Disassembling The 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.

   → WM 158219 REMOVING AND INSTALLING CYLINDER HEAD COVER - engine removed.

   1. 1.1. Unscrew one external Torx screw (E12, M8 x 20) for the engine ground strap on cylinder bank 4-6 and remove the ground strap.
2. Check visually to see which cylinder bank is at overlapping position. Remove this cylinder bank first.
   1. 2.1. Check visually to see which cylinder bank is at overlapping position. Remove this cylinder bank first.

      Cam positions: 

      • Overlapping position of cylinder bank 1-3: Cams on cylinder 1 are facing outward at a slant. → Cam position on cylinder 1 at overlap
      • Overlapping position of cylinder bank 4-6: Cams on cylinder 4 are facing inward at a slant to the spark-plug recess. → Cam position on cylinder 4 at overlap
        Fig 1: Locating Cylinder Cam Position (1)

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        Fig 2: Locating Cylinder Cam Position (4)

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

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

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

   Information 

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

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

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

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

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

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      Fig 9: Locating Oil Supply Valve On Vacuum Pump

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

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   6. 5.6. The bearing pin for the tensioning rail 4-6 -1-  is longer than the five other pins -2-  for the timing chain rails.
      Fig 11: Identifying Difference Between Bearing Pins

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

   → 157019 REMOVING AND INSTALLING CYLINDER HEAD .

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

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
8. Turn the engine at the engine assembly support so that the oil pan is at the top.
9. Remove the 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 (E10, M6 x 12) -2-  and remove the pipe.
       Fig 13: Identifying Coolant Pump And Pipe

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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 AND HANDLING TOOLS .

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 screw -17-  .
       Fig 14: Outer Cross Bolt Connection Loosening Sequence

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

       18  - External Torx screw, M6 x 40

       19-32  - External Torx screw, M6 x 25

       33  - External Torx screw, M8 x 120

    2. 14.2. Loosen and unscrew through-bolt screws (E14) M10 x 195 in the opposite sequence to the tightening sequence.
       Fig 15: Crankcase Through-Bolt Screws Loosening Sequence

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.

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

    3. 14.3. Check screws for damage and replace them if necessary or only replace the sealing washers.
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 using a large slotted screwdriver.
       Fig 16: Locating Crankcase Lever Positions

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

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

    → 131020 REMOVING AND INSTALLING PISTONS AND HANDLING TOOLS .

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

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    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.

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

20. Clean the crankcase and sealing surfaces.