Disassembling Engine

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

Information 

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

1. Remove cylinder head cover.

   → 158219 REMOVING AND INSTALLING CYLINDER HEAD COVER .

   1. 1.1. Unscrew one external Torx screw for the engine ground strap on cylinder bank 4-6 and remove ground strap.
2. Check visually to see which cylinder bank is at overlapping position. Remove this cylinder bank first.
   1. 2.1. Cam positions on intake -1- and outlet camshaft -2-: 
      • Overlapping position of cylinder bank 1-3: Cams on cylinder 1 are facing outward at an angle.
      • Overlapping position of cylinder bank 4-6: Cams on cylinder 4 are facing inward at an angle with respect to the spark-plug recess.

        Cylinder 1: 

        Fig 1: Locating Cam (Cylinder 1)

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        Cylinder 4: 

        Fig 2: Locating Cam (Cylinder 4)

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   2. 2.2. If the camshafts are at overlapping position, rectangular markings -1-  can be seen on the outlet and intake camshaft (data matrix code).
      Fig 3: Identifying Camshaft Part Number And Data Matrix Code Marking

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3. Remove camshafts.

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

   Information 

   • Position hydraulic tappets on a surface you have prepared and labelled yourself in accordance with their installation position in the cylinder head. 
   • Components have been run in in fitted bores and must not be confused. 
   • Do not use magnets for removal or installation. This can cause the components to malfunction. 
4. Remove hydraulic tappets.
   1. 4.1. Pull bucket tappets -1-  and switching tappets -2-  out of the fitting bores in the cylinder head. Do not use magnets.
      Fig 4: Identifying Hydraulic Tappets For Valve Control

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   2. 4.2. Lay components on a clean, labelled surface.
      Fig 5: Example Of Bucket Tappets

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

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   2. 5.2. Pull out the tensioning and guide rails -1-  using flat-nosed pliers -3-  .
      Fig 7: Pulling Guide Rail

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

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      View of oil supply valve -1-  with O-ring -2-  removed:

      Fig 9: Identifying Oil Supply Valve And O-Ring

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   5. 5.5. Cylinders 4-6:  Unscrew two bearing pins -2-  for the guide rail and one bearing pin for the tensioning rail -3-  .
      Fig 10: Identifying Cylinder Bank Bearing Pins (4-6)

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   6. 5.6. The bearing pin for the tensioning rail on bank 4-6 -1-  is longer than the five other bearing pins -2-  for the timing chain rails.
      1. Bearing pins for tensioning rail on cylinder bank 4-6
      2. Bearing pins for both guide rails and tensioning rail on cylinder bank 1-3
      Fig 11: Identifying Bearing Pins

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   7. 5.7. Replace O-rings -3-  .
6. Remove cylinder head with cylinder-head gasket.

   → 157019 REMOVING AND INSTALLING CYLINDER HEAD .

7. Pull out displacement bodies -1-  on cylinder bank 1-3 using flat-nosed pliers.
   Fig 12: Identifying Cylinder Bank Marking Pistons (1-3)

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8. Turn the engine at the engine assembly support so that the oil pan is at the top.
9. Remove oil pan.

   → 175019 REMOVING AND INSTALLING OIL PAN

10. Remove coolant pipe -1-  for the coolant pump.
    1. 10.1. Unscrew two external Torx screws -2-  and remove the pipe.
       Fig 13: Identifying Coolant Pipe Screws

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11. Remove oil pump and oil guide.

    → 172019 REMOVING AND INSTALLING OIL PUMP .

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

    → 131020 REMOVING AND INSTALLING PISTONS .

14. Remove crankcase half 1-3.
    1. 14.1. Unscrew 19 external Torx screws for the outer cross bolt connection. The threaded bolt must be removed for the screw -item 17-  .
       Fig 14: Identifying Outer Cross Bolt Connection Screws

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       1. 15, 16 and 17  - External Torx screw, M8 x 35
       2. External Torx screw, M6 x 40
       3. 19-32  - External Torx screw, M6 x 25
       4. External Torx screw, M8 x 120
    2. 14.2. Loosen and unscrew through bolts (M10 x 195) in the opposite sequence to the tightening sequence.
       Fig 15: Crankcase Screws Loosening Sequence

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       1. 1-14  - External Torx screw (M10 x 1.5 x 195) with sealing washer
    3. 14.3. Replace screws.

       Once the sealing washers are approved as spare parts in the Spare Parts Catalogue, new sealing washers can be fitted and the screws can be re-used! 

15. Unscrew two mounting parts 9590  for bolting crankcase half 1-3 to the engine support.
16. Lift off crankcase 1-3.
    1. 16.1. To do this, put on heat-resistant gloves and heat the sealant at the joint slightly with a hot-air gun.
    2. 16.2. Lift up crankcase half 1-3 at the positions shown -arrows-  using a large slotted screwdriver.
       Fig 16: Locating Lever Positions On Crankcase

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    3. 16.3. Slide in two pieces of wood -1-  above the oil-pump pressure channels and lift up the crankcase half using a mounting lever -items 2 and 3-  .
       Fig 17: Locating Crankcase Mounting Lever Position

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17. Remove pistons with connecting rods for cylinders 4-6.

    → 131020 REMOVING AND INSTALLING PISTONS .

    1. 17.1. Remove connecting rods 1-3 on the crankshaft.
18. Remove and dispose of crankshaft sealing rings.
19. Lift crankshaft with timing chains out of crankcase half 4-6.
    Fig 18: Identifying Crankshaft And Timing Chains

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    1. 19.1. Remove bearing shells from the crankcase halves and dispose of them.
    2. 19.2. The deviation sample catalogue for the Cayenne can be used to assess the cylinder linings.
20. Clean the crankcase and sealing faces.