Part 2

WM 1001Z1 Disassembling engine - Turbo

32.3. Open two spring band clamps -1- and pull the coolant hoses -2- off the oil/water heat exchanger.





Coolant hoses on heat exchanger

32.4. Replace O-rings -1- and grease new O-rings with Kluber plus Gel (Part No. 000.043.205.93).





O-rings for connecting pipes for coolant distributor

33. Remove transport eyebolt.
33.1. Unscrew two external Torx screws (E10, M6 x 25).
34. Remove coolant run-on pump -1-.
34.1. Cable plug -2- for coolant run-on pump (already disconnected).
34.2. Open spring band clamps -3 and 4- and pull off hoses.
34.3. Remove run-on pump.





Coolant run-on pump (turbocharger cooling)

35. Remove fuel connection line -1- to the fuel collection pipes.
35.1. Loosen two external Torx screws (E10, M6 x 12) at the clamps.
35.2. Unscrew two external Torx screws (E10) on the fuel line holders. One screw on the centre holder M6 x 16 -3- and one screw on the right holder M6 x 60 (screw point for bracket for oil/water heat exchanger) -2-.
35.3. Screw off three union nuts (a/f 17) -4- and remove the line. Soak up emerging fuel with a cloth.





Fuel connection line to the fuel collection pipes

36. Remove oil/water heat exchanger -1-.
36.1. Unscrew six internal Torx screws (T30, M6 x 20) -2- and remove heat exchanger.
36.2. Collect any drops of fluid with a clean cloth and clean the sealing faces.
36.3. 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 aluminium supports in the crankcase.

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





Bracket for oil/water heat exchanger

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





Threaded joint for fuel collection pipe

38.2. Close off fitted bores in the cylinder head with stoppers.
39. Remove knock sensors (mark installation position using a water-resistant marker).
-> 287219 Removing and installing knock sensor - Turbo.
39.1. Unscrew one external Torx screw (E12, M8 x 35) on each sensor and remove sensors.
40. Remove fuel lines for the high and low-pressure side and remove cover.
40.1. Unscrew three external Torx screws (E10, M6 x 12) on the heat shield and remove the heat shield.
40.2. Unscrew three external Torx screws (E10) on the cover -1- : two M6 x 25 screws -2- and one M6 x 40 screw -3-.
40.3. Loosen and screw off hexagon union nuts on the high-pressure pump. Low-pressure line -5- : a/f 17, high-pressure line -4- : a/f 14.
40.4. Unscrew one external Torx screw (E10) M6 x 16 and one M6 x 12 screw at the retaining points and remove the lines.





Cover and fuel lines on high-pressure pump

41. Remove high-pressure pump -6-.
-> 246319 Removing and installing high-pressure pump - Turbo Service and Repair.
41.1. Unscrew two external Torx screws (E10, M6 x 25) -7- and pull out the pump.
41.2. Replace O-ring.





High-pressure pump with cover and cylinder head cover

42. Remove vacuum line -1- for brake booster.
-> 477755 Replacing vacuum line for brake booster (section at engine) 477755 Replacing vacuum line for brake booster (section at engine).
42.1. Unscrew external Torx screws (E10, M6 x 12) -2- and pull out line at the vacuum pump.





Vacuum line for brake booster

43. Remove vacuum pump -3-.
-> 477619 Removing and installing vacuum pump.
43.1. Remove vacuum line. Unscrew one M6 external Torx screw (E10) and pull off the line.
43.2. Unscrew three M6 external Torx screws (E10) -4- and remove the pump.
43.3. Replace O-ring.





Vacuum pump

44. Remove lower coolant guide -1-.
44.1. Unscrew six external Torx screws (E10, M6 x 25) -2-.
44.2. Check moulded seals and replace if necessary.





Lower coolant guide

45. 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

45.1. Secure the engine using one of the locating pins 9595/1 -2- on the vibration damper.
46. Remove vibration damper.
-> 137519 Removing and installing vibration damper - Turbo Service and Repair.
46.1. Loosen and unscrew six external Torx screws (E12, M8 x 25 x 1) and remove the vibration damper.
46.2. Check dowel sleeve and crankshaft flange for damage.
47. Loosen bracket for coolant pump -1-.
47.1. 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-.
47.2. Unscrew four external Torx 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

47.3. Unscrew M10 threaded bolt (engine carrier mounting) -7- (two M10 lock nuts).
48. Remove coolant connection pipe -1- to the thermostat housing.
48.1. Unscrew one external Torx screw (E10, M6 x 12) -2- on the retaining bracket for the crankcase.
48.2. Pull out pipe -1- on the thermostat housing.





Coolant connection pipe to thermostat housing

49. Remove thermostat housing -2-.
49.1. Unscrew three external Torx screws (E10) M6 x 25 -4- and one M6 x 50 -3-.





Thermostat housing

49.2. Turn bracket for coolant pump slightly to the right.
49.3. 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.
49.4. 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

49.5. Replace moulded seal on the connecting tube -3-.





Thermostat housing and connecting tube for coolant pump

50. 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.
-> 195919 Removing and installing unit carrier (coolant distributor housing) - Turbo 195919 Removing And Installing Unit Carrier (coolant Distributor Housing) - Turbo.
50.1. Unscrew one external Torx screw M8 x 50 -3 (right)- and one M8 x 35 -4-. Remove carrier, check dowel sleeve for damage and replace if necessary.
50.2. Replace moulded seals.





Unit carrier

51. Remove cover for positive crankcase ventilation at the cylinder head.
51.1. Cover on cylinder bank 1-3 -1- : Unscrew three external Torx screws (M6 x 20) -4- and replace O-ring -3- and moulded seal -2-.





Cover on positive crankcase ventilation 1-3

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





Cover on positive crankcase ventilation 4-6

52. Remove solenoid hydraulic valves for camshaft control.
52.1. Unscrew two external Torx screws (E8, M5 x 12) on each valve and pull off the valves.
52.2. Replace O-rings.
53. Remove hall senders on the cylinder head cover.
-> 283919 Removing and installing hall sender Service and Repair.
53.1. Unscrew one external Torx screw (T40, M6 x 16) on each and pull off the hall senders.
53.2. Replace O-ring.
54. Remove solenoid hydraulic valves for valve lift adjustment.
-> 155519 Removing and installing solenoid hydraulic valve for valve lift adjustment Service and Repair.
54.1. Unscrew two external Torx screws (E8, M5 x 12) on each valve and pull off the valves.

Disassembling 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.
-> 158219 Removing and installing cylinder head cover - Turbo Service and Repair.
1.1. Unscrew one external Torx 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. Cam positions:
- Overlapping position of cylinder bank 1-3: Cams on cylinder 1 are facing outward at a slant -arrows-.





Cam position on cylinder 1 at overlap

- Overlapping position of cylinder bank 4-6: Cams on cylinder 4 are facing inward at a slant to the spark-plug recess -arrows-.





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. These markings are facing the observer (data matrix code) -inset-.





Marking on camshafts 4-6 at overlap

3. Remove camshafts.
-> 150520 Removing and installing camshafts (includes setting timing) Service and Repair.

Information

- Position hydraulic tappets on a surface you have prepared and labelled 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, labelled cardboard => Example of laying aside bucket tappets.





Example of laying aside bucket tappets

5. Remove tensioning and guide rails.
5.1. Cylinder 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 the 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. Cylinder 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.
-> 157019 Removing and installing cylinder head Service and Repair.
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 lower part of oil pan.
-> 175019 Removing and installing oil pan Service and Repair.
9.1.
10. Remove oil lines in the oil pan.
10.1. Remove return lines -1 and 3- for the turbocharger by unscrewing two external Torx screws (E10) M6 x 16 -2- and one (E10) M6 x 12 on each -4-.
10.2. Remove supply line -5- by unscrewing three external Torx screws (E10, M6 x 16) -2-.





Oil lines in the oil pan

11. Remove upper part of oil pan.
-> 175019 Removing and installing oil pan Service and Repair.
12. Remove coolant pipe -1- for the coolant pump.
12.1. Unscrew two external Torx screws (E10, M6 x 12) -2- and remove the pipe.





Coolant pipe for coolant pump

13. Remove oil pump and oil guide.
-> 172019 Removing and installing oil pump Service and Repair.
14. Turn the engine at the engine assembly support so that cylinder bank 1-3 is facing upwards.
15. Remove pistons for cylinders 1-3.
-> 131020 Removing and installing pistons - Turbo Service and Repair.
16. Remove crankcase half 1-3.
16.1. Unscrew 19 external Torx screws for the outer cross bolt connection. The threaded bolt must be removed for the screw -17-.





Outer cross bolt connection





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





Through-bolt screws on crankcase





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





Lever positions on crankcase

18.3. 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

19. Remove pistons and connecting rods on cylinders 4-6.
-> 131020 Removing and installing pistons - Turbo Service and Repair.
19.1. Remove connecting rods 1-3 on the crankshaft.
20. Remove and dispose of crankshaft sealing rings.
21. Lift crankshaft and timing chains out of crankcase half 4-6.
Get another person to help if necessary.





Crankshaft and timing chains in crankcase half 4-6

21.1. Remove bearing shells from the crankcase halves and dispose of them.
21.2. The deviation sample catalogue for the Cayenne can be used to assess the cylinder linings.
-> 101001 Assessment of cylinder liners (checking crankcase).
22. Carefully clean the crankcase and sealing surfaces.