Part 2

WM 134819 Removing and installing crankshaft on V6 DFI engines

1.2. Oil the piston well and insert it into the funnel.
1.3. Align all pistons so that the deep valve recesses -1 and 2- are facing the middle of the cylinder block and the arrows -3- on the pistons are facing the vibration damper.





Installation direction of pistons on V6 DFI engine





1.4. 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.





Positioning piston funnel on cylinder block

1.5. Slide piston fully into the cylinder bore.
1.5.1. Turn the crankshaft back and forth if necessary.
1.6. Insert dowel sleeves back into the bore holes -arrow-.
1.7. Oil connecting-rod bearing shells -5-.

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.





Twist lock

- 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.

1.8. Assign connecting rod bearing caps correctly and screw in the connecting rod bolts -7- by hand. When doing so, make sure that the locking lugs on the bearing shells are aligned.
1.9. 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.
1.10. Tighten all connecting rod bearing screws -7- to the specified tightening torque.
1.11. Turn the crankshaft several times to check that it turns smoothly.
1.12. Align the crankshaft so that the gap -arrow- on the drive plate for the inductive pickup is facing downwards (rough TDC presetting).





Setting of drive plate for inductive pickup





2. Fit joint flange for vibration balancer. => 137419 Removing and installing sealing ring for vibration balancer on DFI engines





Crankshaft joint flange





2.1. Apply a bead of sealant -arrows- with a thickness of 2 mm.





Applying sealant on joint flange

2.2. Fit assembly fixture T10215 (guide sleeve) -1- on the crank pin -3- to prevent damage to the vibration balancer joint flange.
2.3. Slide the joint flange -2- over the guide sleeve -1- until it is touching the cylinder block.





Joint flange on front of crankshaft





2.4. Tighten hexagon-head bolts -3- on joint flange -2- to the specified torque.
3. Fit vibration balancer for crankshaft. => 137619 Removing and installing vibration balancer (crankshaft pulley) on V6 DFI engines





Brace

3.1. Tighten hexagon-head bolt on crankshaft vibration balancer => Initial tightening: 100 Nm (74 ftlb.) => Torque angle: 180°.
4. Position engine to the compression TDC of cylinder 1.





TDC marking on pulley and housing cover





5. If the oil retaining valve was removed during removal, fit a new sealing ring on the oil retaining valve before inserting it into the crankcase -arrow-.





Oil retaining valve





6. Install cylinder head. => 157019 Removing and installing cylinder head on V6 DFI engines





Cylinder head





6.1. Thoroughly clean all sealing faces before assembly.
6.2. Cylinder head gasket must always be replaced.
6.3. Always observe tightening sequence (1-20) for cylinder-head screws -1-20- and tighten to the specified torque.
6.3.1. Tighten cylinder-head screws to an initial tightening torque of 15 Nm (11 ftlb.).
6.3.2. Tighten cylinder-head screws to 30 Nm (22 ftlb.).
6.3.3. Then tighten all cylinder-head screws a second time to 30 Nm (22 ftlb.).
6.3.4. And finally, tighten the cylinder-head screws to a torque angle of 180°.
7. Fit timing chains. => 153519 Removing and installing timing chains on V6 DFI engines





Component overview of timing chains





7.1. Install timing chain housing.





Removing timing chain housing





7.2. Install chain tensioner. => 153619 Removing and installing chain tensioner on V6 DFI engines
7.3. Install camshaft controllers. => 158419 Removing and installing camshaft controller on V6 DFI engines
8. Check the timing. => 150502 Checking the timing on V6 DFI engines
9. Fit upper and lower timing-case cover. => 153319 Removing and installing timing-case cover on V6 DFI engines
9.1. Fit lower timing-case cover.





Crankshaft joint flange





9.2. Fit upper timing-case cover.





Removing and installing vacuum pump





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.

10. Install oil pan. => 175019 Removing and installing oil pan on V6 DFI engines





Removing and installing upper timing chain housing cover





Observe tightening sequence for hexagon-head bolts (1 to 25) on oil pan.
11. Install cylinder head cover. => 158219 Removing and installing cylinder head cover on V6 DFI engines





Removing and installing valve cover seal





12. Install flywheel/drive plate.
12.1. Install dual-mass flywheel on vehicles with manual transmission. => 136219 Removing and installing dual-mass flywheel - section on "Installing"
12.2. Install drive plate on vehicles with automatic transmission. => 136319 Removing and installing drive plate for torque converter
13. Install oil/water heat exchanger. => 174019 Removing and installing oil/water heat exchanger (oil cooler) on V6 DFI engines





Oil-filter housing





14. Install coolant regulator. => 195819 Removing and installing coolant regulator (thermostat) on DFI engines





Coolant regulator





14.1. Fit thermostat housing -1- completely into the cylinder block.
14.2. Slide coolant hose -3- onto the thermostat housing.
14.3. Fasten spring band clamp -2-.
15. Install fuel distribution pipe and fuel injectors. => 243019 Removing and installing fuel distribution pipe (fuel rail) on DFI engines





Fuel distribution pipe for cylinders





16. Install coolant pump.=> 195019 Removing and installing coolant pump on DFI engines





Coolant pump





17. Install exhaust manifold.
=> 261019 Removing and installing exhaust manifold - section on "Installing"





Exhaust manifold





18. Install intake-air distributor. => 244619 Removing and installing DFI intake-air distributor
19. Install guide tube for oil dipstick. Sealing ring must always be replaced. => 171719 Removing and installing guide tube for oil dipstick on DFI engines
20. Install unit carrier.





Removing and installing unit carrier





21. Install the generator. => 272219 Removing and installing the generator
22. Install hydraulic pump (power-steering pump). => 48981900 Removing and installing hydraulic pump (Cayenne V6)
23. Install belt tensioner. => 137319 Removing and installing belt tensioner on DFI engines





Belt tensioner





24. Fit and tension the drive belt.
=> 137819 Removing and installing drive belt





Fitting sequence





25. Install bar ignition modules. => 282020 Removing and installing DFI bar ignition modules





Removing and fitting ignition coils and spark plugs





26. Fit engine wire harness. => 97522100 Removing wire harness for engine (V6)
26.1. Clip in engine wire harness at the rear engine housing using the retaining clips -arrows-.





Clipping in engine wire harness at the rear





26.2. Connect engine wire harness to the oil/water heat exchanger.





Clipping in engine wire harness at the front left