Installing Oil Pan (Includes Sealing)
Installing oil pan (includes sealing)Tools
Tools and materials
Special tools
Installing oil pan
ATTENTION Leaks due to components being at too low a temperature or at different temperatures!
^ If components that are cold or at different temperatures are sealed together by the application of sealant, adhesion problems and leaks can arise due to the build-up of condensation water or component distortion.
^ Components must have reached at least 17°C throughout.
^ Components must not be too hot (distortion).
^ Spare parts that are stored in the cold or heat (strong sunlight), must be brought to room temperature or the same temperature as other parts before installation.
ATTENTION Risk of damage and leaks!
^ 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 rubber profiles.
2. Apply liquid sealant. Apply the sealing agent Loctite 5970 (000 043 300 39, status 12/05) using the hand-held cartridge. The contour of the bead of sealant must comply with the figure shown below. The bead of sealant should be approx. 1.5 mm high. The oil duct in the timing-case cover -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 cover.
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. Tighten the 29 fastening screws beginning at the transmission flange and proceed forwards. Tightening torque: 10 (7.5 ft-lb.) Nm
7. Screw down the timing case cover. Tighten the 5 fastening screws M6 x 25 with an E10 wrench. Tightening torque: 10 (7.5 ft-lb.) Nm
Note: In the Cayenne Turbo (M48/50), the oil suction pump of the turbocharger must also be fitted.
8. Install oil transfer flange. Replace and grease the O-rings of the flange. Then place the connection piece on the assembly driver 9691 in such a way that the slightly thicker end points forwards.
9. Insert the socket with the thicker end into the oil pan and push the assembly mandrel all the way by knocking it slightly.
Aligning the oil pan with a dial gauge
Fitting the oil pan with a dial gauge
ATTENTION Risk of damage and leaks!
^ 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. Place the oil pan on the crankcase and position a fastening screw on each corner.
Note: The following work steps are only necessary if the transmission is disconnected at the time the oil pan is being installed.
1. Insert the dial gauge into the universal dial 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.
ATTENTION 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. Tightening torque: 7.5 ft-lb. The check the position of the oil pan again with the dial gauge.
6. Tightening the remaining fastening screws. Tightening torque: 7.5 ft-lb.
Subsequent work
1. Tighten the 2 fastening screws of the transmission bell housing. Tightening torque: 59 ft-lb.
2. Install bracket for oil-water heat exchanger.
3. Install crankshaft pulley.
4. Install engine carrier.
5. Install the suspension subframe (front-axle carrier).
6. Remove engine bridge.
7. Install oil dipstick.
8. Tighten lock carrier.
9. Fill in engine oil.
10. Bleed and fill the cooling circuit.
11. Carry out a check. After a test drive, check to ensure that the oil pan is not leaking. Then check the oil level.