Lubrication Porsche Cayenne S I

Scheme 1

Engine oil change (without oil filter)

> Let the oil cool down

> Wear personal protective gear (goggles, gloves)

Note. The engine must be at operating temperature to change the oil.

Note. Engine oil should not be removed by suction as particles of dirt may remain in the oil pan.

1. Jack up the vehicle at the points provided. --> 03 Entire vehicle -General

2. Remove the underbody panel. Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

Scheme 2

Note. Engine oil should not be removed by suction as particles of dirt may remain in the oil pan.

3. Loosen oil drain plug and collect the engine oil in a disposal container (dripping time approximately 20 minutes). Dispose of waste oil in accordance with legal requirements.

4. Replace and fit oil drain plug. --> Tightening torque: 22 ftlb.

5. Fill in engine oil of the stipulated viscosity and quality. The oil change quantity is --> filling capacity: 5.7 liter .

6. Fit the underbody panel. Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

7. Start engine and check oil level. > 170117 Engine oil and oil filter change - chapter on "Checking"

Engine oil change (with oil filter)

> Let the oil cool down

> Wear personal protective gear (goggles, gloves)

Note. Engine oil should not be removed by suction as particles of dirt may remain in the oil pan.

1. Jack up the vehicle at the points provided. --> 03 Entire vehicle -General

2. Remove the underbody panel. Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

Note. Engine oil should not be removed by suction as particles of dirt may remain in the oil pan.

3. Loosen oil drain plug and collect the engine oil in a disposal container (dripping time approximately 20 minutes). Dispose of waste oil in accordance with legal requirements.

4. Replace and fit oil drain plug. --> Tightening torque: 22 ftlb.

Scheme 3

5. Loosen the oil filter cover with a socket (a/f 36). Then check the sealing ring and coat with new engine oil.

6. Remove the oil filter housing vertically downwards. Drain the remaining oil into a disposal container.

7. Remove the filter element. Remove the filter downwards and dispose of in accordance with legal requirements.

Note. Do not remove the O-ring with a sharp object. The oil filter housing contains a cutout via which the O-ring can be removed.

8. Clean the oil filter housing and replace the O-ring seal. Clean the oil filter housing thoroughly inside and outside and replace the O-ring. Carefully lever off the O-ring. The oil filter housing must not be damaged during this procedure.

9. Insert filter element in the housing.

Note. Lightly oil the O-ring when installing the oil filter housing.

10. Install oil filter housing. --> Tightening torque: 19 ftlb. Lightly oil the O-ring when doing this.

11. Fill in engine oil. The oil change quantity is --> filling capacity: 6.3 liter .

Scheme 4

12. Fit the underbody panel. Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

13. Start engine and check oil level. > 170117 Engine oil and oil filter change - chapter on "Checking"

Markings on the oil dipstick (checking engine oil level)

The vehicle must stand horizontally. The engine must be switched off and at operating temperature. Before measuring, allow engine oil to flow back into the oil pan for approximately 3 minutes.

1. Pull out oil dipstick and wipe it off with a clean, lint-free cloth. Insert dipstick again fully, pull it out again, and read off the oil level. Correct engine-oil level if necessary.

The oil level on the oil dipstick must never be below the MIN mark or above the MAX mark.

The difference quantity between the marks -1 and 2- is --> Filling capacity: 1.5 liter. (Scheme 5)

Scheme 5

Note. After changing the oil, the oil level must be checked using the dipstick. The engine must have reached its operating temperature.

1. 1 - max. marking
2. 2 - min. marking
3. a - Area above cross-hatched area up to max. mark: no more oil must be added.
4. b - Oil level within cross-hatched area: additional engine oil can be added.
5. c - Area from min. mark to cross-hatched area: refill engine oil up to the cross-hatched area.

Tools

Scheme 6

Note. Engine oil should not be extracted as particles of dirt may remain in the oil pan.

1. Jack up the vehicle at the points provided --> 03 Entire vehicle, general information .

> Wear protective clothing specified!

2. Remove engine guard . Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

Scheme 7

3. Loosen the 2 oil drain plugs and collect engine oil in a disposal container. Dispose of waste oil in accordance with legal requirements.

4. Clean oil drain plugs and screw in with a new aluminum sealing ring. --> Tightening torque: 37 ftlb.

5. Fill in engine oil of the stipulated viscosity and quality. The oil change quantity is --> filling capacity: 8.25 liter .

6. Fit engine guard. Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

Changing the engine oil (with oil filter)

Note. Engine oil should not be extracted as particles of dirt may remain in the oil pan.

1. Jack up the vehicle at the points provided --> 03 Entire vehicle, general information .

2. Remove engine guard . Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

> Wear protective clothing specified!

3. Loosen the 2 oil drain plugs and collect engine oil in a disposal container. Dispose of waste oil in accordance with legal requirements.

4. Clean oil drain plug and screw in with new aluminum sealing ring. --> Tightening torque: 37 ftlb.

Scheme 8

5. Loosen oil filter with special tool oil filter spanner P 9204 and unscrew it.

6. Remove the oil filter housing vertically downwards. Drain the remaining oil into a disposal container.

7. Remove the filter element. Remove the filter downwards and dispose of in accordance with legal requirements.

Note. Do not remove the O-ring with a sharp object. The oil filter housing contains a cutout via which the O-ring can be removed.

Scheme 9

8. Clean the oil filter housing and replace the O-ring seal. Clean the oil filter housing thoroughly inside and outside and replace the O-ring. Carefully lever off the O-ring. The oil filter housing must not be damaged during this procedure.

9. Install the filter element.

Note. Lightly oil the O-ring when installing the oil filter housing.

10. Install the oil filter housing and tighten using special tool oil filter spanner P 9204 . Lightly oil the O-ring when doing this. --> Tightening torque: 19 ftlb.

11. Fill in engine oil. The oil change quantity is --> filling capacity: 8.75 liter .

12. Fit engine guard. Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

Checking engine oil level

The vehicle must stand horizontally. The engine must be switched off and at operating temperature. Before measuring, allow engine oil to flow back into the oil pan for approximately 3 minutes.

1. Pull out oil dipstick and wipe it off with a clean, lint-free cloth. Insert oil dipstick again fully, pull it out again, and read off the oil level. Correct engine-oil level if necessary.

The oil level on the oil dipstick must never be below the MIN mark or above the MAX mark.

The difference quantity between the marks is --> Filling capacity: 1.5 liter .

Note. After changing the oil, the oil level must be checked using the dipstick. The engine must have reached its operating temperature.

Scheme 10

1. Max. mark
2. Min. mark
3. Range from min up to max. mark: no more oil must be added.
4. Range below Min. mark: refill engine oil up to Max. mark.

Scheme 11

Checking oil pressure

> Do not consume food or drink while working (danger of mixing).

> If swallowed, observe the warning information on the containers, contact a doctor if necessary and show the information on the containers.

> Engine oil and components of the oil circuit can become very hot!

> Allow engine and components to cool down.

> Avoid contact with the skin and eyes.

> Wear suitable protective clothing.

> Do not pour engine oil over very hot components (e. g. turbocharger).

> Never place cloths soaked with oil on hot engine components.

> In case of fire, use CO 2 or dry powder fire extinguishers.

Note. The oil pressure may be too low for a number of reasons: Oil is diluted. Oil pump is faulty. Bearing clearance is too large (e. g. crankshaft bearing). Oil level is too low. Oil pressure regulating valve is faulty. Incorrect oil has been used. Use only oil that has been approved by Porsche for the measurement.

Note. The oil pressure switch is located on the oil-filter console to the right (in the direction of travel) under the generator.

1. Remove front engine guard. Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

Scheme 12

2. Pull off connector on oil pressure sensor. To do this, press on the button.

Scheme 13

Note. When the oil pressure switch is unscrewed, approx. 0.3 liters of engine oil escapes.

3. Loosen the oil pressure switch and unscrew it. Collect the emerging oil and dispose of it in accordance with the applicable national laws.

4. Screw in test adapter 4 with sealing ring in the oil-filter console and tighten by hand.

Scheme 14

5. Connect pressure gauge on the hose and tighten it hand-tight.

Note. The oil temperature must range between 80°C and 100°C when performing the measurement. Check the oil temperature using a special thermometer or the PST II tester.

6. Start the engine and move off at the required test speed. Read off the oil pressure on the pressure gauge when doing so.

Note. When the pressure gauge is unscrewed, approx. 0.3 l of engine oil escapes.

7. Remove pressure gauge with test hose. Collect the emerging engine oil and dispose of it in accordance with the applicable national laws.

8. Install oil temperature switch with new sealing ring. --> Tightening torque: 15 ftlb.

9. Push electric connector onto oil pressure switch. The connector must engage audibly.

10. Install front engine guard. Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

11. Check oil level and correct if necessary.

Special tools

Component overview

> Do not consume food or drink while working (danger of mixing).

> If swallowed, observe the warning information on the containers, contact a doctor if necessary and show the information on the containers.

> Engine oil and components of the oil circuit can become very hot!

> Allow engine and components to cool down.

> Avoid contact with the skin and eyes.

> Wear suitable protective clothing.

> Do not pour engine oil over very hot components (e. g. turbocharger).

> Never place cloths soaked with oil on hot engine components.

> In case of fire, use CO 2 or dry powder fire extinguishers.

Note. The oil pressure may be too low for a number of reasons: Oil is diluted. Oil pump is faulty. Bearing clearance is too large (e. g. crankshaft bearing). Oil level is too low. Oil pressure regulating valve is faulty. Incorrect oil has been used. Use only oil that has been approved by Porsche for the measurement.

Note. The oil pressure switch is located in the oil filter housing/engine support arm.

Note. When the oil pressure switch is unscrewed, approx. 0.3 litres of engine oil escapes.

Scheme 15

1. Remove oil pressure switch/sender. > 170419 Removing and installing oil-pressure sender - section on "Removing"

2. Use adapter insert 4 and tighten by hand with suitable sealing ring instead of oil pressure sender/switch.

3. Connect pressure gauge to hose.

Note. The oil temperature must range between 80°C and 100°C when performing the measurement. Check the oil temperature using a special thermometer or the PST II tester.

4. Start the engine and move off at the required test speed. Read off the oil pressure on the pressure gauge while doing so.

Note. When the pressure gauge is unscrewed, approx. 0.3 l of engine oil escapes.

5. Remove pressure gauge with test hose. Collect the emerging engine oil and dispose of it in accordance with the applicable national laws.

6. Install oil temperature switch with new sealing ring. > 170419 Removing and installing oil-pressure sender - section on "Installing"

Removing oil-pressure sender

> Do not consume food or drink while working (danger of mixing).

> If swallowed, observe the warning information on the containers, contact a doctor if necessary and show the information on the containers.

> Engine oil and components of the oil circuit can become very hot!

> Allow engine and components to cool down.

> Avoid contact with the skin and eyes.

> Wear suitable protective clothing.

> Do not pour engine oil over very hot components (e. g. turbocharger).

> Never place cloths soaked with oil on hot engine components.

> In case of fire, use CO 2 or dry powder fire extinguishers.

Note. The oil pressure may be too low for a number of reasons: Oil is diluted. Oil pump is faulty. Bearing clearance is too large (e. g. crankshaft bearing) Oil level is too low. Oil pressure regulating valve is faulty. Incorrect oil has been used. Use only oil that has been approved by Porsche for the measurement.

Note. The oil pressure switch is located on the oil-filter console to the left under the generator.

1. Remove engine guard. Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

2. Pull off connector on oil pressure sensor. To do this, press on the button.

Note. When the oil pressure switch is unscrewed, approx. 0.3 litres of engine oil escapes.

3. Loosen the oil pressure sender and unscrew it. Collect the emerging oil and dispose of it in accordance with the applicable national laws.

Installing oil pressure sender

1. Install oil pressure sender with new sealing ring. --> Tightening torque: 15 ftlb.

2. Push electric connector onto oil pressure sender. The connector must engage audibly.

3. Install engine guard. Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

4. Check oil level and correct if necessary.

> Do not consume food or drink while working (danger of mixing).

> If swallowed, observe the warning information on the containers, contact a doctor if necessary and show the information on the containers.

> Engine oil and components of the oil circuit can become very hot!

> Allow engine and components to cool down.

> Avoid contact with the skin and eyes.

> Wear suitable protective clothing.

> Do not pour engine oil over very hot components (e. g. turbocharger).

> Never place cloths soaked with oil on hot engine components.

> In case of fire, use CO 2 or dry powder fire extinguishers.

Note. The oil pressure may be too low for a number of reasons: Oil is diluted. Oil pump is faulty. Bearing clearance is too large (e. g. crankshaft bearing) Oil level is too low. Oil pressure regulating valve is faulty. Incorrect oil has been used. Only use oil that has been approved by Porsche for the measurement.

Note. The oil pressure switch is located on the oil-filter console to the right under the generator.

1. Remove front underside panel. Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

2. Pull off connector on oil pressure sensor. To do this, press on the button.

Note. When the oil pressure switch is unscrewed, approx. 0.3 liters of engine oil escapes.

3. Loosen the oil pressure switch and unscrew it. Collect the emerging oil and dispose of it in accordance with the applicable national laws.

17 11 19 Removing and installing oil level sensor - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan)

1. Install oil temperature switch with new sealing ring. --> Tightening torque: 15 ftlb. .

2. Push electric connector onto oil pressure switch. The connector must engage audibly.

3. Install front underbody panel. Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

4. Check oil level and correct if necessary.

Removing oil level sensor

> Do not consume food or drink while working (danger of mixing).

> If swallowed, observe the warning information on the containers, contact a doctor if necessary and show the information on the containers.

> Engine oil and components of the oil circuit can become very hot!

> Allow engine and components to cool down.

> Avoid contact with the skin and eyes.

> Wear suitable protective clothing.

> Do not pour engine oil over very hot components (e. g. turbocharger).

> Never place cloths soaked with oil on hot engine components.

> In case of fire, use CO 2 or dry powder fire extinguishers.

Scheme 16

1. Remove underbody panel. Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

Note. If the oil is to be used again, it must be collected in a clean container.

2. Undo the 2 oil drain plugs and collect engine oil in a container. Dispose of waste oil in accordance with legal requirements.

3. Clean oil drain plug and screw in with new aluminum sealing ring. --> Tightening torque: 37 ftlb.

Scheme 17

4. Disconnect the electric connector on the oil level sensor.

Scheme 18

5. Loosen the 3 fastening screws and pull the oil level sensor out of the oil pan.

Installing oil level sensor

1. Install the new oil level sensor with a new seal. Tighten the 3 fastening screws. --> Tightening torque: 7.5 ftlb.

Scheme 19

2. Fill in engine oil of the stipulated viscosity and quality.

3. Start the vehicle briefly. Then check the oil level. It must be between the MIN and MAX markings on the dipstick.

4. Install underbody panels. Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

> Do not consume food or drink while working (danger of mixing).

> If swallowed, observe the warning information on the containers, contact a doctor if necessary and show the information on the containers.

> Do not pour engine oil over very hot components (e. g. turbocharger).

> Never place cloths soaked with oil on hot engine components.

> In case of fire, use CO 2 or dry powder fire extinguishers.

1. Remove engine guard Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

> Engine oil and components of the oil circuit can become very hot!

> Allow engine and components to cool down.

> Avoid contact with the skin and eyes.

> Wear suitable protective clothing.

2. Undo oil drain plug and collect the engine oil in a container. Dispose of waste oil in accordance with legal requirements.

3. Replace oil drain plug. --> Tightening torque: 22 ftlb.

4. Disconnect the electric connector on the oil level sensor (TOC).

5. Loosen the 3 fastening screws and pull the oil level sensor out of the oil pan.

1. Install the new oil level sensor with a new seal. Tighten the 3 fastening screws. --> Tightening torque: 7.5 ftlb.

2. Fit cable plug.

3. Fill in engine oil. Start the vehicle briefly. Then check the oil level. This must reach mark -b- on the oil dipstick. see scheme 49

Scheme 20

4. Mount engine guard. Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

Scheme 21

1. Remove throttle body cover. Pull the cover up and off. Refer to 10 83 19 Removing and installing design cover. - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

2. Remove Y-shaped pipe. Refer to 24 35 19 Removing and installing cowl for throttle housing (Y-shaped pipe) - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne S TIO Titan) . Refer to 24 35 19 Removing and installing cowl for throttle housing (Y-shaped pipe) - as of MY 2003 (Cayenne Turbo, Cayenne Turbo S) .

Removing and installing guide for oil dipstick

1. Loosen the 2 fastening screws.

Scheme 22

2. Pull out oil dipstick.

3. Pull guide tube out of oil pan.

4. Replace O-ring.

5. Insert guide tube into oil pan.

6. Tighten the 2 fastening screws. First position the two screws. Then tighten the upper fastening screw. --> Tightening torque: 7.5 ftlb. and then the lower fastening screw --> Tightening torque: 7.5 ftlb. .

Subsequent work

1. Reinstall the Y pipe. Refer to 24 35 19 Removing and installing cowl for throttle housing (Y-shaped pipe) - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne S TIO Titan) . Refer to 24 35 19 Removing and installing cowl for throttle housing (Y-shaped pipe) - as of MY 2003 (Cayenne Turbo, Cayenne Turbo S) .

Scheme 23

2. Reinstall throttle body cover. To do this, press the 4 rubber elements on the ball heads.

Scheme 24

1. Pull off design cover of engine.

Scheme 25

Note. Before disassembly, measure the oil level and make a mark of the level on the dipstick as a check.

2. Unscrew fastening nuts of sheetmetal holder -arrows- and push sheetmetal holder aside. (Scheme 25)

Scheme 26

3. Unscrew the fastening screw of guide tube on intake-air distributor -1-. (Scheme 26)

Scheme 27

4. Push cable plug of crankshaft pulse sender to the cylinder block -arrow- and disassemble from guide tube. (Scheme 27)

Scheme 28

1- - --> Tightening torque: 6 ftlb. (Scheme 28)

2- - Guide tube for oil dipstick (Scheme 28)

3- - Oil dipstick (Scheme 28)

4- - Oil check valve, pay attention to direction of installation. (Scheme 28)

5- - Knock sensor; right with and left without cable. (Scheme 28)

6- - --> Tightening torque: 15 ftlb. (Scheme 28)

7- - --> Tightening torque: 7.5 ftlb. (Scheme 28)

8- - Cover for oil pump drive. (Scheme 28)

9- - O-ring; replace. (Scheme 28)

10- - Oil pump drive. (Scheme 28)

11- - Crankcase. (Scheme 28)

12- - Intermediate shaft. (Scheme 28)

13- - Thrust washer. (Scheme 28)

14- - --> Tightening torque: 7.5 ftlb., use impact bolter as needed; insert screws with screw locking agent. (Scheme 28)

15- - Drive shaft for oil pump; pay attention to the assembly of plastic washer (Scheme 28)

16- - Crankshaft reference mark sender. (Scheme 28)

17- - Oil pump, observe tightening sequence. (Scheme 28)

18- - --> Tightening torque: 17 ftlb. (Scheme 28)

19- - --> Tightening torque: 6 ftlb. (Scheme 28)

20- - Replacing --> Tightening torque: 22 ftlb.; (Scheme 28)

21- - Oil pan (Scheme 28)

22- - Oil level sensor (Scheme 28)

23- - Sealing ring; replace (Scheme 28)

24- - --> Tightening torque: 9 ftlb. (Scheme 28)

25- - Sealing ring; replace (Scheme 28)

26- - Engine support arm/oil filter housing (Scheme 28)

27- - --> Tightening torque: 15 ftlb. (Scheme 28)

28- - To thermostat; replace O-ring. (Scheme 28)

29- - --> Tightening torque: 19 ftlb. (Scheme 28)

30- - --> Tightening torque: 19 ftlb. (Scheme 28)

31- - Secondary unit holder. (Scheme 28)

32- - Coolant pipe; replace O-ring. (Scheme 28)

33- - Knock sensor (without cable). (Scheme 28)

34- - Torsional vibration damper. (Scheme 28)

35- - --> Initial tightening: 74 ftlb. --> Final tightening: 90°; replace screw (Scheme 28)

Removing guide tube for oil dip stick

1. Pull the guide tube with oil dip stick carefully out of the cylinder block. If necessary, carefully turn it back and forth. Check if the sealing ring is still on the guide tube or pull the sealing ring out of the bore with a angled wire.

Scheme 29

Note. The sealing ring of the guide tube is to be replaced.

1. Replace sealing ring and push until the stop using some grease on the guide tube -arrow-. Remove the dipstick for assembly from the guide tube. (Scheme 29)

Note. Illuminate the installation location well for assembling the guide tube.

2. Insert guide tube in the bore of the cylinder block. Align the guide tube and position fastening screw to intake-air distributor. Tighten fastening screw. --> Tightening torque: 6 ftlb.

1. Check oil level with dipstick and compare to prepared sketch (used to check if the guide tube was correctly mounted in the cylinder block).

2. Fit cable connector again.

3. Position sheetmetal holder in the installation position and fasten. --> Tightening torque: 6 ftlb.

Scheme 30

4. Press design cover on the engine again.

Preliminary work

1. Remove oil pan. > 175021 Removing oil pan - chapter on "Removing"

Scheme 31

Note. The oil pump must not be disassembled and reassembled! When carrying out work on the oil circuit, it must be ensured that no dirt gets into the engine!

Note. The oil pump can be replaced while installed.

Scheme 32

1 - Rear intake pipe

2 - Fastening screw, M6 x 25

3 - Front intake pipe

4 - Fastening screw M6 x 25

5 - Pin

6 - Tensioning rail

7 - Mounting chain case cover

8 - Fastening screw M5 x 20

9 - Guide rail

10 - When reusing drive chain, mark running direction.

11 - Drive wheel on the drive chain, pay attention to the feather key

Scheme 33

1. Unscrew chain tensioner of timing chain.

Scheme 34

2. Unscrew the 4 fastening screws M6 x 25 of the oil suction pipe on the lower section of the crankcase.

Scheme 35

3. Unscrew oil return line from the oil pump.

Scheme 36

4. Remove the oil pump timing chain cover. To do this, unscrew the 2 fastening screws M5 x 25.

Scheme 37

5. Release the 3 fastening screws M8 x 50.

Scheme 38

6. Tilt the oil pump forwards.

Scheme 39

7. Push the tensioning rail for the oil pump drive aside with a finger. At the same time, raise the oil pump slightly and tilt forwards.

8. Take the oil pump drive chain off the oil pump sprocket and remove the oil pump.

9. Unscrew the oil suction snorkel from the oil pump.

Installing oil pump

Note. In order to make it easier to install the oil suction pumps in the Cayenne Turbo (M48/50), it should be ensured that the driving slits on the chain sprocket are as horizontal as possible.

1. Position the oil pump slanting forwards on the lower section of the crankcase. At the same time, put the drive chain over the chain sprocket.

2. Tighten the 3 fastening screws. --> Tightening torque: 17 ftlb.

> Ensure that the drive chain is tense!

3. Check that the tensioning rail is in the correct position. To do this, use a finger to push the tensioning rail away slightly from the chain. When doing this, the tensioning rail must be under pressure and holding the chain under tension.

4. Mount the plastic cover of the chain sprocket. Tighten the two fastening screws. --> Tightening torque: 4.2 ftlb.

5. Secure the oil return line. Tighten fastening screw. --> Tightening torque: 7.5 ftlb.

6. Attach the four fastening screws for the oil suction tube to the lower part of the crankshaft housing. --> Tightening torque: 9.5 ftlb.

7. Fit tensioner for the timing chain. For tightening torque, refer to 15 36 19 Removing and installing chain tensioner - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

1. Check that the timing chain has not jumped over. To do this, turn the engine by two turns at the crankshaft. Make sure you can turn the engine without any mechanical resistance. Otherwise, set the timing. Refer to 15 05 16 Adjusting the timings for the camshafts - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

2. Reinsert the cleaned oil pan. > 175023 Installing oil pan (includes sealing) - chapter on "Installing" .

Scheme 40

1- - Drive shaft for oil pump drive; component is symmetrical, thus it is not possible to install incorrectly. (Scheme 40)

2- - Oil pump. (Scheme 40)

3- - --> Tightening torque: 17 ftlb. (Scheme 40)

4- - Gear wheels; tooth flank play: 0.20 mm; axial flank play: 0.10 mm. (Scheme 40)

5- - --> Opening pressure: 5.5 bar +/-0.2 bar; clean intake strainer. (Scheme 40)

6- - --> Tightening torque: 6 ftlb.; with screw locking agent medium-tight. (Scheme 40)

7- - Oil pressure pipe; insert with sealant. (Scheme 40)

8- - --> Tightening torque: 6 ftlb. (Scheme 40)

9- - Sealing ring; replace if damaged. (Scheme 40)

Remove oil pan. > 175019 Removing and installing oil pan - chapter on "Removing"

Removing oil pump

To remove the oil pump, the engine must be removed or supported on the body so that the engine carrier can be removed.

Scheme 41

> Secure and carefully remove the shaft by hand when working over your head.

1. Loosen the 2 fastening screws -1- on the oil pipe. Then loosen the 2 fastening screws -2- on the oil pump. Remove pump. (Scheme 41)

Scheme 42

2. Remove drive shaft.

Note. Seals must always be replaced.

1. Insert drive shaft for oil pump into the cylinder block. When doing so, make sure that the two plastic washers are in place.

2. Fit new seal under the intake manifold.

3. Position oil pump on cylinder block and screw in the 2 fastening screws -2-. Then fit a new seal under the oil tube. Insert the fastening screws -1- with screw locking agent and tighten. --> Tightening torque: 6 ftlb. Then tighten the fastening screws of the oil pump. --> Tightening torque: 17 ftlb. see scheme 85

Install oil pan. > 175019 Removing and installing oil pan - chapter on "Installing"

1- - --> Tightening torque: 6 ftlb. see scheme 86

2- - Guide tube for oil dipstick. see scheme 86

3- - Oil dipstick. see scheme 86

4- - Oil check valve, pay attention to direction of installation. see scheme 86

5- - Knock sensor; right with and left without cable. see scheme 86

6- - --> Tightening torque: 15 ftlb.. see scheme 86

7- - --> Tightening torque: 7.5 ftlb.. see scheme 86

8- - Cover for oil pump drive. see scheme 86

9- - O-ring; replace. see scheme 86

10- - Oil pump drive. see scheme 86

11- - Crankcase. see scheme 86

12- - Intermediate shaft. see scheme 86

13- - Thrust washer. see scheme 86

14- - --> Tightening torque: 7.5 ftlb., use impact bolter as needed; insert screws with screw locking agent. see scheme 86

15- - Drive shaft for oil pump; pay attention to the assembly of plastic washer. see scheme 86

16- - Crankshaft reference mark sender. see scheme 86

17- - Oil pump, observe tightening sequence. see scheme 86

18- - --> Tightening torque: 17 ftlb. see scheme 86

19- - --> Tightening torque: 6 ftlb. see scheme 86

20- - Replacing --> Tightening torque: 22 ftlb.; see scheme 86

21- - Oil pan see scheme 86

22- - Oil level sensor. see scheme 86

23- - Sealing ring; replace. see scheme 86

24- - --> Tightening torque: 9 ftlb. see scheme 86

25- - Sealing ring; replace. see scheme 86

26- - Engine support arm/oil filter housing. see scheme 86

27- - --> Tightening torque: 15 ftlb. see scheme 86

28- - To thermostat; replace O-ring. see scheme 86

29- - --> Tightening torque: 19 ftlb. see scheme 86

30- - --> Tightening torque: 19 ftlb. see scheme 86

31- - Secondary unit holder. see scheme 86

32- - Coolant pipe; replace O-ring. see scheme 86

33- - Knock sensor (without cable). see scheme 86

34- - Torsional vibration damper. see scheme 86

35- - --> Initial tightening: 74 ftlb. --> Final tightening: 90 °; replace screw. see scheme 86

1- - Drive shaft for oil pump drive; component is symmetrical, thus it is not possible to install incorrectly. see scheme 87

2- - Oil pump. see scheme 87

3- - --> Tightening torque: 17 ftlb.. see scheme 87

4- - Gear wheels; tooth flank play: 0.20 mm; axial flank play: 0.10 mm. see scheme 87

5- - --> Opening pressure: 5.5 bar +/-0.2 bar; clean intake strainer. see scheme 87

6- - --> Tightening torque: 6 ftlb.; with screw locking agent medium-tight. see scheme 87

7- - Oil pressure pipe; insert with sealant. see scheme 87

8- - --> Tightening torque: 6 ftlb.. see scheme 87

9- - Sealing ring; replace if damaged. see scheme 87

Removing oil pump drive

Note. Please read the most important working regulations and warning notes! --> 10 The most important working regulations and warning notes. The components of the oil pump drive must be handled carefully. Set down the disassembled components of the oil pump drive on a clean surface. The oil pump drive should be examined if the oil pressure is low. The shafts and transmission parts must be visually inspected for missing teeth and wear.

Remove oil pump drive at the top

1. Remove rear exhaust manifold for cyl. 4, 5 and 6. For details, refer to 26 01 19 Removing and installing exhaust system - as of MY 2003 (All Models) .

Scheme 43

2. Remove fastening screws of the oil pump drive cover. Carefully lever off the oil pump drive cover with a small screwdriver -Arrow-. (Scheme 43)

Scheme 44

3. Remove oil pump drive cover --> Removing oil pump drive cover. Check sealing ring and replace if necessary. (Scheme 44)

Scheme 45

4. Pull the oil pump drive from the cylinder block with a rotary movement --> Oil pump drive. (Scheme 45)

Scheme 46

5. Using a suitable tool (e. g. pointed-nose pliers, magnet), pull the drive shaft of the oil pump from the cylinder block --> Drive shaft of oil pump. (Scheme 46)

Remove oil pump drive at rear

Note. If you now want to take out the intermediate shaft, you will have to remove the engine Refer to 10 01 19 Removing and installing V6 3.2 l engine - as of MY 2004 (Cayenne TIP, Cayenne MAN) . and the timing chains. Refer to 15 35 21 Removing timing chains - as of MY 2004 (Cayenne TIP, Cayenne MAN) .. The fastening screws of the intermediate shaft thrust plate will probably be destroyed during disassembly as they are bonded in.

Scheme 47

6. Remove fastening screws of the intermediate shaft thrust plate --> Thrust plate for intermediate shaft. Remove thrust plate. (Scheme 47)

Scheme 48

7. Carefully pull intermediate shaft from the cylinder block --> Intermediate shaft. (Scheme 48)

Scheme 49

Component arrangement --> Component arrangement for oil pump drive. (Scheme 49)

Install oil pump drive at rear

1. Coat the intermediate shaft with engine oil and carefully guide it into the cylinder block --> Intermediate shaft. see scheme 95

2. Oil the thrust plate and locate in the installation position (fits in only one position because of the bores).

3. Lightly coat four new fastening screws with medium-tight thread locking compound. Fit the thrust plate fastening screws --> Thrust plate with fastening screws. --> Tightening torque: 10 (7.5 ftlb.) Nm see scheme 96

4. Install timing chains. Refer to 15 35 23 Installing timing chains - as of MY 2004 (Cayenne TIP, Cayenne MAN) ..

5. Install engine. Refer to 10 01 19 Removing and installing V6 3.2 l engine - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

Install oil pump drive at top

6. Insert oil pump drive shaft into the bore. The drive shaft is symmetrical and cannot be incorrectly installed.

7. Using rotary movements, engage oil pump drive into the teeth of the intermediate shaft and slide it onto the drive shaft --> Oil pump drive. see scheme 97

8. Check seal of the oil pump drive cover and replace if necessary. Oil the cover and fit with two fastening screws . --> Tightening torque: 8 (6 ftlb.) Nm

9. Fit rear exhaust manifold for cyl. 4, 5 and 6. For details, refer to 26 10 19 Removing and installing exhaust manifold - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

1- - Drive shaft for oil pump drive; component is symmetrical, thus it is not possible to install incorrectly. see scheme 99

2- - Oil pump. see scheme 99

3- - --> Tightening torque: 17 ftlb. see scheme 99

4- - Gear wheels; tooth flank play: 0.20 mm; axial flank play: 0.10 mm. see scheme 99

5- - --> Opening pressure: 5.5 bar +/-0.2 bar; clean intake strainer. see scheme 99

6- - --> Tightening torque: 6 ftlb.; with screw locking agent medium-tight. see scheme 99

7- - Oil pressure pipe; insert with sealant. see scheme 99

8- - --> Tightening torque: 6 ftlb. see scheme 99

9- - Sealing ring; replace if damaged. see scheme 99

Removing and installing oil pressure control valve

Note. The complete oil pump is replaced if there is a defect in the oil pressure control valve.

1. Replace oil pump, see > 172019 Removing and installing oil pump .

Disassembling oil pressure control valve

Note. The description only applies when installed.

Scheme 50

1 - Valve body; pay attention to the installation position

2 - Spring

3 - Sealing ring; replace

4 - M22 screw plug

1. Remove oil pan. > 175021 Removing oil pan - chapter on "Removing"

Scheme 51

Note. When unscrewing the oil pressure control valve, ensure that the screw plug is under spring pressure. Do not let the valve body fall. Note the installation location of the valve body. More oil can leak out from the opening.

2. Unscrew screw plug of oil pressure control valve (a/f 19) -arrow-. (Scheme 51)

Scheme 52

3. Remove the four components of the oil pressure control valve --> Valve body. Always replace sealing ring. (Scheme 52)

Assembling oil pressure control valve

Note. Ensure that the installation opening of the oil pump housing is clean! Note the installation location of the valve body. Always replace sealing ring.

1. Guide in the valve body with the bores into the oil pump housing first --> Valve body. see scheme 104

Note. Screw in the screw plug by hand against the spring pressure.

2. Prevent the valve body from falling and screw in the spring, new sealing ring and screw plug.

3. Tighten screw plug (a/f 19) -arrow-. --> Tightening torque: 33 ftlb. see scheme 105

4. Install oil pan. > 175023 Oil pan installed (includes sealing) - chapter on "Installing"

Removing and installing oil filter

> Do not consume food or drink while working (danger of mixing).

> If swallowed, observe the warning information on the containers, contact a doctor if necessary and show the information on the containers.

> Engine oil and components of the oil circuit can become very hot!

> Allow engine and components to cool down.

> Avoid contact with the skin and eyes.

> Wear suitable protective clothing.

1. Remove engine guard. Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

2. Loosen oil filter with special tool oil filter spanner P 9204 and unscrew it.

3. Remove the oil filter housing vertically downwards. Drain the remaining oil into a disposal container.

4. Remove the filter element. Remove the filter downwards and dispose of in accordance with legal requirements.

Note. Do not remove the O-ring with a sharp object. The oil filter housing contains a cutout via which the O-ring can be removed.

5. Clean the oil filter housing and replace the O-ring seal. Clean the oil filter housing thoroughly inside and outside and replace the O-ring. Carefully lever off the O-ring. The oil filter housing must not be damaged during this procedure.

6. Install the filter element.

Note. Lightly oil the O-ring when installing the oil filter housing.

7. Install the oil filter housing and tighten using special tool oil filter spanner P 9204 . --> Tightening torque: 19 ftlb. Lightly oil the O-ring when doing this.

8. Fit engine guard. Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

9. Fill engine oil, start engine and check oil level. > 170117 Engine oil and oil filter change - chapter on "Checking"

> Let the oil cool down

> Wear personal protective gear (goggles, gloves)

1. Jack up the vehicle at the points provided. --> 03 Entire vehicle -General

2. Remove the underbody panel. Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

3. Loosen oil filter cover with a socket (a/f 36).

4. Remove the oil filter housing vertically downwards. Drain the remaining oil into a disposal container.

5. Remove the filter element. Remove the filter downwards and dispose of in accordance with legal requirements.

Note. Do not remove the O-ring with a sharp object. The oil filter housing contains a cutout via which the O-ring can be removed.

6. Clean the oil filter housing and replace the O-ring seal. Clean the oil filter housing thoroughly inside and outside and replace the O-ring. Carefully lever off the O-ring. The oil filter housing must not be damaged during this procedure.

7. Insert filter element in the housing.

Note. Lightly oil the O-ring when installing the oil filter housing.

8. Install oil-filter housing. --> Tightening torque: 25 (19 ftlb.) Nm Lightly oil the O-ring when doing this.

9. Correct engine oil level. First fill in 0.5 litres of engine oil and check it again after starting the engine.

10. Start engine and check oil level. > 170117 Engine oil and oil filter change - section on "Checking"

11. Fit the underbody panel. Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

The vehicle must stand horizontally. The engine must be switched off and at operating temperature. Before measuring, allow engine oil to flow back into the oil pan for approximately 3 minutes.

1. Pull out oil dipstick and wipe it off with a clean, lint-free cloth. Insert dipstick again fully, pull it out again, and read off the oil level. Correct engine-oil level if necessary.

The oil level on the oil dipstick must never be below the MIN mark or above the MAX mark.

The difference quantity between the marks -1 and 2- is --> Filling capacity: 1.5 liter. see scheme 111

Note. After changing the oil, the oil level must be checked using the dipstick. The engine must have reached its operating temperature.

1. 1 - max. marking
2. 2 - min. marking
3. a - Area above cross-hatched area up to max. mark: no more oil must be added.
4. b - Oil level within cross-hatched area: additional engine oil can be added.
5. c - Area from min. mark to cross-hatched area: refill engine oil up to the cross-hatched area.

1. Remove engine guard . Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

2. Support the engine on the body. --> 10 Supporting the engine on the body

3. Remove the front-axle carrier. Refer to 40 06 19 Removing and installing front-axle carrier - as of MY 2003 (Cayenne TIP, Cayenne MAN) .

4. Remove engine carrier. Refer to 10 30 19 Removing and installing engine carrier - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

Note. If the oil is to be used again, it must be collected in a clean container.

5. Loosen oil drain plug and collect the engine oil in a container. Dispose of waste oil in accordance with legal requirements.

6. Replace oil drain plug. --> Tightening torque: 22 ftlb.

1- - --> Tightening torque: 6 ftlb. see scheme 115

2- - Guide tube for oil dipstick. see scheme 115

3- - Oil dipstick. see scheme 115

4- - Oil check valve, pay attention to direction of installation. see scheme 115

5- - Knock sensor; right with and left without cable. see scheme 115

6- - --> Tightening torque: 15 ftlb.. see scheme 115

7- - --> Tightening torque: 7.5 ftlb.. see scheme 115

8- - Cover for oil pump drive. see scheme 115

9- - O-ring; replace. see scheme 115

10- - Oil pump drive. see scheme 115

11- - Crankcase. see scheme 115

12- - Intermediate shaft. see scheme 115

13- - Thrust washer. see scheme 115

14- - --> Tightening torque: 7.5 ftlb., use impact bolter as needed; insert screws with screw locking agent. see scheme 115

15- - Drive shaft for oil pump; pay attention to the assembly of plastic washer. see scheme 115

16- - Crankshaft reference mark sender. see scheme 115

17- - Oil pump, observe tightening sequence. see scheme 115

18- - --> Tightening torque: 17 ftlb. see scheme 115

19- - --> Tightening torque: 6 ftlb. see scheme 115

20- - Replacing --> Tightening torque: 22 ftlb.; see scheme 115

21- - Oil pan. see scheme 115

22- - Oil level sensor. see scheme 115

23- - Sealing ring; replace. see scheme 115

24- - --> Tightening torque: 9 ftlb. see scheme 115

25- - Sealing ring; replace. see scheme 115

26- - Engine support arm/oil filter housing. see scheme 115

27- - --> Tightening torque: 15 ftlb. see scheme 115

28- - To thermostat; replace O-ring. see scheme 115

29- - --> Tightening torque: 19 ftlb. see scheme 115

30- - --> Tightening torque: 19 ftlb. see scheme 115

31- - Secondary unit holder. see scheme 115

32- - Coolant pipe; replace O-ring. see scheme 115

33- - Knock sensor (without cable). see scheme 115

34- - Torsional vibration damper. see scheme 115

35- - --> Initial tightening: 74 ftlb. --> Final tightening: 90 °; replace screw. see scheme 115

Removing the oil pan

> Do not consume food or drink while working (danger of mixing).

> If swallowed, observe the warning information on the containers, contact a doctor if necessary and show the information on the containers.

> Engine oil and components of the oil circuit can become very hot!

> Allow engine and components to cool down.

> Avoid contact with the skin and eyes.

> Wear suitable protective clothing.

> Do not pour engine oil over very hot components (e. g. turbocharger).

> Never place cloths soaked with oil on hot engine components.

> In case of fire, use CO 2 or dry powder fire extinguishers.

1. Disconnect the electric connector on the oil level sensor.

2. Loosen fastening screws on oil pan. When doing so, start at the front (reverse the sequence shown).

Scheme 53

3. Remove oil pan. If the oil pan is stuck, loosen it by gently tapping with a plastic hammer.

Scheme 54

4. Remove any residual sealant on the crankcase with a plastic wedge.

Scheme 55

5. Clean the oil pan thoroughly. Remove silicone residue. A special plastic brush for drills can be used for this purpose.

Scheme 56

> The bead of sealing compound must not be thicker than 2-3 mm, as otherwise excess sealing compound will enter the oil pan and can clog the strainer in the intake pipe of the oil pump.

1. Apply a bead of silicone sealant 000.043.300.39 all around the cleaned and degreased oil pan. Run the bead of sealant past the screw holes on the inside.

2. Press the oil pan against the crankcase. Then tighten the fastening screws in the sequence shown. --> Tightening torque: 12 (9 ftlb.) Nm

Note. After assembly of oil pan, the sealing compound must dry for approx. 30 min. Afterwards, fill engine oil.

3. Fill and check engine oil of the stipulated viscosity and quality. > 170117 Engine oil and oil filter change - chapter on "Checking"

1. Install engine carrier . Refer to 10 30 19 Removing and installing engine carrier - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

2. Install the front-axle carrier. Refer to 40 06 19 Removing and installing front-axle carrier - as of MY 2003 (Cayenne TIP, Cayenne MAN) .

3. Take off the engine carrier.

4. Fit engine guard. Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

Designation Type Number Explanation Workshop equipment description special tool special tool 62-1 Dial gauge commercially available tool NR.136 Gauge holder special tool P 207 spacer ring special tool P 9597/1 Assembly driver special tool P 9691

1. Remove engine guard . Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

Scheme 57

2. Drain coolant circuit. Refer to 19 38 17 Draining and filling in coolant (includes bleeding) - as of MY 2003 (All Models) .

Note. If the oil does not yet have to be replaced, collect it in a clean container and use again.

3. Drain oil. To do this, loosen and unscrew the two oil drain plugs.

4. Clean oil drain plugs and screw in with a new sealing ring. --> Tightening torque: 37 ftlb.

Scheme 58

Scheme 59

Note. If the transmission is still connected, the 2 lower transmission screws must be removed first.

5. Support the engine on the body. --> 10 Supporting the engine on the body

6. Remove the front-axle carrier. Refer to 40 06 19 Removing and installing front-axle carrier - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo) . Refer to 40 06 19 Removing and installing front-axle carrier - as of MY 2003 (Cayenne Turbo S, Cayenne S TIO Titan) .

7. Remove engine carrier. Refer to 10 30 19 Removing and installing engine carrier - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

8. Loosen lock carrier (service position). Refer to 50 38 19 Removing and installing lock carrier - as of MY 2003 (All Models) .

9. Remove oil dipstick. > 171719 Removing and installing guide for oil dipstick - chapter on "Removing"

10. Disconnect oil level sensor. To do this, pull off the connector and take the cable out of the fixing clip on the oil pan.

Scheme 60

11. Remove pulley from the crankshaft. Refer to 13 76 19 Removing and installing crankshaft belt pulley - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .The central screw must not be reused.

Scheme 61

12. Remove oil-filter console. To do this, unscrew the 4 fastening screws (3x M 8 x 70 and 1x M 8 x 45). Pull oil-filter console off forwards. Further details: > 176721 Removing bracket for oil-water heat exchanger - chapter on "Removing"

Scheme 62

Scheme 63

1 - Oil pan; plastic feeder must not be removed.

2 - Sealant application; remove silicone residues; no more than 5 minutes should pass between the time application begins and screwing. Do not smear the sealing bead when putting on the oil pan.

3 - Fastening screw M6 x 25

4 - Sealing ring 18 x 24; replace

5 - Drain plug; clean

6 - Oil level sensor (TOC); replace seal

7 - Fastening screw M6 x 25

8 - O-ring, 11.2 x 2.65, replace

9 - Oil dipstick

10 - Fastening screw with coned half dog M6 x 16

11 - O-ring, 23 x 3, replace, grease before assembly

12 - Socket; disassembly with spacer ring P 9597/1 and internal puller; assembly with assembly driver P 9691

13 - O-ring, 25; replace, grease before assembly

14 - Moulded seal; replace

Note. The description only applies when installed. If the oil pan is removed when the transmission is disconnected, the oil pan must be aligned with the aid of a dial gauge (see chapter Aligning oil pan with a dial gauge). To remove the oil pan, it is not necessary to remove the timing case cover. If the timing case cover is removed while carrying out work later, the oil pan must be removed with it.

Scheme 64

Scheme 65

Note. In the case of the Cayenne Turbo, the oil suction pump of the turbocharger must also be removed. To do this, release screws -1 to 6- one after the other. (Scheme 65)

1. Remove oil transfer sleeve. To do this, insert internal puller into the opening and tighten. While doing this, counter the puller with an open-ended wrench.

Scheme 66

2. Subsequently, tighten the nut on the puller until the sleeve can be pulled out.

3. Release foot of timing-case cover. Unscrew the 5 lower fastening screws M 6 x 25 with an E10 wrench.

4. Release oil pan. To do this, unscrew the 24 fastening screws M 6 x 20 with an E10 key.

Note. If the oil pan is stuck, loosen it by gently tapping with a plastic hammer.

5. Remove oil pan. Remove the oil pan from the crankshaft. At the same time, swing downwards and forwards.

6. Clean sealing faces. Brush off rest of the sealant with a plastic brush and then degrease the sealing face.

Note. The black plastic feeder must not be taken out of the oil pan. If this component has been damaged or removed, the entire oil pan must be removed.

Designation Type Number Explanation Workshop equipment description special tool special tool 62-1 Dial gauge commercially available tool NR.136 Gauge holder special tool P 207 Assembly driver special tool P 9691

Installing oil pan

> 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.

Scheme 67

> 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 Dreibond 2210 (000 043 204 58, status 03/06) 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. (Scheme 67)

Scheme 68

Note. If the transmission is removed, the oil pan must be aligned with the aid of a dial gauge. > 175023 Oil pan installed (includes sealing) - chapter on "Fitting"

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 ftlb.) Nm

Scheme 69

7. Screw down the timing case cover. Tighten the 5 fastening screws M 6 x 25 with an E10 wrench. --> Tightening torque: 10 (7.5 ftlb.) Nm

Scheme 70

Note. In the Cayenne Turbo (M48/50), the oil suction pump of the turbocharger must also be fitted. Further details: --> 218023 23 Installing oil suction pump for turbocharger - chapter on "Installing"

8. Install oil transfer flange. Replace and grease the O-rings of the flange. Then place the connection piece on the assembly driver P 9691 in such a way that the slightly thicker end points forwards.

Scheme 71

9. Insert the socket with the thicker end into the oil pan and push the assembly mandrel all the way by knocking it slightly.

Fitting the oil pan with a dial gauge

> 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.

Scheme 72

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.

Scheme 73

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.

Scheme 74

> 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 ftlb. The check the position of the oil pan again with the dial gauge.

6. Tightening the remaining fastening screws. --> Tightening torque: 7.5 ftlb.

1. Tighten the 2 fastening screws of the transmission bell housing. --> Tightening torque: 59 ftlb.

Scheme 75

2. Install bracket for oil-water heat exchanger. > 176723 Installing bracket for oil-water heat exchanger

Scheme 76

3. Install crankshaft pulley. Refer to 13 76 19 Removing and installing crankshaft belt pulley - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

Scheme 77

4. Install engine carrier. Refer to 10 30 19 Removing and installing engine carrier - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

5. Install the suspension subframe (front-axle carrier). Refer to 40 06 19 Removing and installing front-axle carrier - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo) . Refer to 40 06 19 Removing and installing front-axle carrier - as of MY 2003 (Cayenne Turbo S, Cayenne S TIO Titan) .

6. Remove engine bridge. Refer to 10 01 IN Supporting the engine on the body - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

7. Install oil dipstick. > 171719 Removing and installing guide for oil dipstick - chapter on "Installing"

8. Tighten lock carrier. Refer to 50 38 19 Removing and installing lock carrier - as of MY 2003 (All Models) .

9. Fill in engine oil.

10. Bleed and fill the cooling circuit. Refer to 19 38 17 Draining and filling in coolant (includes bleeding) - as of MY 2003 (All Models) .

11. Carry out a check. After a test drive, check to ensure that the oil pan is not leaking. Then check the oil level.

1. Drain cooling system. Refer to 19 38 17 Draining and filling in coolant (includes bleeding) - as of MY 2003 (All Models) .

2. Loosen lock carrier. Refer to 50 38 09 Detaching and fastening lock mount (service position) - as of MY 2003 (All Models) .

Note. The illustrations apply to the Cayenne Turbo (M48/50).

Scheme 78

Scheme 79

1 - Oil transfer flange

2 - 5 O-rings

3 - 2 fastening screws

4 - Length-compensating element

5 - Fastening screw, M8 x 50

6 - 2 fastening screws, M8 x 70

Scheme 80

1 - Oil filter bracket

2 - 6 lens-head screws M6 x 20 (only loosen the screws if absolutely necessary)

3 - Lids

4 - Seal

5 - 2 seals

6 - O-ring

7 - Oil filter element

8 - Oil filter housing

9 - 4 oval-head screws, M6 x 20

10 - Oil-water heat exchanger

11 - Screw plug, M26 x 1.5

12 - Sealing ring, A26 x 31

13 - Oil pressure switch (hot oil can leak out while removing)

Removing oil-water heat exchanger

Note. The illustrations apply to the Cayenne Turbo (M48/50). If a fault in the oil-water heat exchanger has caused oil and coolant to mix, the oil circuit should be checked to see if there is coolant in the engine or, if necessary, be cleaned. If oil has entered the coolant circuit, this is to be cleaned after repair . Refer to 19 01 29 Cooling system cleaned (after oil/coolant mixing) - as of MY 2003 (All Models) .

Scheme 81

1. Release coolant hoses from oil/water heat exchanger. To do this, release the two spring-band clamps and pull the lines upwards.

2. Release the 4 fastening screws on the heat exchanger and pull the heat exchanger down and off. During this process, both engine oil and coolant will leak out. Collect leaking liquids and dispose of in accordance with legal requirements.

Ol/Wasser-Warmetauscher einbauen

Note. The illustrations apply to the Cayenne Turbo (M48/50). If a fault in the oil-water heat exchanger has caused oil and coolant to mix, the oil circuit should be checked to see if there is coolant in the engine or, if necessary, be cleaned. If oil has entered the coolant circuit, this is to be cleaned after repair . Refer to 19 01 29 Cooling system cleaned (after oil/coolant mixing) - as of MY 2003 (All Models) .

1. Replace the 2 sealing rings of the oil circuit. When doing this, pay attention to the lugs on the sealing ring. Subsequently, push the oil-water heat exchanger from underneath against the bracket and tighten the 4 fastening screws. --> Tightening torque: 7.5 ftlb.

2. Push the coolant hoses onto the connecting flanges and secure with the spring-band clamps.

1. Fasten lock mount. Refer to 50 38 09 Detaching and fastening lock mount (service position) - as of MY 2003 (All Models) .

Scheme 82

2. Fit the sheetmetal brace under the radiator. To do this, tighten the four fastening screws. --> Tightening torque: 17 ftlb.

Scheme 83

3. Tighten the front spoiler on the underside.

4. Fit engine guard. Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

5. Fill cooling system. Refer to 19 38 17 Draining and filling in coolant (includes bleeding) - as of MY 2003 (All Models) .

6. Check oil level and adjust.

1. Pull the design cover straight up and off.

2. Remove engine compartment cover at the left. Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) ..

3. Remove air cleaner housing lid and air-cleaner element. Refer to 24 25 19 Removing and installing air cleaner housing - as of MY 2004 (Cayenne TIP, Cayenne MAN) ..

4. Remove engine guard. Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) ..

5. Drain coolant. Refer to 19 38 17 Draining and filling in coolant (includes bleeding) - as of MY 2003 (All Models) ..

1- - Oil filter housing/engine support arm. see scheme 163

2- - Sealing ring. see scheme 163

3- - Sealing ring. see scheme 163

4- - Oil cooler. see scheme 163

5- - --> Tightening torque: 19 ftlb. see scheme 163

6- - --> Tightening torque: 15 ftlb. see scheme 163

7- - Oil filter element. see scheme 163

8- - --> Tightening torque: 19 ftlb. see scheme 163

9- - --> Tightening torque: 7.5 ftlb. see scheme 163

10- - --> Tightening torque: 17 ftlb. see scheme 163

Removing oil/water heat exchanger (oil cooler)

> Allow engine to cool down.

> Wear personal protective gear (e. g. safety goggles, gloves).

1. Remove two fastening nuts for the hose holder and press the holder aside -arrows-. see scheme 164

Scheme 84

Note. When opening the oil/water heat exchanger, collect emerging fuel (engine oil and coolant) with a pan and cloth.

2. Remove the two coolant hoses from the oil/water heat exchanger -arrow-. (Scheme 84)

3. Grip the oil cooler cover at the hexagon with a suitable tool and loosen carefully. Take oil cooler cover (banjo bolt) out of the oil/water heat exchanger and remove together with the oil/water heat exchanger.

4. Observe installation position of both sealing rings. Sealing rings must be replaced.

5. Clean sealing faces.

Installing oil/water heat exchanger (oil cooler)

Note. Sealing rings must be replaced.

1. Place the two sealing rings in installation position.

2. Position the oil/water heat exchanger on the oil-filter housing/assembly mount and insert the oil cooler cover through. Screw the oil cooler cover (banjo bolt) on hand-tight.

3. Tighten the oil cooler cover (banjo bolt). --> Tightening torque: 19 ftlb. .

4. Fit the two coolant hoses on the oil/water heat exchanger -arrow-. see scheme 166

5. Place holder in installation position. Fit fastening nuts for the hose holder -arrows-. --> Tightening torque: 6 ftlb.. see scheme 167

1. Install engine guard. Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) ..

2. Fill coolant and bleed system. Refer to 19 38 17 Draining and filling in coolant (includes bleeding) - as of MY 2003 (All Models) ..

3. Fit air cleaner housing lid and air-cleaner element. Refer to 24 25 19 Removing and installing air cleaner housing - as of MY 2004 (Cayenne TIP, Cayenne MAN) ..

4. Fit engine compartment cover at the left. Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) ..

5. Fit the design cover.

6. Check engine-oil level and correct if necessary.

1. Drain cooling system. Refer to 19 38 17 Draining and filling in coolant (includes bleeding) - as of MY 2003 (All Models) .

2. Loosen lock carrier. Refer to 50 38 09 Detaching and fastening lock mount (service position) - as of MY 2003 (All Models) .

3. Undo the 2 oil drain plugs and collect engine oil in a disposal container.

4. Clean oil drain plug and screw in with new aluminum sealing ring. --> Tightening torque: 37 ftlb.

Note. The illustrations apply to the Cayenne Turbo (M48/50).

1 - Oil transfer flange

2 - 5 O-rings

3 - 2 fastening screws

4 - Length-compensating element

5 - Fastening screw, M8 x 50

6 - 2 fastening screws, M8 x 70

1 - Oil filter bracket

2 - 6 lens-head screws M6 x 20 (only loosen the screws if absolutely necessary)

3 - Lids

4 - Seal

5 - 2 seals

6 - O-ring

7 - Oil filter element

8 - Oil filter housing

9 - 4 oval-head screws, M6 x 20

10 - Oil-water heat exchanger

11 - Screw plug, M26 x 1.5

12 - Sealing ring, A26 x 31

13 - Oil pressure switch (hot oil can leak out while removing)

Scheme 85

Note. The following step must only be performed for the M48/50 engine.

1. Undo both oil return lines from the turbochargers to the oil filter bracket. Pull the connections slightly out of the bracket.

2. Release coolant lines from oil-water heat exchanger. To do this, release the two spring-band clamps and pull the lines upwards.

3. Unscrew the 3 fastening screws on the bracket.

> Proceed carefully when pulling out the bracket.

> Collect escaping fluids.

4. Pull off the bracket from the engine in a forward direction. If the bracket is stuck very firmly, lever it off very carefully using a suitable implement.

Note. The illustrations apply to the Cayenne Turbo (M48/50).

1 - Oil transfer flange

2 - 5 O-rings

3 - 2 fastening screws

4 - Length-compensating element

5 - Fastening screw, M8 x 50

6 - 2 fastening screws, M8 x 70

1 - Oil filter bracket

2 - 6 lens-head screws M6 x 20 (only loosen the screws if absolutely necessary)

3 - Lids

4 - Seal

5 - 2 seals

6 - O-ring

7 - Oil filter element

8 - Oil filter housing

9 - 4 oval-head screws, M6 x 20

10 - Oil-water heat exchanger

11 - Screw plug, M26 x 1.5

12 - Sealing ring, A26 x 31

13 - Oil pressure switch (hot oil can leak out while removing)

Installing bracket for oil-water heat exchanger

1. Replace both O-rings in the flange. To do this, carefully lever out the O-rings with a non-abrasive implement (plastic wedge) and replace them with new ones.

2. Replace the O-rings on the oil transfer flange. To do this, lever off the O-rings with a non-abrasive implement (plastic wedge) and replace them with new ones.

> Before installing the bracket, screw the compensating element in completely.

3. Screw in length-compensating element. To do this, insert an Allen key through the screw hole into the bracket and turn the key anti-clockwise until the compensating element touches the bracket.

4. Apply a thin coat of engine oil to the two transfer flanges and position the bracket on the engine. Then push the bracket hard against the engine until the fastening screws can be put into place.

Scheme 86

5. The sleeve -1- is screwed in. Position the two fastening screws -arrows- and tighten until hand-tight. (Scheme 86)

Scheme 87

6. Adjust compensating element. To do this, insert an Allen key -picture- through the screw hole into the bracket and turn the key clockwise until the compensating element touches the engine. --> Tightening torque: 1.5 ftlb. +2 ftlb. (Scheme 87)

Scheme 88

7. Fit the upper fastening screw -arrow- . Insert the screw through the compensating element and tighten it. --> Tightening torque: 17 ftlb. Then tighten the 2 other fastening screws. --> Tightening torque: 17 ftlb.

8. Fit coolant lines from oil-water heat exchanger. Push both coolant lines onto the socket piece and fit the spring-band clamps using the spring-band clamp pliers.

Note. The following step must only be performed for the M48/50 (V8 Turbo) engine.

9. Fit oil return lines for turbochargers. Insert the lines into the connections and align them. Then screw in the union nuts by hand and tighten them. --> Tightening torque: 26 ftlb.

1. Fasten lock mount. Refer to 50 38 09 Detaching and fastening lock mount (service position) - as of MY 2003 (All Models) .

2. Fit the support plate under the radiator. To do this, tighten the 4 fastening screws. --> Tightening torque: 17 ftlb.

3. Tighten the front apron on the underside.

4. Fit engine guard. Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

Scheme 89

5. Fill and bleed the cooling system. Refer to 19 38 17 Draining and filling in coolant (includes bleeding) - as of MY 2003 (All Models) .

6. Check oil level and adjust.

Poses Online

See also:
• 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models)
• 24 35 19 Removing and installing cowl for throttle housing (Y-shaped pipe) - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne S TIO Titan)
• 15 36 19 Removing and installing chain tensioner - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan)
• 26 01 19 Removing and installing exhaust system - as of MY 2003 (All Models)
• 40 06 19 Removing and installing front-axle carrier - as of MY 2003 (Cayenne TIP, Cayenne MAN)
• 19 38 17 Draining and filling in coolant (includes bleeding) - as of MY 2003 (All Models)
• 50 38 19 Removing and installing lock carrier - as of MY 2003 (All Models)
• 13 76 19 Removing and installing crankshaft belt pulley - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan)
• 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models)
• > 170117 Engine oil and oil filter change - chapter on "Checking"