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  .

Information 

• Fit connecting rod and the relevant cover  .
• Replace connecting rod bolts and bearing shells  .
• Replace crankshaft sealing rings  .

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 the ground strap.
2. Check visually to see which cylinder bank is at overlapping position. Remove this cylinder bank first.
   1. 2.1. Cam positions 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 Position On Cylinder 1

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        Cylinder 4: 

        Fig 2: Locating Cam Position On 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 Camshafts 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 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 Bucket Tappets And Switching Tappets

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   2. 4.2. Lay components on a clean, labelled surface.
      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 for the tensioning rail -2-  and two bearing pins for the guide rail -1-  .
      Fig 6: Identifying Bearing Pins On Cylinder Bank 1-3

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   2. 5.2. Pull out the guide and tensioning rails -1-  using a pair of flat-nosed pliers -3-  .
      Fig 7: Pulling Out Guide And Tensioning Rails Using Pair Of Flat-Nosed Pliers

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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 With 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

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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 and cylinder-head gasket.

   → 157019 REMOVING AND INSTALLING CYLINDER HEAD .

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

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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 External Torx 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: Outer Cross Bolt Connection Screws 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 (M10 x 195) in the opposite sequence to the tightening sequence.
       Fig 15: Through-Bolt Screws Tightening Sequence

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

    3. 14.3. Replace screws.

       The sealing washers can be replaced 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 using a large slotted screwdriver -arrows-  .
       Fig 16: Locating Crankcase Lever Positions

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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 Wood Positions And Crankcase Mounting Lever Position

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17. Remove pistons and connecting rods on 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 and 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 for the Cayenne can be used to assess the cylinder linings.

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

20. Clean the crankcase and sealing surfaces.