Subsequent Work

WARNING: This page is about a different car, the 2010 Porsche Cayenne, 2009 Porsche Cayenne, and 2008 Porsche Cayenne. However, it is still accessible from the selected car via links, so may be relevant.

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: Arrangement Of Pistons And Connecting Rods
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Install pistons. → 131019 REMOVING AND INSTALLING PISTONS ON V6 DFI ENGINES

Fig 2: Overview Of Piston/Connecting Rod
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Piston rings (move gap by 120°)
2. Pistons
3. Circlip
4. Bearing shells must always be replaced . Observe relevant classification.
5. Connecting rod bearing
6. Connecting rod bearing cap
7. Connecting rod bolts → Initial tightening: 30 Nm (22 ft lbs.) → Torque angle: 90°
8. Cylinder block
9. Piston pins
1. 1.1. Pull dowel sleeve -arrow- out of the bore hole so that special tool funnel T10333 can be positioned flat on the cylinder block.
  
  Fig 3: Locating Dowel Sleeve On Cylinder Block
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Pfeil - Dowel pin
2. 1.2. Oil the piston well and insert it into the funnel.
3. 1.3. 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.
  
  Fig 4: Identifying Cylinder Valve Recesses
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. Valve recesses on cylinders 1, 3 and 5
  2. Valve recesses on cylinders 2, 4 and 6
  3. Arrow pointing towards vibration balancer
4. 1.4. 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.
  
  Fig 5: Positioning Piston Funnel On Cylinder Block
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. 1.5. Slide piston fully into the cylinder bore.
6. 1.5.1. Turn the crankshaft back and forth if necessary.
7. 1.6. Insert dowel sleeves back into the bore holes -arrow- .
8. 1.7. 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 6: Identifying Retaining Lugs
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  - 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.
9. 1.8. 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.
10. 1.9. 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.
11. 1.10. Tighten all connecting rod bearing screws -7- to the specified tightening torque.
12. 1.11. Turn the crankshaft several times to check that it turns smoothly.
13. 1.12. Align the crankshaft so that the gap -arrow- on the drive plate for the inductive pickup is facing downwards (rough TDC presetting).
  Pfeil - Setting of gap on drive plate for inductive pickup (speed sender)
  
  Fig 7: Setting Of Drive Plate For Inductive Pickup
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit joint flange for vibration balancer. → 137419 REMOVING AND INSTALLING SEALING RING FOR VIBRATION BALANCER ON DFI ENGINES

Fig 8: Identifying Cylinder Block, Vibration Balancer Joint Flange, Lower Timing-Case Cover And Bolts
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Cylinder block
2. Vibration balancer joint flange
3. Hexagon-head bolt on vibration balancer joint flange → Tightening torque: 10 Nm (7.5 ft lbs.)
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 ft lbs.)
1. 2.1. Apply a bead of sealant -arrows- with a thickness of 2 mm.
  
  Fig 9: Applying Sealant On Joint Flange
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 2.2. Fit assembly fixture T10215 (guide sleeve) -1- on the crank pin -3- to prevent damage to the vibration balancer joint flange.
3. 2.3. Slide the joint flange -2- over the guide sleeve -1- until it is touching the cylinder block.
  1. Assembly fixture (guide sleeve)
  2. Vibration balancer joint flange
  3. Crankshaft flange
    
    Fig 10: Fitting Assembly Fixture T10215 On Crank Pin
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. 2.4. Tighten hexagon-head bolts -3- on joint flange -2- to the specified torque.
Fit vibration balancer for crankshaft. → 137619 REMOVING AND INSTALLING VIBRATION BALANCER (CRANKSHAFT PULLEY) ON V6 DFI ENGINES

Fig 11: Installing Vibration Balancer
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. 3.1. Tighten hexagon-head bolt on crankshaft vibration balancer → Initial tightening: 100 Nm (74 ft lbs.) → Torque angle: 180°.
Position engine to the compression TDC of cylinder 1.
Pfeil - Crankshaft/vibration balancer marking

Fig 12: Locating TDC Marking On Pulley And Housing Cover
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
If the oil retaining valve was removed during removal, fit a new sealing ring on the oil retaining valve before inserting it into the crankcase -arrow- .
Pfeil - Oil retaining valve

Fig 13: Locating Oil Retaining Valve
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install cylinder head. → WM 157019 REMOVING AND INSTALLING CYLINDER HEAD ON V6 DFI ENGINES

Fig 14: Identifying Cylinder Head Screws Tightening Sequence
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1-6 - Pistons of cylinders 1 - 6

1-20 - Tightening sequence for cylinder-head screws → Initial tightening: 15 Nm (11 ft lbs.) → Tightening torque: 30 Nm (22 ft lbs.) → Torque angle: 180°
1. 6.1. Thoroughly clean all sealing faces before assembly.
2. 6.2. Cylinder head gasket must always be replaced .
3. 6.3. Always observe tightening sequence (1-20) for cylinder-head screws -1-20- and tighten to the specified torque.
4. 6.3.1. Tighten cylinder-head screws to an initial tightening torque of 15 Nm (11 ft lbs.).
5. 6.3.2. Tighten cylinder-head screws to 30 Nm (22 ft lbs.).
6. 6.3.3. Then tighten all cylinder-head screws a second time to 30 Nm (22 ft lbs.).
7. 6.3.4. And finally, tighten the cylinder-head screws to a torque angle of 180°.
Fit timing chains. → WM 153519 REMOVING AND INSTALLING TIMING CHAINS ON V6 DFI ENGINES

Fig 15: Overview Of Timing Chain
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Timing chain housing
2. Oval-head screw on timing chain housing → Tightening torque: 8 Nm (6 ft lbs.)
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 ft lbs.)
8. Tensioning rail
9. Chain tensioner on timing chain → Tightening torque: 40 Nm (30 ft lbs.)
10. Sealing ring (A22 x 27), always replace
11. Bearing pin on guide rail → Tightening torque: 10 Nm (7.5 ft lbs.)
12. Sprocket
13. Drive wheel for timing chain
14. Hexagon-head bolt → Initial tightening: 60 Nm (44 ft lbs.) → 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 ft lbs.)
20. Fastening screw on guide rail → Tightening torque: 20 Nm (15 ft lbs.)
21. Hexagon-head bolt on guide rail → Tightening torque: 23 Nm (17 ft lbs.)
22. Hexagon-head bolts on camshaft controllers → Initial tightening: 60 Nm (44 ft lbs.) → 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
1. 7.1. Install timing chain housing.
  
  Fig 16: Removing Timing Chain Housing
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. Cheese head bolt → Tightening torque: 8 Nm (6 ft lbs.)
  2. Timing chain housing
2. 7.2. Install chain tensioner. → WM 153619 REMOVING AND INSTALLING CHAIN TENSIONER ON V6 DFI ENGINES
3. 7.3. Install camshaft controllers. → WM 158419 REMOVING AND INSTALLING CAMSHAFT CONTROLLER ON V6 DFI ENGINES
Check the timing. → WM 150502 CHECKING THE TIMING ON V6 DFI ENGINES
Fit upper and lower timing-case cover. → WM 153319 REMOVING AND INSTALLING TIMING-CASE COVER ON V6 DFI ENGINES
1. 9.1. Fit lower timing-case cover.
  
  Fig 17: Identifying Cylinder Block, Vibration Balancer Joint Flange, Lower Timing-Case Cover And Bolts
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  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 ft lbs.)
2. 9.2. Fit upper timing-case cover.
  1. 1 - Drive shaft
  2. 2 - Upper timing-case cover
  3. 3 - Oval-head screw → Tightening torque: 8 Nm (6 ft lbs.)
  4. 4 - Oval-head screw on vacuum pump → Tightening torque: 8 Nm (6 ft lbs.)
  5. 6 - Seal
  6. 7 - Sealing ring
    
    Fig 18: Exploded View Of Vacuum Pump
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  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.
Install oil pan. → WM 175019 REMOVING AND INSTALLING OIL PAN ON V6 DFI ENGINES

Fig 19: Oil Pan Hexagon-Head Bolts Tightening Sequence
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

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

Observe tightening sequence for hexagon-head bolts (1 to 25) on oil pan.
Install cylinder head cover. → WM 158219 REMOVING AND INSTALLING CYLINDER HEAD COVER ON V6 DFI ENGINES

Fig 20: Identifying Cylinder Head Cover, Gasket, Lid And Fastening Screws
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Cylinder head cover
2. Cylinder head gasket
3. Fastening screw on cylinder head cover → Tightening torque: 10 Nm (7.5 ft lbs.)
4. Lid
Install flywheel/drive plate.
1. 12.1. Install dual-mass flywheel on vehicles with manual transmission. → Removing Flywheel (Dual-Mass Flywheel)
2. 12.2. Remove drive plate on vehicles with automatic transmission. → 136319 REMOVING AND INSTALLING DRIVE PLATE FOR TORQUE CONVERTER
Install oil/water heat exchanger. → 174019 REMOVING AND INSTALLING OIL/WATER HEAT EXCHANGER (OIL COOLER) ON V6 DFI ENGINES

Fig 21: Overview Of Oil-Filter Housing
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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 ft lbs.)
6. Oil pressure switch → Tightening torque: 20 Nm (15 ft lbs.)
7. Oil filter
8. Lower part of oil filter → Tightening torque: 25 Nm (19 ft lbs.)
9. Oil drain plug → Tightening torque: 10 Nm (7.5 ft lbs.)
10. Hexagon-head bolt on oil/water heat exchanger → Tightening torque: 23 Nm (17 ft lbs.)
Install coolant regulator. → 195819 REMOVING AND INSTALLING COOLANT REGULATOR (THERMOSTAT) ON DFI ENGINES

Fig 22: Identifying Thermostat Housing, Spring Band Clamp And Coolant Hose
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Thermostat housing
2. Spring band clamp
3. Coolant hose
1. 14.1. Fit thermostat housing -1- completely into the cylinder block.
2. 14.2. Slide coolant hose -3- onto the thermostat housing.
3. 14.3. Fasten spring band clamp -2- .
Install fuel distribution pipe and fuel injectors. → WM 243019 REMOVING AND INSTALLING FUEL DISTRIBUTION PIPE (FUEL RAIL) ON DFI ENGINES

Fig 23: Identifying Fuel Low-Pressure Line, Fuel Injectors And Fuel Distribution Pipe Bolts
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Fuel low-pressure line → Tightening torque: 22 Nm (16 ft lbs.) → Tightening torque: 35 Nm (26 ft lbs.)
2. Cheese head bolts on fuel distribution pipe → Initial tightening: 30 Nm (22 ft lbs.) → Torque angle: 90°
3. Fuel injectors
Install coolant pump. → WM 195019 REMOVING AND INSTALLING COOLANT PUMP ON DFI ENGINES
Pfeile - Oval-head screw (coolant pump) → Tightening torque: 8 Nm (6 ft lbs.)

Fig 24: Locating Coolant Pump Head Screws
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install exhaust manifold.
→ Installing Exhaust Manifold

Pfeile - Hexagon nut on exhaust manifold → Tightening torque: 25 Nm (19 ft lbs.)

Fig 25: Locating Exhaust Manifold Hexagon Nuts
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install intake-air distributor. → WM 244619 REMOVING AND INSTALLING DFI INTAKE-AIR DISTRIBUTOR
Install guide tube for oil dipstick. Sealing ring must always be replaced . → WM 171719 REMOVING AND INSTALLING GUIDE TUBE FOR OIL DIPSTICK ON DFI ENGINES
Install unit carrier.

Fig 26: Identifying Unit Carrier Components
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Belt tensioner
2. Cheese head bolt on belt tensioner
3. Unit carrier
4. Fit bolt on unit carrier → Tightening torque: 23 Nm (17 ft lbs.)
5. Cheese head bolt on unit carrier → Tightening torque: 23 Nm (17 ft lbs.)
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
Install the generator. → WM 272219 REMOVING AND INSTALLING THE GENERATOR
Install hydraulic pump (power-steering pump). → WM 489819 REMOVING AND INSTALLING HYDRAULIC PUMP (PDCC/V6) (CAYENNE TIP, CAYENNE MAN)
Install belt tensioner. → 137319 REMOVING AND INSTALLING BELT TENSIONER ON DFI ENGINES
Pfeile - Cheese head bolts on belt tensioner → Tightening torque: 25 Nm (19 ft lbs.)

Fig 27: Locating Belt Tensioner Mounting Bolts
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit and tension the drive belt.
→ 137819 REMOVING AND INSTALLING DRIVE BELT

Fig 28: Drive Belt Routing Diagram
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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
Install bar ignition modules. → WM 282020 REMOVING AND INSTALLING DFI BAR IGNITION MODULES

Fig 29: Identifying Bar Ignition Module Connectors, Retaining Clips And Engine Wire Harness
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
1. Connectors for bar ignition modules
2. Retaining clips
3. Engine wire harness
Fit engine wire harness. → WM 975219 Removing and installing wire harness for engine
1. 26.1. Clip in engine wire harness at the rear engine housing using the retaining clips -arrows- .
  Pfeile - Retaining clips
  
  Fig 30: Locating Rear Engine Housing Retaining Clips
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 26.2. Connect engine wire harness to the oil/water heat exchanger.
  
  Fig 31: Locating Oil/Water Heat Exchanger Wire Harness Clips
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.