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Home >> Porsche >> 2017 >> Cayenne S >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> 10 - Engine - Crankcase, Suspension -- 92AA1 Cayenne 3.6L >> WM, 100137 Disassembling And Assembling V6 DFI Engine >> Assembling V6 DFI Engine

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 for Ming or components distorting. Components must have a uniform temperature of at least 17°C.

G14735199Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Arrangement of pistons and connecting rods 

Information 

  1. Install crankshaft

    > WM 134819 REMOVING AND INSTALLING CRANKSHAFT (CAYENNE TIP)

    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. Oil bearing shells with engine oil and place them on the crankshaft/crankcase. Make sure that the twist lock > Twist lock is inserted clean in the crankcase.
    2. Always replace bearing shells. Observe relevant classification.
    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. 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. Internal serration screws on the crankshaft bearing covers -2- must always be replaced  and screwed in by hand.
    6. Then gradually tighten the bearing covers from the inside out to the specified torque -2-  .
    7. As a test, turn the crankshaft several times to check that it turns smoothly.
    8. If the drive plate -6-  for the inductive pickup (speed sender) was removed from the crankshaft, the drive plate must be replaced. 
      1. Tighten the countersunk screws -7-  on the drive plate to the specified tightening torque.
    G14735200Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Crank drive on V6  DFI engine

    1. Crankshaft bearing cover
    2. Internal serration screw on crankshaft bearing cover > Initial tightening 30 Nm  > 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  > Torque angle 90° 
    8. Oil spray jet
    G14735201Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Twist lock 

  2. Install pistons

    > WM, 131020 REMOVING AND INSTALLING PISTONS

    1. Pull dowel sleeve out of the bore hole so that the special tool > T10333 - funnel can be positioned flat on the cylinder block.
    2. Oil the piston well and insert it into the funnel.
    3. Align all pistons so that the deep valve recesses -1 and 2-  are facing the middle of the cylinder block and the arrows -2-  on the pistons are facing the vibration damper.
    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. Slide piston fully into the cylinder bore.
      1. Turn the crankshaft back and forth if necessary.
    6. Insert dowel sleeves back into the bore hole -Arrow-  .
    7. Oil connecting-rod bearing shells
      G14735202Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Twist lock 

      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.
      • 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. Assign connecting rod bearing caps correctly and screw in the connecting rod bolts -7-  by hand. When doing so, make sure that the retaining lugs on the bearing shells are aligned.
    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. Tighten all connecting rod bearing screws -1-  to the specified tightening torque.
    11. Turn the crankshaft several times to check that it turns smoothly.
    12. Align the crankshaft so that the gap -Arrow-  on the drive plate for the inductive pickup is facing downwards (rough TDC presetting).
    G14735203Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Overview of piston/connecting rod 

    1. Piston rings (move gap by 120°)
    2. Pistons
    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  > Torque angle 90° 
    8. Cylinder block
    9. Piston pin
    G14735204Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Dowel sleeve on cylinder block 

    Arrow  Dowel pin

    G14735205Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Installation direction of pistons on V6 DFI engine 

    1. Valve recesses on cylinders 1, 3 and 5
    2. Valve recesses on cylinders 2, 4 and 6
    3. Arrow pointing towards vibration balancer
    G14735206Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Positioning piston funnel on cylinder block 

    G14735207Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Setting of drive plate for inductive pickup 

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

  3. Fit joint flange for vibration balancer

    > WM, 137419 REMOVING AND INSTALLING JOINT FLANGE WITH SEALING RING FOR VIBRATION BALANCER

    1. Apply 2-mm thick bead of sealant -Arrows-  .
    2. Fit > T10215 - assembly fixture  (guide sleeve) -1-  on the crank pin -3-  to prevent damage to the vibration balancer joint flange.
    3. Slide the joint flange -2-  over the guide sleeve -1-  until it is touching the cylinder block.
    4. Tighten hexagon-head bolts -3-  on joint flange -2-  to the specified torque.
    G14735208Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Crankshaft joint flange 

    1. Cylinder block
    2. Vibration balancer joint flange
    3. Hexagon-head bolt on vibration balancer joint flange > Tightening torque 10 Nm 
    4. Straight pin, M8x 18
    5. Lower timing-case cover
    6. Hexagon-head bolt for lower timing-case cover > Tightening torque 8 Nm 
    G14735209Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Applying sealant to joint flange 

    G14735210Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Joint flange on front of crankshaft 

    1. Assembly fixture (guide sleeve)
    2. Vibration balancer joint flange
    3. Crankshaft flange
  4. Fit vibration balancer for crankshaft. 

    > WM, 137619 REMOVING AND INSTALLING VIBRATION DAMPER (CRANKSHAFT PULLEY)

    1. Tighten hexagon-head bolt on crankshaft vibration balancer to > Initial tightening 100 Nm  > Torque angle 180° 
    G14735211Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Brace 

  5. Position engine to the compression TDC of cylinder 1.
    G14735212Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    TDC marking on pulley and housing cover 

    Arrow  Crankshaft/vibration balancer marking

  6. Install oil pump.

    > WM, 172019 REMOVING AND INSTALLING OIL PUMP

    G14735213Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Arrows  Hexagon-head bolts on oil pump > Tightening torque 8 Nm (6 ftlb.) 

  7. Install cylinder head.

    > WM 157019 REMOVING AND INSTALLING CYLINDER HEAD ON V6 DFI ENGINES (CAYENNE)

    1. Thoroughly clean all sealing faces before assembly.
    2. Cylinder head gasket must always be replaced. 
    3. Always observe tightening sequence (1-20) for cylinder head screws -1-20-  and tighten to the specified torque.
      1. Tighten cylinder head screws.

        > Initial tightening 15 Nm (11 ftlb.) 

      2. Tighten cylinder head screws.

        > Tightening Torque 30 Nm (22 ftlb.) 

      3. Then, re-tighten all cylinder head screws a second time. 

        > Tightening Torque 30 Nm (22 ftlb.) 

      4. And finally, tighten the cylinder head screws.

        > Torque angle 180°

    Fig 1: Cylinder Head Tightening Sequence
    G14735214Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Cylinder head 

    1-6  Pistons of cylinders 1-6

    1-20  Tightening sequence for cylinder head screws

  8. Install hydraulic tappets.

    > WM 155919 REMOVING AND INSTALLING HYDRAULIC TAPPETS (CAYENNE TIP & CAYENNE TIP "PLATINUM EDITION")

  9. Install camshafts.
    1. Insert the camshafts into the cylinder head in such a way that the > T10068A - camshaft bar fits into the slots on the intake and outlet camshafts at the same time.

      > WM, 150520 REMOVING AND 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. Install intake camshaft. Note the sequence in which the bearing covers are installed.
      1. First fit bearing covers 5 and 9 and tighten the hexagon nuts alternately in diagonally opposite sequence.
      2. Repeat the process for bearing covers 1 and 13.
      3. Repeat the process for bearing cover 5.
      4. Repeat the process for bearing covers 3 and 11.
    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. First fit bearing covers 6 and 10 and tighten the hexagon nuts alternately in diagonally opposite sequence.
      2. Repeat the process for bearing covers 2 and 14.
      3. Repeat the process for bearing cover 8.
      4. Repeat the process for bearing covers 4 and 12.
    4. Install timing chain housing.
    G14735215Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Overview of cylinder head on V6 DFI engine 

    1. Intake camshaft
    2. Camshaft bearing cover
    3. Outlet camshaft
    4. Hexagon nut on camshaft bearing cover  > Initial tightening 5 Nm  > 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 gearwheel 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
    G14735216Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Installation position of camshaft 

    Arrow  Hexagon for countering the camshaft

    G14735217Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Installing timing chain housing 

    1. Cheese head bolt > Torque support 8 Nm 
    2. Timing chain housing
  10. Fit timing chains.

    > WM 153519 REMOVING AND INSTALLING TIMING CHAIN (CAYENNE GTS, CAYENNE S, CAYENNE TURBO & CAYENNE TURBO S)

    1. Install chain tensioner.

      > WM 153619 REMOVING AND INSTALLING CHAIN TENSIONER (CAYENNE)

    2. Install camshaft controllers.

      > WM, 158419 REMOVING AND INSTALLING CAMSHAFT CONTROLLER

    G14735218Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Component overview for timing chains 

    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 for 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 for 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 gearwheel 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
  11. Check the timing.

    > WM, 150502 CHECKING THE TIMING

  12. Fit upper and lower timing-case cover.

    > WM 153319 REMOVING AND INSTALLING TIMING-CASE COVER (CAYENNE S & CAYENNE GTS)

    1. Install lower timing-case cover.
    2. Install upper timing-case cover.
    G14735219Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Crankshaft joint flange 

    1. Cylinder block
    2. Vibration balancer joint flange
    3. Hexagon-head bolt on vibration balancer joint flange
    4. Straight pin, M8x 18
    5. Lower timing-case cover
    6. Hexagon-head bolt for lower timing-case cover > Tightening torque 10 Nm 
    G14735220Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Removing and installing vacuum pump 

    1. Drive shaft
    2. Upper timing-case cover
    3. Oval-head screw > Tightening torque 8 Nm (6 ftlb.) 
    4. Oval-head screw on vacuum pump > Tightening torque 8 (ftlb.) Nm 
    5. Seal
    6. Sealing ring

    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.

    > WM, 175019 REMOVING AND INSTALLING OIL PAN

    G14735221Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Removing and installing upper timing chain housing cover 

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

  14. Install cylinder head cover.

    > WM, 158219 REMOVING AND INSTALLING CYLINDER HEAD COVER (VALVE COVER)

    G14735222Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Removing and installing valve cover seal 

    1. Cylinder head cover
    2. Cylinder-head gasket
    3. Fastening screw for cylinder head cover > Tightening torque 10 Nm (7.5 ftlb.) 
    4. Cap
  15. Install flywheel/drive plate.
    1. Remove drive plate on vehicles with automatic transmission.

      > WM, 136319 REMOVING AND INSTALLING DRIVE PLATE FOR TORQUE CONVERTER ON V6 DFI ENGINES

  16. Install oil/water heat exchanger.

    > WM, 174019 REMOVING AND INSTALLING OIL COOLER

    Fig 2: Exploded View Of Oil Filter Housing
    G14735223Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Oil filter housing 

    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 
    6. Oil pressure switch > Tightening torque 20 Nm (15 ftlb.) 
    7. Oil filter
    8. Lower part of oil filter > Tightening torque 25 Nm 
    9. Oil drain plug > Tightening torque 10 Nm 
    10. Hexagon-head bolt for oil/water heat exchanger > Tightening torque 23 Nm 
  17. Install coolant regulator.

    > WM, 195819 REMOVING AND INSTALLING COOLANT REGULATOR (THERMOSTAT)

    1. Fit thermostat housing -1-  completely into the cylinder block.
    2. Slide coolant hose -3-  onto the thermostat housing.
    3. Fasten spring band clamp -2-. 
    G14735224Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Coolant regulator 

    1. Thermostat housing
    2. Spring band clamp
    3. Coolant hose
  18. Install fuel distributor pipe and fuel injectors.

    > WM, 243019 REMOVING AND INSTALLING FUEL DISTRIBUTOR PIPE (FUEL RAIL) ON DFI ENGINES

    G14735225Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Fuel rail for cylinders 

    1. Fuel low-pressure line  > Tightening torque 22 Nm (16 ftlb.)  > Tightening torque 35 Nm (26 ftlb.) 
    2. Cheese head bolts for fuel distributor pipe  > Initial tightening 30 Nm (22 ftlb.)  > Torque angle 90° 
    3. Fuel injectors
  19. Install coolant pump.

    > WM, 195019 REMOVING AND INSTALLING COOLANT PUMP

    G14735226Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Coolant pump 

    Arrows  Oval-head screw (coolant pump) > Tightening torque 8 Nm 

  20. Install exhaust manifold.

    > WM 261019 REMOVING AND INSTALLING EXHAUST MANIFOLD (CAYENNE)

    G14735227Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Exhaust manifold 

    Arrows  Hexagon nut on exhaust manifold > Tightening torque 25 Nm (19 ftlb.) 

  21. Install intake-air distributor.

    > WM 244619 REMOVING AND INSTALLING INTAKE-AIR DISTRIBUTOR (CAYENNE)

  22. Install guide tube for oil dipstick. Sealing ring must always be replaced. 

    > WM, 171719 REMOVING AND INSTALLING GUIDE FOR OIL DIPSTICK

  23. Install unit carrier.
    G14735228Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Removing and installing unit carrier 

    1. Belt tensioner
    2. Cheese head bolt on belt tensioner
    3. Unit carrier
    4. Fit bolt for unit carrier > Tightening torque 23 Nm (17 ftlb.) 
    5. Cheese head bolt for 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
  24. Install generator.

    > WM 272219 REMOVING AND INSTALLING GENERATOR (CAYENNE)

  25. Install hydraulic pump (power-steering pump).

    > WM 489819 REMOVING AND INSTALLING HYDRAULIC PUMP - 3.6 V6 (CAYENNE TIP "PLATINUM EDITION", CAYENNE TIP, CAYENNE MAN)

  26. Install belt tensioner.

    > WM, 137319 REMOVING AND INSTALLING BELT TENSIONER

    G14735229Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Belt tensioner 

    Arrows  Cheese head bolts on belt tensioner > Tightening torque 25 Nm 

  27. Fit and tension the drive belt.

    > WM, 137819 REMOVING AND INSTALLING DRIVE BELT

    G14735230Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Fitting sequence 

    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
  28. Install bar ignition modules.

    > WM, 282020 REMOVING AND INSTALLING BAR IGNITION MODULES

    G14735231Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Removing and installing ignition coils and spark plugs 

    1. Connectors for bar ignition modules
    2. Retaining clips
    3. Engine wire harness
  29. Fit engine wire harness.

    > WM 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE

    1. Clip in engine wire harness at the rear engine housing using the retaining clips -Arrows-  .
    2. Connect engine wire harness to the oil/water heat exchanger.
    G14735232Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Clipping in engine wire harness at the rear 

    Arrows  Retaining clips

    G14735233Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Clipping in engine wire harness at the front left 

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