Assembling V6 (BFD) engine
| WARNING | Danger of cutting oneself on sharp metal edges! |
> Wear suitable protective clothing (e. g. gloves).
| CAUTION | Damage to sensitive engine components (e. g. speed sensor wheel) |
> Conscientious and precise work
> Use suitable storage places.
| WARNING | Risk of crushing your hands when lifting the crankshaft! |
> Hold the very outside of the crankshaft.
> Wear gloves.
> Get an assistant to help lift the crankshaft.
| CAUTION | Leaks due to components being at too low a temperature or at different temperatures! If components that are cold or at different temperatures are sealed together by the application of sealant, adhesion problems and leaks can arise due to the build-up of condensation water or component distortion. |
> Components must have reached at least 17°C throughout.
> Components must not be too hot (distortion).
> Spare parts that are stored in the cold or heat (strong sunlight), must be brought to room temperature or the same temperature as other parts before installation.
Scheme 46
1. Replace crankshaft bearing shells (color markings must match). Insert and oil crankshaft bearing shells (on crankcase side). Make sure the twist lock is positioned in the corresponding cut-out --> Bearing shell. For details, refer to 13 48 19 Removing and installing crankshaft - as of MY 2004 (Cayenne TIP, Cayenne MAN). (Scheme 40)
2. Insert crankshaft into the oiled bearing.
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
3. Fit thrust bearing no. 5 with thrust washers -4- (insert with grease, lubricating groove facing outwards), then fit the remaining bearing covers -1- (from exhaust side no. 1, numbering legible opposite output). (Scheme 41)
4. Position bearing covers by tapping with a rubber hammer.
5. Replace bearing screws -2- and tighten to the specified tightening torque in stages from the middle outwards. --> 10 01 IN Tightening torques for Cayenne (engine type BFD) - as of MY 2004 (Cayenne TIP, Cayenne MAN) (Scheme 41)
6. Turn crankshaft to try it out.
Scheme 47
Note. Piston installation instructions must be followed at all times. Refer to 13 10 19 Removing and installing pistons - as of MY 2004 (Cayenne TIP, Cayenne MAN) .
- The cast lugs, twist locks (retaining lugs) -1- and the flat side of the piston crown -2- are on the same side. (Scheme 42)
7. Insert oiled pistons and connecting rods using a funnel T10147 . Turn the crankshaft back and forth as required so that there is sufficient room for installation. Align flat side of piston crown to the middle of the cylinder block. Always align the pins -arrow- on the funnel T10147 to the middle of the cylinder block.
Note. Always replace the connecting-rod bearing shells and oil them before inserting them into the bearing covers.
Scheme 48
- The connecting-rod big end and connecting-rod bearing caps must be aligned according to the cast lugs -B and C-. The retaining lugs of the connecting-rod bearing shells are on one side. Connecting-rod bearing caps are legible on alternate sides. (Scheme 43)
- Install connecting rod and connecting-rod bearing caps unrestrained. If necessary, remove them again, position the bearing caps by tapping lightly with a plastic hammer and then refit them.
8. Align the connecting rods of the pistons to the crank pins. Oil the bearings. Position connecting-rod bearing covers in the correct sequence and screw bolts into the connecting-rod big end by hand. Retaining lugs of bearing shells must be pressed together.
9. Position the connecting-rod bearings by tapping with a plastic hammer. Tighten all connecting-rod screws to the prescribed tightening torque. --> 10 01 IN Tightening torques for Cayenne (engine type BFD) - as of MY 2004 (Cayenne TIP, Cayenne MAN) .
10. Turn the crankshaft provisionally with belt pulley and fastening screw to check for smooth operation.
Scheme 49
11. Turn the crankshaft so that the sender gap on the speed sender ring gear is pointing downwards to the middle (rough TDC presetting).
12. Fit the sealing flange behind the crankshaft belt pulley. For details, refer to 13 48 19 Removing and installing crankshaft - as of MY 2004 (Cayenne TIP, Cayenne MAN) .
13. Fit the crankshaft belt pulley with a helper. To do this, block the pulley using an arm bracket T10069 and fit the M18 x 40 fastening screw. Use a new fastening screw. --> 10 01 IN Tightening torques for Cayenne (engine type BFD) - as of MY 2004 (Cayenne TIP, Cayenne MAN) .
14. Install oil pump. Refer to 17 20 19 Removing and installing oil pump - as of MY 2004 (Cayenne TIP, Cayenne MAN) .
15. Turn engine in engine support.
16. Install oil pump drive. Refer to 17 22 19 REMOVING AND INSTALLING OIL PUMP DRIVE - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN) LUBRICATION .
17. Insert oil retaining valve with sealing ring in crankcase -arrow-. (Scheme 47)
18. Turn engine to the ignition TDC of cylinder 1. To do this, turn the crankshaft so that the notch on the pulley is aligned with the marking on the housing cover.
19. Position cylinder-head gasket correctly on the dowel sleeves (inscription pointing upwards) and install the cylinder head. For details, refer to 15 70 23 Installing cylinder head - as of MY 2004 (Cayenne TIP, Cayenne MAN) .
Scheme 50
20. Assemble support element, roller-type cam followers and safety clips or check that they are assembled correctly. Make sure the support elements and roller-type cam followers are joined correctly by the safety clips -1 and 2-. (Scheme 49)
Scheme 51
21. Oil the components. Install support element/roller-type cam follower. Make sure that the safety clip does not slip out of place during installation. The pressure face of the roller-type cam follower -3- must rest on the valve pressure face. This can slip out of place when the camshaft is installed later. see scheme 463
22. Install camshafts. Refer to 15 05 23 Installing camshafts - as of MY 2004 (Cayenne TIP, Cayenne MAN) .
23. Check that the crankshaft is positioned at the TDC of cylinder 1.
Scheme 52
24. Fit timing chain housing. To do this, slide the timing chain housing on to the oiled sealing rings of the camshafts. If necessary, press the sealing rings together in the ring stacks -arrows-. Push the timing chain housing up as far as the centering pins. see scheme 466
Scheme 53
25. Fit the four M6 x 30 fastening screws with securing liquid -arrows-. --> Tightening torque: 8 (6 ftlb.) Nm. see scheme 467
26. Install camshaft adjusters. Refer to 15 84 23 Installing camshaft adjusters - as of MY 2004 (Cayenne TIP, Cayenne MAN) .
27. Set the timing. Refer to 15 05 16 Setting the timing - as of MY 2004 (Cayenne TIP, Cayenne MAN) .
28. Install bottom chain case lid. Refer to 15 33 23 INSTALLING CHAIN CASE LID - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN) or 15 33 23 INSTALLING CHAIN CASE LID - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN) .
29. Install top chain case lid. Refer to 15 33 23 INSTALLING CHAIN CASE LID - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN) or 15 33 23 INSTALLING CHAIN CASE LID - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN) .
30. Fit water tube -6- in water pump housing (tap pointing downwards). (Scheme 50)
31. Turn engine through two turns at the crankshaft and check the timing again. Refer to 15 05 02 Checking the timing - as of MY 2004 (Cayenne TIP, Cayenne MAN) .
32. Install cylinder head cover. Refer to 15 91 23 INSTALLING COVER FOR CAMSHAFT HOUSING - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN) .
33. Fit oil/water heat exchanger -3 to 5-. Fit oil filter housing/engine support arm -10-. Replace seals -2 and 3-. --> Tightening torque: 23 (17 ftlb.) Nm (Scheme 51)
34. Install fuel distribution pipe and fuel injectors. Refer to 24 30 19 Removing and installing fuel distributor pipe - as of MY 2004 (Cayenne TIP, Cayenne MAN) .
35. Insert water pump with new seal and secure from the front through the belt pulley with three internal-serration screws. Refer to 19 50 19 Removing and installing coolant pump - as of MY 2004 (Cayenne TIP, Cayenne MAN) .
36. Place aluminum water tube in installation position. Secure water hoses. --> Tightening torque: 8 (6 ftlb.) Nm
37. Fit exhaust manifolds. Refer to 26 10 19 Removing and installing exhaust manifold - as of MY 2004 (Cayenne TIP, Cayenne MAN) .
38. Fit intake-air distributor. Refer to 24 46 19 Removing and installing intake-air distributor - as of MY 2004 (Cayenne TIP, Cayenne MAN) .
39. Fit oil dip stick with a new sealing ring and insert into guide tube. Refer to 17 17 19 Removing and installing guide tube for oil dip stick - as of MY 2004 (Cayenne TIP, Cayenne MAN) .
40. Fit unit holder. To do this, insert two fit bolts and three fastening screws and tighten holder. --> Tightening torque: 23 (17 ftlb.) Nm
41. Install generator. Refer to 27 22 19 Removing and installing three-phase generator - as of MY 2004 (Cayenne TIP, Cayenne MAN) .
42. Install servo pump. Refer to 48 98 19 Removing and installing hydraulic pump (Cayenne V6) - as of MY 2004 (Cayenne TIP, Cayenne MAN) .
43. Fit engine wire harness. Refer to 97 52 23 Installing wiring harness for engine (V6) - as of MY 2004 (Cayenne TIP, Cayenne MAN) .
44. Fit the deflection roller in front of the generator. Press on plastic lid.
45. Fit belt tensioner with bracket using three fastening screws. Refer to 13 73 19 Removing and installing belt tensioner - as of MY 2004 (Cayenne TIP, Cayenne MAN) .
46. Fit and tension the drive belt. Refer to 13 78 19 Removing and installing drive belt - as of MY 2004 (Cayenne TIP, Cayenne MAN) .