Part 2
WM 1001Z1 Disassembling engine13. Remove ignition coils.
-> 282020 Removing and installing ignition coils Service and Repair.
14. Remove spark plugs.
-> 287020 Removing and installing spark plugs Service and Repair.
15. Remove crankcase vent line -1-.
15.1. Press locking ring on cylinder head cover 1-3 and pull off the line.
15.2. Press locking ring and pull off line at the oil filler neck.
15.3. Press locking ring on vent cover on cylinder head 4-6 and pull off the line.
15.4. Unscrew one Torx screw (E10, M6 x 20) on the oil separator and pull off the line. Replace O-rings.
Crankcase vent line
16. Remove oil separator -1-.
16.1. Unscrew two external Torx screws (E10, M6 x 25) -2- and pull off the oil separator.
16.2. Replace two O-rings.
Oil separator
17. Remove generator.
-> 272219 Removing and installing generator Service and Repair.
17.1. Pull protection cap -1- off the generator.
Protection cap on generator B+ line
17.2. Disconnect B+ line. To do this, unscrew one M8 collar nut.
17.3. Unscrew two external Torx screws (E12, M8 x 90) and remove the generator.
18. Disconnect B+ wire harness.
18.1. Loosen B+ line at the junction point -1- and pull protection cap -2- off the starter.
Junction point for B+ line and protection cap on starter
18.2. Unscrew M6 hexagon nut (a/f 10) for terminal 50 on the solenoid switch for the starter.
18.3. Unscrew hexagon nut (a/f 13) on the B+ line for the starter.
18.4. Remove wire harness.
19. Remove air conditioning compressor.
-> 873419 Removing and installing air conditioning compressor Service and Repair.
19.1. Pull off cable plug and unscrew three M8 external Torx screws (2 x 90 mm and 1 x 170 mm).
19.2. Lift compressor with lines and holder off the engine.
20. Remove coolant connection piece on cylinder bank 4-6.
-> 195919 Removing and installing coolant connection piece 195919 Removing and installing coolant connection piece on cylinder bank 4-6.
20.1. Unscrew three external Torx screws (E12, M8 x 70).
20.2. Unscrew one external Torx screw (E10, M6 x 25).
20.3. Remove coolant connection piece.
21. Loosen holder for power-steering lines at cylinder head 4-6.
22. Remove hydraulic pump for power steering with lines.
-> 489819 Removing and installing hydraulic pump - as of model year 2009 Service and Repair.
23. 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
23.1. Secure the engine using one of the locating pins 9595/1 -2- on the vibration damper.
24. Remove vibration damper.
-> 137519 Removing and installing vibration damper Service and Repair.
25. Remove coolant regulator cover.
-> 195519 Removing and installing coolant regulator cover 195519 Removing and installing coolant regulator cover.
25.1. Unscrew three external Torx screws (E10, M6 x 50) and remove cover and coolant regulator.
25.2. Replace O-ring.
26. Remove coolant guide -1- at the bottom.
26.1. Unscrew six external Torx screws (E10, M6 x 25) and remove coolant guide.
26.2. Check moulded seals and replace if necessary.
Lower coolant guide
27. Remove coolant pipes -2- at the coolant distributor -1-.
27.1. Unscrew two external Torx screws (E10, M6 x 25) at the distributor.
Coolant distributor and connecting pipes
27.2. Pull distributor up and off.
O-rings for connecting pipes for coolant distributor
27.3. Replace O-rings -1-.
28. Remove coolant pipe -1- for the coolant regulator housing.
28.1. Unscrew external Torx screw (E10, M6 x 12) -2-. Pull coolant pipe out of the housing.
Coolant collecting tube to coolant regulator housing
28.2. Unscrew one external Torx screw (E10, M6 x 50) -3- at the coolant regulator housing.
Thermostat housing
29. Loosen bracket -1- for coolant pump. -> 195919 Removing and installing coolant distributor housing (unit carrier) - Engine installed 195919 Removing and installing coolant distributor housing (unit carrier) - Engine installed.
29.1. Unscrew three external Torx screws (E10, M6 x 25) -1- on the connecting tube for the coolant regulator housing.
Connecting tube from coolant regulator housing to coolant pump
29.2. Turn the belt tensioner clockwise at the hexagon (a/f 30) and secure with an M8 screw -2- or a pin (8 mm).
29.3. Unscrew two external Torx screws (E12) M8 x 50 -3- and one M10 x 65 hexagon-head bolt (a/f 16) -4-.
29.4. Unscrew one external Torx screw (E10) M6 x 20 -5- and one (E12) M8 x 25 -6-.
29.5. Pull off bracket. Replace O-rings on the adapter.
Bracket for coolant pump and belt tensioner
30. Remove unit carrier and coolant regulator housing.
30.1. Unscrew two external Torx screws (E12) - one M8 x 35 -1- and one M8 x 50 -2- - at the unit carrier.
Coolant distributor housing screws
30.2. Remove coolant regulator housing and unit carrier together, then pull the unit carrier off the coolant regulator housing.
31. Remove fuel connection line.
-> 249019 Removing and installing fuel connection line.
32. Remove oil filler neck.
32.1. Unscrew external Torx screw (E10, M6 x 12) -2- on the holder.
32.2. Unscrew two external Torx screws (E10, M6 x 20) -1- on the crankcase flange.
32.3. Pull out oil filler neck.
32.4. Replace O-rings.
Threaded joint securing oil filler neck to crankcase
33. Remove oil/water heat exchanger.
-> 174019 Removing and installing oil/water heat exchanger 174019 Removing and installing oil/water heat exchanger.
33.1. Open four spring band clamps -1- for the coolant hoses and hydraulic lines.
Hose connections for heat exchanger
33.2. Pull off hydraulic lines and coolant hoses.
33.3. Unscrew six internal Torx screws (T30, M6 x 20) at the oil/water heat exchanger.
33.4. Remove oil/water heat exchanger.
34. Remove secondary-air pump.
-> 266519 Removing and installing secondary-air pump Service and Repair.
34.1. Remove connector clip for cable plug.
34.2. Unscrew two external Torx screws (E10, M6 x 20) at the cylinder head and one M6 x 25 -2- on the line bracket for cylinder bank 1-3.
34.3. Unscrew one external Torx screw (E10, M6 x 20) at the cylinder head and one M6 x 25 -3- on the line bracket for cylinder bank 4-6.
34.4. Loosen external Torx screw (E12, M8 x 35) on the knock sensor for cylinder bank 1-3 and turn the knock sensor slightly.
34.5. Unscrew three external Torx screws (E10, M6 x 30) -1- on the bracket for the secondary-air pump.
34.6. Carefully remove secondary-air pump with lines for bank 1-3 and bank 4-6.
Secondary-air pump
35. Remove starter.
-> 276019 Removing and installing starter.
35.1. Unscrew two external Torx screws (E14, M10 x 35) at the starter.
35.2. Remove the starter by pulling it towards the belt side.
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.
36. Remove bracket for oil/water heat exchanger.
-> 176719 Removing and installing bracket for oil cooler 176719 Removing and installing bracket for oil cooler.
36.1. Pull the bracket up and out.
37. Remove fuel collection pipes with fuel injectors.
-> 243019 Removing and installing fuel collection pipe (with fuel injectors) - DFI Service and Repair.
37.1. Unscrew four external Torx screws (E10, M6 x 25) on each fuel collection pipe.
37.2. Pull fuel collection pipe with fuel injectors off completely.
38. Remove high-pressure pump.
-> 246319 Removing and installing high-pressure pump.
38.1. Remove support by unscrewing two external Torx screws (E10) M6 x 25 at the top and one M6 x 40 at the bottom.
38.2. Unscrew two external Torx screws (M6 x 25) on the pump and pull off the pump.
38.3. Replace O-ring.
39. Disconnect vacuum line for brake booster at the oil pan.
40. Remove vacuum pump on cylinder head 4-6.
-> 477619 Removing and installing vacuum pump - as of model year 2009 Service and Repair.
40.1. Unscrew three external Torx screws (M6 x 20).
40.2. Unscrew one external Torx screw (M6 x 12) on the vacuum line holder and pull off the pump and line.
41. Remove positive crankcase ventilation cover -1-.
41.1. Cylinder bank 1-3:
Positive crankcase ventilation cover 1-3
41.2. Cylinder bank 4-6:
Positive crankcase ventilation cover 4-6
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
- 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.
Information
- Guide the timing chains with your hand when turning the crankshaft so that they do not get stuck in the crankcase.
Information
- Fit connecting rod and the relevant cover.
- Replace connecting rod bolts and bearing shells.
- Replace crankshaft sealing rings.
1. Remove cylinder head cover.
-> 158219 Removing and installing cylinder head cover - engine removed 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. 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. => 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. => Cam position on cylinder 4 at overlap
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
Marking on camshafts 4-6 at overlap
3. Remove camshafts.
-> 150520 Removing and installing camshafts (includes setting timing) Service and Repair.
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. 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. 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
5.5. 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
5.6. Replace O-rings on the bearing pins.
5.7. Pull oil supply valve -1- on the vacuum pump out of the cylinder head using a pair of flat-nosed pliers -arrow-. Replace O-ring.
Oil supply valve on vacuum pump
Oil supply valve on vacuum pump for brake booster
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 the oil pan.
-> 175019 Removing and installing oil pan Service and Repair.
10. Remove coolant pipe -1- for the coolant pump.
10.1. Unscrew two external Torx screws (E10, M6 x 12) -2- and remove the pipe.
Coolant pipe for coolant pump
11. Remove oil pump and oil guide.
-> 172019 Removing and installing oil pump Service and Repair.
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.
-> 131020 Removing and installing pistons and handling tools Service and Repair.
14. Remove crankcase half 1-3.
14.1. Unscrew 19 external Torx screws for the outer cross bolt connection. The threaded bolt must be removed for screw -17-.
Outer cross bolt connection
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
14.3. Replace screws and 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.
-> 131020 Removing and installing pistons and handling tools Service and Repair.
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 catalogue for the Cayenne can be used to assess the cylinder linings.
-> 101001 Assessment of cylinder liners (checking crankcase).
20. Clean the crankcase and sealing surfaces.