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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 >> Disassembling V6 DFI Engine

Disassembling V6 DFI Engine

  1. Remove engine wire harness

    > WM 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE

  2. Remove bar ignition modules

    > WM, 282020 REMOVING AND INSTALLING BAR IGNITION MODULES

  3. Remove intake-air distributor

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

  4. Remove drive belt

    > WM, 137819 REMOVING AND INSTALLING DRIVE BELT

  5. Remove belt tensioner

    > WM, 137319 REMOVING AND INSTALLING BELT TENSIONER

    G14735187Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Belt tensioner 

    Arrows  Belt tensioner

  6. Remove unit carrier
    G14735188Courtesy 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
    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
  7. Remove generator

    > WM 272219 REMOVING AND INSTALLING GENERATOR (CAYENNE)

  8. Remove coolant pump

    > WM, 195019 REMOVING AND INSTALLING COOLANT PUMP

    1. Remove coolant pump pulley if necessary.
      G14735189Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Coolant pump 

      Arrows  Oval-head screws for pulley (coolant pump)

  9. Remove all coolant hoses and additional coolant pump with holder.
    1. Remove fastening screws -2-  .
    2. Pull off cable plugs and remove coolant hoses -3.4  and 5-  .
    3. Remove additional coolant pump with sheetmetal holder -1-  .
    G14735190Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Removing and installing additional coolant pump 

    1. Sheetmetal holder
    2. Fastening screws for coolant pump holder
    3. Coolant hose
    4. Coolant hose
    5. Coolant hose
  10. Remove oil/water heat exchanger and engine support arm

    > WM, 174019 REMOVING AND INSTALLING OIL COOLER

  11. Remove exhaust manifold if necessary

    > WM 261019 REMOVING AND INSTALLING EXHAUST MANIFOLD (CAYENNE)

    G14735191Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Exhaust manifold 

    Arrows  Exhaust manifold fastening nuts

  12. Remove fuel distributor pipe (fuel rail)

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

    G14735192Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Fuel distributor pipe 

    1. Fuel line (low pressure)
    2. Cheese head bolts for fuel distributor pipe
    3. Fuel injectors
  13. Remove coolant regulator

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

    1. Release spring band clamp
    2. Pull thermostat housing -1-  completely out of the cylinder block.
    G14735193Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Coolant regulator 

    1. Thermostat housing
    2. Spring band clamp
    3. Coolant hose
  14. Remove cylinder head cover

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

  15. Remove 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. Remove oil pan

    > WM, 175019 REMOVING AND INSTALLING OIL PAN

  17. Remove timing-case cover at the top and bottom

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

  18. Set crankshaft for cylinder 1 to compression TDC

    > WM, 150502 CHECKING THE TIMING

    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

    > WM 153619 REMOVING AND INSTALLING CHAIN TENSIONER (CAYENNE)

  20. Remove timing chains

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

    1. Remove camshaft controllers

      > WM, 158419 REMOVING AND INSTALLING CAMSHAFT CONTROLLER

  21. Remove camshafts

    > WM, 150520 REMOVING AND INSTALLING CAMSHAFTS

    1. Removing timing chain housing
    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. Remove bearing covers 1 and 13.
      2. Remove bearing covers 3 and 11.
      3. Remove bearing cover 7.
      4. Remove bearing covers 5 and 9.
    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. Remove bearing covers 2 and 14.
      2. Remove bearing covers 4 and 12.
      3. Remove bearing cover 8.
      4. Remove bearing covers 6 and 10.
    Fig 1: Exploded View Of Cylinder Head
    G14735194Courtesy 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
    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
    G14735195Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Removing timing chain housing 

    1. Cheese head bolt  > Torque support 8 Nm 
    2. Timing chain housing
  22. Remove hydraulic tappets

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

  23. Remove cylinder head

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

    1. Remove and dispose of cylinder-head gasket.
  24. Remove oil pump

    > WM, 172019 REMOVING AND INSTALLING OIL PUMP

    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

    > WM, 131020 REMOVING AND INSTALLING PISTONS

  26. Remove vibration  balancer.

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

    G14735196Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Brace 

  27. Remove joint flange behind the vibration balancer.
    1. Remove hexagon-head bolts -3-  .
    2. Carefully lever off the joint flange -2-  with a screwdriver.
    G14735197Courtesy 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
    5. Lower timing-case cover
    6. Fastening screw on lower timing-case cover

    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.

    > WM 134819 REMOVING AND INSTALLING CRANKSHAFT (CAYENNE TIP)

    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. Remove crankshaft bearing covers -1-  and lay them down arranged according to cylinder.
    3. Dispose of thrust washers -4-  and crankshaft bearing shells -3-  .
    4. Remove the crankshaft and lay it down on the prepared surface.
    5. Remove oil spray jets -8-  if necessary.
    G14735198Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Crank drive on V6 DFI engine 

    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 jet
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