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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Cayenne/Panamera 3.0 Liter Supercharged V6 Hybrid Engine . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Cayenne 3.2 Liter V6 Engine – 1st Generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Cayenne 3.6 Liter V6 Engine – 2nd Generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Additional Notes - V6 Timing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Conversion Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Cayenne/Panamera Engine Repair


Cayenne/Panamera Engine Repair


Engine Type Designations
Engine Number Identification

Cayenne/Panamera – 3.2 & 3.6 Liter V6 Engines
Digit:

1 2 3

4 5 6 7 8

Example:

M 5 5

0 0 5 0 1

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

1 2 3 4 5 6 7 8 9 10

Example C R C A 1 3 2 4 5 3

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 4

2012

M46.20
M46.40
MCG.FA

3.6 V6
3.6 V6
3.0 V6

220/300
220/300
245/333

Panamera
Panamera 4
Panamera S Hybrid

Page 1.2

Cayenne/Panamera Engine Repair


3.0 Liter Supercharged V6

Subject

Page

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Crank Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
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
6
4
Mechanical supercharger
with charge-air cooling, 2
coolers (water/air), low-temperature cooling system
2,995 cc
84.5 mm
89 mm

10.5 : 1
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 4 bearings
Binary bearings with anti-friction coating, dia. 65 mm
Forged, l = 153 mm
Ternary bearings, dia. 56 mm
Cast aluminum
2 compression rings, 1 oil
scraper ring
Honed aluminum
Two-part, aluminum with
guide frame
Brass on intake side, sinter
on exhaust side
2 parallel overhead inlet
valves
2 parallel overhead exhaust
valves

Water cooler at front/chargeair cooler
13.2 l - 17.6 l (dependent on
equipment version)
1 DC* + 1 DC or 1 DC + 1
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 2
Oil consumption
< 1 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
2 )
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 2 main catalytic converters (close-coupled), front and
rear muffler
EU 5 & EU 4
Oxygen sensor closed-loop
control + postcatalytic
control (4 sensors)
3-way catalytic converter system with 2 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


3.0 Liter Supercharged V6
Special Tools Required For Engines Repairs (cont’d)
Description: Gear support
Tool Number: T40206
Use: Mounting for supercharger
leak testing

Description: Engine mounting
Tool Number: WE 1384
Use: Used in conjunction with
universal mounting VAS 6095/1

Description: Mounting
Tool Number: T40206/2
Use: Used in conjunction with
T40206

Description: Mandrel
Tool Number: T10060A

Use: For locking the tensioning
element to remove drive belt

Description: Charge air tester
Tool Number: WE 1407
Use: For testing the supercharger module

Description: Socket insert
Tool Number: T10070
Use: For R & R cylinder-head

Description: Adapter set
Tool Number: WE 1408
Use: Used in conjunction with
WE 1407

Description: Coolant fill pipe
Tool Number: WE 1387
Use: Used in conjunction with
WE 1386

Description : Adapter
Tool Number: WE 1386
Use: Used in conjunction with
WE 1387

Description: Upgrade kit
Tool Number: WE 1406
Use: Tool for valve key
disassembly/installation

Description: Socket
Tool Number: T10133/16
Use: For removing high-pressure
fuel 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 S Hybrid and in the Cayenne
version for China. In the Cayenne S Hybrid, the 3.0 l V6
supercharged engine in conjunction with an electric
machine guarantees high efficiency and sporty performance at the level of an 8-cylinder engine. The Cayenne S
Hybrid is the most economical Cayenne model with
gasoline engine to date.
The displacement tax in China means that vehicles with a
displacement of > 3.0 l have a significantly higher tax
burden than vehicles with a displacement < 3.0 l. For this
reason, the 3.0 l V6 supercharged engine is used instead
of the 3.6 l V6 naturally aspirated engine in the new
Cayenne in China. Performance figures compared with the
Cayenne 3.6 l V6

Main Features
The most important characteristics of the new 3.0 l V6
supercharged engine include:
•
•
•
•
•
•
•
•
•
•
•
•

Displacement of 2,995 cc
Aluminum cylinder head
Fully aluminum engine block
Four-valve technology
Continuous intake camshaft control
Controlled oil pump
Cylinder bank angle of 90°
Wet-sump lubrication
Supercharger
Charge-air cooling
Thermal management
Fuel economy measures

The innovative drive system of the new Cayenne S Hybrid

shows that 8-cylinder acceleration performance is possible
with fuel consumption at the level of a 6 cylinder engine. It
uses a modern 3.0 l V6 supercharged engine and an
electric machine with a maximum power output of 46 hp
and 221 ft lb (300 Nm) torque. In Boost mode (combustion engine and electric machine accelerate the vehicle at
the same time), the parallel full hybrid drive system offers
up to:
> 380 hp (279 kW) power output at 5,500 rpm and
> maximum torque of up to 428 ft lb (580 Nm) between
1,000 and 3,000 rpm

Notes:

Page 2.6

Cayenne/Panamera Engine Repair


3.0 Liter Supercharged V6
Crankcase
On the power output side, the crankcase is sealed by a
sealing flange made from aluminum (timing-case cover).
To optimize robustness and stability, the bearing block
areas undergo special heat treatment in the manufacturing
process. Cylinder 1 is positioned opposite the power
output side on the right in driving direction.

1

3 Upper part of oil pan

• Made from die-cast AlSi12Cu
• With check valve
• A baffle plate and a honeycomb insert made from
plastic are used to settle the engine oil in the oil pan
4 Lower part of oil pan
• Made from sheet steel
• Oil drain plug and oil-level sensor integrated
Technical Specifications for Crankcase
Cylinder spacing in mm . . . . . . . . . . . . . . . . . . . . . .90
Cylinder bank offset in mm . . . . . . . . . . . . . . . . . .18.5
Main bearing diameter in mm . . . . . . . . . . . . . . . . . .65
Connecting rod bearing diameter in mm . . . . . . . . . .56
Connecting rod length in mm . . . . . . . . . . . . . . . . .153
Block height in mm . . . . . . . . . . . . . . . . . . . . . . . .228
Crankcase assembly: length in mm . . . . . . . . . . . . .360
Crankcase assembly: width in mm . . . . . . . . . . . . . .430

2

Crank Drive

3

4

1 Cylinder block
• 90° V-cylinder crankcase
• Homogeneous monobloc made from hypereutectic
AlSi17Cu4Mg alloy
• Manufactured in a low-pressure chill casting process

• Final machining of the aluminum cylinder lining in a
three-stage honing and exposure process

1 - Piston-pin circlip
2 - Piston pin
3 - Piston
4 - Connecting-rod bearing cap
5 - Bearing shell
6 - Crankshaft
7 - Trapezoidal connecting rod

2 Lower part of cylinder crankcase (bed plate)
• Made from die-cast AlSi9Cu3
• Cast-in bearing saddles made from GJS50
• With switching valve and oil ducts for 2 stage control
of the oil pump

Cayenne/Panamera Engine Repair

Page 2.7


3.0 Liter Supercharged V6
Crankshaft

This is a forged steel crankshaft (6) made from high-grade
steel (C38). It has a split-pin design due to the 90° V-angle
of the cylinders. The crankshaft stroke is 89 mm. The
crankshaft is supported by four bearings. Binary bearing
shells with anti-friction coating are used. Main bearing 3

acts as a thrust bearing to compensate for the axial play.

Allocation of crankshaft bearing shells for cylinder block
The allocation of the bearing shells to the cylinder block is
indicated by a letter at the relevant bearing position 1 … 4 on
the guide frame.

Colored dots on the side of the bearing shells indicate the
bearing shell thickness.
Letter on the crankshaft
R=
G=
B=
S=

Color of bearing
Red
Yellow
Blue
Black
Allocation of crankshaft bearing shells for guide frame
The allocation of bearing shells to the guide frame is indicated by
a series of letters on the transmission flange of the crankshaft.
The first letter stands for bearing "1", the second for bearing "2",
and so on.

Notes:

Page 2.8

Cayenne/Panamera Engine Repair


3.0 Liter Supercharged V6
Connecting Rods
The cracked, rigid connecting rods are
manufactured from C70 and have a
trapezoidal connecting-rod eye. The
connecting-rod bushing is made from
bronze. Lead-free ternary bearings are
used on the crankshaft.
Pistons

1 - Ring carrier
2 - 1.2 mm asymmetrically crowned steel ring
3 - 1.5 mm stepped taper faced ring
4 - 2.0 mm two-piece oil scraper ring

The cast aluminum pistons from Mahle are designed as a
ring carrier piston with a compression ratio of 10.5:1. The
piston shanks have a wear-free Ferrostan coating. The
Ferrostan coating consists of a galvanic iron coating on
the piston shanks. The iron coating on the pistons results
in very low friction values for the ALUSIL engine block,
thus increasing the service life of the engine. The piston
pin is secured using two circlips.
At high power levels, the piston ring combination
used ensures:
• Low blow-by values
• Low oil consumption

• Minimal friction and wear

When installing the connecting rods, make sure that the cast lugs
on the ground surfaces of the rod pairs are facing each other (1
& 2, 3 & 4, as well as 5 & 6).

Important!

Important!
For weight tolerance reasons, connecting rods may only
be replaced in sets

When reinstalling the pistons, their correct allocation to the
cylinder must be ensured by means of color coding. The
markings should be made on the piston crowns (Cyl. 1,
etc.). The markings should not be made using mechanical
means (e.g. center punch), as otherwise the piston crown
coating will be damaged.

Cayenne/Panamera Engine Repair

Page 2.9


3.0 Liter Supercharged V6
Crankcase Ventilation With Integrated Cyclone Oil
Separator

Labyrinth Oil Separator
With the labyrinth oil separator, the blow-by gases are

routed through labyrinth-type ducts. The heavier oil
droplets are deposited on the labyrinth walls and are
routed back into the oil pan via the return line.

Crankcase ventilation prevents blow-by gases generated
during engine operation from getting into the atmosphere.
The crankcase ventilation is a combination of labyrinth oil
separators in the cylinder head covers and a cyclone oil
separator in the inner V of the engine block. The two
labyrinth oil separators are connected to the cyclone oil
separator using flexible plastic lines. The coolant ducts are
integrated in the cyclone oil separator module.
The cyclone oil separator module thus forms the cover for
the engine block. The blow-by gases are first roughly precleaned by the labyrinth oil separators integrated in the
cylinder head covers and then routed to the cyclone oil
separator module. The cleaned blow-by gases are introduced into the intake area of the supercharger module
(underside) using an intermediate piece.

1 - Cyclone oil separator
2 - Pressure-regulating valve
3 - Intermediate piece (supercharger module connection)
4 - Cylinder head cover connection on right
5 - PCV connection with check valve
6 - Cylinder head cover connection on left

Notes:

Page 2.10

Cayenne/Panamera Engine Repair

3.0 Liter Supercharged V6
Cyclone Oil Separator Module

In the oil separator module, oil mist is removed from the
blow-by gases from the cylinder heads and crankcase by
two cyclones arranged in parallel. Due to their conical
shape, the cyclones set the incoming blow-by gases in
rotation. The resulting centrifugal forces fling the oil onto
the cyclone walls, thus separating it from the air.

vapors or water is located in the area below the pressureregulating valve. The cleaned blow-by gases are fed to the
intake side of the supercharger module using an intermediate piece.

If there is a high vacuum in the intake manifold (e.g. deceleration), the diaphragm is pulled against the spring force in the
direction of the opening cross-section. Less gas is therefore
drawn in from the crankcase.

1 - Cyclones
2 - Pressure-regulating valve
3 - Outlet for cleaned blow-by gases in direction of supercharger
module
4a - Blow-by gases from cylinder heads
4b - Blow-by gases from crankcase
5 - Oil drain valves

The oil accumulates in the lower part of the oil separator,
upstream and downstream of the cyclones. Oil drain
valves close off the collection chambers while the engine

is running. The pressure inside the crankcase forces the
oil drain valves against their sealing face. The collection
chambers are large enough to collect all the oil generated
during the time the engine takes to consume a full tank of
fuel. After the combustion engine is switched off, the
pressure in the crankcase drops and the valves open automatically. The collected oil flows into the crankcase.

If there is a low vacuum in the intake manifold (e.g. full throttle),
the spring pushes the diaphragm back. The cross section is
opened wide and more gas is drawn in from the crankcase.

Pressure-Regulating Valve
The downstream single-stage pressure-regulating valve
ensures consistent pressure inside the engine depending
on the ambient and intake manifold vacuum. It is divided
into two chambers by a diaphragm. One chamber is
connected to the outside air and the other to the intake
manifold. Another drain valve for draining condensed fuel

Cayenne/Panamera Engine Repair

Page 2.11


3.0 Liter Supercharged V6
Cylinder Head

Positive Crankcase Ventilation (PCV)

Design

The PCV is connected to the intake area of the supercharger module and supplies the crankcase with fresh air.
An integrated check valve in the supply line prevents
flowback of uncleaned blow-by gases into the intake duct.
Fuel vapors and moisture are absorbed by the added fresh
air and continuously fed out from the crankcase by means
of positive crankcase ventilation.
Intermediate Piece

• Hollow, friction-optimized camshafts in aluminum
cylinder head
• Guide frame as upper bearing for camshafts
• Four-valve technology
• Rocker arm with static hydraulic clearance compensation
• Intake valve: Solid stem valve, induction-hardened valve
seat
• Exhaust valve: Chrome-plated hollow stem valve with
sodium filling, reinforced valve seat
• Continuous intake camshaft adjuster based on the
"hydraulic vane-type adjuster" operating principle, adjustment range 42° camshaft angle
• 1 Hall-effect sensor per cylinder bank for camshaft
position sensing
• Four-ply cylinder-head gasket made from CrNi spring
steel
• Decoupled cylinder head cover made from plastic with
integrated labyrinth oil separator
• Fuel high-pressure pump driven via triple cam and roller
tappet
• Rotary vane vacuum pump driven via the bank 2 intake
camshaft

Behind the pressure-regulating valve, the cleaned gases
are fed into the supercharger module directly from the Vspace in front of the impellers of the Roots blower using
an intermediate piece. The intermediate piece seals the
feed line against the air-charging module. The intermediate
piece has a lug. This secures the component in the
correct position at the positive crankcase ventilation
output. The opening on the air-charging module is conical
in shape to allow for easier insertion of the intermediate
piece.

Page 2.12

Cayenne/Panamera Engine Repair


3.0 Liter Supercharged V6
Overview of Cylinder Head

Chain Drive

‘

1 - Valve, intake camshaft adjustment
2 - Guide frame
3 - Roller tappet for fuel highpressure pump
4 - Fuel high-pressure pump
5 - Hall-effect sensor
6 - Intake camshaft
7 - Rocker arm with valve clearance compensation elements
8 - Exhaust camshaft

9 - Intake valves
10 - Exhaust valves (hollow stem valves)
11 - Aluminum cylinder head
12 - Dowel pin

1 - Trioval sprocket
2 - Timing chain (bank 2)
3 - Intake camshaft adjuster
4 - Drive sprocket for timing chain (bank 1)
5 - Drive chain for timing drive mechanism
6 - Balance shaft sprocket
7 - Crankshaft
8 - Drive chain for auxiliary drives
9 - Vane oil pump

Chains
The chain drive consists of a total of 4 chains and has a
maintenance-free design. The crankshaft drives the oil
pump (9) in the direction of rotation of the crankshaft and
the balance shaft (6) in the opposite direction via the drive
chain for auxiliary drives (8). At the same time, the crankshaft drives the two drive sprockets (4) via the drive chain
for the timing drive mechanism (5). A connection exists
between the drive sprockets and the camshaft timing
gears or the intake camshaft adjusters (3) via the timing
chains (2). All of the chains are roller-type chains, which
are subject to less wear and produce less noise in
comparison with bush chains. The drive chain for auxiliary
drives (8) is tightened using a mechanical tensioning
device. The drive chain for the timing drive mechanism (5)
and the timing chains (2) are tensioned using spring force

and oil pressure. In some cases, the chains are supplied
with engine oil for lubrication through the ventilation bore
holes of the hydraulic chain tensioner.

Cayenne/Panamera Engine Repair

Page 2.13


3.0 Liter Supercharged V6
Reduction of chain forces by using trioval sprockets

Trioval Sprockets
On a V6 engine, the valve on each cylinder bank and
camshaft opens three times during every working cycle.
As a result, higher forces act on the chain drive every time
the valve opens. These forces may cause vibrations in the
timing drive mechanism that are particularly noticeable at
higher speeds. To minimize vibration and wear, the
camshaft sprockets therefore have a trioval design.

‘
Advantages
The lower chain forces reduce friction and therefore also
reduce fuel consumption. Furthermore, more costeffective chains and chain tensioners with identical performance characteristics can be used. Another advantage
lies in the reduced vibration angle. This allows the chain
drive to run more smoothly.
Function
The trioval sprockets are raised in three places and are
therefore not perfectly circular. The elevations increase

the outer diameter of the sprocket as well as the effect on
the lever arm that acts on the valves. When a cam needs
to open the valve, the elevations (larger arm) act at exactly
the right moment. The extension of the lever arm reduces
the chain forces depending on the engine speed by up to
35% in comparison with conventional sprockets and
dampens disruptive vibrations (see diagram).

Notes:

Page 2.14

Cayenne/Panamera Engine Repair


3.0 Liter Supercharged V6
Camshaft Control

Function

The 3.0 l V6 supercharged engine has hydraulic adjusting
devices on the intake camshafts. The objective is to
improve engine performance, torque, smooth running and
exhaust gas quality by dynamically influencing gear
change operations in the combustion chamber of the
engine.

The camshafts are adjusted continuously by means of
vane-type adjusters and the maximum adjustment is 42°.
The vane-type adjusters are advanced by increasing oil

pressure. The camshaft position is detected by a Halleffect sensor per cylinder bank and sent to the DME
control unit. The control unit determines the current
position of the camshaft in relation to the crankshafts
(actual angle) on the basis of the speed sensor signal and
the Hall-effect sensor signal. The position control in the
control unit receives the desired setpoint angle via the
programmed map values (engine speed, load, engine
temperature). The DME control unit actuates the electrohydraulic control valves when there is a difference between
the setpoint angle and actual angle. When the engine is
not running, the vane-type adjuster is locked in the
retarded position of the intake camshafts using a springloaded locking bolt. After the engine is started, the lock is
removed when the oil pressure reaches approx. 7.25 psi
(0.5 bar).

‘

The camshaft adjuster housings are fixed to the camshaft
timing gears of the intake camshafts and the internal
rotors are fixed to the intake camshafts. The incoming oil
pressure turns the internal rotors relative to the housings
and thus adjusts the camshafts. The valves required for
intake camshaft adjustment are mounted above in the
cylinder heads.
For example, retarding the intake camshafts increases the
valve overlap angle, which in turn increases the internal
exhaust gas recirculation rate. The camshafts are adjusted
according to the map.

‘

Chain Box
The chain box is closed with
a Bondal® cover. Bondal® is
a multi-ply, vibration-damping
structure with a sandwich
design. A viscoelastic core
between the steel band
layers converts mechanical
vibration into heat. These
components are produced in
different versions depending
on the ambient temperature
and area of application.

Cayenne/Panamera Engine Repair

Page 2.15


3.0 Liter Supercharged V6
Auxiliary System Drive
The engine is equipped with two separate belt drives that
power the auxiliary units. The supercharger module is
driven by the crankshaft via a second drive belt.

The Roots blower drive has the same structure in both
engines. However, in the hybrid version, the auxiliary
system drive is used only to drive the mechanical coolant
pump. The poly-V-belt for driving the coolant pump has
lower tensioning, this results in reduced energy losses and

fuel consumption.

1

7

When the combustion engine is used in the hybrid drive
concept, the air-conditioning compressor and powersteering pump are powered electrically. The 12 V
generator is not used in this case. The 12 V system is
supplied with power by the high-voltage system (see
Cayenne S Hybrid Training Information).

2
3
6

Important!

4

4
5

The auxiliary poly-V-belts are not subject to a fixed change
interval. A visual inspection during the service is sufficient.
Poly-V-belts are only replaced if they are in poor condition.
However, the supercharger drive belt has a 60,000 mile or
every 6 year change interval.

Important!

1 - Supercharger drive
2 - Coolant pump
3 - Auxiliary system drive
4 - Tensioners
5 - Crankshaft with vibration damper
6 - Deflection roller
7 - Drive belt for supercharger

The vibration damper must be replaced following a
jammed drive belt, see Workshop Manual.

Notes:

Page 2.16

Cayenne/Panamera Engine Repair


3.0 Liter Supercharged V6
Volume Rate Controlled Oil Pump

Oil Supply
The oil supply is realized as a wet-sump lubrication
system. This is designed to safeguard the functions of the
engine in dynamic driving mode and on slopes or steep
uphill climbs when driving off-road, for example. Optimizing
friction inside the engine was the most important objective
in the development of the lubrication system. A series of
measures was implemented, including the design of the
upper main bearing shells of the crankshaft with a sickle

groove angle of 180°. Furthermore, the oil flow rate was
significantly reduced by using a controlled oil pump and
decoupling the camshaft adjuster oil supply from the
cylinder head oil supply.

‘

The variable vane oil pump is used in the 3.0 l V6 supercharged engine. The delivery rate of the oil pump is
controlled using the DME control unit. This measure has
reduced the overall power consumption of the oil pump.
This has the following advantages:
• Reduced oil flow rate in the oil circuit
• Reduced fuel consumption

‘
1 - Stationary oil filter module
2 - Valve for oil pressure control
3 - Oil cooler (coolant-cooled)
4 - Controled oil pump

Upper main bearing shell for the 3.0 l V6 supercharged engine.

Cayenne/Panamera Engine Repair

Page 2.17


3.0 Liter Supercharged V6
One measure to reduce the required drive power of the oil
pump is use of volume flow control. The delivery characteristic of the vane pump can be changed while the engine

is running by opening and closing an oil duct (red arrows)
on the adjusting ring of the oil pump. This control duct is
opened by a solenoid valve activated on the ground side
(oil pressure present) and keeps the oil duct closed when
de-energized (oil pressure not present).

Low Delivery Rate
The lower pressure level is switched depending on the
following:
•
•
•
•

engine load
engine speed
oil temperature and
other operating parameters.

‘

1 - Control surface 1
2 - Adjusting ring
3 - Support
4 - Oil duct, permanently open
5 - Control spring
6 - Control surface 2
7 - Vane
8 - Delivery space

1 - Solenoid valve
2 - Oil pressure switch
3 - Oil supply (coming from oil filter)
4 - Control duct
5 - Cold-start valve

A second oil duct (green arrows) is always open towards
the oil duct. Oil pressure is applied to control surface 1 of
the adjusting ring in the vane pump via this duct for the
entire time the engine is running.

Page 2.18

The adjusting ring is turned by the oil pressure (red) now
present at control surface 2. The resultant forces are
greater than the force of the control springs and swivel
the adjusting ring in a counter-clockwise direction. The
adjusting ring swivels into the centre of the vane pump and
reduces the delivery space between the pump cells. The
oil quantity delivered and therefore the oil pressure are
reduced.

Cayenne/Panamera Engine Repair


3.0 Liter Supercharged V6
High Delivery Rate

High delivery rate Solenoid valve closed

As from an engine speed of 2,500 rpm or a torque of
221 ft lb (300 Nm) (full-throttle acceleration), the DME
control unit isolates the solenoid valve from the ground
connection so that the oil duct to control surface 2 is
closed. The oil pressure present then acts only on control
surface 1 and opposes the force of the control spring with
a lower force. The control spring then pivots the adjusting
ring around the support in a clockwise direction. The
adjusting ring now rotates out of the center position and
increases the delivery space between the individual cells.
A greater quantity of oil is delivered and the oil pressure
increases.

Oil pressure curve at 212 ° F. (100° C.)

Notes:

Cayenne/Panamera Engine Repair

Page 2.19