Part 2

Disassembling the engine (Continued)

31. Remove oil/water heat exchanger -1-.
31.1. Unscrew six internal Torx(R) screws (T30, M6 x 20) -2- and remove heat exchanger.
31.2. Collect any drops of fluid with a clean cloth and clean the sealing faces.
31.3. Replace O-rings.





Oil/water heat exchanger

Information
^ The bracket for the oil/water heat exchanger must not be removed at an angle or levered off at one side. This can break the aluminum supports in the crankcase.

32. Remove bracket for oil/water heat exchanger -1-.
32.1. Unscrew six external Torx(R) screws (E10): four M6 x 45 screws -2- and two M6 x 60 screws -3-. Pull the bracket up and out.
32.2. Close off oil ducts with stoppers.
32.3. Replace two O-rings at the top -4- and four O-rings on the underside.





Bracket for oil/water heat exchanger

33. Remove fuel collection pipes.
33.1. Unscrew four external Torx(R) screws (E10, M6 x 30) -1- and pull the fuel collection pipes -2- out of the cylinder heads.





Threaded joint for fuel collection pipe

33.2. Close off fitted bores in the cylinder head with stoppers.
34. Remove knock sensors (mark installation position using a water-resistant marker).
34.1. Unscrew one external Torx(R) screw (E12, M8 x 16) on each sensor and remove sensors.
35. Remove fuel lines for the high and low-pressure side.
35.1. Loosen and screw off hexagon union nuts on the high-pressure pump -1-. Low-pressure line -2-: a/f 17, high-pressure line -4-: a/f 14.
35.2. Unscrew one external Torx(R) screw (E10) M6 x 16 -3- and one M6 x 12 screw -5- at the retaining points and remove the lines.





Fuel lines for high/low-pressure connection

36. Remove high-pressure pump.





Heat shield for high-pressure pump

36.1. Unscrew three external Torx(R) screws (E10, M6 x 12) on the heat shield and remove the heat shield.
36.2. Unscrew three external Torx(R) screws (E10) on the support: two M6 x 25 screws -1- and one M6 x 40 screw -2-.
36.3. Unscrew two external Torx(R) screws (E10, M6 x 25) -3- and pull out the pump.
36.4. Replace O-ring.
37. Remove vacuum line -1- for brake booster.
37.1. Unscrew external Torx(R) screws (E10, M6 x 12) -2- and pull out line at the vacuum pump.





Vacuum line for brake booster

38. Remove vacuum pump.
39. Remove lower coolant guide -1-.
39.1. Unscrew six external Torx(R) screws (E10, M6 x 25) -2-.
39.2. Check molded seals and replace if necessary.





Lower coolant guide

40. Use turning device 9773 -1- to turn the engine clockwise at the vibration damper until the TDC 1/4 marking on the vibration damper is aligned with the bore in the crankcase.





TDC marking on cylinder 1/4 on vibration damper

40.1. Secure the engine using one of the locating pins 9595/1 -2- on the vibration damper.
41. Remove vibration damper.
41.1. Loosen and unscrew six external Torx(R) screws (E12, M8 x 25 x 1) and remove the vibration damper.
41.2. Check dowel sleeve and crankshaft flange for damage.
42. Loosen bracket for coolant pump -1-.
42.1. Turn the belt tensioner clockwise as far as it will go at the hexagon (a/f 30). Lock the tensioner at the crankcase bore using an M8 screw (e.g. M8 x 50) -2-.
42.2. Unscrew four external Torx(R) screws: one M8 x 70 (E12) -3-, one M8 x 50 (E12) -4-, one M6 x 20 (E10) -5- and one M8 x 25 (E12) -6-.





Bracket for coolant pump

42.3. Unscrew one M10 threaded bolt (engine carrier mounting) -7- (two M10 lock nuts).
43. Remove coolant connection pipe -1- to the thermostat housing.
43.1. Unscrew one external Torx(R) screw (E10, M6 x 12) -2- on the retaining bracket for the crankcase.





Coolant connection pipe to thermostat housing

43.2. Pull out pipe -1- on the thermostat housing.
44. Remove thermostat housing -2-.
44.1. Unscrew three external Torx(R) screws (E10) M6 x 25 -4- and one M6 x 50 -3-.





Thermostat housing

44.2. Turn bracket for coolant pump slightly to the right.
44.3. Pull the thermostat housing -1- down at the unit carrier (double O-ring seal) and lift it off at the connecting tube -2- to the coolant pump at the same time.
44.4. Pull off bracket for coolant pump -1-. Replace O-rings -2- + -3-. Check seal for damage and replace it if necessary.





O-rings for coolant pipes at coolant pump

44.5. Replace molded seal on the connecting tube -3-.





Thermostat housing and connecting tube for coolant pump

45. Remove unit carrier (coolant distributor housing). The screws for the engine connection piece -2- and the additional attachment for the coolant pump bracket -3 (left) and 5- have already been removed.
45.1. Unscrew another external Torx(R) screws M8 x 50 -3 (right)- and one M8 x 35 -4-. Remove carrier, check dowel sleeve for damage and replace if necessary.
45.2. Replace molded seals.





Unit carrier

46. Remove cover for positive crankcase ventilation.
46.1. Cover on cylinder bank 1-3 -1-: Unscrew three external Torx(R) screws (M6 x 20) -4- and replace O-ring -3- and molded seal -2-.





Cover on positive crankcase ventilation 1-3

46.2. Cover on cylinder bank 4-6 -1-: Unscrew two external Torx(R) screws (M6 x 20) -3- and replace O-ring -2-.





Cover on positive crankcase ventilation 4-6

47. Remove solenoid hydraulic valves for camshaft control.
47.1. Unscrew two external Torx(R) screws (E8, M5 x 12) on each valve and pull off the valves.
47.2. Replace O-rings.
48. Remove hall senders on the cylinder head cover.
48.1. Unscrew one external Torx(R) screw (T40, M6 x 16) on each and pull off the hall senders.
48.2. Replace O-ring.
49. Remove solenoid hydraulic valves for valve lift adjustment.
49.1. Unscrew two external Torx(R) screws (E8, M5 x 12) on each valve and pull off the valves.

Disassembly

Disassembling the engine

Notice
Dirt and contamination
^ Risk of damage to units or components

- Protect components from dirt and contamination.
- Clean or replace dirty components.

Information
^ Guide the timing chains with your hand when turning the crankshaft so that they do not get stuck in the crankcase.

1. Remove cylinder head cover.
1.1. Unscrew one external Torx(R) screw (E12, M8 x 20) for the engine ground strap on cylinder bank 4-6 and remove the ground strap.
2. Check visually to see which cylinder bank is at overlapping position. Remove this cylinder bank first.
2.1. Check visually to see which cylinder bank is at overlapping position. Remove this cylinder bank first.

Cam positions:
^ Overlapping position of cylinder bank 1-3: Cams on cylinder 1 are facing outward at a slant.
^ Overlapping position of cylinder bank 4-6: Cams on cylinder 4 are facing inward at a slant to the spark-plug recess.





Cam position on cylinder 1 at overlap





Cam position on cylinder 4 at overlap

2.2. If the camshafts are at overlapping position, square markings can be seen on the outlet and intake camshaft (data matrix code).





Marking on camshafts 4-6 at overlap

3. Remove camshafts.

Information
^ Position hydraulic tappets on a surface you have prepared and labeled yourself in accordance with their installation position in the cylinder head.
^ Components have been run in in fitted bores and must not be confused.
^ Do not use magnets for removal or installation. This can cause the components to malfunction.

4. Remove hydraulic tappets.
4.1. Pull six bucket tappets -1- and six switching tappets -2- out of the fitted bores in the cylinder head with your thumb and index finger. Do not use a magnet.





Hydraulic tappets for valve control

4.2. Lay components on clean, labeled cardboard.





Example of laying aside bucket tappets

5. Remove tensioning and guide rails.
5.1. Cylinders 1-3: Unscrew one bearing pin -2- for the tensioning rail and two bearing pins -1- for the guide rail.





Bearing pins on cylinder bank 1-3

5.2. Pull out the guide and tensioning rails -1- using a pair of flat-nosed pliers.





Guide and tensioning rails

5.3. Lay the timing chain in the chain slot.
5.4. Pull oil supply valve on vacuum pump -1- out of the cylinder head using a pair of flat-nosed pliers -arrow-. Replace O-ring.





Oil supply valve on vacuum pump for brake booster





Oil supply valve on vacuum pump

5.5. Cylinders 4-6: Unscrew two bearing pins -2- for the guide rail and one bearing pin -3- for the tensioning rail.





Bearing pins on cylinder bank 4-6

5.6. The bearing pin for the tensioning rail 4-6 -1- is longer than the five other pins -2- for the timing chain rails.





Difference between bearing pins

5.7. Replace O-rings on the bearing pins.
6. Remove cylinder head and cylinder head gasket.
7. Pull out twelve displacement bodies -1- on cylinder bank 1-3 using a pair of flat-nosed pliers.





Piston marking and displacement bodies on cylinder bank 1-3

8. Turn the engine at the engine assembly support so that the oil pan is at the top.
9. Remove the oil pan.
10. Remove coolant pipe -1- for the coolant pump.
10.1. Unscrew two external Torx(R) screws (E10, M6 x 12) -2- and remove the pipe.





Coolant pipe for coolant pump

11. Remove oil pump and oil guide.
12. Turn the engine at the engine assembly support so that cylinder bank 1-3 is facing upwards.
13. Remove pistons for cylinders 1-3.
14. Remove crankcase half 1-3.
14.1. Unscrew 19 external Torx(R) screws for the outer cross bolt connection. The threaded bolt must be removed for screw -17-.





Outer cross bolt connection

15, 16 and 17 - External Torx(R) screw, M8 x 35
18 - External Torx(R) screw, M6 x 40
19-32 - External Torx(R) screw, M6 x 25
33 - External Torx(R) screw, M8 x 120

14.2. Loosen and unscrew through-bolt screws (E14) M10 x 195 in the opposite sequence to the tightening sequence.





Through-bolt screws on crankcase

1-14 - External Torx(R) screw M10 x 1.5 x 195 with sealing washer

14.3. Check screws for damage and replace them if necessary or only replace the sealing washers.
15. Unscrew two mounting parts 9590 for bolting crankcase half 1-3 to the engine support.
16. Lift off crankcase 1-3.
16.1. To do this, put on heat-resistant gloves and heat the sealant at the joint slightly with a hot-air gun.
16.2. Lift up crankcase half 1-3 at the positions shown using a large slotted screwdriver.





Lever positions on crankcase

16.3. Slide in two pieces of wood above the oil-pump pressure channels and lift up the crankcase half using a mounting lever.





Mounting lever position on crankcase

17. Remove pistons and connecting rods on cylinders 4-6.
17.1. Remove connecting rods 1-3 on the crankshaft.
18. Remove and dispose of crankshaft sealing rings.
19. Lift crankshaft and timing chains out of crankcase half 4-6.





Crankshaft and timing chains in crankcase half 4-6

19.1. Remove bearing shells from the crankcase halves and dispose of them.
19.2. The deviation sample catalog for the Cayenne can be used to assess the cylinder linings.
20. Clean the crankcase and sealing surfaces.