Crankshaft, Pistons Porsche Cayenne S I

Preliminary work

1. Remove pistons. > 131019 Removing and installing pistons - "Removing"

Scheme 270

Measuring pistons

1. Clean removed pistons with solvent naphtha. To achieve an accurate result, any carbon deposits must be carefully removed, e. g. with a brass brush.

Scheme 271

2. Test piston diameter -D- at the piston shank (at 90° to the axis of the piston pins) using a micrometer (measuring range 75 - 100 mm). Measured from the lower edge of the shank, the height X -X- on the shank is 6 mm. (Scheme 271)

Scheme 272

Note. If the wear limit is exceeded, the piston must be replaced!

The maximum wear allowed on specified measuring point is 0.04 mm. If this measurement is exceeded, the piston must be replaced. The reference measurement for the piston dimensions is to be taken from the following Table.

When pistons are worn, the wear on the cylinder should also be tested (see below: "Measuring cylinder bore").

Measuring piston ring play

1. Remove crankshaft. > 134819 Removing and installing crankshaft - "Removing" chapter

2. Insert the piston ring from top to bottom at right angles to the cylinder wall, about 1.5 mm from the edge of the cylinder. To insert it, use a piston with no piston ring

Scheme 273

3. Measure the play in the ring gap with a feeler gauge. Compare the value with the Table.

4. If the measurement for the wear equals or exceeds the limit, the piston rings should be replaced. In addition, the wear on the cylinder should also be determined (see below: "Measuring cylinder bore").

Measuring piston ring height play

1. Clean removed pistons with solvent naphtha. To achieve an accurate result, any carbon deposits must be carefully removed, e. g. with a brass brush.

2. Take special care to clean the ring groove before testing

Scheme 274

3. Determine the play in height between the piston ring and the ring groove.

4. If the measurement for the wear equals or exceeds the limit, the piston rings and the corresponding piston should be replaced.

Measuring cylinder bore.

1. Prepare the cylinder bore for measuring and clean it with a cloth. Any carbon deposits should be removed using a soft brass wire brush

Scheme 275

2. Using a vernier gauge for measuring internal dimensions -1 and 2- (measuring range 50 - 100 mm) make measurements of the diagonals at three positions in transverse and longitudinal directions --> Dial gauge - 1 and internal vernier gauge - 2 inside the cylinder bore. (Scheme 275)

Scheme 276

3. The measuring device should be zero calibrated within the top 10 mm from the edge before the actual measurement is made, since in this region there will be no wear. Thereafter perform the measurement

4. If the measurement for the wear equals or exceeds the limit, the engine should be replaced.

Subsequent work

1. Install pistons. > 131019 Removing and installing pistons - "Installing" .

Tools

Scheme 277

1 - Three piston rings (lowest is the oil scraper ring)

2 - Piston (arrow on piston crown points in direction of travel)

3 - Two piston-pin circlips

4 - Piston pin

5 - Connecting rod and connecting-rod bearing cap

6 - Two connecting rod bolts

7 - Two bearing shells

Scheme 278

Markings on piston crown: Replacement pistons from Porsche Parts Service are only obtainable in one dimensional group 'X' and in two weight tolerances '+' and '-' . The weight tolerances are listed in the table.

1. Marking X appears as a large colored stamp in the center of the piston crown and as a small engraved feature (Scheme 278) -1-.
2. Marking + or - appears as a large colored stamp in the center of the piston crown and as a small engraved feature (Scheme 278) -2-.

Note. Pistons are installed as standard in three dimensional groups: I, X and II . Pistons are installed as standard in two weight tolerances: + and - . These data are all engraved on the piston crown. To uniquely identify a piston, it must be carefully cleaned (brass brush, ultrasonic bath). If, in spite of very thorough cleaning, the data are unreadable, the piston must be weighed together with piston rings, piston pin and the two circlips. Thorough cleaning (ultrasonic bath) is also absolutely essential to the weighing operation as otherwise the measurement result will be false.

1. A piston removed for repair is cleaned and identified. If it needs to be replaced, an X - piston with the identified weight tolerance + or - is ordered as a replacement part and installed.

Preliminary work for removing pistons

1. Remove engine. Refer to 10 01 19 Removing and installing V8 4.5 l engine - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

2. Remove cylinder head. Refer to 15 70 21 Removing cylinder head - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

3. Remove chain case cover. Refer to 15 33 21 REMOVING CHAIN CASE LID - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN) or 15 33 21 REMOVING CHAIN CASE LID - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN) .

4. Remove oil pan. Refer to 17 50 21 Removing oil pan - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

5. Remove lower section of crankcase. > Removing and installing crankshaft

Scheme 279

1. Secure crankshaft with holding bridges P 9677 at bearings 3 and 5 to prevent it from falling out.

Note. Connecting rod bolts and bearing shells must always be replaced. Turn the crankshaft so that the crank pin of the piston to be removed stands vertically upwards.

2. Remove one piston after another, mark them and place them on a clean tray. The arrow on the bottom of the piston points in the direction of travel.

3. Remove the piston of cylinder 1 by unscrewing the connecting-rod bolts.

4. Remove the connecting-rod bearing cap and place it on a clean surface.

5. Press the piston downwards out of the cylinder, for example with the handle of a hammer, and receive it with the other hand.

Scheme 280

6. Fit the connecting-rod bearing cap again immediately on the big end of the connecting-rod bearing with the bearing shells and place the entire piston on a clean surface.

7. Mark piston with No. 1 (with a felt-tip, not with a prick punch or other sharp-edged tool).

8. Remove the remaining pistons using the same procedure.

Scheme 281

Note. Note the association between the connecting-rod big end and the connecting-rod bearing cap as the cracked connecting rods only fit in one position. The retaining lugs of the connecting-rod bearing shells are always located on the same side in order to prevent the bearing shells from turning. The connecting-rod bearing cap and the big end of the connecting-rod bearing have the same connecting-rod numbers.

Scheme 282

Note. Note the association between the connecting-rod big end and the connecting-rod bearing cap as the cracked connecting rods only fit in one position. The retaining lugs of the connecting-rod bearing shells are always located on the same side in order to prevent the bearing shells from turning. The connecting-rod bearing cap and the big end of the connecting-rod bearing have the same connecting-rod numbers.

Installing pistons

Note. Connecting rod bolts and bearing shells must always be replaced. The identification of the connecting-rod bearings is located on the connecting-rod journal of the crankshaft > Removing and installing crankshaft .

Note. The pistons must already be pre-fitted (pistons, piston rings, connecting rods and fastening material) before performing the next step. > 131037 Disassembling and assembling pistons - "assembling". Install with the number on the connecting rod -A- to the exhaust side. see scheme 14 When installing the piston in the crankcase, the direction of travel arrow on the piston crown must point in the direction of travel. The code on the connecting-rod big end and connecting-rod bearing cap must be on the same side -A-. see scheme 14 The direction of travel arrow is on the same side as the connecting rod code -A- as is evident on the piston shown. This can be installed as standard on one cylinder bank side as shown, and on the other cylinder bank side, the connecting rod code is on the opposite side. However, when the pistons are fitted at a later time, it is absolutely necessary that they be aligned in the direction of travel (see the following point). Install with the number on the connecting rod -A- to the exhaust side. see scheme 15, see scheme 14. The direction of travel arrow must be pointing forwards when installed (in direction of travel).

Scheme 283

1. Turn the engine in the engine support so that the crankshaft lies at the bottom.

Scheme 284

2. Install piston. To do this, turn the crankshaft with a wrench (a/f 27) until the corresponding crank pin is pointing vertically downwards.

3. Cylinder, piston and Piston ring restraining strap for 944 - S2 and Boxster and 911 Carrera (996) NR.57 leicht einolen.

Scheme 285

4. Align piston-ring set (staggered by 120°) and compress piston rings using piston ring restraining strap for 944 - S2 and Boxster and 911 Carrera (996) NR.57. Ensure all piston rings are correctly pre-loaded by the special tool -see figure-. (Scheme 285)

5. Position piston on the cylinder from above and push it into the cylinder, using the handle of a hammer if necessary. When doing so, make sure that the direction of travel arrow is pointing forwards -see arrow (illustration shows cylinder 1)-. see scheme 19

Scheme 286

6. Push piston downwards until the connecting-rod bearing sits on the crank pin. If necessary, use the handle of a hammer to push it -see figure-. (Scheme 286)

7. Oil connecting-rod bearing shells and crank pins.

Note. The piston connecting rods are cracked and only fit in one position (in conjunction with the matching numbers). Install con-rod code towards exhaust side -A-. see scheme 21

8. Then fit connecting-rod bearing cap with bearing shell (twist locks facing each other) --> Retaining lugs for connecting-rod bearings -B and C-. The connecting rod numbers must face each other --> View of matching numbers -A-. Screw in con-rod bolts by hand. see scheme 22, see scheme 23.

9. Fit the opposite piston (cylinders 1 and 4).

10. Fit other pistons using the procedure described above.

11. Turn crankcase on the assembly support until the crankshaft is on top.

12. Tighten con-rod bolts that have been replaced. Turn the crankshaft until the corresponding crank pin is pointing vertically upwards. Tighten bolts with a multiple-tooth socket --> Initial tightening 1: 6 ftlb. --> Initial tightening 2: 15 ftlb. --> Initial tightening 3: 30 ftlb. --> Torque angle (final tightening): 90 ° .

13. Once all pistons have been correctly fitted and secured, turn the crankshaft in a clockwise direction to check it, using a ring wrench (a/f 27). When doing so, watch out for stiffness and irregularities. If the crankshaft cannot be turned or if it is very stiff, check whether the installation direction (arrow) of the pistons, the pistons and the cylinders (markings) and the connecting-rod cap and connecting-rod big end all match.

14. Remove holding bridges P 9677 .

Subsequent work for installing pistons

1. Install lower section of crankcase. > Removing and installing crankshaft .

2. Install chain case cover. Refer to 15 33 21 REMOVING CHAIN CASE LID - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN) or 15 33 21 REMOVING CHAIN CASE LID - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN) .

3. Install oil pan. Refer to 17 50 23 Installing oil pan (includes sealing) - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

4. Install cylinder head. Refer to 15 70 23 Installing cylinder head - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

5. Install engine. Refer to 10 01 19 Removing and installing V8 4.5 l engine - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

Designation Type Number Explanation Funnel VW-tool T10147

Scheme 287

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

2. Support engine on engine carrier. Refer to 10 10 55 REPLACING CRANKCASE - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN) .

3. Remove cylinder head and take off cylinder head gasket. Refer to 15 70 21 Removing cylinder head - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

4. Remove oil pan. Refer to 17 50 19 Removing and installing oil pan - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

5. Remove oil pump. Refer to 17 20 19 Removing and installing oil pump - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

Component information

Scheme 288

Removing pistons

Note. The pistons are removed in turn. The pistons, connecting rods and connecting rod caps are marked with a felt-tip pen so that they do not get mixed up. Pistons and connecting rods are laid on a clean surface in cylinder order. Con-rod bolts must always be replaced. If being reinstalled, used bearing shells must not be mixed up. Connecting rod bearing shells should always be replaced.

Note. Note the association between the connecting-rod big end and the connecting-rod bearing cap. The retaining lugs of the connecting-rod bearing shells are always located on the same side in order to prevent the bearing shells from turning. The connecting-rod bearing cap and the connecting-rod big end have cast lugs which must lie above one another. These cast lugs lie on the same side as the twist lock (retaining lugs) of the bearing shells. --> Component arrangement (Scheme 288) The cast lugs, twist locks (retaining lugs) and the flat side of the piston crown are on the same side. --> Component arrangement (Scheme 288) The flat side of the piston crown always points to the center of the cylinder block.. --> Component arrangement (Scheme 288)

Scheme 289

1. Turn the crankshaft so that the crankshaft journal of the piston to be removed stands vertically upwards.

2. Remove one piston after another, mark them and place them on a clean tray. The flat side of the piston crown always points to the center of the cylinder block. --> Component arrangement Remove the piston of cylinder 1 by unscrewing the connecting-rod bolts. Remove the connecting-rod bearing cover and place it on a clean surface. Press the piston downwards out of the cylinder, using the handle of a hammer for example, and receive with the other hand. Refit connecting-rod bearing cap immediately on the connecting-rod big end together with the bearing shells (Caution: retaining lugs point to each other) --> Retaining lugs of connecting-rod bearings and place the entire piston on a clean surface. Mark piston with No. 1 (with a felt-tip, not with a prick punch or other sharp-edged tool). see scheme 29, (Scheme 289).

3. Remove all remaining pistons in the same way.

> Wear suitable protective clothing (e. g. gloves).

> Conscientious and precise work

Note. The pistons must already be pre-fitted (pistons, piston rings, connecting rods and fastening material) before performing the next step. Note the association between the connecting-rod big end and the connecting-rod bearing cap. The retaining lugs of the connecting-rod bearing shells are always located on the same side in order to prevent the bearing shells from turning. The connecting-rod bearing cap and the connecting-rod big end have cast lugs which must lie above one another. These cast lugs lie on the same side as the twist lock (retaining lugs) of the connecting-rod bearing shells. The cast lugs, twist lock (retaining lugs) and the flat side of the piston crown are on the same side. The flat side of the piston crown always points to the center of the cylinder block. Refit pistons according to removal markings (if being reused). If new connecting-rod bearing shells are used, there will be a red marking on the upper shell and a yellow marking on the lower shell.

1. Note that the piston-ring gaps are offset by 120° with respect to each other.

2. Cylinder barrels, piston bearing surfaces, bearings and the tool funnel T10147 must be oiled with engine oil. Pre-fit the upper bearing shell in the connecting-rod big end. Ensure that the retaining lug fits into the appropriate recess of the connecting-rod big end.

Note. A new funnel T10147 must be deburred with an old piston: i. e. draw the old piston with fitted piston rings a couple of times through the funnel to remove all plastic burrs and residues. If the piston used is to be reinstalled then the plastic shavings will have to be carefully removed.

3. Place special tool funnel T10147 on the appropriate cylinder so that the stud -arrow- always points to the center of the cylinder block. A new funnel must be deburred with an old piston: i. e. first draw the old piston with fitted piston rings a couple of times through the funnel to remove all plastic burrs and residues. If the piston used is to be reinstalled then the plastic shavings will have to be carefully removed.

> Do not install pistons against resistance and do not use force! Break off the installation attempt, examine the components and try again!

Note. If the piston rings get caught or jammed in the funnel T10147 during insertion into the cylinder, it may be necessary to press the piston rings back into the ring grooves with a soft tool through the slits in the funnel or break off the installation attempt, free the piston and try again.

4. Press the piston very carefully with both thumbs through the funnel into the cylinder. Always keep a close watch on the pistons rings. If necessary, press the piston rings back into the ring grooves with a soft tool through the slits in the funnel or break off the installation attempt, free the piston and try again.

5. Push piston into the cylinder until the connecting-rod big end is positioned just in front of the corresponding connecting-rod bearing of the crankshaft. Push the piston with one hand further into the cylinder and with the other hand push the connecting-rod big end onto the connecting-rod bearing of the crankshaft.

Note. Oil the bearing shells and bearing with engine oil.

6. Place connecting-rod bearing cap fitted with the correct bearing shell on the connecting-rod big end so that the retaining lugs of the bearing shells are on the same side.

7. Insert connecting-rod bolts. Then tighten to the specified tightening torque. --> Tightening torque: 22 ftlb. --> Torque angle: 90 °

8. Turn the crankshaft further so that the crank pin of the next piston to be removed stands vertically upwards. Install other pistons in the same way.

1. Install oil pump. Refer to 17 20 19 Removing and installing oil pump - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

2. Install oil pan. Refer to 17 50 19 Removing and installing oil pan - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

3. Install cylinder head. Refer to 15 70 23 Installing cylinder head - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

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

Designation Type Number Explanation piston ring restraining strap commercially available tool 57 Piston ring pliers commercially available tool 58 piston ring pliers Gr. 1 commercially available tool NR.58 Assembly aid special tool P 9500/3 Plunger special tool P 9500/8 Assembly sleeve special tool P 9500/9 Retaining device special tool P 9597

Scheme 290

Removing pistons, preliminary work

1. Remove piston > 131019 Removing and installing pistons - "removing" .

Scheme 291

Piston disassembly - component overview

Identification of pistons

Markings on piston crown: Replacement pistons from Porsche Parts Service are only obtainable in one dimensional group 'X' and in two weight tolerances '+' and '-' . The weight tolerances are listed in the table.

1. Marking X appears as a large colored stamp in the center of the piston crown and as a small engraved feature (Scheme 291) -1-.
2. Marking + or - appears as a large colored stamp in the center of the piston crown and as a small engraved feature (Scheme 291) -2-.

Note. Pistons are installed as standard in three dimensional groups: I, X and II . Pistons are installed as standard in two weight tolerances: + and - . These data are all engraved on the piston crown. To uniquely identify a piston, it must be carefully cleaned (brass brush, ultrasonic bath). If, in spite of very thorough cleaning, the data are unreadable, the piston must be weighed together with piston rings, piston pin and the two circlips. Thorough cleaning (ultrasonic bath) is also absolutely essential to the weighing operation as otherwise the measurement result will be false.

1. A piston removed for repair is cleaned and identified. If it needs to be replaced, an X - piston with the identified weight tolerance + or - is ordered as a replacement part and installed.

Disassembling pistons

Note. If reusing a piston, do not remove combustion residues on the piston crown are mechanically!

Note. When disassembling the piston/connecting rod unit, note or mark the position, relationship to cylinder and installation position using a waterproof felt tip pen.

Scheme 292

1. Fix piston on retaining device P 9597 --> Piston on retaining device. see scheme 36

Scheme 293

2. Remove both piston-pin circlips using a small screwdriver. To do this, guide the screwdriver through the small cutout and carefully lever out the piston-pin circlip --> Levering out piston-pin circlips with a small screwdriver. see scheme 37

Scheme 294

3. Insert piston in retaining device P 9597 (leave space below for the piston pin) and drive out piston pin using plunger P 9500/8 --> Piston pin with plunger. (Scheme 292)

4. Remove connecting rods from the pistons and place to one side.

> Do not overstretch piston rings with piston ring pliers. Spread the piston ring until it just fits over the piston.

5. Remove piston rings. Place the piston on a clean surface and look for the gaps in the piston rings.

Scheme 295

Note. Compression rings and oil scraper rings are installed and removed differently.

6. Remove the piston rings starting from the piston crown. To do this, move the middle point of piston ring pliers Gr. 1 NR.58 into the gap in the relevant ring. The holding arms of the piston ring pliers should clasp the piston ring from above --> Piston ring pliers on piston ring. Only open the piston ring as much as is needed to remove the piston ring from the groove. Do not overstretch it! (Scheme 293)

7. Relieve the piston ring pliers and remove the piston ring from the pliers.

8. Remove the three-piece oil scraper ring as follows: First, remove the upper and lower rings by hand by carefully forcing them away from the piston. Then remove the oil scraper spring carefully in the same way.

Assembling pistons

1. First assemble the three-piece oil scraper ring. To do this, carefully stretch the oil scraper spring by hand at its gap to a point where this can be positioned over the piston in ring groove 3. Carefully force apart a ring in the oil scraper ring by hand and fit it into the third piston ring groove below the oil scraper spring. Fit the second ring in the same way over the oil scraper spring.

2. When fitted, the gap in the oil scraper ring must be offset by exactly 180° with respect to the gap in the oil scraper spring. Make sure that the oil scraper spring is in the middle of the oil scraper ring.

Scheme 296

Note. The two compression rings have different strengths and can only be installed in the appropriate groove. If the piston ring has the inscription TOP, this must point to the piston crown.

3. Insert piston ring into the piston ring pliers. Make sure that, when installed, the designation of the piston rings is pointing in the direction of the piston crown -A-. Spread the piston ring until it just fits over the piston. (Scheme 294)

4. Fit piston rings. Using the piston ring pliers, insert the middle piston ring into the second ring groove in such a way that the inscription TOP is facing the piston crown. Insert the top piston ring into ring groove 1 in such a way that the inscription TOP is facing the piston crown.

5. Check that the piston rings are correctly seated and positioned. Make sure that the oil scraper spring is inside the oil scraper ring. In the case of the piston ring in ring groove 2, the inscription TOP must point to the piston crown. The top piston ring must be installed in such a way that the inscription TOP is facing the piston crown. The gaps in the individual piston rings must always be offset by 120°.

Scheme 297

6. Pre-fit piston-pin circlip in assembly sleeve. To do this, insert the ring in assembly sleeve P 9500/9, so that the ring gap is at 6 o'clock or alternatively 11 o'clock (piston crown on top), the assembly groove of the assembly sleeve pointing towards the piston crown --> Ring gap indicating 11 o'clock. (Scheme 295)

Scheme 298

7. Position the assembly sleeve on an even surface with the groove facing downwards and use the assembly aid P 9500/3 to drive down the circlip into the installation position so that the circlip is under tension and sitting in the correct position -arrow-. (Scheme 296)

Scheme 299

8. Check installation position of piston-pin circlip in the assembly sleeve --> Ring gap here at 6 o'clock. (Scheme 297)

Scheme 300

9. Position the assembly sleeve on the piston so that the assembly groove of the assembly sleeve points to the piston crown --> Assembly sleeve on piston. (Scheme 298)

10. Insert plunger P 9500/8 through the assembly sleeve and fit the piston-pin circlip by tapping it with a hammer into the groove of the piston pin eye.

11. Fix piston on retaining device P 9597 with fitted piston-pin circlip facing downwards --> Piston on retaining device. (Scheme 299)

12. Gap of circlip must point downwards away from the piston crown (analogous to 6 o'clock, alternatively 11 o'clock). Place piston pin and connecting rod in installation position. Align connecting rod with matching number so that the matching numbers point to the exhaust side -A-. Illustration shows direction of travel in this case and connecting rod code on one side. (Scheme 300)

13. Fit oiled piston pin through the piston and connecting-rod eye as far as the circlip. Using a plastic hammer, tap gently on plunger P 9500/8, driving the piston pin into the pre-fitted piston-pin circlip -arrow-. see scheme 47

Scheme 301

14. Fit the second piston-pin circlip using the same procedure. Align gap of circlip so that it points downwards away from the piston crown (analogous to 6 o'clock, alternatively 11 o'clock) -arrow-. see scheme 48

15. Check connecting rod and piston for smooth operation.

Note. The connecting rods are cracked and together with the matching numbers cannot be mixed up! Connecting rod bolts and bearing shells must always be replaced. The identification of the connecting-rod bearings is located on the connecting-rod journal of the crankshaft > Removing and installing crankshaft .

16. Fit connecting-rod bearing shells in connecting-rod big end and connecting-rod bearing cap. The retaining lugs must be positioned in the appropriate grooves and on the same side -B and C-. The matching numbers -A- must be the same and on the same side (when installed they point to the exhaust side). Tighten the connecting rod bolts by hand and position the complete connecting rod ready for assembly. see scheme 49, (Scheme 301).

1. Install piston > 131019 Removing and installing pistons - "Installing" section .

Designation Type Number Explanation Piston ring pliers Gr. 1 commercially available tool NR.58 Retaining device special tool P 9597

1. Remove piston. > 131019 Remove and install piston - Chapter "Removing"

Scheme 302

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

> Make sure that the piston pin circlip is secured against jumping off at all times (wear gloves and hold circlip in position with thumb).

Note. Combustion deposits on the piston crown are not to be removed mechanically!

Note. When disassembling the piston/connecting rod unit, note or mark the position, relationship to cylinder and installation position using a waterproof felt tip pen. Some Figures show the piston of the V8 as the work steps are analagous.

1. Fix piston onto retaining device P 9597 --> Retaining device. In order to do this, adapt the tool. Remove both fastening screws of the bracket for the large connecting-rod eye Then adjust tool length accordingly. Position piston with connecting rod. see scheme 53

2. Remove both piston pin circlips using a small screwdriver. To do this, guide the screwdriver through the small cutout and carefully lever out the piston pin circlip --> Removing piston pin circlip. (Scheme 302)

Note. If piston is sluggish, heat to 60 °C and remove and install with mandrel.

3. Insert piston in retaining device P 9597 (leave space below for the piston pins) and drive out piston pin using a suitable mandrel applying force by hand --> Piston pin mandrel. Secure piston pin against falling. see scheme 55

4. Remove connecting rod from the piston and place to one side.

> Force apart the piston rings using the piston ring pliers just far enough for it to be possible to remove or install them.

5. Place the piston on a clean surface and look for the gaps in the piston rings.

Note. Compression rings and oil scraper rings are installed and removed differently.

6. Remove the piston rings starting from the piston crown. In order to do this, move the middle point of the piston ring pliers Gr. 1 NR.58 into the gap in the relevant ring. The holding arms of the piston ring pliers should clasp the piston ring from above --> Piston ring pliers. Only open the piston ring as much as is needed to remove the piston ring from the groove. Do not overstretch it! see scheme 56

7. Relieve the piston ring pliers and remove the piston ring from the pliers.

8. Remove the three-piece oil scraper ring as follows: First, remove the upper and lower rings by hand by carefully forcing them away from the piston. Then remove the oil scraper spring carefully in the same way.

1. First fit the three-piece oil scraper ring. To do this, carefully stretch the oil scraper spring by hand at its gap to a point where this can be positioned over the piston into ring groove 3. Carefully force apart a ring of the oil scraper ring by hand and fit it into the third piston ring groove below the oil scraper spring. Fit the second ring in the same way over the oil scraper spring.

2. When fitted, the gap in the oil scraper ring must be offset by exactly 180° with respect to the gap in the oil scraper spring. Make sure that the oil scraper spring is in the middle of the oil scraper ring.

Note. The TOP marking must always face the piston crown.

3. Insert piston ring into the piston ring pliers. Make sure that, when the piston rings are installed, the designation of the piston rings is pointing in the direction of the piston crown --> Piston ring designation. Force the piston ring apart just enough for it to fit over the piston. see scheme 57

4. Fit piston rings. Using the piston ring pliers, insert the middle piston ring into the second ring groove in such a way that the inscription TOP is facing the piston crown. Insert the top piston ring into ring groove 1 in such a way that the inscription TOP is facing the piston crown.

5. Check that the piston rings are correctly seated and positioned. Make sure that the oil scraper spring is inside the oil scraper ring. In the case of the piston ring in ring groove 2, the inscription TOP must point to the piston crown. The top piston ring must be installed in such a way that the inscription TOP is facing the piston crown. The gaps in the individual piston rings must always be offset by 120°.

Scheme 303

Note. The gap of the piston ring may not be located next to the removal recess.

6. Install a piston circlip. In order to do this, insert the piston circlip into the ring groove of the piston pin eye in such a fashion that the ring gap is offset approx. 30° with respect to the piston crown. Press this gap end into the ring groove with your thumb -1-. see scheme 58

Scheme 304

7. Lever the piston circlip into the ring groove using a small screwdriver while continuing to press it down.

Scheme 305

8. If the piston circlip does not slide into the ring groove right away, press the second gap end of the piston circlip into the ring groove. Ensure correct installation seating.

9. Fix piston on retaining device P 9597 with fitted piston pin circlip facing downwards --> Retaining device. (Scheme 303)

10. Place piston pin and connecting rod in installation position. Make sure that the cast lugs on the connecting rod and connecting-rod big end are on the same side as the flat side of the piston crown.

Note. If piston is sluggish, heat to 60 °C and remove and install with mandrel.

11. Fit the greased piston pin through the piston and connecting-rod eye up to the circlip. If necessary, drive the piston pin up to the prefitted piston circlip by lightly tapping a suitable pressure piece with a plastic hammer --> Piston pin mandrel. (Scheme 305)

12. Fit the second piston pin circlip using the same procedure.

13. Check connecting rod and piston for smooth operation.

Note. The connecting-rod bolts must be replaced!

14. Fit connecting-rod bearing shells in connecting-rod big end and connecting-rod bearing cover. The retaining lugs must be positioned in the appropriate grooves and on the same side -B and C-. Cast lugs on the connecting-rod big end and the connecting-rod cover must lie on the same side as the flat side of the piston crown. Tighten the connecting-rod bolts by hand and set down the complete connecting rod ready for assembly. see scheme 64

1. Install pistons. > 131019 Remove and install piston - Chapter "Installing"

1. Remove piston. > 131019 Remove and install piston - Chapter "Removing"

Replacing piston rings

1. See work step stages in the repair instructions > 131037 Disassembling and assembling pistons .

1. Install pistons. > 131019 Remove and install piston - Chapter "Installing"

1. Remove piston. > 131019 Remove and install piston - Chapter "Removing"

Removing and installing connecting rod

1. See work step stages in the repair instructions > 131037 Disassembling and assembling pistons .

1. Install pistons. > 131019 Remove and install piston - Chapter "Installing"

1. Remove oil pan. Refer to 17 50 19 Removing and installing oil pan - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

2. Remove oil pump. Refer to 17 20 19 Removing and installing oil pump - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

Tools and measuring/test equipment

Scheme 306

Measuring radial play of crankshaft

1. Dismantle bearing cover for shaft journals and remove along with bearing shells.

2. Clean shaft journal and bearing shells with a lint-free cloth.

Scheme 307

Note. When measuring radial play, do not rotate the crankshaft. Plastigage is highly susceptible to damage Insert Plastigage carefully. With the Plastigage strip inserted, do not allow any sideways or axial movement of the bearing shells otherwise the measurements may be incorrect (changes to the Plastigage strip).

3. Lay the 10 mm strip of the red Plastigage on the shaft journals or on the bearing shells. -arrow- see scheme 67

4. Attach the bearing cover along with the bearing shell with the correct tightening torque. For details see > 134819 Removing and installing crankshaft

Scheme 308

Note. The Plastigage packaging features a representation of a measurement scale on both sides, one in inches and the other in millimeters. Do not mix up the two of them when measuring.

5. Remove the bearing cap again and compare the thickness of the Plastigage with the scale on the packaging. If the limit of wear is equalled or exceeded, replace the crankshaft and bearing shells. > 134819 Removing and installing crankshaft. see scheme 68

Scheme 309

1. Measure the axial bearing play (bearing cover 5) between the thrust washer and the crank web -see illustration-. When measuring turn the crankshaft by hand in the direction of travel. If the limit of wear has been equalled or exceeded, dismantle the bearing cover and perform the measurement again with new thrust washers. If the measured values from the last measurement show no improvement, the crankshaft and bearing shells should be replaced. (Scheme 306)

1. Install oil pump. Refer to 17 20 19 Removing and installing oil pump - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

2. Install oil pan. Refer to 17 50 19 Removing and installing oil pan - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

1. Remove engine. Refer to 10 01 19 Removing and installing V8 4.5 l engine - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

2. Remove cylinder head. Refer to 15 70 21 Removing cylinder head - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

3. Remove oil pan. Refer to 17 50 19 REMOVING AND INSTALLING OIL PAN - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN) or 17 50 21 REMOVING OIL PAN - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN) .

4. Remove oil pump. Refer to 17 20 19 Removing and installing oil pump - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

Scheme 310

1 - Crankshaft

2 - Straight pin

3 - Feather key

4 - Thrust washer, insert with grease no. 000.043.204.17

5 - Upper crankshaft bearing shell, lubricate with motor oil

6 - Lower crankshaft bearing shell, lubricate with motor oil

7 - Radial shaft sealing ring, crankshaft

H - Main bearing, location of color dots

P - Connecting rod bearing, location of color dots

Note. The color codes of the crankshaft bearings and bearing shells must match! To ensure that the bearings and bearing shells are of a matching class during installation, the bearing numbers are to be written on the backs of the bearings during removal of the main bearing shells with a waterproof felt-tipped pen, due to that fact that the ink markings wear off of the crankshaft journals as well as the main bearing shells. New bearing shells are always to be installed when the engine is repaired.

Scheme 311

1. Remove chain drive wheel from crankshaft. Unscrew fastening screw on belt pulley. Pull off chain sprocket with drive chain on oil pump; do not lose feather key when doing so.

Scheme 312

Scheme 313

2. Unscrew the four hexagon socket head bolts on the clutch side (M8). --> Clutch side (Scheme 310)

3. Unscrew the outer cross bolt connection (M8 x 70) in the opposite order to the sequence shown.

Scheme 314

4. The figures below indicate the tightening sequence. The fastening screws are undone in the opposite order to the tightening sequence shown. --> Outer bearing seat (Scheme 312)

Scheme 315

5. Undo inner bearing seat in the opposite order to the tightening sequence shown. --> Inner bearing seat (Scheme 313)

Scheme 316

6. Remove lower part of crankcase.

7. Remove any remaining sealant and the old sealing ring in the upper part of the crankcase.

8. Fit holding bridges P 9677 on the crankshaft -arrows-. (Scheme 314)

9. Remove pistons. > 131019 Removing and installing pistons -"Removing" chapter Rotate engine block in engine stand through 180° so that the crankshaft can be removed.

> Hold the very outside of the crankshaft.

> Wear gloves.

10. Undo holding bridges P 9677 and carefully remove crankshaft upwards.

Installing crankshaft

Note. If no clear markings can be seen after thorough cleaning of the crankshaft and the bearings, the crankshaft and the corresponding bearing shells are to be replaced.

Scheme 317

Scheme 318

Note. The bearing shells are available in various tolerance classes. The classes are indicated by the color marking on the outside -refer to Figure-. The color marking must match the corresponding color dot on the crankshaft. The colors are red, yellow and blue and must match between the bearings and the crankshaft. (Scheme 316) To ensure that the bearings and bearing shells are of a matching class during installation, the bearing numbers are to be written on the backs of the bearings during removal of the main bearing shells with a waterproof felt-tipped pen, due to that fact that the ink markings wear off of the crankshaft journals as well as the main bearing shells. New connecting rod bearings main bearing shells are always to be installed when the motor is repaired.

1. Insert the bearing shells with the lubricating groove into the upper part of the crankcase. Make sure the twist locks are positioned correctly -see figure-. Then lightly oil the bearing locations. (Scheme 315)

Scheme 319

2. Insert the sickle-shaped washers (make sure of axial bearing play). To do this, insert the two sickle-shaped washers (thrust washers) on the left and right on crankshaft bearing No. 3 with some grease (000.043.204.17) -see figure- to prevent the sickle-shaped washers from falling off. Each of the lubricating grooves of the sickle-shaped washers must face outwards. see scheme 80

> Hold the very outside of the crankshaft.

> Wear gloves.

3. Insert crankshaft. The connecting flange must point towards the back of the engine. Then secure the crankshaft from falling down using holding bridges P 9677. Fix the holding bridges at bearing locations 3 and 5. Screw the fastening screw from the belt pulley at the front into the crankshaft and tighten slightly so that the crankshaft can be turned -see figure-. (Scheme 317)

4. Turn crankcase by 180° on the assembly support.

5. Install pistons. > 131019 Removing and installing pistons - section on "Installing"

6. Turn crankcase again through 180° on the assembly support.

7. Make sure the crankcase is ready to be screwed in. Check that the sickle-shaped washers are positioned correctly. Degrease parting surfaces between upper and lower parts of the crankcase. A totally grease-free product (e. g. brake cleaner) must be used for this. Then insert a new O-ring at the front of the parting surface -3-. (Scheme 318)

Scheme 320

1 - Crankcase, lower part

2 - Cylindrical pin used to center the lower part of the crankcase on the crankcase

3 - Sealing ring; replace

4 - Application of sealant; Drei Bond Silikon 2210 liquid sealant (000.043.204.58, status 02/06) must be applied and the screws screwed in within five minutes and without interruption

5 - Thrust-bearing screw, M12 x 1.5 x 132

6 - Thrust-bearing screw, M10 x 117

7 - Fastening screw, M8 x 70

8 - Fastening screw, M8 x 35

9 - Fastening screw, M8 x 50

10 - Dowel sleeve

Scheme 321

8. Screw the two thin centring pins P 9321 into the outer fastening bores on the upper part of the crankcase -see illustration (shown without crankshaft)-. (Scheme 319)

9. Insert bearing shells into lower part of crankcase and lightly oil them. When doing so, ensure that the twist locks (retaining lugs) fit into the appropriate recesses in the lower part of the crankcase.

Note. The liquid sealant must be applied and the screws screwed in within five minutes at most and without interruption. The required tool (torque wrench for 15 Nm (11 ftlb.) to 40 Nm (30 ftlb.); torque angle wrench; socket wrench E12, E14 and E14) must be ready for use. The threads and head contact surface of the bearing seat screws (M10 x 1.5 and M12 x 1.5) must be oiled.

10. Apply Drei Bond Silikon 2210 liquid sealant (000.043.204.58, status 02/06) to the lower part of the crankcase as shown. The outer surfaces marked -A- must be cleaned after fitting. (Scheme 320)

Scheme 322

11. Place lower part of crankcase into position. When doing so, make sure that the sealing bead is not destroyed.

Note. Unscrew the centring pins again while securing the lower part of the crankcase.

12. The figures below indicate the tightening sequence. The screws are tightened in four steps. It is essential that the tightening sequence is observed here. The screws must be tightened within five minutes.

> Initial tightening: 40 (30 ftlb.) Nm

> Initial tightening: 22 (16 ftlb.) Nm

> Final tightening: 56 °

> Final tightening: 60 °

Inner bearing seat

Outer bearing seat

13. Then screw on the outer cross bolt connection (M8 x 70) in the sequence shown --> Tightening torque: 23 (17 ftlb.) Nm .

14. Tighten the four hexagon socket bolts on the clutch side (M8 x 35) --> Tightening torque: 23 (17 ftlb.) Nm .

15. Fit chain drive sprocket on the crankshaft. Unscrew fastening screw on belt pulley. Check that the feather keys are fitted correctly and push on the chain sprocket with the oil pump drive chain --> Chain drive wheel. The double-tooth row must be facing forwards. see scheme 90

1. Install oil pump. Refer to 17 20 19 Removing and installing oil pump - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

2. Install oil pan. Refer to 17 50 19 REMOVING AND INSTALLING OIL PAN - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN) or 17 50 23 INSTALLING OIL PAN (INCLUDES SEALING) - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN) .

3. Install cylinder head. Refer to 15 70 23 Installing cylinder head - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

4. Install chain case lid. Refer to 15 33 21 REMOVING CHAIN CASE LID - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN) or 15 33 21 REMOVING CHAIN CASE LID - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN) .

5. Install engine. Refer to 10 01 19 Removing and installing V8 4.5 l engine - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

Designation Type Number Explanation assembly fixture VW-tool T10215

1. Remove pistons. > 131019 Removing and installing pistons - "Removing"

2. Remove front crankshaft belt pulley. > 137619 Removing and installing crankshaft belt pulley - "Removing"

3. Remove timing chains. Refer to 15 35 21 Removing timing chains - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

Component overview

Scheme 323

Removing crankshaft

> Conscientious and precise work

> Use suitable storage places.

Scheme 324

1. Remove the joint flange at the front behind the belt pulley. Do this by removing all the fastening screws and carefully levering out the joint flange. Clean sealing faces.

Scheme 325

Note. 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 color markings

2. Dismantle all bearing covers from the crankshaft. Bearing covers and shells are assigned to specific cylinders and should be set aside on a clean surface where they will not get mixed up. For bearing cover no. 5, carefully remove the thrust washers at the side.

> Hold the very outside of the crankshaft.

> Wear gloves.

> Allow an assistant to help lift the crankshaft.

Note. Prepare a suitable storage space for the crankshaft so that the speed sensor wheel is not damaged.

3. With the help of assistants, carefully lift the crankshaft out of the cylinder block and set aside on a soft, clean surface so that the sensor wheel is not damaged.

1. Replace bearing shells and thrust washers. When replacing bearing shells make sure that the color markings match.

2. Insert bearing shells into the bearings and bearing covers after oiling them. Insert twist locks or retaining lugs for the bearing shells into the recesses. Make sure the twist locks are positioned correctly --> Twist locks. (Scheme 323)

> Hold the very outside of the crankshaft.

> Wear gloves.

> Allow an assistant to help lift the crankshaft.

3. Carefully insert the crankshaft into the cylinder block with the help of an assistant. Test once again that the bearing shells and thrust washers are correctly positioned (they can easily shift out of place). Oil crankshaft journals.

Note. 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 color markings

4. Replace fastening screws for bearing covers. Attach all bearing covers to the crankshaft. Bearing covers and shells should be oiled and installed so that the twist locks or retaining lugs are on the same side.

5. Insert sickle-shaped washers into bearing cover no. 5 (make sure there is axial play in the bearings). Insert the two sickle-shaped washers (thrust washers) to the left and right of bearing cover no. 5 with a certain amount of grease so that the washers do not fall down. Each of the lubricating grooves of the sickle-shaped washers must face outwards. Assemble bearing cover no. 5 along with the greased thrust washers.

6. Pull out all the bearing cover fastening screws diagonally outward from the middle --> Initial tightening: 30 (22 ftlb.) Nm --> Final tightening: 180 ° .

Note. Lubricant must be applied thinly to the inside of the bore.

7. Install joint flange at the front behind the pulley. To do this clean sealing faces. Apply silicon sealant 000.040.300.39 thinly and evenly on the sealing faces of the joint flange. Mount joint flange immediately and fit fastening screws. Tighten fastening screws evenly. --> Tightening torque: 10 (7.5 ftlb.) Nm

Scheme 326

Note. The crankshaft sealing ring for the pulley was changed in model year 2005 as of engine number BFD20319. This crankshaft sealing ring is now permanently integrated in the joint flange and can no longer be changed as a separate item. If there is a leak, the complete joint flange must be replaced.

8. The sealing faces must all be clean and free of grease.

Scheme 327

9. Apply sealant 000 043 300 39 as shown in the illustration -arrows-. Ensure that the bead of sealant is no thicker than approx. 2 to 3 mm and is run past the bores on the inside. Mount the joint flange within five minutes. see scheme 98

Scheme 328

10. Push front of special tool (guide sleeve) assembly fixture T10215 onto the crankshaft journal. Slide joint flange over the guide sleeve and into the installation position.

11. Screw down joint flange. --> Tightening torque: 10 (7.5 ftlb.) Nm

Replacing pick-up (sensor) wheel

1. Remove the crankshaft and set it aside so that the speed sensor wheel is easily accessible and is not in contact with the shaft.

Scheme 329

2. Loosen the fastening screws -1 and 2-. Carefully remove the speed sensor wheel. see scheme 100

3. Clean the attachment surfaces Smear the attachment surfaces thinly with medium locking agent.

4. Immediately position a new speed sensor wheel on the crankshaft and align it. Align the VR6 marking to the individual bore on the crankshaft. Apply medium-tight screw locking agent to all fastening screws with and tighten the screws hand-tight. Tighten the fastening screw -1- first. Insert --> Initial tightening: 7.5 ftlb. Insert --> Final tightening: 90 ° Then tighten the screw -2- firmly. Insert --> Initial tightening: 7.5 ftlb. Insert --> Final tightening: 90 °. see scheme 100

5. Install crankshaft.

Scheme 330

6. Check whether the gap in the teeth of the speed sensor wheel points downwards in the top dead center position -arrow-. At the same time, the ground tooth of the crankshaft sprocket must align with the joint face of the bearing cover -B-. (Scheme 327), (Scheme 328).

Scheme 331

1. Replace sealing ring on pulley. > 137419 Removing and installing sealing ring for crankshaft belt pulley - "Installing"

2. Install pistons. > 131019 Removing and installing pistons - "Installing"

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

Designation Type Number Explanation Drift punch, 1 mm tip, commercially available tool NR.167 Slide hammer kit commercially available tool NR.168 Multiple-tooth socket wrench insert M12 commercially available tool NR.31 Toothed segment special tool P 201a insertion device VW-tool T10122

Scheme 332

Scheme 333

Scheme 334

1. Remove drive plate or double-mass flywheel (DMF). To do this, loosen the fastening screws crosswise. > Removing and installing double-mass flywheel (DMF) [9PAAD7] or > 136319 Removing and installing drive plate for torque converter [9PAAD1]

Scheme 335

Removing crankshaft sealing ring on flywheel side

Note. Here are some pictures showing the engine from the Cayenne V8. The work steps are to be performed in the same way.

Scheme 336

1. Using the drift punch (1-mm tip) NR.167 , punch a small hole into a non-rubberised spot (rectangular window in the ring) of the sealing ring.

Scheme 337

2. Screw in the extractor tip. Knock out the extractor tip using slide hammer kit NR.168 in conjunction with the sealing ring.

Scheme 338

Note. If a crankshaft stub is dirty or slightly rusted, this will damage the new sealing ring when it is fitted. The crankshaft stub must be cleaned before the old sealing ring is removed so that no particles of dirt can reach the engine. Use a metal-polishing pad (e. g. Never Dull) for this.

3. Clean the crankshaft stub. The crankshaft stub must not be dirty or rusty. If necessary, clean it with brake cleaner and grind off any rust with a metal-polishing pad (e. g. Never Dull).

Installing crankshaft sealing ring on flywheel side

> Never deform or touch the sealing lips.

> Only install dry sealing ring.

Note. The insertion device T10122 tool set consists of a sleeve, an assembly sleeve and a pressure piece.

Scheme 339

1. Insert sleeve into the assembly sleeve.

Scheme 340

2. Push sealing ring (with outer side first) over the sleeve until it is on the assembly sleeve.

Scheme 341

3. Pull sleeve out of the assembly sleeve.

4. Position the assembly sleeve on the crankshaft stub.

Scheme 342

5. Position the pressure piece and use a rubber hammer to tap evenly around the edges of the pressure piece until it is fitted evenly all round.

6. Remove pressure piece and assembly sleeve.

1. Fit drive plate or double-mass flywheel (DMF). > 136319 Removing and installing drive plate for torque converter [9PAAD1] or > Removing and installing double-mass flywheel (DMF) [9PAAD7] .

Designation Type Number Explanation Drift punch, 1 mm tip, commercially available tool NR.167 Slide hammer kit commercially available tool NR.168 Multiple-tooth socket wrench insert M12 commercially available tool NR.31 Toothed segment special tool P 9538/1 Pressure piece special tool P 9609/1 spacer special tool P 9609/2

1. Remove drive plate or flywheel. > 136019 Removing and installing flywheel [9PAAE7] or > 136319 Removing and installing drive plate for torque converter [9PAAE1 9PAAF1 9PAAJ1 9PAAK1] .

Scheme 343

1. Using the tool drift punch (1-mm tip) NR.167 , beat a small hole into a non-rubberised spot (rectangular window in the ring) of the sealing ring.

2. Screw in the extractor tip. Knock out the extractor tip using slide hammer kit NR.168 in conjunction with the sealing ring.

3. Clean the crankshaft flange The crankshaft flange must not be dirty or rusty. If necessary, clean it with brake cleaner and grind off any rust with a metal-polishing pad (e. g. Never Dull).

> The sealing ring is provided on a sleeve.

> Never remove the sealing ring from the sleeve.

> Never deform or touch the sealing lips.

> Never oil the sealing lips.

Scheme 344

1. Connect the sealing ring and sleeve to the tool.

Scheme 345

2. Position the centring device on the crankshaft flange. Pay attention to the centring pin when doing this. Tighten the two fastening screws to 23 Nm (17 ftlb.).

Scheme 346

3. Position the retracting bell and tighten the central screw (a/f 19) to 25 Nm (19 ftlb.).

4. Undo the retracting bell and screw it down.

5. Undo the two fastening screws on the centring device and remove the tool.

1. Install drive plate or flywheel. > 136019 Removing and installing flywheel [9PAAE7] or > 136319 Removing and installing drive plate for torque converter [9PAAE1 9PAAF1 9PAAJ1 9PAAK1] .

Designation Type Number Explanation toothed segment special tool P 201a toothed segment special tool P 9538/1

1. Remove transmission. Refer to 34 35 19 Removing and installing transmission - as of MY 2003 (Cayenne S MAN) .

2. Remove clutch pressure plate and clutch. Refer to 30 50 19 Removing and installing clutch - as of MY 2003 (Cayenne MAN, Cayenne S MAN) .

Scheme 347

Scheme 348

1. Block the flywheel. To do this, attach a suitable toothed segment toothed segment P 201a or toothed segment P 9538/1 to a screw hole in the crankcase so that at least one tooth is in contact with the starter teeth. Place a washer (approx. 5 mm) under the segment if necessary.

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

> Work carefully (get another person to help you to install and remove the flywheel, if necessary).

Note. To make it easier to re-install a used flywheel, use a felt-tip pen to mark the crankshaft stub and flywheel before removing it. This makes it easier to install it again later. If the flywheel is stuck, loosen it by levering it at the sides with two screwdrivers and then remove it.

2. Remove the flywheel. To do this, loosen the ten fastening screws crosswise.

Note. Clean the crankshaft stub before installing the flywheel (remove rust). Use a special metal-polishing pad (e. g. Never Dull) for this.

3. Remove the flywheel and clean the flange.

Installing flywheel

Note. Clean the crankshaft stub before installing the flywheel (remove rust). Use a special metal-polishing pad (e. g. Never Dull) for this.

1. Clean the flange and fit the flywheel (align according to the previously applied markings if necessary). Screw on the ten fastening screws hand-tight.

2. Block the flywheel. To do this, attach a toothed segment P 201a or toothed segment P 9538/1 to a screw hole in the crankcase so that at least one tooth is in contact with the starter teeth. Place a washer (approx. 5 mm) under the segment if necessary.

3. Tighten the ten new fastening screws crosswise. --> Tightening torque: 44 ftlb. --> Torque angle: 90 ° --> Torque angle: 30 °

4. Remove toothed segment.

1. Install transmission. Refer to 34 35 19 Removing and installing transmission - as of MY 2003 (Cayenne S MAN) .

2. Install clutch pressure plate and clutch. Refer to 30 50 19 Removing and installing clutch - as of MY 2003 (Cayenne MAN, Cayenne S MAN) .

Designation Type Number Explanation arm bracket VW-tool T10069

1. Remove transmission. Refer to 34 35 19 Removing and installing transmission - as of MY 2003 (Cayenne MAN) .

2. Remove clutch pressure plate and clutch. Refer to 30 50 19 Removing and installing clutch - as of MY 2003 (Cayenne MAN, Cayenne S MAN) .

1 - Fastening screw for vibration damper

2 - Vibration damper

3 - Fastening screw M6

4 - Sealing ring

5 - Sealing flange

6 - Cylinder block

7 - Chain case lid, bottom

8 - Sealing ring

9 - Double-mass flywheel

10 - Fastening screw for double-mass flywheel, M10 x 20

11 - Fastening screw, M8 x 28

Removing double-mass flywheel (DMF)

> Wear suitable protective clothing (e. g. gloves).

Scheme 349

1. Block the crankshaft. To do so, with the help of an assistant, hold the belt pulley in place at the front with the arm bracket T10069 --> Block the crankshaft.. see scheme 125

Note. Mark the installation positions of the components for the crankshaft with a felt-tipped pen. The DMF fastening screws are to be replaced.

2. Undo fastening screws and remove DMF.

Install double-mass flywheel (DMF)

> Wear suitable protective clothing (e. g. gloves).

Note. The DMF fastening screws are to be replaced. The DMF bores for the crankshaft only fit in one position

1. Position DMS in the installation position and screw in new fastening screws.

2. Block the crankshaft. To do so, with the aid of an assistant, hold the belt pulley in place at the front with the arm bracket T10069 --> Block the crankshaft.. (Scheme 347)

3. Tighten the fastening screws of the DMF diagonally --> Initial tightening: 44 ftlb. --> Torque angle: 90 ° .

1. Install clutch pressure plate and clutch. Refer to 30 50 19 Removing and installing clutch - as of MY 2003 (Cayenne MAN, Cayenne S MAN) .

2. Install transmission. Refer to 34 35 19 Removing and installing transmission - as of MY 2003 (Cayenne MAN) .

Designation Type Number Explanation Arm bracket VW-tool T10069

1. Remove transmission. Refer to 37 35 19 Removing and installing transmission - as of MY 2003 (Cayenne TIP) .

Removing drive plate for torque converter

Note. Shims are fitted under or on the drive plate. These must be refitted again at the same place they were before the drive plate was removed. The shims are to be marked with a felt-tip pen before removal.

1. Block drive plate. For this, block the crankshaft at the belt pulley with the arm bracket Arm bracket T10069 .

2. Unscrew drive plate. To do this, loosen the diagonal fastening screws.

3. Remove drive plate.

4. If drive plate is tight, lever off with a screwdriver where necessary.

Installing drive plate for torque converter

Note. Clean the crankshaft flange before installing the drive plate (remove rust). Use a special metal-polishing pad (e. g. Never Dull) for this.

1. Fit drive plate.

2. Block drive plate. For this, block the crankshaft at the belt pulley with the arm bracket Arm bracket T10069 .

3. Correctly fit the shims according to the removal marking.

4. Tighten the new fastening screws diagonally. --> Initial tightening: 44 ftlb.

> Torque angle: 90 °

> Torque angle: 30 °

Setting drive plate installation position

1. Secure drive plate to crankshaft flange using three old screws (approx. 30 Nm (22 ftlb.)).

Scheme 350

2. Measure dimension a --> Measuring tool and drive plate with a depth gauge. Nominal value: 21.00 mm to 23.00 mm. see scheme 131

3. If the measurement is less than the nominal value, remove drive plate and fit an adjusting shim of the required thickness between the crankshaft and drive plate.

4. Adjust as required, then fit drive plate. > 136319 Removing and installing drive plate for torque converter - "Installing"

1. Install transmission. Refer to 37 35 19 Removing and installing transmission - as of MY 2003 (Cayenne TIP) .

Designation Type Number Explanation toothed segment special tool 95381 Internal puller commercially available tool NR.108 Striker VW-tool VW 771/1

Scheme 351

1. Remove transmission. Refer to 37 35 19 Removing and installing transmission - as of MY 2003 (Cayenne S TIP, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

Scheme 352

1. Block drive plate. To do this, attach toothed segment 95381 to a screw hole in the crankcase so that at least one tooth is in contact with the starter teeth.

2. Unscrew drive plate. To do this, loosen the ten diagonally opposite fastening screws.

3. Remove drive plate.

4. If the drive plate is stuck, remove it using an internal puller and slide hammer.

Scheme 353

5. To do this, insert internal puller into the middle of the drive plate and tighten.

Scheme 354

6. Then screw on the slide hammer and knock off the drive plate.

Note. Clean the crankshaft stub before installing the drive plate (remove rust). Use a special metal-polishing pad (e. g. Never Dull) for this.

1. Fit drive plate.

2. Block drive plate. To do this, attach toothed segment 95381 to a screw hole in the crankcase so that at least one tooth is in contact with the starter teeth.

3. Tighten the ten new fastening screws crosswise. --> Tightening torque: 44 ftlb. ; then --> Torque angle: 90 °

4. Remove toothed segment 95381 .

1. Install transmission. Refer to 37 35 19 Removing and installing transmission - as of MY 2003 (Cayenne S TIP, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

1. Loosen drive belt around the belt tensioner. For details, see > 137819 Removing and installing drive belt

Scheme 355

1. Slacken off the belt tensioner. To do this, screw an M8 x 50 screw into the belt tensioner. Do not turn the belt tensioner as far as the stop. Only slacken the tensioner until the drive belt is loose.

Scheme 356

2. Undo the three fastening screws on the belt tensioner and remove the component.

Installing belt tensioner

1. Screw a screw (M8 x 50) into the new belt tensioner until the belt tensioner is slightly tensioned.

2. Tighten the three fastening screws. --> Tightening torque: 19 ftlb.

1. Fit drive belt. For details, see > 137819 Removing and installing drive belt

1. Loosen drive belt around the belt tensioner. > 137819 Removing and installing drive belt - "Removing" [9PAAE1 9PAAE7] > 137819 Removing and installing drive belt - "Removing" [9PAAK1] > 137819 Removing and installing drive belt - "Removing" [9PAAF1 9PAAJ1]

Scheme 357

1 - Deflection roller, cylinder bank 1-4 --> Tightening torque: 32 (24 ftlb.) Nm +/-3 (2 ftlb.) Nm

2 - Tensioning roller

3 - Holder for deflection roller

4 - Fastening screw for damper --> Tightening torque: 32 (24 ftlb.) Nm +/-3 (2 ftlb.) Nm

5 - Support for tensioning roller --> Tightening torque: 32 (24 ftlb.) Nm +/-3 (2 ftlb.) Nm

6 - Shock absorber/tensioning element; bellows must be facing upwards. Observe code on the component.

7 - Deflection roller, cylinder bank 5-8 --> Tightening torque: 32 (24 ftlb.) Nm +/-3 (2 ftlb.) Nm

8 - Sheetmetal holder

Removing belt tensioner

1. Loosen the bottom fastening screw on the shock absorber.

2. Loosen the top fastening screw.

3. Remove components and repair appropriate components.

Scheme 358

4. In order to remove the tensioning roller -figure shows deflector roller-, the cap must be levered off first. To do this, insert a small screwdriver underneath the cap and lever it off. (Scheme 354)

Note. When fitting the shock absorber/tensioning element, ensure that the label can be read from outside. The bellows must be facing upwards.

Scheme 359

1. Install holder with tensioning element. Tighten the top fastening screw. --> Tightening torque: 24 ftlb.

2. Tighten the bottom fastening screw. --> Tightening torque: 24 ftlb.

1. Fit drive belt. > 137819 Removing and installing drive belt - "Installing" [9PAAE1 9PAAE7] > 137819 Removing and installing drive belt - "Installing" [9PAAK1] > 137819 Removing and installing drive belt - "Installing" [9PAAF1 9PAAJ1]

Scheme 360

1- - Radial shaft seal (align using the plastic sleeve provided)

2- - Upper fastening screw

3- - Lower fastening screw

4- - Chain tensioner

Preliminary work for removing sealing ring for crankshaft sealing ring

1. Remove pulley (vibration balancer) of the crankshaft > 137619 Removing and reinstalling crankshaft belt pulley - "Removing" .

Scheme 361

1. Undo the 4 fastening screws and remove the cover and sealing ring.

2. Clean the sealing surface of the sheetmetal cover.

Installing sealing ring for crankshaft pulley

> Sealing lip can be damaged!

Note. If the joint flange on the pulley or the surface on the crankshaft stub is slightly rusted, polish the rust off with a special polishing pad. If there is bad corrosion or deep grooves, replace these components.

Scheme 362

1. Place seal with plastic sleeve across crankshaft.

Scheme 363

2. Tighten the 2 upper fastening screws by hand --> Tightening torque: 7.5 ftlb. , and then the lower fastening screws --> Tightening torque: 7.5 ftlb. . Then tighten the screws in diagonally opposite sequence to the specified torque.

Scheme 364

3. Pull off plastic sleeve evenly from sealing ring.

Subsequent work: installing sealing ring for crankshaft pulley

1. Install pulley (vibration balancer) of crankshaft > 137619 Removing and reinstalling crankshaft belt pulley - "Installing" .

Designation Type Number Explanation Sealing ring extractor VW-tool 3203 Assembly fixture VW-tool T10215

1. Remove crankshaft belt pulley. > 137619 Removing and installing crankshaft belt pulley - section on "Removing"

Note. The crankshaft sealing ring for the pulley was changed in model year 2005 as of engine number BFD20319. This crankshaft sealing ring is now permanently integrated in the joint flange and can no longer be changed as a separate item. If there is a leak, the complete joint flange must be replaced.

1. Remove crankshaft belt pulley. > 137619 Removing and installing crankshaft belt pulley - section on "Removing"

2. Remove oil pan. Refer to 17 50 19 Removing and installing oil pan - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

Scheme 365

Scheme 366

1. Screw extraction tool apart and position on the crankshaft stub. Then tighten the fastening screw -A-. (Scheme 358)

Scheme 367

2. Push on change-over ratchet. Press the tool firmly against the sealing ring while turning it in a clockwise direction until the extraction tool is pulled into the sealing ring.

Scheme 368

3. Undo the screw -A- and turn the change-over ratchet in a clockwise direction -B- until the sealing ring falls out. (Scheme 360)

Removing sealing ring for crankshaft belt pulley

Note. The crankshaft sealing ring for the pulley was changed in model year 2005 as of engine number BFD20319. This crankshaft sealing ring is now permanently integrated in the joint flange and can no longer be changed as a separate item. If there is a leak, the complete joint flange must be replaced.

1. Remove joint flange behind the crankshaft pulley. To do this, remove the remaining fastening screws -A- (excluding the screws of the removed oil pan -B- ) and lever off with a screwdriver --> Levering off joint flange. (Scheme 361), (Scheme 362).

2. Remove any sealant residue from all sealing faces.

3. Clean crankshaft journal. Remove any oil residues from the crankshaft journal with a cloth. The crankshaft journal must not be dirty or rusty. If necessary, clean it with brake cleaner and grind off any rust with a metal-polishing pad (e. g. Never Dull).

Installing sealing ring for crankshaft belt pulley

> Never deform or touch the sealing lips.

> Only install dry sealing ring.

1. Clean crankshaft and installation location and remove all traces of oil. Clean off patches of dirt or rust using a special polishing pad (e. g. Never Dull).

Scheme 369

2. Position guide sleeve on the crankshaft stub.

Scheme 370

3. Place sealing ring on the guide sleeve.

Scheme 371

4. Push sealing ring down from the guide sleeve on to the crankshaft stub.

Scheme 372

5. Position insertion tool and screw in using the old belt pulley fastening screw. Screw insertion tool in until it is supported on the lid. Then screw out the screw anti-clockwise.

6. Do not re-use the old belt pulley fastening screw.

Note. The crankshaft sealing ring for the pulley was changed in model year 2005 as of engine number BFD20319. This crankshaft sealing ring is now permanently integrated in the joint flange and can no longer be changed as a separate item. If there is a leak, the complete joint flange must be replaced.

1. The sealing faces must all be clean and free of grease.

2. Apply the sealant 000 043 300 39 according to the illustration -arrows- (version 11/2005, for current sealant, see Spare Parts Catalogue). Ensure that the bead of sealant is no thicker than approx. 2 to 3 mm and is run past the bores on the inside. Mount the joint flange within five minutes. (Scheme 367)

3. Push front of special tool (guide sleeve) assembly fixture T10215 -1- onto the crankshaft journal -3-. Slide joint flange -2- over the guide sleeve and into the installation position. (Scheme 368)

4. Screw down joint flange. --> Tightening torque: 10 (7.5 ftlb.) Nm

Scheme 373

1. Install crankshaft belt pulley. > 137619 Removing and installing crankshaft belt pulley - section on "Installing" .

Note. The crankshaft sealing ring for the pulley was changed in model year 2005 as of engine number BFD20319. This crankshaft sealing ring is now permanently integrated in the joint flange and can no longer be changed as a separate item. If there is a leak, the complete joint flange must be replaced.

1. Fit oil pan. Refer to 17 50 19 Removing and installing oil pan - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

2. Install crankshaft belt pulley. > 137619 Removing and installing crankshaft belt pulley - section on "Installing" .

Designation Type Number Explanation arm bracket special tool 96790 Mechanical angle disc for torque angle threaded joint commercially available tool NR.88-1 socket wrench insert special tool P 9714

Scheme 374

Preliminary work for removing crankshaft pulley

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

2. Loosen drive belt and remove from the pulley. For details see > 137819 Removing and reinstalling drive belt - "Removing" [9PAAE1 9PAAE7] > 137819 Removing and reinstalling drive belt - "Removing" [9PAAK1] > 137819 Removing and reinstalling drive belt - "Removing" [9PAAF1 9PAAJ1] .

Scheme 375

1. Position arm bracket 96790 in the pulley and turn it until it locks.

> Only use an appropriately strong tool (e. g. 3/4 inch)

> Ensuring that the tool is seated correctly

> Never use the special wrench socket wrench insert P 9714 , for loosening or tightening

> Working with a second worker

Scheme 376

2. Position a large torque wrench and loosen the central screw. Do not use the screw again.

Scheme 377

3. Remove the central screw and pull the pulley down and forward.

Scheme 378

Note. A key is inserted into the crankshaft. When fitting the pulley, ensure that the key lies in the groove in the pulley. The key must not fall into the engine. The pulley and crankshaft stub must be cleaned.

1. Position the pulley on the crankshaft stub. Then press the pulley slightly in the direction of the engine, while at the same time twisting it until it slips definitively in the direction of the timing-case cover. When doing so, pay attention to the key.

2. Mount the new central screw hand tight into the crankshaft.

> Only use an appropriately strong tool (e. g. 3/4 inch)

> Ensuring that the tool is seated correctly

> Never use the special wrench socket wrench insert P 9714 , for loosening or tightening

> Working with a second worker

3. Position arm bracket 96790 in the pulley and turn it until it locks. Have a second worker operate the arm bracket.

Scheme 379

> Only use an appropriately strong tool (e. g. 3/4 inch)

> Ensuring that the tool is seated correctly

> Never use the special wrench socket wrench insert P 9714 , for loosening or tightening

> Working with a second worker

4. Tighten central screw. --> Initial tightening: 20 (15 ftlb.) Nm , then --> Initial tightening: 50 (37 ftlb.) Nm , then --> Initial tightening: 250 (185 ftlb.) Nm

Scheme 380

5. Push on torque angle disc Mechanical angle disc for torque angle threaded joint NR.88-1 . Attach a magnetic foot to a metal part and set the scale by turning the pointer to 0. As an alternative to the torque angle disc, marks can be made on the vibration balancer (crankshaft pulley) and the central screw using a waterproof pen. A continuous line between the central screw and vibration balancer represents the starting point, another line only on the vibration balancer at an angular distance of 90° shows the torque angle target.

> Only use an appropriately strong tool (e. g. 3/4 inch)

> Ensuring that the tool is seated correctly

> Never use the special wrench socket wrench insert P 9714 , for loosening or tightening

> Working with a second worker

6. Tighten central screw to torque angle. --> Torque angle - final tightening: 90 °

Scheme 381

1. Mount drive belt. For details see > 137819 Removing and reinstalling drive belt - "Installing" [9PAAE1 9PAAE7] > 137819 Removing and reinstalling drive belt - "Installing" [9PAAK1] > 137819 Removing and reinstalling drive belt - "Installing" [9PAAF1 9PAAJ1] .

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

Designation Type Number Explanation Torque angle torque key commercially available tool NR.88 mechanical angle disc for torque-angle threaded joints commercially available tool NR.88-1 Arm bracket VW-tool T10069

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

Scheme 382

2. Remove cowl for throttle body Refer to 24 35 19 Removing and installing cowl for throttle housing (intake manifold) - as of MY 2004 (Cayenne TIP, Cayenne MAN) ..

Scheme 383

3. Mark the rolling direction of the drive belt with chalk and remove drive belt around the crankshaft belt pulley. For details see > 137819 Removing and installing drive belt - section on "Removing" .

Scheme 384

Removing crankshaft belt pulley

> Ensure that the tool is seated correctly.

1. Block the crankshaft belt pulley using an arm bracket and undo the central screw (a/f 27). Do not use the screw again.

2. Remove the central screw and pull the pulley down and forward.

Installing crankshaft belt pulley

Note. A key is inserted into the crankshaft. When fitting the belt pulley, ensure that the key slots into the groove in the belt pulley. The key must not fall into the engine.

Scheme 385

1. Position the belt pulley on the crankshaft stub. Then press the belt pulley slightly in the direction of the engine, while at the same time twisting it until it slips definitively in the direction of the timing case cover. When doing so, pay attention to the key. --> Key (Scheme 379)

Scheme 386

2. Screw the new central screw into the crankshaft.

3. Block the crankshaft belt pulley using an arm bracket and tighten the central screw (a/f 27) to the specified tightening torque. For torque-angle screws, use the torque angle torque key NR.88 (or a mechanical angle disc for torque-angle threaded joints NR.88-1 ). Attach the magnetic foot to a metal part and set the scale by turning the pointer to 0. --> Initial tightening: 74 ftlb. --> Final tightening: 90 °

Scheme 387

1. Fit drive belt. > 137819 Removing and installing drive belt

2. Fit cowl for throttle body. Refer to 24 35 19 Removing and installing cowl for throttle housing (intake manifold) - as of MY 2004 (Cayenne TIP, Cayenne MAN) ..

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

1. Remove intake manifold (cowl). 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) .

Information

> Never remove drive belt when it is hot.

> Following a belt breakage the surrounding components and the interior of the engine compartment must be inspected for damage, and if necessary damaged parts (sealing ring of the crankshaft vibration balancer, deflection rollers, panelling, lines, electric cables etc.) repaired or replaced.

> The reason for the belt breakage must be established. Check deflection rollers or crankshaft vibration balancers for prior damage.

> The power supply to the radiator fans or the battery must be disconnected before starting to work on the radiator or fans (remove fuse, refer to 97 84 IN Fuse carrier - as of MY 2003 (All Models) ). Refer to 90 IN Work instructions after disconnecting the battery - as of MY 2003 (All Models Except Cayenne S TIO Titan) .

Scheme 388

Damage symptoms

Note. The following table indicates damage which necessitates replacement.

Scheme 389

Checking drive belt

Note. If spark plugs must be changed in the course of maintenance operations, the drive belt should be checked when the spark plugs are removed. The engine can then be cranked easier.

Scheme 390

1. Using chalk, mark the drive belt in the area around the tensioning roller.

2. Turn engine at the vibration damper in the direction of movement using a socket wrench (a/f 27) until the chalk mark is at the same place again. While turning at the crankshaft, check the belt at the deflection rollers for signs of damage.

1. Fit intake manifold (cowl). 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) .

1. Remove connecting tube from air cleaner to engine. Refer to 24 35 19 Removing and installing cowl for throttle housing (intake manifold) - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

> Never remove the drive belt when it is hot - let the engine cool down!

> Following a belt breakage the surrounding components and the interior of the engine compartment must be inspected for damage, and if necessary damaged parts (sealing ring of the crankshaft vibration balancer, deflection rollers, panelling, lines, electric cables etc.) repaired or replaced.

> The reason for the belt breakage must be established. Check deflection rollers or crankshaft vibration balancers for prior damage.

Note. If spark plugs must be changed in the course of maintenance operations, the drive belt should be checked when the spark plugs are removed. The engine can then be cranked easier.

1. Mark the rolling direction of the drive belt with chalk.

2. Turn engine at the vibration damper in the direction of movement using a socket wrench (a/f 19) until the chalk mark is at the same place again. While turning at the crankshaft, check the belt at the deflection rollers for signs of damage.

Note. The following table indicates damage which necessitates replacement.

1. Fit connecting tube from air cleaner to engine. Refer to 24 35 19 Removing and installing cowl for throttle housing (intake manifold) - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

Removing drive belt

> Never remove the drive belt when it is hot - let the engine cool down!

> Following a belt breakage the surrounding components and the interior of the engine compartment must be inspected for damage, and if necessary damaged parts (sealing ring of the crankshaft vibration balancer, deflection rollers, panelling, lines, electric cables etc.) repaired or replaced.

> The reason for the belt breakage must be established. Check deflection rollers or crankshaft vibration balancers for prior damage.

Note. If the drive belt is to be re-used, mark the rolling direction with chalk so that the belt can be re-installed later in the same rolling direction.

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

Scheme 391

2. Pull the design cover vertically upwards and off.

3. Remove connecting tube from air cleaner to engine. Refer to 24 35 19 Removing and installing cowl for throttle housing (intake manifold) - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

4. Mark the rolling direction of the drive belt with chalk.

5. Slacken off the belt tensioner. To do this, screw an M8 x 50 screw into the belt tensioner. Do not turn the belt tensioner as far as the stop; only slacken the tensioner until the drive belt is loose.

6. Remove the drive belt from all pulleys.

Installing drive belt

Note. The figure shows the complete belt threading course. The pulleys are numbered according to the sequence of fitting.

Scheme 392

1. Place drive belt around the crankshaft gearwheel and bundle in left direction of travel.

Scheme 393

2. Guide the top end of the belt around the coolant pump. Then, position the belt vertically (turn by 90°) and guide in behind the belt tensioner.

Scheme 394

3. Guide the lower end of the belt on the crankshaft gearwheel around the air-conditioning compressor and then around the hydraulic pump. Push the belt upwards from there.

Scheme 395

4. Guide the drive belt over the drive roller of the generator and then pull a loop down around the deflection roller and lay into position.

5. Check that the drive belt is positioned correctly.

6. Fit connecting tube from air cleaner to engine. Refer to 24 35 19 Removing and installing cowl for throttle housing (intake manifold) - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

Scheme 396

7. Fit the design cover.

8. Install front engine compartment cover. Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .

1. Remove intake manifold (cowl). 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) .

> Never remove drive belt when it is hot.

> Following a belt breakage the surrounding components and the interior of the engine compartment must be inspected for damage, and if necessary damaged parts (sealing ring of the crankshaft vibration balancer, deflection rollers, panelling, lines, electric cables etc.) repaired or replaced.

> The reason for the belt breakage must be established. Check deflection rollers or crankshaft vibration balancers for prior damage.

> The power supply to the radiator fans or the battery must be disconnected before starting to work on the radiator or fans (remove fuse, refer to 97 84 IN Fuse carrier - as of MY 2003 (All Models) ). Refer to 90 IN Work instructions after disconnecting the battery - as of MY 2003 (All Models Except Cayenne S TIO Titan) .

Removing drive belt - Cayenne S

1. Mark the rolling direction of the drive belt with chalk.

Scheme 397

2. Relieve and remove drive belt. To do this, use an open-ended wrench (a/f 30) to turn the belt tensioner clockwise and remove the drive belt from the tensioning roller. Relieve the belt tensioner slowly.

Scheme 398

3. Remove the drive belt from all pulleys.

Installing drive belt - Cayenne S

Note. Figure --> Drive belt threading course, shows the complete belt threading course. The pulleys are numbered according to the sequence of fitting. (Scheme 392)

Scheme 399

1. Make the belt into a loop and place over the crankshaft belt pulley behind the dipstick.

Scheme 400

2. Place the top part of the belt loop over the coolant pump pulley -1- .

Scheme 401

3. Place the lower part of the belt loop around the crankshaft belt pulley at the bottom -2- .

Scheme 402

4. Guide the belt section from the coolant pump around the deflector wheel -3- on cylinder bank 5 - 8. (Scheme 395)

Scheme 403

5. Then guide the section of the belt around the air-conditioning compressor belt pulley -4- at the bottom.

Scheme 404

6. Lay a loop around the power-steering pump -5-. see scheme 209

Scheme 405

7. Lay the loose end of the drive belt from the coolant pump downwards and around the generator pulley -6- and deflector roller -7- of cylinder bank 1 - 4. (Scheme 397)

8. Gather the belt section between the deflection roller of cylinder bank 1 - 4 and the crankshaft pulley to form a loop and guide it upwards to the tensioning roller -8-. Use a wrench (a/f 30) to turn the tensioning roller -8- in a clockwise direction at the hexagon and put on the drive belt. Slowly relieve the tensioning roller. (Scheme 399)

9. Check that the drive belt is positioned correctly on the pulleys.

1. Fit intake manifold (cowl). 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) .

1. Remove intake manifold (cowl). 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) .

> Never remove drive belt when it is hot.

> Following a belt breakage the surrounding components and the interior of the engine compartment must be inspected for damage, and if necessary damaged parts (sealing ring of the crankshaft vibration balancer, deflection rollers, panelling, lines, electric cables etc.) repaired or replaced.

> The reason for the belt breakage must be established. Check deflection rollers or crankshaft vibration balancers for prior damage.

> The power supply to the radiator fans or the battery must be disconnected before starting to work on the radiator or fans (remove fuse, refer to 97 84 IN Fuse carrier - as of MY 2003 (All Models) ). Refer to 90 IN WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY - AS OF MY 2003 (ALL MODELS EXCEPT CAYENNE S TIO TITAN) .

1. Mark the rolling direction of the drive belt with chalk.

2. Relieve and remove drive belt. To do this, use an open-ended wrench (a/f 30) to turn the belt tensioner clockwise and remove the drive belt from the tensioning roller. Relieve the belt tensioner slowly.

3. Remove the drive belt from all pulleys.

Note. Figure --> Drive belt threading course, shows the complete belt threading course. The pulleys are numbered according to the sequence of fitting. (Scheme 402)

1. Make the belt into a loop and place over the crankshaft belt pulley behind the dipstick.

2. Place the top part of the belt loop over the coolant pump pulley -1- .

3. Place the lower part of the belt loop around the crankshaft belt pulley at the bottom -2- .

4. Guide the belt section from the coolant pump around the deflector wheel -3- on cylinder bank 5 - 8. see scheme 220

5. Then guide the section of the belt around the air-conditioning compressor belt pulley -4- at the bottom.

6. Lay a loop around the power-steering pump -5-. see scheme 222

7. Lay the loose end of the drive belt from the coolant pump downwards and around the generator pulley -6- and deflector roller -7- of cylinder bank 1 - 4. see scheme 223

8. Gather the belt section between the deflection roller of cylinder bank 1 - 4 and the crankshaft pulley to form a loop and guide it upwards to the tensioning roller -8-. Use a wrench (a/f 30) to turn the tensioning roller -8- in a clockwise direction at the hexagon and put on the drive belt. Slowly relieve the tensioning roller. see scheme 225

9. Check that the drive belt is positioned correctly on the pulleys.

Scheme 406

1. Disconnect the positive crankcase ventilation line -1- and the control line -2- of the bypass valves at the disconnection points under the left deflection roller. see scheme 226

Scheme 407

2. Mark the rolling direction of the drive belt with chalk.

3. Relieve and remove drive belt. To do this, use an open-ended wrench (a/f 30) to turn the belt tensioner clockwise and remove the drive belt from the tensioning roller. Then relieve the belt tensioner slowly.

4. Remove the drive belt from all pulleys.

Installing drive belt - Cayenne Turbo

Note. Figure --> Drive belt threading course, shows the complete belt threading course. The pulleys are numbered according to the sequence of fitting. (Scheme 402)

1. Make the belt into a loop and place over the crankshaft belt pulley behind the dipstick.

2. Place the top part of the belt loop over the coolant pump pulley -1-. see scheme 232

3. Place the lower part of the belt loop around the crankshaft belt pulley at the bottom -2-. see scheme 233

4. Guide the belt section from the coolant pump around the deflector wheel -3- on cylinder bank 5 - 8. see scheme 234

5. Then guide the section of the belt around the air conditioning compressor belt pulley -4- at the bottom. (Scheme 406)

6. Then lay a loop around the power pump -5-. (Scheme 407)

7. Lay the loose end of the drive belt from the coolant pump downwards and around the generator pulley -6- and deflector roller -7- of cylinder bank 1 - 4. see scheme 237

8. Gather the belt section between the deflector roller of cylinder bank 1 - 4 and the crankshaft pulley to form a loop and guide it upwards to the tensioning roller -8-. Use an open-ended wrench (a/f 30) to turn the tensioning roller -8- clockwise at the hexagon and put on the drive belt. Slowly relieve the tensioning roller. see scheme 239

9. Check that the drive belt is positioned correctly on the pulleys.

10. Connect the positive crankcase ventilation line -1- and the control line -2- of the bypass valves at the disconnection points under the left deflection roller. see scheme 240

1. Fit intake manifold (cowl). 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) .

1. Remove intake manifold (cowl). Refer to 24 35 19 Removing and installing cowl for throttle housing (Y-shaped pipe) - as of MY 2003 (Cayenne Turbo, Cayenne Turbo S) .

> Never remove drive belt when it is hot.

> Following a belt breakage the surrounding components and the interior of the engine compartment must be inspected for damage, and if necessary damaged parts (sealing ring of the crankshaft vibration balancer, deflection rollers, panelling, lines, electric cables etc.) repaired or replaced.

> The reason for the belt breakage must be established. Check deflection rollers or crankshaft vibration balancers for prior damage.

> The power supply to the radiator fans or the battery must be disconnected before starting to work on the radiator or fans (remove fuse, refer to 97 84 IN Fuse carrier - as of MY 2003 (All Models) ). Refer to 90 IN Work instructions after disconnecting the battery - as of MY 2003 (All Models Except Cayenne S TIO Titan) .

Removing drive belt - Cayenne Turbo

1. Disconnect the positive crankcase ventilation line -1- and the control line -2- of the bypass valves at the disconnection points under the left deflection roller. see scheme 242

2. Mark the rolling direction of the drive belt with chalk.

3. Relieve and remove drive belt. To do this, use an open-ended wrench (a/f 30) to turn the belt tensioner clockwise and remove the drive belt from the tensioning roller. Then relieve the belt tensioner slowly.

4. Remove the drive belt from all pulleys.

Note. Figure --> Drive belt threading course, shows the complete belt threading course. The pulleys are numbered according to the sequence of fitting. see scheme 246

1. Make the belt into a loop and place over the crankshaft belt pulley behind the dipstick.

2. Place the top part of the belt loop over the coolant pump pulley -1-. see scheme 248

3. Place the lower part of the belt loop around the crankshaft belt pulley at the bottom -2-. see scheme 249

4. Guide the belt section from the coolant pump around the deflector wheel -3- on cylinder bank 5 - 8. see scheme 250

5. Then guide the section of the belt around the air conditioning compressor belt pulley -4- at the bottom. see scheme 251

6. Then lay a loop around the power pump -5-. see scheme 252

7. Lay the loose end of the drive belt from the coolant pump downwards and around the generator pulley -6- and deflector roller -7- of cylinder bank 1 - 4. see scheme 253

8. Gather the belt section between the deflector roller of cylinder bank 1 - 4 and the crankshaft pulley to form a loop and guide it upwards to the tensioning roller -8-. Use an open-ended wrench (a/f 30) to turn the tensioning roller -8- clockwise at the hexagon and put on the drive belt. Slowly relieve the tensioning roller. see scheme 255

9. Check that the drive belt is positioned correctly on the pulleys.

10. Connect the positive crankcase ventilation line -1- and the control line -2- of the bypass valves at the disconnection points under the left deflection roller. see scheme 256

1. Fit intake manifold (cowl). Refer to 24 35 19 Removing and installing cowl for throttle housing (Y-shaped pipe) - as of MY 2003 (Cayenne Turbo, Cayenne Turbo S) .

Poses Online

See also:
• 10 01 19 Removing and installing V8 4.5 l engine - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan)
• 15 70 21 Removing cylinder head - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan)
• 17 50 21 Removing oil pan - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan)
• 37 35 19 Removing and installing transmission - as of MY 2003 (Cayenne TIP)
• 50 38 09 Detaching and fastening lock mount (service position) - as of MY 2003 (All Models)
• 24 35 19 Removing and installing cowl for throttle housing (intake manifold) - as of MY 2004 (Cayenne TIP, Cayenne MAN)
• 97 84 IN Fuse carrier - as of MY 2003 (All Models)
• 90 IN Work instructions after disconnecting the battery - as of MY 2003 (All Models Except Cayenne S TIO Titan)
• 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models)
• > 131019 Removing and installing pistons - "Removing"