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Home >> Porsche >> 2016 >> Cayman GTS, Standard Trans >> Repair and Diagnosis >> External Pages >> Different car >> Section 232 (10 - Engine - Crankcase, Suspension -- 92A Cayenne) >> WM 100137 Disassembling And Assembling V6 DFI Engine (Cayenne Tip "Platinum Edition", Cayenne Tip, Cayenne Man) >> Disassembling V6 DFI Engine

Disassembling V6 DFI Engine

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  1. Remove engine wire harness → REMOVING WIRE HARNESS FOR ENGINE .
  2. Remove bar ignition modules → REMOVING BAR IGNITION MODULES .
  3. Remove intake-air distributor → REMOVING INTAKE-AIR DISTRIBUTOR .
  4. Remove drive belt → REMOVING DRIVE BELT .
  5. Remove belt tensioner → 137319 REMOVING AND INSTALLING BELT TENSIONER ON DFI ENGINES .

    arrows  - Belt tensioner

    Fig 1: Locating Belt Tensioner
    G09931503Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  6. Remove unit carrier
    1. Belt tensioner
    2. Cheese head bolt on belt tensioner
    3. Unit carrier
    4. Fit bolt for unit carrier
    5. Cheese head bolt for unit carrier
    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 2: Identifying Unit Carrier Components
    G09931504Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  7. Remove generator → REMOVING GENERATOR .
  8. Remove coolant pump → REMOVING COOLANT PUMP .
    1. 8.1. Remove coolant pump pulley if necessary.

    arrows  - Oval-head screws for pulley (coolant pump)

    Fig 3: Locating Coolant Pump
    G09931505Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  9. Remove all coolant hoses and additional coolant pump with holder.
    1. 9.1. Unscrew fastening screws -2-  .
    2. 9.2. Pull off cable plugs and remove coolant hoses -3, 4 and 5-  .
    3. 9.3. Remove additional coolant pump with sheetmetal holder -1-  .
      1. Sheetmetal holder
      2. Fastening screws for coolant pump holder
      3. Coolant hose
      4. Coolant hose
      5. Coolant hose
      Fig 4: Identifying Coolant Pump Components
      G09931506Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  10. Remove oil/water heat exchanger and engine support arm → REMOVING ENGINE OIL COOLER .
  11. Remove exhaust manifold if necessary → REMOVING EXHAUST MANIFOLD .

    arrows  - Exhaust manifold fastening nuts

    Fig 5: Locating Exhaust Manifold Nuts
    G09931507Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  12. Remove fuel distributor pipe (fuel rail) → REMOVING FUEL DISTRIBUTOR PIPE (FUEL RAIL) .
    1. Fuel line (low-pressure)
    2. Cheese head bolts for fuel distributor pipe
    3. Fuel injectors
      4. Fig 6: Identifying Fuel Distributor Pipe
      G09931508Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  13. Remove coolant regulator → REMOVING COOLANT REGULATOR .
    1. 13.1. Loosen spring band clamp -2-  .
    2. 13.2. Pull thermostat housing -1-  completely out of the cylinder block.
      1. Thermostat housing
      2. Spring band clamp
      3. Coolant hose
      Fig 7: Identifying Thermostat Housing, Coolant Hose And Spring Band Clamp
      G09931509Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  14. Remove cylinder head cover → REMOVING CYLINDER HEAD COVER .
  15. Remove flywheel/drive plate.
    1. 15.1. Remove dual-mass flywheel on vehicles with manual transmission → REMOVING DRIVE PLATE .
    2. 15.2. Remove drive plate on vehicles with automatic transmission → REMOVING DRIVE PLATE FOR TORQUE CONVERTER .
  16. Remove oil pan → REMOVING OIL PAN .
  17. Remove timing-case cover at the top and bottom → REMOVING TIMING-CASE COVER .
  18. Set crankshaft for cylinder 1 to compression TDC → 150502 CHECKING THE TIMING .

    Information 

    Removal of chain tensioner 

    • Press the bottom chain tensioner together during removal because otherwise it will push out due to spring tensioning. Secure chain tensioner with a tie-wrap in tensioned state  .
  19. Remove chain tensioner → REMOVING CHAIN TENSIONER .
  20. Remove timing chains → REMOVING TIMING CHAINS .
    1. 20.1. Remove camshaft controllers → REMOVING CAMSHAFT CONTROLLER .
  21. Remove camshafts → REMOVING CAMSHAFTS .
    1. 21.1. Remove timing chain housing
    2. 21.2. Remove intake camshaft. Loosen the hexagon nuts on the bearing covers alternately and crosswise. Note the sequence in which the bearing covers are removed.
      1. 21.2.1. Remove bearing covers 1 and 13.
      2. 21.2.2. Remove bearing covers 3 and 11.
      3. 21.2.3. Remove bearing cover 7.
      4. 21.2.4. Remove bearing covers 5 and 9.
    3. 21.3. Remove outlet camshaft. Loosen the hexagon nuts on the bearing covers alternately and crosswise. Note the sequence in which the bearing covers are removed.
      1. 21.3.1. Remove bearing covers 2 and 14.
      2. 21.3.2. Remove bearing covers 4 and 12.
      3. 21.3.3. Remove bearing cover 8.
      4. 21.3.4. Remove bearing covers 6 and 10.
        1. Intake camshaft
        2. Camshaft bearing cover
        3. Outlet camshaft
        4. Hexagon nut on camshaft bearing cover
        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
          26. Fig 8: Overview Of Cylinder Head (V6 DFI Engine)
          G09931510Courtesy of PORSCHE CARS NORTH AMERICA, INC.
        1. Cheese head bolt → Tightening torque: 8 Nm (6 ftlb.) 
        2. Timing chain housing
        5. Fig 9: Removing Timing Chain Housing
        G09931511Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  22. Remove hydraulic tappets → REMOVING HYDRAULIC TAPPETS .
  23. Remove cylinder head → REMOVING CYLINDER HEAD .
    1. 23.1. Remove and dispose of cylinder head gasket.
  24. Remove oil pump → REMOVING OIL PUMP .

    Information 

    Removal of connecting-rod bearing cap  :

    • Connecting-rod bearing caps must be marked and numbered during removal. Retaining lugs of bearing shells are pressed together. The cast lugs of connecting-rod bearings and connecting-rod big end are identical! 
  25. Remove pistons → REMOVING PISTONS .
  26. Remove vibration balancer. → REMOVING VIBRATION DAMPER
    Fig 10: Removing Vibration Balancer
    G09931512Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  27. Remove joint flange behind the vibration balancer.
    1. 27.1. Unscrew hexagon-head bolts -3-  .
    2. 27.2. Carefully lever off the joint flange -2-  with a screwdriver.
      1. Cylinder block
      2. Vibration balancer joint flange
      3. Hexagon-head bolt on vibration balancer joint flange
      4. Straight pin
      5. Lower timing-case cover
      6. Fastening screw on lower timing-case cover
      3. Fig 11: Identifying Crankshaft Joint Flange And Bolts
      G09931513Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    Removal of crankshaft 

    Before removing the crankshaft, have a suitable tray ready so that the pulse-generating wheel is not damaged as a result of excessive contact.

    The engine is secured on the engine support to facilitate assembly work.

    When replacing bearing shells, only use bearing shells with the same color coding.

  28. Remove crankshaft. → REMOVING CRANKSHAFT
    1. 28.1. Prepare a clean surface for laying down the crankshaft. Make sure not to damage the drive plate for the inductive pickup (speed sender) when laying down the crankshaft.
    2. 28.2. Remove crankshaft bearing covers -1-  and lay them down arranged according to cylinder.
    3. 28.3. Dispose of thrust washers -4-  and crankshaft bearing shells -3-  .
    4. 28.4. Remove the crankshaft and lay it down on the prepared surface.
    5. 28.5. Remove oil spray nozzles -8-  if necessary.
      1. Crankshaft bearing covers
      2. Internal serration screws on crankshaft bearing covers
      3. Crankshaft bearing shells must always be replaced 
      4. Thrust washer for bearing cover 5 must always be replaced 
      5. Crankshaft
      6. Drive plate for inductive pickup (speed sender)
      7. Fastening screw on drive plate for inductive pickup (speed sender)
      8. Oil spray nozzle
      Fig 12: Identifying Crank Drive (V6 DFI Engine)
      G09931514Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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