOVING AND INSTALLING PISTONS

Remove crankshaft holding bridge. Apply Doboseal 224N sealant (999.915.573.43, status 09/09) to the lower part of the crankcase as shown. Insert sealing ring -14- into the upper part of the crankcase and position the lower part of the crankcase onto the upper part of the crankcase. Insert all the fastening screws, fit to the prescribed tightening torque within 5 minutes and wipe off excess sealant.

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Applying sealant

1	Wipe off residual sealant after fitting
A	Direction of travel

Screw down M11 and M10 bearing screws to the prescribed torques. -12 and 13- . The bearing screws for the 4WD shaft are shorter. Do not confuse them.

Fig 6: Thrust-Bearing Screws Tightening Sequence

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Tightening sequence for thrust-bearing screws

1 to 20	Tightening sequence for Ml 1 and M10 screws => Observe different torques!
A	Direction of travel

Fig 7: 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, 6x18
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 four-wheel drive cross shaft
11	Aluminium screw, M8 x 70; (cross bolt connection); always use new aluminium screws
12	Thrust-bearing screw M10; tighten screws within 5 minutes; observe tightening sequence.
13	Thrust-bearing screw M11; tighten screws within 5 minutes; observe tightening sequence.
14	Sealing ring
-	Sealant application - Doboseal 224N (999.915.573.43, status 09/08)

Fit cross bolt connection.

Fig 8: 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)
Fit M8 screws on the side -7 and 8- , Remove emerging sealant.
Punch in or imprint the engine number if necessary (when replacing engine). Use a 4-mm number embossing tool and counter at the cast-metal part with a hammer.

Move oil plate with all the seals into installation position and secure to the lower part of the crankcase.

Fig 9: 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

Fit the oil pump > Oil pump, turbo engine. Fit suction tube for auxiliary sump > Suction tube for auxiliary sump.

Fig 10: 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

Fig 11: Suction Tube For Auxiliary Sump Components Location

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Suction tube for auxiliary sump

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

Fit oil pump sprocket with drive chain with respect to the crankshaft chain pinion > Oil pump chain. Counter the oil pump sprocket at the oil pump using a screwdriver and fit a new screw.

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Oil pump chain

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Countering oil pump pinion
Fit cover plate for oil pump drive (drive pinion cover) using three screws.
Turn engine and clean sealing faces. Blow out bores of cylinder head screws. Position both cylinder head seals. Part number/marking facing upward. When doing so, make sure that the cylinder head gasket is positioned on the dowel sleeves.

Unscrew front camshaft mounting saddles (lower parts) of the cylinder heads (if you have not already done so), as the bores in the cylinder head screws are covered. -8- .

Fig 12: Camshafts Components Location (Cylinder Bank 1 To 4)

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Camshafts (cylinder bank 1 to 4 shown)

1	Camshaft (outlet)
2	Camshaft (intake)
3	Hydraulic valve for variable valve lift control
4	Screw, M5 x 12
5	Switching tappet (oil with engine oil)
6	Bucket tappet (oil with engine oil)
7	Stopper
8	Mounting saddle 1 to 4
9	Stopper
10	Bearing locations (oil with engine oil)
A	Direction of travel

Position cylinder heads, insert cylinder head screws and fit them. Observe tightening sequence and prescribed tightening torque.

Fig 13: Cylinder Head Components Location

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Cylinder head (1 to 4 shown)

1	Cylinder head 1 to 4
2	Cylinder head gasket 1 to 4
3	M8 screw
4	Lid
5	Stopper
6	Stopper
7	Restrictor for valve lift adjustment
8	Cylinder head screws => For tightening specifications, see Tightening sequence for cylinder head
9	Spark plug

Fig 14: Cylinder Head Screws Tightening Sequence

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Tightening sequence for cylinder head

Fit front M8 screw of cylinder head 1 to 4. -3-
Coat camshaft bearings with normal multipurpose grease or engine oil.
Insert bucket tappets into the cylinder head if necessary (bucket tappets for intake and outlet side have different diameters). The bucket tappets have a twist lock that fits into a guide groove in the cylinder head. Fit used bucket tappets at the same position.
Position vibration balancer with screw tightened by hand. Turn crankshaft to just before cylinder 1 TDC (prevents the valves from sitting on the piston when directly at TDC). -2- .

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Staking bore 45 degrees before TDC

Information
- A data matrix code is shown on the staking dihedron of the camshafts.
- This is a square black/white dotted marking used for identification purposes during the production process.
- This marking can be used as an aid when inserting the camshafts into the cylinder head. All four camshafts exert the least amount of pressure on the valves when the data matrix code is facing upwards during installation.

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Camshaft identification on V8 turbo engine

A	Cylinders 1 to 4
B	Cylinders 5 to 8
1	Outlet camshaft identification (green)
2	Intake camshaft identification (blue)
3	Intake camshaft identification (blue)
4	Outlet camshaft identification (green)

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Camshaft bearing cover identification

All markings can be read from the exhaust side/main diagram applies symmetrically for both cylinder heads

1	Matching number for cylinder head/intake camshaft bearing cover, cylinder 1 (E1)
2	Matching number for cylinder head/intake camshaft bearing cover, cylinder 2 (E2)
3	Matching number for cylinder head/intake camshaft bearing cover, cylinder 3 (E3)
4	Matching number for cylinder head/intake camshaft bearing cover, cylinder 4 (E4)
5	Matching number for cylinder head/outlet camshaft bearing cover, cylinder 1 (A1)
6	Matching number for cylinder head/outlet camshaft bearing cover, cylinder 2 (A2)
7	Matching number for cylinder head/outlet camshaft bearing cover, cylinder 3 (A3)
8	Matching number for cylinder head/outlet camshaft bearing cover, cylinder 4 (A4)
arrow	Direction of travel

Fig 15: Camshaft Mount Components Location

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Camshaft mount, cylinders 5 to 8

1	Dowel sleeves
2	Bearing cover (intake)
3	Screw, M6 x 70
4	Bearing cover
5	Screw, M6 x 35
6	Bearing cover (outlet)
7	Bearing surfaces (oil with engine oil)
A	Direction of travel

Move both hydraulic valves for camshaft control into installation position and fit them. -3 and 4-

Fig 16: Camshaft Adjustment Components Location

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Camshaft adjustment

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

Fit threaded peg for tensioning and guide rails if necessary. -1 and 2-

Fig 17: Timing Chain And Chain Guide Components Location

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Timing chain and chain guide

1	Threaded peg
2	Threaded peg
3	Guide rail
4	Tensioning rail
5	Chain tensioner with sealing ring
6	Pin (for locking the oil-pump tensioning rail)
A	Direction of travel

Fit guide rail with tensioning rail for oil pump chain and pull locking pin (tensioning rail will be released).

Fit "U"-shaped deflection rail

Fig 18: Timing Chain And Sprockets Components Location

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Timing chain and sprockets

1	Double-chain camshaft drive
2	Camshaft sprocket
3	Screw, M12 Tighten fully after setting timing.
4	Deflector rail
5	Screw, M8 x 35
6	Camshaft-to-camshaft guide pad
A	Direction of travel

Fit tensioning rail and let it hang.
Fit both small guide rail pieces between the camshaft controller and sprocket (if removed).
Loosely fit camshaft controller and sprockets using screws.
Position timing chain and guide correctly over guide and tensioning rails.
Fit chain housing cover. Secure sheetmetal holder for the tank vent valve to the upper screw on the chain housing cover at the 1 st cylinder.
> 153319 REMOVING AND INSTALLING CHAIN HOUSING COVER

; chain tensioner is still removed.
Replace and fit joint flange (sealing ring) between the vibration damper and chain housing cover.
> 137419 REMOVING AND INSTALLING CRANKSHAFT SEALING RING FOR PULLEY/VIBRATION BALANCER
Turn the engine around. Oil pump is upright.
Lay sealing ring in the lower part of the crankcase.

Apply sealant to the oil guide housing as specified. Sealant should be applied thinly and evenly. Screw down within 5 minutes.

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Applying sealant to oil guide housing (4WD)

1	Sealant application (geometry, sealing bead = 1 mm); Doboseal 224N (999.915.573.43, status 09/09)

Position oil guide housing and align against transmission or projection of lower part of the crankcase. On the transmission side the oil guide housing must not project further than the crankcase. Make sure that the transmission can later be screwed evenly to the block. The oil guide housing can be adjusted in the same way as the chain housing cover (using a dial gauge, etc.). For details, see
> 175019 REMOVING AND INSTALLING OIL GUIDE HOUSING

Screw down oil guide housing. Tighten all screws uniformly in diagonally opposite sequence -4- . Don't forget the screws between the oil guide housing and chain housing cover (five screws behind front vibration balancer, bores are currently overhead). -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; always use new aluminium screws
5	Oil level sensor
6	Oil level sensor to oil guide housing (steel screw)
7	Chain housing cover to oil guide housing - aluminium screw; always use new aluminium screws

Place sealing ring on intake manifold and fit intake manifold. Tighten all oil pipes. Replace sealing rings.

Fig 20: Oil Lines On Turbo Engine Components Location

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Oil lines on turbo engine

1	Suction pipe between the oil pump and turbocharger (fitted in oil guide housing)
2	Suction pipe between the 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 21: Oil Lines On Turbo Engine Components Location

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Oil lines on turbo engine, view with oil pan removed

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

Push joint flange of the oil pressure control valve through the side opening in the housing via the oil pressure control valve and secure using two screws -1. 2 and 3- ,
Fit oil level sensor (turn carefully when inserting sensor). -5 and 6-

Fit oil Pan with a new seal and tighten evenly and in diagonally opposite sequence.

Fig 22: Oil Pan Components Location

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Oil pan

1	Oil pan
2	Seal; replace following removal
3	Seal; replace following removal
4	Oil drain plug, M18; aluminium screw; reusable
5	Screw, M6 x 20

Turn the engine around.
Position vibration balancer with screw tightened by hand.
Set the timing. Follow procedure exactly.
> 150516 SETTING TIMING FOR CAMSHAFTS
WARNING:
Risk of damage to the engine and danger of crushing if the engine tips over
- When removing and installing the vibration damper with the engine removed (engine on assembly support), excessive use of force can cause the assembly mounting to become kinked.
  → The engine must be supported at the oil pan or engine carrier using suitable lifting equipment and a wide wooden block. This applies to all engines and assembly mountings.

Tighten vibration balancer -3 and 4- to the specified torque (use a brace > 9679/1 - brace) Make a mark between the screw and the vibration balancer using a water-resistant marker (continuous line from screw to vibration balancer). Mark a second line on the vibration balancer at 180° from the first marking. Tighten from first marking to the second marking (torque-angle tightening). For details, see

> 137619 REMOVING AND INSTALLING PULLEY (VIBRATION BALANCER)

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Supporting engine (illustration shows V8 engine supported on assembly support)

Fig 23: Pulleys Components Location

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Pulleys

1	Water pump pulley
2	Screw, M8 x 16
3	Vibration damper
4	Screw, M18x1.5x72; use new screw
5	Power-steering pump pulley
6	Screw, M8 x 16
7	Tandem pump pulley

Fit high-pressure pump at cylinder head for cylinders 5 to 8. For details, see
> 246319 REMOVING AND INSTALLING HIGH-PRESSURE PUMP

Move vacuum pump at cylinder head for cylinders 1 to 4 into installation position and fit it.

> WM 477619 REMOVING AND INSTALLING VACUUM PUMP (ALL MODELS)

Fig 24: Vacuum Pump Components Location

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Vacuum pump

1	Vacuum pump
2	Screw, M6 x 25
3	0-ring
4	0-ring

Fit spark plugs if necessary.
> 287020 REMOVING AND FITTING SPARK PLUGS
Fit both cylinder head covers (valve covers). Centre cylinder head cover over the bar ignition modules. For details, see
> 158219 REMOVING AND INSTALLING CYLINDER HEAD COVER
Fit both eyelets.

Fig 25: Thermostat Housing And Coolant Regulator Components Location

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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

Grease sealing rings on the thermostat housing with Kluberplus S06-100 assembly gel (diluted 50: 50 with water) and press them as far as they will go into the thermostat housing. For details, see
> 195819 REMOVING AND INSTALLING COOLANT REGULATOR (THERMOSTAT INSERT)

Route boost-pressure control and wastegate lines and fit holder.

Fig 26: Boost Pressure And Wastegate 2 Components Location

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Boost pressure and wastegate 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
A	View A; pressure line/intake-air distributor connection

Fig 27: Boost Pressure And Wastegate 1 Components Location

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Boost pressure and wastegate 1

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

Fig 28: Coolant Guide Components Location

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Coolant guide

1	Heater coolant pipe
2	M6 screw
3	Sealing ring
4	Screw plug, Ml6 x 1.5
5	M6 screw
6	Coolant guide tube (collection pipe)
7	Metal seal
8	Stopper

Fit water pump. Fit pulley for water pump. For details, see
> 195019 REMOVING AND INSTALLING COOLANT PUMP

Fit oil pressure sensor with adapter. Replace sealing rings.

Fig 29: Oil Pressure Sensor And Oil Pressure Measuring Point Components Location

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Oil pressure sensor and oil pressure measuring point

1	Oil pressure sensor adapter
2	0-ring
3	Oil-pressure sender with temperature sensor
4	Screw, M6 x 40
5	Stopper
6	Sealing ring
A	Direction of travel

On 4WD vehicles, install one cross shaft cover with the cross shaft pipe -1- . Replace sealing rings in the covers.

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Cross shaft pipe with cover

Apply housing seal -2- (Doboseal 224N (999.915.573.43 status 09/09)) to the seating points of the two cross shaft covers close to the edge of the housing.

Position cross shaft cover with cross shaft pipe -1- .

Make sure that the cross shaft pipe is protruding at a centre position from the opposite opening on the oil guide housing.

The -TOP- marking must be facing upwards.

Screw in fastening screws -arrows- .
Install the second cross shaft cover -1- .

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Cross shaft cover

Position the cross shaft cover -1- .

Make sure that the cross shaft pipe is inserted into the centre opening on the cover.

The -TOP- marking must be facing upwards.

Screw in fastening screws.

Fit bracket for auxiliary units for power-steering pump or tandem pump (PDCC) and air conditioning compressor

Fig 30: Left Bracket For Auxiliary Units And 4WD Turbo Engine Mounting Components Location

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Left bracket for auxiliary units and 4WD turbo engine mounting

1	Bracket for auxiliary units
2	Screw, M10x 45
3	Dowel sleeve
4	Engine carrier/cross-shaft engine carrier
5	Hydraulic mount, left
6	M12 nut
7	Heat protection panel
8	Screw, M6 x 12

Fit front-wheel drive (all-wheel drive) for 4WD vehicles.
> 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)
Fit and secure the engine mountings. When doing so, make sure to fit the mountings at the correct installation position.
> 103519 REMOVING AND INSTALLING ENGINE MOUNTING

Fit coolant pipe between coolant collection pipe and generator. Replace sealing rings.

Fig 31: Coolant Supply On Turbo Engine Components Location

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Coolant supply on turbo engine

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

Fit the generator and crash support. For details, see

> 272219 REMOVING AND INSTALLING GENERATOR

Fig 32: Generator Components Location

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Generator

1	Generator
2	Screw, M8 x 95
3	Screw, M8 x 35
4	Bores for screws, M8 x 95
A	View

Fit deflection rollers and belt tensioner and press on cover.

Fig 33: Belt Drive Components Location

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Belt drive

1	Deflection roller
2	Hydraulic belt tensioner; tensioner at the lever, tensioning roller at the tensioning lever
3	M8 screw; complete lever on timing-case cover and cylinder head; belt tensioner and timing-case cover at the console
4	Deflection roller
5	Dual poly-V-belt

Fit crankshaft sealing ring on flywheel side. See
> 135919 REMOVING AND INSTALLING SEALING RING FOR CRANKSHAFT (ON TRANSMISSION SIDE)

Fit coolant hosing and secure clamps.

Fig 34: Coolant Return On Turbo Engine Components Location

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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	M6 screw Aluminium screw; always use new aluminium screws
8	Clip

Fig 35: Coolant Supply On Turbo Engine Components Location

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Coolant supply on turbo engine

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

Lay coolant vent line at both cylinder heads (grease sealing rings sparingly with Kluber Syntheso GLEP 1). Pull off injector plug if necessary and fit coolant vent line into the clips at the rear. Screw down coolant vent line with seals at both cylinder heads.

Fig 36: Ventilation Components Location
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Ventilation

1 Vent line

2 Screw, M6 x 16
Roughly position engine wire harness. Fit cable duct onto coolant collection pipe and route both harnesses for the cylinder banks. At the chain housing cover, route them down to the generator. Wire up air-conditioning compressor, insert injectors and wire up bar ignition modules. Screw down ground points. For details, see
> WM 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE (EXCEPT PANAMERA S E-HYBRID, PANAMERA S HYBRID)

Fit high-pressure line and low-pressure line. To do this, fit union nut in the cylinder head. Clip in cable duct at the union nut.

Fig 37: 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 turns: tighten, loosen, tighten)
3	M6 screw on low-pressure line
4	Low-pressure line; (3 turns: tighten, loosen, tighten); counter at hexagon on 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

Fit high-pressure fuel distribution pipe. For details, see
> 243019 REMOVING AND INSTALLING FUEL DISTRIBUTION PIPE
Check the DFI high-pressure system for leaks.
> 243001 CHECKING FUEL DISTRIBUTOR PIPE FOR LEAKS

Fit the turbocharger. Fit seals correctly. Observe tightening sequence. It is best to fit the turbocharger to the engine with the lines connected and fitted and then screw it on.

Fig 38: 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	Clamp
4	Coolant supply hose for turbocharger
5	Turbocharger; exhaust manifold/turbocharger module

Fig 39: 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	Coolant supply line holder to oil guide housing

Fig 40: 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; o 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 and oil feed line for turbocharger at the holder
7	Screw, M6 x 16

Fig 41: 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	Retaining clip
5	Oil extraction line
6	Screw, M6 x 16
7	Seal

Fig 42: 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	Nut M8; turbocharger exhaust manifold to cylinder head; replace

Fig 43: 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
	Nut M8; turbocharger exhaust manifold to cylinder head; replace
4	Upper tab washer
5	Lower tab washer

Fig 44: Turbocharger Exhaust Manifold Screws Tightening Sequence

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Tightening sequence for turbocharger exhaust manifold

1 to 12

applies to both sides, always start at the chain housing cover

Lay tank vent with plastic line at cylinder bank 1 to 4 and clip it in at the sheetmetal brackets. > Ventilation on turbo engines

Fig 45: 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

Prepare and fit intake-air distributor. Ensure that the seals are seated correctly. Move intake-air distributor into installation position. Check that the switch-over valve is seated and connected properly. For details, see
> 244619 REMOVING AND INSTALLING INTAKE-AIR DISTRIBUTOR
Fit oil mist separator. For details, see
> 105519 REMOVING AND INSTALLING OIL MIST SEPARATOR
Fit power-steering pump. For details, see installation description
> Refer to 489855 Replacing hydraulic pump
Fit air-conditioning compressor.
> WM 873419 REMOVING AND INSTALLING ELECTRIC AIR-CONDITIONING COMPRESSOR (PANAMERA S E-HYBRID, PANAMERA S HYBRID)

Fit pulley for power-steering pump or tandem pump.

Fig 46: Pulleys Components Location

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Pulleys

1	Water pump pulley
2	Screw, M8 x 16
3	Vibration damper
4	Screw, M18; use a new screw
5	Power-steering pump pulley
6	Screw, M8 x 16
7	Tandem pump pulley

Fit drive belt and then tighten it (manipulate belt tensioner using a socket or ring wrench).
> 137819 REMOVING AND INSTALLING DRIVE BELT
Fit heat protection panels on generator and on exhaust manifold.
Check to ensure that all the lines and connections have been routed and tightened correctly. Check that no lines were forgotten.