Installing Oil Pan

Oil pan installed (includes sealing)
Installing oil pan

Caution: Risk of damage
^ If the oil pan is not correctly aligned, it can become leaky during operation.
^ Align the oil pan extremely accurately in compliance with this description.
^ Ensure that there is no dirt between the 2 components.





1. Replace the 9 molded rubbers.





2. Apply liquid sealant. Apply the sealing agent Loctite 5900 with the hand-held cartridge. The contour of the sealing bead must comply with the figure shown. The sealing bead should be approximately 1.5 mm high. The oil duct in the timing chain lid -A- must remain clear and must not be obstructed with silicone.

Note: If the transmission is removed, the oil pan must be aligned with the aid of a dial gauge.

3. Place the oil pan on the crankcase and push evenly against the transmission bell.
4. Screw in a fastening screw on each corner of the oil pan and tighten them by hand.
5. Then screw in all fastening screws by hand. While doing this, push the oil pan towards the transmission.





6. Beginning at the transmission flange and proceeding forwards, tighten the 29 fastening screws to 10 Nm (7.5 ft. lbs.).
7. Screw down the timing case cover. Tighten the 5 fastening screws M6 x 25 to 10 Nm (7.5 ft. lbs.) with an E10 wrench.

Note:
^ In the Cayenne Turbo (M48150), the oil extraction pump of the turbocharger must also be fitted.
^ Place a new seal on the pump. Align the drive and tighten the fastening screws to 10 Nm (7.5 ft. lbs.).





8. Install oil transfer flange. Replace and grease the O-rings of the flange. Then place the flange on the assembly mandrel 9691 in such a way that the slightly thicker end points forwards.





9. Insert the connection flange with the thicker end into the oil pan and push the assembly mandrel all the way by knocking it slightly.





10. Screw in length compensating element. To do this, insert an Allen key through the screw hole into the bracket and turn the key anti-clockwise until the compensating element touches the bracket.
11. Brush the two transfer flanges slightly with engine oil and position the bracket on the engine. Then push the bracket hard against the engine until the fastening screws can be put into place.





12. The sleeve -1- is screwed in. Position the 3 fastening screws and tighten until hand-tight.





13. Adjust compensating element. To do this, insert an Allen key through the screw hole in the bracket and turn the key clockwise until the compensating element touches the engine. Tightening torque 2 to 5 Nm (1.5 to 3.5 ft. lbs.).





14. Position the belt pulley on the crankshaft stub. Then press the belt pulley slightly in the direction of the engine, simultaneously twisting it until it slips definitively in the direction of the timing case cover. When doing so, pay attention to the feather key.





15. Install crankshaft belt pulley. Tighten new screw to 250 Nm (185 ft. lbs.) and then tighten to a torque angle of 90°.
16. Fit the upper fastening screw. Insert the screw through the compensating element and tighten to 32 Nm (17 ft. lbs.). Then tighten the other 3 fastening screws to 23 Nm (17 ft. lbs.).





17. Tighten the 2 fastening screws of the transmission bell to 80 Nm (58 ft. lbs.).





18. Install engine carrier.
19. Install the suspension subframe.
20. Remove engine bridge.
21. Install oil dipstick.
22. Secure cross member.
23. Fill in engine oil.
24. Bleed and fill the cooling circuit.
25. Carry out a check. After a test drive, check to ensure that the oil pan is not leaking. Then check the oil level.

Aligning the oil pan with a dial gauge

Note: The following work steps are only necessary if the transmission is disconnected at the time the oil pan is being installed.

Caution: Danger of leakage
^ If the oil pan is not aligned properly, this component may become leaky during operation.
^ The oil pan lid must not project over the crankcase.
^ It cannot go under 0.1 mm.

Place the oil pan on the crankcase and position a fastening screw on each corner.





1. Insert the dial gauge into the universal gauge holder and position it such that the dial gauge has a preload of about 1 mm.





2. Set dial gauge scale to 0. To do this, place the dial gauge holder on a completely flat surface (e.g. crankcase flange) and turn the dial gauge scale until the pointer is on 0.

Warning: Oil leakage!
^ If the oil pan is not correctly aligned, it can become leaky.
^ The oil pan lid must not project over the crankcase.
^ The oil pan must not go under 0.1 mm.
^ Oil pan must be installed in a straight position.





3. Measure offset. In order to do this, push with the holder starting from the crankcase flange towards the oil pan flange (the foot of the dial gauge holder is located on the other component like the dial gauge probe) and measure the offset. The oil pan must not be set back any more than 0.1 mm. A projection is not permissible.
4. Align the oil pan by knocking lightly with a rubber hammer.





5. After the oil pan has been aligned, tighten the 4 fastening screws to 10 Nm (7.5 ft. lbs.). Subsequently, check the position of the oil pan again with the dial gauge.





6. Tighten the remaining fastening screws to 10 Nm (7.5 ft. lbs.).








Torques