Assembling engine Porsche Cayenne I рестайлинг

Assembling engine

> 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 56

Note. The engine must be disassembled in accordance with the detailed descriptions in the article! This article does not provide details or further information. Further details can be found in the relevant individual descriptions.

Note. Four oil spray nozzle are installed in the M48/50 engine instead of the caps used in the M48/00 engine.

1. Fit caps on crankcase. When doing so, make sure that new O-rings are fitted. Tighten the --> Tightening torque: 10 (7.5 ftlb.) Nm .

Scheme 57

Note. The bearing shells are available in various tolerance classes. The classes are indicated by the color marking on the outside. The color marking must match the corresponding color dot on the crankshaft. Further details: Refer to 13 48 19 Removing and installing crankshaft - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

2. Insert the bearing shells with the lubricating groove into the upper part of the crankcase --> Inserting bearing shells. Make sure the twist locks are positioned correctly. Then lightly oil the bearing locations. see scheme 476

Scheme 58

3. Insert the sickle-shaped washers (make sure of axial bearing play). To do this, insert the two sickle-shaped washers to the left and right on crankshaft bearing no. 3. Apply some grease (000.043.204.17) between the crankshaft bearing and the sickle washers so that the sickle washers do not fall down. Each of the lubricating grooves of the sickle-shaped washers must face outwards. see scheme 478

Scheme 59

> Hold the very outside of the crankshaft.

> Wear gloves.

4. 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. Attach the holding bridges at bearing locations 3 and 5 --> Crankshaft holding bridges. Then screw the fastening screw of the front pulley into the crankshaft until they just make contact. see scheme 479

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

Scheme 60

Note. The pistons must already be pre-fitted (pistons, piston rings, connecting rods and fastening material) before performing the next step. The required bearing shells must be inserted in the connecting rods.

1. The connecting rod is symmetrical and can be fitted either on the piston so that the number on the connecting rod is facing outwards or inwards, or the tolerance class designation of the piston does not have to be on the same side as the connecting rod code. 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 on the same side as shown here, and on the other cylinder bank side, the connecting rod code is on the opposite side. The connecting rod code is installed to the exhaust side as standard. see scheme 481

Scheme 61

1. When installing the piston in the crankcase, the direction of travel arrow must point in the direction of travel.

1. For further information, refer to «13 10 19 Removing and installing pistons - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan)»(ref-274616-S06049118092007121900000) .

Scheme 62

1. The code on the connecting-rod big end and connecting-rod bearing cap must be on the same side and at the exhaust side.

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

7. Lightly oil cylinder and piston.

Scheme 63

8. Align piston-ring set (offset by 120°) and compress piston rings using piston ring restraining strap for 944 - S2 and Boxster and 911 Carrera (996) 57 .

Scheme 64

9. Place piston onto cylinder from above and push into cylinder. When doing so, make sure that the direction of travel arrow is pointing forwards (in direction of travel). -Arrow- (Scheme 55)

Scheme 65

Sliding in the piston

10. Push the piston downwards until the connecting-rod bearing is sitting on the lift pin. Then fit connecting-rod bearing cap with bearing shell. The connecting rod numbers must face each other. Screw in con-rod bolts by hand. Make sure the twist locks and connecting rod code are positioned correctly during assembly.

11. Fit the opposite piston (e. g. 1 and 4).

12. Fit other pistons in accordance with the step above.

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

Note. Con-rod bolts must always be replaced.

14. Tighten con-rod bolts that have been replaced., refer to 13 10 19 Removing and installing pistons - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

15. Holding bridges P 9677 must be removed from the crankshaft.

Scheme 66

16. Screw the two thin centering pins P 9321 into the outer fastening bores on the upper part of the crankcase -Arrows- (crankshaft not fitted in illustration). (Scheme 58)

17. Insert the bottom bearing shells into the lower part of the crankcase (bed plate) and lightly oil running surfaces. Pay attention to the twist locks when doing so.

18. 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.

Scheme 67

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; 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

Note. Liquid sealant must be applied and screws tightened immediately and without interruption. The threads and head contact surface of the bearing seat screws (M10 x 1.5 and M12 x 1.5) must be oiled.

19. Apply liquid sealant 000.043.204.58 (status 02/06, for details of current sealant, see Parts Catalogue) to the lower part of the crankcase as shown. The surfaces marked -A- must be cleaned after fitting. (Scheme 61)

Scheme 68

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

21. For details of the tightening sequence for the lower part of the crankcase and tightening torques, refer to 13 48 19 Removing and installing crankshaft - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

Scheme 69

22. Then tighten the four fastening screws on the clutch side --> Tightening torque: 23 (17 ftlb.) Nm -Arrows-. (Scheme 62)

Scheme 70

23. 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. The double-tooth row must be facing forwards.

Scheme 71

24. 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) .

25. Fit guide rail -9- and tensioning rail -6- for the oil pump drive. Push the tensioning rail over the fastening pin and engage the guide rail in the lower part of the crankcase as shown in the illustration. (Scheme 65)

Scheme 72

Scheme 73

26. Fit timing chain cover on oil pump. Tighten --> Tightening torque: 10 (7.5 ftlb.) Nm .

27. Turn engine 180° on the assembly support.

Scheme 74

28. Install starter Refer to 27 60 19 Removing and installing starter - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo) or 27 60 19 REMOVING AND INSTALLING STARTER - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN) .

Scheme 75

29. Fit knock sensors. Align the knock sensors as shown in the illustration and tighten the --> Tightening torque: 23 (17 ftlb.) Nm .

Scheme 76

30. Install thermostat housing. Fit a new O-ring at the water pump inlet and then insert the thermostat housing. Tighten the two --> Tightening torque: 10 (7.5 ftlb.) Nm .

31. Mount cylinder heads. To do this, turn the engine on the assembly support so that the required cylinder row is pointing vertically upwards.

Scheme 77

32. Fit new cylinder-head gasket. The gasket designation is shown on the back and is legible from above when fitted correctly.

Scheme 78

33. Fit cylinder head. The fastening screws must be tightened in the sequence shown below. The tightening sequences and step-by-step tightening torques must be observed! For details, 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) .

Scheme 79

34. Fit camshaft housing. Apply a bead of liquid sealant 000.043.204.58 (status 02/06, for details of current sealant, see Parts Catalogue) -A- as shown. Then screw two thin centering pins P 9321 into two opposing blind holes in the cylinder head. Insert the O-ring -B- into the oil duct. Wipe off any sealant -C- that emerges as a result of screwing. (Scheme 70)

Scheme 80

35. Position camshaft housing and then unscrew the two centering pins.

36. Tighten the camshaft housing screws in the sequence shown. Don't forget the two hexagon socket head bolts at the front of the camshaft housing. For details, refer to 15 03 23 Installing camshaft housing - as of MY 2005 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

Scheme 81

Scheme 82

Note. The bearing locations of the camshafts must be lightly oiled. Place the camshafts in such a way that the cams are positioned as shown below!

37. Install camshafts. Refer to 15 05 23 Installing camshafts - as of MY 2005 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

Scheme 83

1 - Cam position cylinder 6

2 - Cam position cylinder 2 (A) and cylinder 3 (B)

D - Cam position cylinder row 5 - 8 exhaust side

C - Cam position cylinder row 5 - 8 inlet side

B - Cam position cylinder row 1 - 4 inlet side

A - Cam position cylinder row 1 - 4 exhaust side

38. Fit oil return line to camshaft housing 5 - 8. Fit oil return line -1- with a new O-ring -2-. Tighten the four --> Tightening torque: 10 (7.5 ftlb.) Nm -3 and 4- (camshaft housing, cylinder head, crankcase and oil pan). (Scheme 74)

Scheme 84

39. Position oil feed housing of inlet camshaft and tighten --> Tightening torque: 10 (7.5 ftlb.) Nm .

Scheme 85

Note. If the camshaft timing gears and camshaft adjusters are removed completely, the diamond washers and fastening screws must be replaced!

40. Replace the diamond washer and fastening screw located underneath the camshaft adjuster and camshaft timing gear.

41. Fit deflection rail -4-. Refer to 15 47 19 REMOVING AND INSTALLING GUIDE AND TENSIONING RAILS - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN) or 15 47 19 REMOVING AND INSTALLING GUIDE AND TENSIONING RAILS - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN). (Scheme 76)

Scheme 86

Scheme 87

> Do not turn camshaft switch-over valve.

42. Install camshaft switch-over valves --> Tightening torque: 10 (7.5 ftlb.) Nm. --> Fastening screw for camshaft switch-over valve shows procedure with timing-case cover fitted. (Scheme 77)

43. Fit timing drive mechanism. Fit guide rail of cylinder bank 5 - 8. Tighten the leaf spring of the oil pump tensioning rail at the same time. Refer to 15 47 19 REMOVING AND INSTALLING GUIDE AND TENSIONING RAILS - AS OF MY 2003 (CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO, CAYENNE TURBO S, CAYENNE S TIO TITAN) or 15 47 19 REMOVING AND INSTALLING GUIDE AND TENSIONING RAILS - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN) .

44. Fit tensioning rail to cylinder bank 1 - 4.

Scheme 88

45. Install timing chain. Position the chain on the crankshaft gear wheel and then fit it over all four camshaft timing gears. To do this, use both hands to carefully insert the camshaft adjuster and camshaft timing gear into the timing chain. Screw in fastening screws on the timing gears loosely to half a turn. --> Installing timing chain shows procedure with timing-case cover fitted. Screw in fastening screws on the timing gears loosely to half a turn. Refer to 15 35 23 Fitting timing chain - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan). (Scheme 78)

46. Fit U-rail. Insert the U-rail into the timing drive mechanism from above. Tighten the four fastening screws.

Scheme 89

47. Fit the short guide rails between the camshaft timing gears. --> Guide rails shows assembly with timing-case cover fitted. (Scheme 79)

48. Fit timing-case cover. 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) .

Scheme 90

49. Place sealing ring over crankshaft using assembly sleeve.

Scheme 91

50. Tighten the two upper fastening screws (M6 x 50) and the lower fastening screws (M6 x 12) by hand.

51. Tighten the two upper fastening screws (M6 x 50) and the lower fastening screws (M6 x 12) by hand. Then tighten the screws crosswise. --> Tightening torque: 10 (7.5 ftlb.) Nm

Scheme 92

52. Pull assembly sleeve evenly off the sealing ring.

Scheme 93

Note. If the sealing flange on the pulley is slightly rusted, polish the rust off with a special polishing pad (e. g. Never Dull). If the sealing flange is badly corroded or contains deep grooves, replace it.

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

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

Scheme 94

54. Fit 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) .

55. Fit drive plate or flywheel.

Scheme 95

56. Install chain tensioner with new sealing ring. --> Tightening torque: 60 (44 ftlb.) Nm

Note. To remove the play from the timing chain for the setting process, the crankshaft must be positioned approx. 45° in front of the TDC of cylinder 1 before turning!

57. Set the timing. Refer to 15 05 16 Adjusting the timings for the camshafts - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

58. Install the camshaft housing cover on both cylinder rows 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) .

59. Fit water pump. Refer to 19 50 19 Removing and installing coolant pump - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S) .