Assembling Engine

Information 

Detailed information on 

• tightening torque,
• tightening sequence,
• component allocations, classification,
• surface treatment,
• replacing parts,
• Applying sealant

can be found in the following documents: 

• > WM, 1X00IN TECHNICAL VALUES - V6 BITURBO
• > 2X00IN TECHNICAL VALUES
• > WM 3X00IN TECHNICAL VALUES, TRANSMISSION (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE (3.0))

1. Clean components.
   1. Remove residual sealant.
   2. Sealing faces must be free of oil and grease.
   3. Clean the thread and re-cut it if necessary.
2. Insert bearing shells and crankshaft into the crankcase.
3. Install connecting rod with piston.

   > 131020 REMOVING AND INSTALLING PISTONS

4. Install lower part of crankcase.
   1. Group 10 - Crankcase:

      > WM, 1X00IN TECHNICAL VALUES - V6 BITURBO

5. Install oil pump, oil pump drive and accessories.

   > 172019 REMOVING AND INSTALLING OIL PUMP

6. Install the starter.

   > WM 276019 REMOVING AND INSTALLING STARTER (V6) (CAYENNE GTS & CAYENNE S)

7. Install knock sensor.

   > 287219 REMOVING AND INSTALLING KNOCK SENSOR

8. Install cylinder head with new seals.

   > 157019 REMOVING AND INSTALLING CYLINDER HEAD

   1. The cylinder head can also be installed pre-assembled. with hall sender

      > WM 283919 REMOVING AND INSTALLING HALL SENDER (CAMSHAFT) (CAYENNE S & CAYENNE GTS)

      with complete valve drive

      > WM 156120 REMOVING AND INSTALLING VALVES (CAYENNE TURBO & CAYENNE TURBO S)

      with fuel collection pipe

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

9. Install camshafts.

   > WM 150520 REMOVING AND INSTALLING CAMSHAFTS (V6) (CAYENNE S & CAYENNE GTS)

10. Install camshaft controllers.

    > WM, 158419 REMOVING AND INSTALLING ACTUATOR FOR CAMSHAFT

11. Install timing chain.

    > 153519 REMOVING AND INSTALLING TIMING CHAIN

12. Install timing-case cover.

    > WM, 153319 REMOVING AND INSTALLING UPPER CHAIN HOUSING COVER

13. Install sealing ring for crankshaft pulley.

    > WM 137419 REPLACING SEALING RING FOR CRANKSHAFT PULLEY (ALL MODELS)

14. Install oil guide housing.

    > WM 175019 REMOVING AND INSTALLING OIL GUIDE HOUSING (CAYENNE S, CAYENNE TURBO, CAYENNE GTS, CAYENNE TURBO S)

15. Install crankshaft sealing ring.

    > WM 135919 REPLACING CRANKSHAFT SEALING RING (ON TRANSMISSION SIDE) (CAYENNE, CAYENNE S, CAYENNE S DIESEL, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE GTS, CAYENNE (3.0) & CAYENNE TURBO S)

16. Install hall-sender rotor.

    > 284419 REMOVING AND INSTALLING ROTOR FOR HALL SENDER

17. Install oil cooler.

    > WM, 174019 REMOVING AND INSTALLING OIL COOLER

18. Install pulley.

    > WM, 137619 REMOVING AND INSTALLING PULLEY

19. Install oil pipes and oil plate.
20. Set the timing.

    > 150516 SETTING TIMING FOR CAMSHAFTS

21. Install oil pressure regulator (oil pan).

    > WM 172619 REMOVING AND INSTALLING PRESSURE-REGULATING VALVE (CAYENNE S, CAYENNE TURBO, CAYENNE GTS, CAYENNE TURBO S)

22. Install oil pressure sensor.

    > 170419 REMOVING AND INSTALLING OIL-PRESSURE SENDER

23. Install coolant pump housing and coolant pump.

    > 195019 REMOVING AND INSTALLING COOLANT PUMP

24. Install cylinder head cover.

    > WM 158219 REMOVING AND INSTALLING CYLINDER HEAD COVER (V6) (CAYENNE GTS & CAYENNE S)

25. Install belt tensioner.

    > WM, 137319 REMOVING AND INSTALLING BELT TENSIONER DAMPER

26. Install the high-pressure pump.

    > WM 246319 REMOVING AND INSTALLING HIGH-PRESSURE PUMP (CAYENNE)

27. Install camshaft controller valves.

    > WM 153719 REMOVING AND INSTALLING HYDRAULIC VALVE FOR CAMSHAFT CONTROL (CAYENNE)

28. Install spark plugs.

    > WM 287020 REMOVING AND INSTALLING SPARK PLUGS (CAYENNE)

29. Install the ignition coils.

    > WM 282020 REMOVING AND INSTALLING IGNITION COILS (CAYENNE S & CAYENNE GTS)

30. Install fuel injectors with fuel collection pipe.

    > WM 244020 REMOVING AND INSTALLING FUEL INJECTORS (V6) [CAYENNE S, CAYENNE (3.0)]

31. Install oil filter.

    > WM 173019 REMOVING AND INSTALLING OIL FILTER (CAYENNE)

32. Install oil pan.

    > 175019 REMOVING AND INSTALLING OIL PAN

33. Install generator.

    > WM 272219 REMOVING AND INSTALLING GENERATOR (CAYENNE S, CAYENNE TURBO)

34. Install front coolant line
35. Install pulse sender.

    > WM 287319 REMOVING AND INSTALLING CRANKSHAFT PULSE SENDER (CAYENNE S & CAYENNE GTS)

36. Install vacuum reservoir and vacuum lines.

    > WM 245419 REMOVING AND INSTALLING VACUUM RESERVOIR (CAYENNE S & CAYENNE GTS)

37. Install fuel lines.

    > WM 249019 REMOVING AND INSTALLING FUEL LINE (HIGH-PRESSURE) [CAYENNE S E-HYBRID & CAYENNE (3.0)]

38. Install secondary-air pump.

    > 266519 REMOVING AND INSTALLING SECONDARY-AIR PUMP

39. Install secondary-air lines and secondary air valves.

    > 266919 REMOVING AND INSTALLING SECONDARY AIR VALVE

40. Install wiring harness.

    > WM 975219 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE

41. Install intake-air distributor with throttle valve.

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

42. Install positive crankcase ventilation valves.

    > 105119 REMOVING AND INSTALLING POSITIVE CRANKCASE VENTILATION VALVE 

43. Install exhaust manifold with turbocharger.

    > 261019 REMOVING AND INSTALLING EXHAUST MANIFOLD

    1. Install turbocharger oil lines.
    2. Install turbocharger coolant lines.
44. Install drive belt and deflection rollers.

    > 137819 REMOVING AND INSTALLING DRIVE BELT

45. Install brackets for engine mounts.
46. Install and connect vacuum lines and valves.

Subsequent work 

1. Loosen engine from assembly support.
2. Mount transmission.
3. Install the engine.

   > 100119 REMOVING AND INSTALLING ENGINE 

4. Fill in engine oil.

   > WM, 170117 DRAINING AND FILLING ENGINE OIL