Part 2
WM 100137 Disassembling and assembling V6 DFI engine
Assembling V6 DFI engine
Information
If cold or excessively low-tempered components are sealed to each other by applying sealant, leaks can occur because of condensed water forming or components distorting. Components must be uniformly at least => Temperature: 17°C.
Information
- Detailed instructions for installing pistons must be observed at all times.
- The cast lugs, the twist lock (locking lugs) -1- and the flat side of the piston crown -2- are on the same side.
Arrangement of pistons and connecting rods
1. Install crankshaft. -> 134819 Removing and installing crankshaft on V6 DFI engines Removal and Replacement
Crank drive on V6 DFI engine
Information
- Bearing covers for the crankshaft are numbered 1 to 7 and the numbers can be read on the side facing the exhaust.
- Bearing no. 5 is a guide or thrust bearing with two thrust washers at the side.
- The twist locks or retaining lugs are on the same side.
- Bearing screws must be replaced.
- Bearing shells must be replaced. Use only identical colour markings
1.1. Oil bearing shells with engine oil and place them on the crankshaft/crankcase. Make sure that the twist lock => Twist locks is inserted cleanly in the crankcase.
Twist locks
1.2. Always replace bearing shells. Observe relevant classification.
1.3. Fit thrust bearing no. 5 with thrust washers -4- (insert using grease, lubricating groove facing outwards) and then fit the remaining bearing covers.
1.4. Tap crankshaft bearing covers on securely as far as they will go using a rubber hammer so that the tightening torque will be accurate.
1.5. Internal serration screws on the crankshaft bearing covers -2- must always be replaced and screwed in by hand.
1.6. Then gradually tighten the bearing covers from the inside out to the specified torque -2-.
1.7. As a test, turn the crankshaft several times to check that it turns smoothly.
1.8. If the drive plate -6- for the inductive pickup (speed sender) was removed from the crankshaft, the drive plate must always be replaced.
1.8.1. Tighten the countersunk screws -7- on the drive plate to the specified tightening torque.
2. Install piston. -> 131019 Removing and installing pistons on V6 DFI engines Removal and Replacement
Overview of piston/connecting rod
2.1. Pull dowel sleeve -arrow- out of the bore hole so that special tool funnel T10333 can be positioned flat on the cylinder block.
Dowel sleeve on cylinder block
2.2. Oil the piston well and insert it into the funnel.
2.3. 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
2.4. 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
2.5. Slide piston fully into the cylinder bore.
2.5.1. Turn the crankshaft back and forth if necessary.
2.6. Insert dowel sleeves back into the bore holes -arrow-.
2.7. 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.
2.8. 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.
2.9. 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.
2.10. Tighten all connecting rod bearing screws -7- to the specified tightening torque.
2.11. Turn the crankshaft several times to check that it turns smoothly.
2.12. 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
3. Fit joint flange for vibration balancer. -> 137419 Removing and installing sealing ring for vibration balancer on DFI engines Removal and Replacement
Crankshaft joint flange
3.1. Apply a bead of sealant -arrows- with a thickness of 2 mm.
Applying sealant on joint flange
3.2. Fit assembly fixture T10215 (guide sleeve) -1- on the crank pin -3- to prevent damage to the vibration balancer joint flange.
3.3. Slide the joint flange -2- over the guide sleeve -1- until it is touching the cylinder block.
Joint flange on front of crankshaft
3.4. Tighten hexagon-head bolts -3- on joint flange -2- to the specified torque.
4. Fit vibration balancer for crankshaft. -> 137619 Removing and installing vibration balancer (crankshaft pulley) on V6 DFI engines Removal and Replacement
Brace
4.1. Tighten hexagon-head bolt on crankshaft vibration balancer => Initial tightening: 100 Nm (74 ftlb.) => Torque angle: 180°.
5. Position engine to the compression TDC of cylinder 1.
TDC marking on pulley and housing cover
6. Install oil pump. -> 172019 Removing and installing oil pump on V6 DFI engines Service and Repair
Piston funnel
7. 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
8. Install cylinder head. -> 157019 Removing and installing cylinder head on V6 DFI engines Removal and Replacement
Cylinder head
8.1. Thoroughly clean all sealing faces before assembly.
8.2. Cylinder head gasket must always be replaced.
8.3. Always observe tightening sequence (1-20) for cylinder-head screws -1-20- and tighten to the specified torque.
8.3.1. Tighten cylinder-head screws to an initial tightening torque of 15 Nm (11 ftlb.).
8.3.2. Tighten cylinder-head screws to 30 Nm (22 ftlb.).
8.3.3. Then tighten all cylinder-head screws a second time to 30 Nm (22 ftlb.).
8.3.4. And finally, tighten the cylinder-head screws to a torque angle of 180°.
9. Install hydraulic tappets.-> 155919 Removing and installing hydraulic tappets on DFI engines Service and Repair
10. Install the camshafts.
Overview of cylinder head on V6 DFI engine
10.1. Insert the camshafts into the cylinder head in such a way that the camshaft guide T10068A fits into the slots on the intake and outlet camshafts at the same time.-> 150520 Removing and installing camshafts on V6 DFI engines Removal and Replacement
Installation position of camshaft
10.2. Install intake camshaft. Note the sequence in which the bearing covers are installed.
10.2.1. First fit bearing covers 5 and 9 and tighten the hexagon nuts alternately and crosswise.
10.2.2. Repeat the process for bearing covers 1 and 13.
10.2.3. Repeat the process for bearing cover 5.
10.2.4. Repeat the process for bearing covers 3 and 11.
10.3. Install outlet camshaft. Note the sequence in which the bearing covers are installed. Use the same torque and torque angle as for the intake camshaft.
10.3.1. First fit bearing covers 6 and 10 and tighten the hexagon nuts alternately and crosswise.
10.3.2. Repeat the process for bearing covers 2 and 14.
10.3.3. Repeat the process for bearing cover 8.
10.3.4. Repeat the process for bearing covers 4 and 12.
10.4. Install timing chain housing.
Removing timing chain housing
11. Fit timing chains. -> 153519 Removing and installing timing chains on V6 DFI engines Service and Repair
Component overview of timing chains
11.1. Install chain tensioner. -> 153619 Removing and installing chain tensioner on V6 DFI engines Service and Repair
11.2. Install camshaft controllers. -> 158419 Removing and installing camshaft controller on V6 DFI engines Service and Repair
12. Check the timing. -> 150502 Checking the timing on V6 DFI engines Testing and Inspection
13. Fit upper and lower timing-case cover. -> 153319 Removing and installing timing-case cover on V6 DFI engines Service and Repair
13.1. Fit lower timing-case cover.
Crankshaft joint flange
13.2. 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.
14. Install oil pan. -> 175019 Removing and installing oil pan on V6 DFI engines Service and Repair
Removing and installing upper timing chain housing cover
15. Install cylinder head cover. -> 158219 Removing and installing cylinder head cover on V6 DFI engines Removal and Replacement
Removing and installing valve cover seal
16. Install flywheel/drive plate.
16.1. Install dual-mass flywheel on vehicles with manual transmission. -> 136219 Removing and installing dual-mass flywheel - section on "Removing"
16.2. Remove drive plate on vehicles with automatic transmission. -> 136319 Removing and installing drive plate for torque converter
17. Install oil/water heat exchanger. -> 174019 Removing and installing oil/water heat exchanger (oil cooler) on V6 DFI engines
Oil-filter housing
18. Install coolant regulator. -> 195819 Removing and installing coolant regulator (thermostat) on DFI engines Service and Repair
Coolant regulator
18.1. Fit thermostat housing -1- completely into the cylinder block.
18.2. Slide coolant hose -3- onto the thermostat housing.
18.3. Fasten spring band clamp -2-.
19. Install fuel distribution pipe and fuel injectors. -> 243019 Removing and installing fuel distribution pipe (fuel rail) on DFI engines Service and Repair
Fuel distribution pipe for cylinders
20. Install coolant pump.-> 195019 Removing and installing coolant pump on DFI engines Service and Repair
Coolant pump
21. Install exhaust manifold.
-> 261019 Removing and installing exhaust manifold - section on "Installing" Service and Repair
Exhaust manifold
22. Install intake-air distributor. -> 244619 Removing and installing DFI intake-air distributor Removal and Replacement
23. Install guide tube for oil dipstick. Sealing ring must always be replaced. -> 171719 Removing and installing guide tube for oil dipstick on DFI engines Service and Repair
24. Install unit carrier.
Removing and installing unit carrier
25. Install the generator. -> 272219 Removing and installing the generator Service and Repair
26. Install hydraulic pump (power-steering pump). -> 48981900 Removing and installing hydraulic pump (Cayenne V6) 48981900 Removing and installing hydraulic pump (Cayenne V6)
27. Install belt tensioner. -> 137319 Removing and installing belt tensioner on DFI engines Service and Repair
Belt tensioner
28. Fit and tension the drive belt.
-> 137819 Removing and installing drive belt Service and Repair
Fitting sequence
29. Install bar ignition modules. -> 282020 Removing and installing DFI bar ignition modules Service and Repair
Removing and fitting ignition coils and spark plugs
30. Fit engine wire harness. -> 97522100 Removing wire harness for engine (V6) 975219 Removing and installing wire harness for engine
30.1. Clip in engine wire harness at the rear engine housing using the retaining clips -arrows-.
Clipping in engine wire harness at the rear
30.2. Connect engine wire harness to the oil/water heat exchanger.
Clipping in engine wire harness at the front left
Subsequent work
1. Remove engine from the mounting bracket. -> 1001IN Supporting V6 3.6-litre DFI engine on mounting bracket 1001IN Supporting V6 3.6 l DFI engine on the mounting bracket
2. Mount the transmission. -> 100127 Removing engine from transmission and mounting engine on transmission 100127 Removing engine from transmission and mounting engine on transmission
3. Install the engine. -> 100119 Removing and installing 3.6-litre DFI engine 100119 Removing and Installing 3.6-Litre DFI Engine
4. Perform a test drive and check for leaks and correct function.
4.1. Clean the engine and carry out a thorough check for leaks after the test drive.