Porsche training p10c v6 cayenne panamera engine repair

® AfterSales Training Cayenne/Panamera Engine Repair P10C V6 Porsche AfterSales Training Student Name: Training Center Location: Instructor Name: Date: _ Important Notice: Some of the contents of this AfterSales Training brochure was originally written by Porsche AG for its restof-world English speaking market The electronic text and graphic files were then imported by Porsche Cars N.A, Inc and edited for content Some equipment and technical data listed in this publication may not be applicable for our market Specifications are subject to change without notice We have attempted to render the text within this publication to American English as best as we could We reserve the right to make changes without notice © 2011 Porsche Cars North America, Inc All Rights Reserved Reproduction or translation in whole or in part is not permitted without written authorization from publisher AfterSales Training Publications Dr Ing h.c F Porsche AG is the owner of numerous trademarks, both registered and unregistered, including without limitation the Porsche Crest®, Porsche®, Boxster®, Carrera®, Cayenne®, Cayman™, Panamera®, Tiptronic®, VarioCam®, PCM®, 911®, 4S®, FOUR, UNCOMPROMISED.SM and the model numbers and distinctive shapes of Porsche's automobiles such as, the federally registered 911 and Boxster automobiles The third party trademarks contained herein are the properties of their respective owners Specifications, performance standards, options, and other elements shown are subject to change without notice Some vehicles may be shown with non-U.S equipment Porsche recommends seat belt usage and observance of traffic laws at all times Printed in the USA Part Number - PNA P10 CV6 01 Edition - 12/11 Table of Contents Description Section Engine Type Designations Cayenne/Panamera 3.0 Liter Supercharged V6 Hybrid Engine Cayenne 3.2 Liter V6 Engine – 1st Generation Cayenne 3.6 Liter V6 Engine – 2nd Generation Additional Notes - V6 Timing Information Conversion Charts Cayenne/Panamera Engine Repair Cayenne/Panamera Engine Repair Engine Type Designations Engine Number Identification Cayenne/Panamera – 3.2 & 3.6 Liter V6 Engines Digit: Example: M 5 0 Engine Version: Serial Number: V6 – The engine number is located on the front right of the crankcase next to the crankshaft pulley 2012 Cayenne S Hybrid & Panamera S Hybrid – 3.0 Liter V6 Engines Change to engine numbering system with introduction of new engine identification codes (EIC) Due to the standardization of production processes in the integrated automotive group, a different engine numbering system for group engines has been used in vehicle production at Porsche since the beginning of June 2011 The engine identification code combination is shown as a 4-character code in applicable vehicle documents and labels, where the fourth letter indicates the performance version of the engine, followed by the 6-digit serial number The 4-character engine identification code combination is also stored in the DME control unit Since this change was introduced, the 3-character engine identification code combination as well as a 6-digit serial number is engraved on the engine block The letter indicating the performance version is no longer shown on the engine block With the change to the engine numbering system, the model year is no longer shown as part of the engine identification code combination Engine Identification Code Performance Version Position Serial Number 10 Example C R C A For all versions, the engine number is located on the front right of the crankcase (in direction of travel) behind the cast coolant adapter Alternatively, a sticker may be located on the upper right chain case cover In order to be able to read off the engine ID here, the air guide pipe lying over the sticker must be removed Cayenne/Panamera Engine Repair Page 1.1 Engine Type Designations Cayenne V6 Engine Type Designations Since Model Year 2004 Model Year Engine Type 2004 Displ Liters Engine Power kW / HP Installed In M02.2Y (BFD) 3.2 V6 184/250 Cayenne 2005 M02.2Y (BFD) 3.2 V6 184/250 Cayenne 2006 M02.2Y (BFD) 3.2 V6 184/250 Cayenne 2008 M55.01 3.6 V6 213/290 Cayenne 2009 M55.01 3.6 V6 213/290 Cayenne 2010 M55.01 3.6 V6 213/290 Cayenne 2011 M55.02 M06.EC 3.6 V6 3.0 V6 220/300 245/333 Cayenne Cayenne S Hybrid 2012 M55.02 MCG.FA 3.6 V6 3.0 V6 220/300 245/333 Cayenne Cayenne S Hybrid Panamera V6 Engine Type Designations Since Model Year 2011 Model Year Engine Type Displ Liters Engine Power kW / HP Installed In 2011 M46.20 M46.40 3.6 V6 3.6 V6 220/300 220/300 Panamera Panamera 2012 M46.20 M46.40 MCG.FA 3.6 V6 3.6 V6 3.0 V6 220/300 220/300 245/333 Panamera Panamera Panamera S Hybrid Page 1.2 Cayenne/Panamera Engine Repair 3.0 Liter Supercharged V6 Subject Page Technical Data Special Tools General Information Engine Data Crankcase Crank Drive Crankshaft Crankcase Ventilation 10 Cylinder Head 12 Chain Drive 13 Auxiliary System Drive 16 Oil Supply 17 Low Delivery Rate 18 High Delivery Rate 19 Checking the Engine-Oil Level 22 Cooling System 22 High-Temperature Cooling System 23 Low-Temperature Cooling System 24 Supercharger 26 Intake Manifold Flaps 30 Sound Insulation 31 Air Injection System 32 Cayenne/Panamera Engine Repair Page 2.1 3.0 Liter Supercharged V6 Technical Data Valve clearance Engine Specifications for the 3.0 l V6 Supercharged Engine (MY 2011) Engine type Number of cylinders Valves per cylinder Turbocharging Effective displacement Bore Stroke Compression ratio Max power At engine speed Max torque At engine speed Idle speed Max engine speed Engine speed limitation 90° V-engine Mechanical supercharger with charge-air cooling, coolers (water/air), low-temperature cooling system 2,995 cc 84.5 mm 89 mm 10.5 : 333 hp (245 kW) 5,500 - 6,500 rpm 327 ft lb (440 Nm) 3,000 - 5,250 rpm 800 rpm 6,500 rpm Electronic throttle and fuel cutoff Crankshaft bearings Connecting rods Connecting-rod bearings Pistons Piston rings Cylinders Cylinder head Valve guide Valve arrangement Valve control Page 2.2 Engine Cooling Coolers Coolant Fan motors Engine Design Engine weight (hybrid only) Type 6-cylinder Crankcase Crankshaft Hydraulic valve clearance compensation Valve diameter Inlet 32.85 mm Exhaust 26.59 mm Valve lift, inlet 10 mm Valve lift, exhaust 10 mm Camshaft Built with steel cams Camshaft drive Roller chain Intake camshaft adjustment Vane-type adjuster, 42° camshaft angle, continuously adjustable Valve timing, inlet opens 14° before TDC to 28° after TDC Valve timing, inlet closes 6° to 48° after BDC Valve timing, exhaust opens 39° before BDC Valve timing, exhaust closes 9° before TDC Switching rpm Map-controlled Intake manifold Intake module with integrated air/water charge-air coolers 398 lbs (180.7 kg) 90° V-engine Hypereutectic aluminum Forged, supported by bearings Binary bearings with anti-friction coating, dia 65 mm Forged, l = 153 mm Ternary bearings, dia 56 mm Cast aluminum compression rings, oil scraper ring Honed aluminum Two-part, aluminum with guide frame Brass on intake side, sinter on exhaust side parallel overhead inlet valves parallel overhead exhaust valves Water cooler at front/chargeair cooler 13.2 l - 17.6 l (dependent on equipment version) DC* + DC or DC + EC** (dependent on country/equipment version) * DC = Direct current **EC = Electronically commutated Rocker arm Cayenne/Panamera Engine Repair 3.0 Liter Supercharged V6 Electrical System (low voltage) Engine Lubrication Type Oil cooling Oil filter Oil pressure when n=5,000 rpm; at 194° F (90° C.) Pressure-fed lubrication with wet sump Oil/water heat exchanger On pressure side behind oil pump Rated voltage Battery capacity, basic equipment Battery capacity, available to order 12 V 92 Ah, 520 A 105 Ah, 580 A Exhaust System Approx 66.7 psi (4.6 bar) absolute Oil pressure indication Warning via instrument cluster Oil level check Via instrument cluster/PIWIS Tester Oil consumption < qt./600 miles Engine oil quantity 8.6 qt (8.1 l) Oil change quantity w/filter 7.1 qt (6.75 l) Engine oil specification In accordance with technical literature Engine control Engine control unit Bosch DME 17 with EOBD (USA: OBD II) Ignition Single-spark ignition modules Firing order 1-4-3-6-2-5 Fuel delivery Demand-controlled EC fuel pump, two supply driven sucking jet pumps Fuel system Returnless Min fuel quality 93 octane ( R+M ) Fuel consumption Fuel consumption in USA (ULEV II) City 20 mpg Highway 24 mpg Combined 21 mpg Exhaust system structure Emission control system Twin-branch exhaust system with main catalytic converters (close-coupled), front and rear muffler EU & EU Oxygen sensor closed-loop control + postcatalytic control (4 sensors) 3-way catalytic converter system with close-coupled main catalytic converters, ceramic substrate in main catalytic converter Front and rear silencers with secondary air EOBD, in USA: OBD II Notes: Cayenne/Panamera Engine Repair Page 2.3 3.0 Liter Supercharged V6 Special Tools Required For Engines Repairs Description: Guide pins Tool Number: T10441 Use: For R & R the hybrid module Description: Puller hook Tool Number: T 20143 Use: For removing sealing rings Description: Centering mandrel Tool Number: T10442 Use: For centering the clutch plate Description: Socket insert Tool Number: T10035 Use: For removing camshaft timing chains from the camshafts Description: Puller Tool Number: T40039 Use: For R & R ignition coils with output final stage Description: Removal lever Tool Number: 80-200 Use: For pressing off the selector lever Description: Mandrel Tool Number: VW 222 A Use: For R & R piston pins, for installing starter bushing Description: Adapter Tool Number: T40058 Use: For turning the crankshaft at the front end Description: Support bridge Tool Number: 30-211 A Use: For securing the torque converter in the transmission Description: Locking pins Tool Number: T40071 Use: For securing the chain tensioner in pressed position Description: Spanner wrench Tool Number: T10172 Use: For countering sprocket for oil pump gear and drive plate Description: Locating pins Tool Number: T40116 Use: For removing and installing camshafts Description: Oil level tester Tool Number: T40178 Use: For checking the oil level after replacing the oil sensor Description: Locating screw Tool Number: T40069 Use: For securing the crankshaft and setting the timing Description: Seal installer Tool Number: T10124 Use: For installing PTFE crankshaft sealing ring (side of vibration damper) Description: Holding device Tool Number: T40133 Use: For securing camshafts when setting the timing Page 2.4 Cayenne/Panamera Engine Repair Cayenne 3.6 (V6) – 2nd Generation Cyclone Oil Separator Function The cyclone oil separator separates the oil from the oil vapor that is drawn in It works according to the principle of centrifugal separation The cyclone design of the oil separator means that the oil vapors are moved in a rotating movement The centrifugal force that is created flings the oil onto the partition wall, where it combines to form larger drops While the separated oil drips into the cylinder head, the gas particles are fed into the intake manifold through a flexible pipe - Cyclone oil separator - Pressure regulating valve - To intake manifold - Oil discharge opening The cyclone oil separator is in the cylinder head cover Its main function is to separate oil from the blow-by gases in the crankcase and return it to the oil circuit A pressure regulating valve limits the intake manifold vacuum from approx 700 mbar to approx 40 mbar This prevents the entire intake manifold vacuum and the internal crankcase pressure from affecting positive crankcase ventilation, thereby drawing in engine oil or damaging seals - Intake - Gas feed to intake manifold - Gas particles - Oil drops - Oil-discharge opening in crankcase Positive Crankcase Ventilation Heating - Cyclone oil separator - Oil-discharge opening The heating element -1- is inserted in the flexible pipe connecting the cyclone oil separator to the intake manifold and prevents the incoming blow-by gases from freezing when the intake air is very cold - Vacuum valve - Intake manifold Page 4.10 Cayenne/Panamera Engine Repair Cayenne 3.6 (V6) – 2nd Generation Oil Pump With Oil Reservoir Oil Circuit The oil reservoir is formed in the cylinder block by a cavity behind the oil pump It has a volume of approx 280 ml and is retained even after the engine is stopped - Cylinder head - Oil reservoir - Service opening - Cylinder block - Camshaft adjuster - Drive gear - Camshaft bearing - Oil pump - Chain tensioner Notes: - Chain tensioner - Oil pump - Oil reservoir - Intake duct - Oil pan - Oil return 10 - Oil filter / oil/water heat exchanger 11 - Crankshaft bearing 12 - Piston spray nozzles 13 - Oil reservoir 14 - Fuel high-pressure pump drive 15 - Hydraulic tappet 16 - Camshaft adjuster The oil pressure is generated by a self-priming oil pump -5- This is mounted in the cylinder block and is driven by the chain drive The installation position ensures a long suction route -7-, which lasts for the duration of time required to supply initial oil to the components For this reason, oil is taken from a reservoir -6- behind the oil pump to guarantee the initial oil supply The oil pump draws the oil from the oil pan -8- and then pumps it to the oil filter and oil/water heat exchanger -10- Cayenne/Panamera Engine Repair Page 4.11 Cayenne 3.6 (V6) – 2nd Generation Service Opening Oil Return - Cover screw - Pressure piston The service opening allows access to the oil pressure regulating piston in the oil pump when the engine is installed The pressure piston in the oil pump can be removed through the opening without having to remove the chain drive by unscrewing the cover screw and a second inner screw The oil that flows back is routed into a central oil return duct -1- in the cylinder block via three return ducts in the cylinder head The oil then flows back under the oil level into the oil pan In addition to the central oil return system, oil at the front is also returned to the oil pan via the chain drive housing Notes: Oil/Water Heat Exchanger With Oil Filter The oil/water heat exchanger and the oil filter with bypass valve form one unit Page 4.12 Cayenne/Panamera Engine Repair Cayenne 3.6 (V6) – 2nd Generation Cooling System - Reservoir - Heat exchanger - Coolant pump - ATF/water heat exchanger - Coolant thermostat - Oil/water heat exchanger - Check valve - Electric additional coolant pump - Check valve 10 - Additional radiator 11 - Vehicle radiator Coolant is circulated by the mechanical coolant pump The pump is driven by the poly V-belt The circuit is controlled by the thermostat The check valves are integrated into the circuit in such a way as to prevent coolant flowback Notes: The amount of coolant depends on the vehicle equipment and is generally between 14 qts (13.2 liters) and 18.6 qts (17.6 liters) Cayenne/Panamera Engine Repair Page 4.13 Cayenne 3.6 (V6) – 2nd Generation Notes: Page 4.14 Cayenne/Panamera Engine Repair Additional Notes Cayenne V6 – Setting Engine Timing 1st Generation V6 engine 2003-2006 referred to as MPI (manifold injection) 2nd Generation V6 engine 2008 >, referred to as FSI (DFI) engine Important! > Care must be taken to align copper links, double arrows (on adjusters) and notches for the correct engine otherwise other faults can show up, especially for rough running > When aligning the intake adjuster, draw a straight line from the double arrow on the adjuster thru the copper link and then to the correct notch in the housing Otherwise you may get a signal for faulty camshaft reference sensor.(see picture) > When aligning the exhaust adjuster, draw a straight line from the double arrow (it is at a 45° angle) thru the copper link and then to the correct notch in the housing Otherwise you may get a signal for faulty camshaft reference sensor.(see picture) > There should be no slack in the chain from the oil pump gear up and over the adjusters to the high pressure fuel pump > Any time that the cylinder head is removed all timing positions must be set > Also, if the fuel pump is not set up as shown you may also get a fault for high fuel pressure at idle Set up TDC mark as shown Cayenne/Panamera Engine Repair Page 5.1 Additional Notes Assembly aid - cut tooth Assembly aid - cut tooth alignment Align oil pump as shown Page 5.2 Cayenne/Panamera Engine Repair Additional Notes With crankshaft to oil pump chain installed Although the workshop manual does not note this position, here are the copper links and how they align on the oil pump drive Special tool T10068A installed on Camshafts Cayenne/Panamera Engine Repair Page 5.3 Additional Notes Marking on fuel pump gear Dot on cam must be facing up Here is alignment of the high pressure fuel pump with the timing chain (copper link) and special tool T10363 Please note special tool, casing tab, dot on gear and copper link must aligned otherwise a fault code P-2293 may occur 10 With crankshaft to oil pump chain installed Page 5.4 Cayenne/Panamera Engine Repair Additional Notes 11 After rotating the adjuster as far as it will go to the right, install chain with copper link in the position shown A line between the double arrow on adjuster, the copper link and the correct (determined by the type engine) notch must align perfectly As of the middle of 2005, timing chain housings with two notches were installed with the inscription MPI (intake manifold injection engine) and FSI (DFI engine) Intake Adjustment 12 Exhaust adjuster align with double arrow, copper link and notch on housing as shown As of the middle of 2005, timing chain housings with two notches were installed with the inscription MPI (intake manifold injection engine) and FSI (DFI engine) Exhaust Adjustment 13 This is a good indication that timing is correct, when pulling out the Hall sensor on the camshaft adjustor you will see this position Cayenne/Panamera Engine Repair Page 5.5 Additional Notes Notes: Page 5.6 Cayenne/Panamera Engine Repair Conversion Charts Metric Conversion Formulas Temperature Conversion INCH X MM X MILE X KM (KILOMETER) X OUNCE X GRAM X POUND (lb) X kg (KILOGRAM) X CUBIC INCH X cc (CUBIC CENTIMETER) X LITERS X CUBIC FEET (cu.ft.) X CUBIC METERS X FOOTPOUND(ft lb) X Nm (NEWTON METER) X HORSEPOWER (SAE) X HORSEPOWER (DIN) X Kw (KILOWATT) X HORSEPOWER (SAE) X MPG (MILES PER GALLON) X BAR X PSI (POUND SQUARE INCH) X GALLON X LITER X FAHRENHEIT CELSIUS X 25.4 0394 1.609 621 28.35 0352 454 2.2046 16.387 061 0353 28.317 35.315 1.3558 7376 746 9861 1.34 1.014 4251 14.5 0689 3.7854 2642 32÷1.8 1.8+32 Cayenne/Panamera Engine Repair = = = = = = = = = = = = = = = = = = = = = = = = = = MM INCH KILOMETER (KM) MILE GRAM OUNCE KILOGRAM (kg) lb (POUND) CUBIC CENTIMETER (cc) CUBIC INCH CUBIC FEET (cu.ft.) LITERS CUBIC FEET (cu.ft.) NEWTON METER (Nm) ft lb (FOOT POUND) KILOWATT (Kw) HORSEPOWER (SAE) HORSEPOWER (SAE) HORSEPOWER (DIN) Km/l (KILOMETER PER LITER) POUND/SQ INCH (PSI) BAR LITER GALLON CELSIUS FAHRENHEIT Page 6.1 Conversion Charts Notes: Page 6.2 Cayenne/Panamera Engine Repair Part Number - PNA P10 CV6 01 ... 3.6 V6 3.6 V6 220/300 220/300 Panamera Panamera 2012 M46.20 M46.40 MCG.FA 3.6 V6 3.6 V6 3.0 V6 220/300 220/300 245/333 Panamera Panamera Panamera S Hybrid Page 1.2 Cayenne/ Panamera Engine Repair. .. 3.6 V6 213/290 Cayenne 2009 M55.01 3.6 V6 213/290 Cayenne 2010 M55.01 3.6 V6 213/290 Cayenne 2011 M55.02 M06.EC 3.6 V6 3.0 V6 220/300 245/333 Cayenne Cayenne S Hybrid 2012 M55.02 MCG.FA 3.6 V6. .. injectors Cayenne/ Panamera Engine Repair Page 2.5 3.0 Liter Supercharged V6 Description of Engine Engine Data Porsche uses a 3.0 l V6 supercharged engine with direct fuel injection in the Cayenne