Assembling V6 DFI Engine

Information 

If cold or excessively low-tempered components are sealed to each other by applying sealant, leaks can occur because of condensed water forming or components distorting. Components must be uniformly at least → Temperature: 17°C  .

Information 

• Detailed instructions for installing pistons must be observed at all times  .
• The cast lugs, the twist lock (locking lugs) -1- and the flat side of the piston crown -2- are on the same side  .
  Fig 1: Locating Pistons And Connecting Rods

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1. Install crankshaft → INSTALLING CRANKSHAFT .

   Information 

   • Bearing covers for the crankshaft are numbered 1 to 7 and the numbers can be read on the side facing the exhaust  .
   • Bearing no. 5 is a guide or thrust bearing with two thrust washers at the side  .
   • The twist locks or retaining lugs are on the same side  .
   • Bearing screws must be replaced  .
   • Bearing shells must be replaced. Use only identical color markings 
   1. 1.1. Oil bearing shells with engine oil and place them on the crankshaft/crankcase. Make sure that the twist lock → Twist lock  is inserted cleanly in the crankcase.
   2. 1.2. Always replace bearing shells. Observe relevant classification.
   3. 1.3. Fit thrust bearing no. 5 with thrust washers -4-  (insert using grease, lubricating groove facing outwards) and then fit the remaining bearing covers.
   4. 1.4. Tap crankshaft bearing covers on securely as far as they will go using a rubber hammer so that the tightening torque will be accurate.
   5. 1.5. Internal serration screws on the crankshaft bearing covers -2- must always be replaced  and screwed in by hand.
   6. 1.6. Then gradually tighten the bearing covers from the inside out to the specified torque -2-  .
   7. 1.7. As a test, turn the crankshaft several times to check that it turns smoothly.
   8. 1.8. If the drive plate -6-  for the inductive pickup (speed sender) was removed from the crankshaft, the drive plate must be replaced  .
      1. 1.8.1. Tighten the countersunk screws -7-  on the drive plate to the specified tightening torque.
   1. Crankshaft bearing covers
   2. Internal serration screw on crankshaft bearing cover → Initial tightening: 30 Nm (22 ftlb.) → Torque angle: 180° 
   3. Bearing shell
   4. Thrust washer for bearing cover 5
   5. Crankshaft
   6. Drive plate for inductive pickup
   7. Countersunk screw on drive plate for inductive pickup → Initial tightening: 10 Nm (7.5 ftlb.) → Torque angle: 90° 
   8. Oil spray nozzle
   Fig 2: Identifying Crank Drive (V6 DFI Engine)
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   Fig 3: Twisting Drive Plate Lock

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2. Install pistons → INSTALLING PISTONS .
   1. 2.1. Pull dowel sleeve -arrow-  out of the bore hole so that special tool funnel T10333  can be positioned flat on the cylinder block.
   2. 2.2. Oil the piston well and insert it into the funnel.
   3. 2.3. Align all pistons so that the deep valve recesses -1 and 2-  are facing the middle of the cylinder block and the arrows -3-  on the pistons are facing the vibration damper.
   4. 2.4. Position the piston funnel on the cylinder block and align it so that the high edge -arrow-  is facing the middle of the cylinder block.
   5. 2.5. Slide piston fully into the cylinder bore.
      1. 2.5.1. Turn the crankshaft back and forth if necessary.
   6. 2.6. Insert dowel sleeves back into the bore hole -arrow-  .
   7. 2.7. Oil connecting-rod bearing shells -5-  .

      Information 

      • Always replace the connecting-rod bearing shells and oil them before inserting them into the bearing covers  .
      • The connecting-rod big end and connecting-rod bearing caps must be aligned according to the cast lugs -B and C- . The retaining lugs of the connecting-rod bearing shells are on one side. Connecting-rod bearing caps are legible on alternate sides  .
        Fig 4: Identifying Connecting-Rod Bearing Cast Lugs

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      • Install connecting rod and connecting-rod bearing caps unrestrained. If necessary, remove them again, position the bearing caps by tapping lightly with a plastic hammer and then refit them  .
   8. 2.8. Assign connecting rod bearing caps correctly and screw in the connecting rod bolts -7-  by hand. When doing so, make sure that the locking lugs on the bearing shells are aligned.
   9. 2.9. Carefully tap the connecting rod bearing caps -6 -  with a plastic hammer until they are seated correctly so that the tightening torque will be accurate.
   10. 2.10. Tighten all connecting rod bearing screws -7-  to the specified tightening torque.
   11. 2.11. Turn the crankshaft several times to check that it turns smoothly.
   12. 2.12. Align the crankshaft so that the gap -arrow-  on the drive plate for the inductive pickup is facing downwards (rough TDC presetting).
       1. Piston rings (move gap by 120°)
       2. Piston
       3. Circlip
       4. Connecting rod
       5. Connecting rod bearings must always be replaced  . Observe relevant classification.
       6. Connecting rod bearing cap
       7. Connecting rod bolts → Initial tightening: 30 Nm (22 ftlb.) → Torque angle: 90° 
       8. Cylinder block
       9. Piston pin
       Fig 5: Overview Of Piston/Connecting Rod

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       arrow  - Dowel pin

       Fig 6: Locating Cylinder Block Dowel Sleeve

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       1. Valve recesses on cylinders 1, 3 and 5
       2. Valve recesses on cylinders 2, 4 and 6
       3. Arrow pointing towards vibration balancer
       Fig 7: Identifying Pistons Installation Direction (V6 DFI Engine)
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       Fig 8: Locating Cylinder Block Piston Funnel

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       arrow  - Setting of gap on drive plate for inductive pickup (speed sender)

       Fig 9: Locating Inductive Pickup Drive Plate

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3. Fit joint flange for vibration balancer → 137419 REMOVING AND INSTALLING SEALING RING FOR VIBRATION BALANCER .
   1. 3.1. Apply 2-mm thick bead of sealant -arrows-  .
   2. 3.2. Fit assembly fixture T10215  (guide sleeve) -1-  on the crank pin -3-  to prevent damage to the vibration balancer joint flange.
   3. 3.3. Slide the joint flange -2-  over the guide sleeve -1-  until it is touching the cylinder block.
   4. 3.4. Tighten hexagon-head bolts -3-  on joint flange -2-  to the specified torque.
      1. Cylinder block
      2. Vibration balancer joint flange
      3. Hexagon-head bolt on vibration balancer joint flange → Tightening torque: 10 Nm (7.5 ftlb.) 
      4. Straight pin, M8 x 18
      5. Lower timing-case cover
      6. Hexagon-head bolt on lower timing-case cover → Tightening torque: 8 Nm (6 ftlb.) 
      Fig 10: Identifying Crankshaft Joint Flange, Guide Sleeve And Head Bolts

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      Fig 11: Applying Sealant To Joint Flange

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      1. Assembly fixture (guide sleeve)
      2. Vibration balancer joint flange
      3. Crankshaft flange
      Fig 12: Identifying Crankshaft And Vibration Balancer Joint Flange

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4. Fit vibration balancer for crankshaft. → INSTALLING VIBRATION DAMPER
   1. 4.1. Tighten hexagon-head bolt on crankshaft vibration balancer → Initial tightening: 100 Nm (74 ftlb.) → Torque angle: 180°  .
      Fig 13: Tightening Crankshaft Vibration Balancer Bolt

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5. Position engine to the compression TDC of cylinder 1.

   arrow  - Crankshaft/vibration balancer marking

   Fig 14: Locating Pulley And Housing Cover TDC Marking

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6. Install oil pump. → INSTALLING

   arrows  - Hexagon-head bolt on oil pump → Tightening torque: 8 Nm (6 ftlb.) 

   Fig 15: Locating Oil Pump Bolts

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7. Install cylinder head. → INSTALLING CYLINDER HEAD
   1. 7.1. Thoroughly clean all sealing faces before assembly.
   2. 7.2. Cylinder head gasket must always be replaced  .
   3. 7.3. Always observe tightening sequence (1-20) for cylinder-head screws -1-20-  and tighten to the specified torque.
      1. 7.3.1. Tighten cylinder-head screws to an initial tightening torque of 15 Nm (11 ftlb.).
      2. 7.3.2. Tighten cylinder-head screws to 30 Nm (22 ftlb.).
      3. 7.3.3. Then tighten all cylinder-head screws a second time  to 30 Nm (22 ftlb.).
      4. 7.3.4. And finally, tighten the cylinder-head screws to a torque angle of 180°.
         Fig 16: Identifying Engine Cylinder Sequence

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         1-6  - Pistons of cylinders 1-6

         1-20  - Tightening sequence for cylinder-head screws → Initial tightening: 15 Nm (11 ftlb.) → Tightening torque: 30 Nm (22 ftlb.) → Torque angle: 180° 

8. Install hydraulic tappets. → INSTALLING HYDRAULIC TAPPETS
9. Install the camshafts.
   1. 9.1. Insert the camshafts into the cylinder head in such a way that the camshaft bar T10068A  fits into the slots on the intake and outlet camshafts at the same time. → INSTALLING CAMSHAFTS .

      1, 3, 5, 7, 9, 11, 13	Bearing covers on intake camshaft
      2, 4, 6, 8, 10, 12, 14	Bearing covers on outlet camshaft

   2. 9.2. Install intake camshaft. Note the sequence in which the bearing covers are installed.
      1. 9.2.1. First fit bearing covers 5 and 9 and tighten the hexagon nuts alternately and crosswise.
      2. 9.2.2. Repeat the process for bearing covers 1 and 13.
      3. 9.2.3. Repeat the process for bearing cover 5.
      4. 9.2.4. Repeat the process for bearing covers 3 and 11.
   3. 9.3. Install outlet camshaft. Note the sequence in which the bearing covers are installed. Use the same torque and torque angle as for the intake camshaft.
      1. 9.3.1. First fit bearing covers 6 and 10 and tighten the hexagon nuts alternately and crosswise.
      2. 9.3.2. Repeat the process for bearing covers 2 and 14.
      3. 9.3.3. Repeat the process for bearing cover 8.
      4. 9.3.4. Repeat the process for bearing covers 4 and 12.
   4. 9.4. Install timing chain housing.
      1. Intake camshaft
      2. Camshaft bearing cover
      3. Outlet camshaft
      4. Hexagon nut on camshaft bearing cover → Initial tightening: 5 Nm (3.5 ftlb.) → Torque angle: 45° 
      5. Sealing rings (40 x 1.5)
      6. Timing chain housing
      7. Oval-head screw on timing chain housing
      8. Outlet camshaft controller (marking 32 A)
      9. Intake camshaft controller (marking 24 E)
      10. Hexagon-head bolts on camshaft controllers
      11. Cylinder head height (min. height a=139.9 mm)
      12. Drive gear wheel for high-pressure pump
      13. Bearing shaft
      14. Valves
      15. Dowel sleeve
      16. Cylinder head
      17. Pump tappet
      18. Support element
      19. Valve stem seal
      20. Timing chain
      21. Safety clip
      22. Rocker arm
      23. Valve spring
      24. Valve-spring plate
      25. Valve collets
      Fig 17: Overview Of Cylinder Head (V6 DFI Engine)
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      arrow  - Hexagon for countering the camshaft

      Fig 18: Locating Camshaft Installation Position

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      1. Cheese head bolt → Tightening torque: 8 Nm (6 ftlb.) 
      2. Timing chain housing
      Fig 19: Installing Timing Chain Housing

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10. Fit timing chains. → INSTALLING TIMING CHAINS
    1. 10.1. Install chain tensioner. → INSTALLING CHAIN TENSIONER
    2. 10.2. Install camshaft controllers. → INSTALLING CAMSHAFT CONTROLLER
       1. Timing chain housing
       2. Oval-head screw on timing chain housing → Tightening torque: 8 Nm (6 ftlb.) 
       3. Timing chain
       4. Outlet camshaft controller (marking 32 A)
       5. Sealing ring
       6. Oil pump
       7. Fastening screw on oil pump → Tightening torque: 8 Nm (6 ftlb.) 
       8. Tensioning rail
       9. Chain tensioner on timing chain → Tightening torque: 50 Nm (37 ftlb.) 
       10. Sealing ring (A22 x 27), always replace 
       11. Bearing pin on guide rail → Tightening torque: 10 Nm (7.5 ftlb.) 
       12. Sprocket
       13. Drive wheel for timing chain
       14. Hexagon-head bolt → Initial tightening: 60 Nm (44 ftlb.) → Torque angle: 90° 
       15. Chain tensioner for drive chain
       16. Drive gear wheel for drive chain
       17. Drive chain
       18. Guide rail for drive chain
       19. Bolt for guide rail → Tightening torque: 10 Nm (7.5 ftlb.) 
       20. Fastening screw on guide rail → Tightening torque: 20 Nm (15 ftlb.) 
       21. Hexagon-head bolt on guide rail → Tightening torque: 23 Nm (17 ftlb.) 
       22. Hexagon-head bolts on camshaft controllers → Initial tightening: 60 Nm (44 ftlb.) → Torque angle: 90° 
       23. Guide rail for timing chain
       24. Drive gear wheel for high-pressure pump
       25. Intake camshaft controller (marking 24 E)
       26. Valve for outlet camshaft controller
       27. Valve for intake camshaft controller
       28. Guide rail
       Fig 20: Overview Of Timing Chains

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11. Check the timing. → 150502 CHECKING THE TIMING ON V6 DFI ENGINES
12. Fit upper and lower timing-case cover. → INSTALLING TIMING-CASE COVER
    1. 12.1. Fit lower timing-case cover.
    2. 12.2. Fit upper timing-case cover.
       1. Cylinder block
       2. Vibration balancer joint flange
       3. Hexagon-head bolt on vibration balancer joint flange
       4. Straight pin, M8 x 18
       5. Lower timing-case cover
       6. Hexagon-head bolt on lower timing-case cover → Tightening torque: 10 Nm (7.5 ftlb.) 
       Fig 21: Identifying Crankshaft Joint Flange, Cylinder Block, Pin And Bolt
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       1. 1  - Drive shaft
       2. 2  - Upper timing-case cover
       3. 3  - Oval-head screw → Tightening torque: 8 Nm (6 ftlb.) 
       4. 4  - Oval-head screw on vacuum pump → Tightening torque: 8 Nm (6 ftlb.) 
       5. 6  - Seal
       6. 7  - Sealing ring
       Fig 22: Identifying Vacuum Pump Components

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    Information 

    Installation of oil pan 

    Check the best-before date on the sealing compound.

    The oil pan must be installed within 5 minutes of applying the silicone sealant.

    The bead of sealant that is applied must not be thicker than the specified thickness because otherwise excess sealant can get into the oil pan and can block the strainer in the oil pump intake pipe.

    Allow the sealant to dry for at least 30 minutes after installing the oil pan. Only then can engine oil be filled in.

13. Install oil pan. → INSTALLING OIL PAN

    1-25  - Hexagon-head bolts on oil pan → Tightening torque: 12 Nm (9 ftlb.) 

    Fig 23: Timing Chain Housing Cover Bolts Tightening Sequence

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14. Install cylinder head cover. → INSTALLING CYLINDER HEAD COVER
    1. Cylinder head cover
    2. Cylinder-head gasket
    3. Fastening screw on cylinder head cover → Tightening torque: 10 Nm (7.5 ftlb.) 
    4. Cover
    Fig 24: Identifying Valve Cover Seal, Cylinder Head Cover And Gasket
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15. Install flywheel/drive plate.
    1. 15.1. Install dual-mass flywheel on vehicles with manual transmission.
    2. 15.2. Remove drive plate on vehicles with automatic transmission. → REMOVING DRIVE PLATE
16. Install oil/water heat exchanger. → INSTALLING ENGINE OIL COOLER
    1. Oil-filter housing
    2. Seal must always be replaced 
    3. Sealing rings must always be replaced 
    4. Oil cooler
    5. Oil cooler cover → Tightening torque: 25 Nm (19 ftlb.) 
    6. Oil pressure switch → Tightening torque: 20 Nm (15 ftlb.) 
    7. Oil filter
    8. Lower part of oil filter → Tightening torque: 25 Nm (19 ftlb.) 
    9. Oil drain plug → Tightening torque: 10 Nm (7.5 ftlb.) 
    10. Hexagon-head bolt on oil/water heat exchanger → Tightening torque: 23 Nm (17 ftlb.) 
    Fig 25: Identifying Oil-Filter Housing
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17. Install coolant regulator. → INSTALLING
    1. 17.1. Fit thermostat housing -1-  completely into the cylinder block.
    2. 17.2. Slide coolant hose -3-  onto the thermostat housing.
    3. 17.3. Fasten spring band clamp -2-  .
       1. Thermostat housing
       2. Spring band clamp
       3. Coolant hose
       Fig 26: Identifying Coolant Regulator, Thermostat Housing And Coolant Hose

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18. Install fuel distributor pipe and fuel injectors. → INSTALLING FUEL DISTRIBUTOR PIPE (FUEL RAIL)
    1. Fuel low-pressure line → Tightening torque: 22 Nm (16 ftlb.) → Tightening torque: 35 Nm (26 ftlb.) 
    2. Cheese head bolts on fuel distributor pipe → Initial tightening: 30 Nm (22 ftlb.) → Torque angle: 90° 
    3. Fuel injectors
    Fig 27: Identifying Cylinders Fuel Distributor Pipe
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19. Install coolant pump.→ INSTALLING COOLANT PUMP

    arrows  - Oval-head screw (coolant pump) → Tightening torque: 8 Nm (6 ftlb.) 

    Fig 28: Locating Coolant Pump Screws

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20. Install exhaust manifold.

    → INSTALLING EXHAUST MANIFOLD

    arrows  - Hexagon nut on exhaust manifold → Tightening torque: 25 Nm (19 ftlb.) 

    Fig 29: Locating Exhaust Manifold Nut

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21. Install intake-air distributor. → INSTALLING INTAKE-AIR DISTRIBUTOR
22. Install guide tube for oil dipstick. Sealing ring must always be replaced  . → INSTALLING GUIDE FOR OIL DIPSTICK
23. Install unit carrier.
    1. Belt tensioner
    2. Cheese head bolt on belt tensioner
    3. Unit carrier
    4. Fit bolt on unit carrier → Tightening torque: 23 Nm (17 ftlb.) 
    5. Cheese head bolt on unit carrier → Tightening torque: 23 Nm (17 ftlb.) 
    6. Dowel sleeve for unit carrier
    7. Deflection roller with fastening screw
    8. Drive belt (poly-rib belt)
    9. Generator
    10. Coolant pump pulley
    11. Drive wheel for air-conditioning compressor
    12. Power-steering pump pulley
    13. Crankshaft vibration damper
    Fig 30: Identifying Generator, Coolant Pump Pulley And Crankshaft Vibration Damper

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24. Install the generator. → INSTALLING GENERATOR
25. Install hydraulic pump (power-steering pump). → 48981900 REMOVING AND INSTALLING HYDRAULIC PUMP (CAYENNE V6)
26. Install belt tensioner. → INSTALLING BELT TENSIONER

    arrows  - Cheese head bolts on belt tensioner → Tightening torque: 25 Nm (19 ftlb.) 

    Fig 31: Locating Belt Tensioner Bolt

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27. Fit and tension the drive belt.

    → INSTALLING DRIVE BELT

    1. Crankshaft vibration balancer
    2. Coolant pump
    3. Drive belt tensioning roller
    4. Air-conditioning compressor
    5. Power-steering pump/tandem pump
    6. Generator
    7. Deflection roller
    Fig 32: Drive Belt Routing Diagram
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28. Install bar ignition modules. → INSTALLING BAR IGNITION MODULES
    1. Connectors for bar ignition modules
    2. Retaining clips
    3. Engine wire harness
    Fig 33: Identifying Ignition Coils And Spark Plugs

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29. Fit engine wire harness. → REMOVING WIRE HARNESS FOR ENGINE
    1. 29.1. Clip in engine wire harness at the rear engine housing using the retaining clips -arrows-  .
    2. 29.2. Connect engine wire harness to the oil/water heat exchanger.

    arrows  - Retaining clips

    Fig 34: Locating Engine Wire Harness (Rear)

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    Fig 35: Locating Engine Wire Harness (Front Left)

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