Cayenne 2 II Workshop Service Repair Manual

Porsche Cayenne
Service Manual: 01 - SALES CHECK -- 92A CAYENNE

WM 0101IN DIAGNOSTIC SYSTEM: PERFORMING VEHICLE HANDOVER (CAYENNE,
CAYENNE (3.0), CAYENNE GTS, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE
TURBO & CAYENNE TURBO S > TOOLS
Designation Type Number Description
PIWIS Tester II Special tool 9818

TURBO & CAYENNE TURBO S > TECHNICAL VALUES
Location Description Type Basic value Tolerance 1 Tolerance 2
Current rating Nominal value 40 A

TURBO & CAYENNE TURBO S > INFORMATION > PERFORMING VEHICLE
HANDOVER
NOTE: Voltage drop
Risk of irreparable damage to control unit
Risk of damage to control unit
Fault entries in the control unit
Coding in the control unit is aborted
Malfunctions in control unit, even during programming
→ Prior to disconnecting the control unit, switch off ignition and remove ignition key.
→ Ensure that the power supply is not interrupted during programming.
→ Connect a battery charger with a current rating of at least → Nominal value: 40 A to the vehicle
battery.
1. PIWIS Tester II 9818 must be connected to the vehicle. Then start the System Tester. Switch
on ignition .
Fig 1: Identifying Vehicle Diagnostic Socket
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Select the vehicle.

3. In the Control unit overview , press [F7] to continue.
4. Select the Vehicle handover function, then press [F12].
5. When Remove transport protection is displayed, press [F12] to continue.
6. Create vehicle handover log , then press [F12].
7. Write service interval, then press [F8] (Yes).
8. Select the individual maintenance intervals for the maintenance interval allocation for each
specific country and engine. [F12].
9. Write maintenance interval , then press [F12].
10. The control units are activated and the status is displayed. Compare the chassis number
displayed on the Tester with the vehicle identification number of the vehicle. Press [F12] to
continue.
11. Conclude vehicle handover and press [F12]. The log you created is saved under the vehicle
identification number.
12. Test-drive the vehicle and read out the fault memory. Check faults after diagnosis if necessary
and erase the fault memory before delivering the vehicle.
WM 010100 SALES CHECK (CAYENNE TIP, CAYENNE TIP (3.0), CAYENNE S,

CAYENNE TURBO & CAYENNE S HYBRID) > SALES CHECK
WARNING: High voltage at the high-voltage system on hybrid vehicles
Danger of electric shock from live parts
Risk of serious burns or death
Health risks for persons with medical devices/life-support systems.
→ Before working on the high-voltage electrical system and carrying out any repair work to the body, a
high-voltage technician must switch off the power to the system.
→ All work on vehicles with a high-voltage electrical system may only be carried out by electrically
instructed persons. The work must be done under the instruction of a high-voltage technician.
→ Observe general warning notes for working on the high-voltage electrical system. → 2X00IN
GENERAL WARNING NOTES FOR WORKING ON THE HIGH-VOLTAGE ELECTRICAL SYSTEM
Information
The term "checking" includes all necessary subsequent work such as adjusting, readjusting,
correcting and topping up, but does not include repairing, replacing and reconditioning parts or
assemblies.
Work instruction for order no.
Dealer No.
Vehicle Ident. No.
Not
OK
(1) OK
(2)
Check PIWIS information system for open workshop campaigns and recall campaigns for
the vehicle
Check consistency of Vehicle Ident. No. on vehicle, data bank, vehicle registration
documents and on-board documentation → 0X01IN CHECKING VEHICLE IDENT . No.
Remove transport locks, transport protection → 0X01IN REMOVING TRANSPORT

PROTECTION→ 966015 SWITCHING ON MAIN POWER SUPPLY SWITCH
Diagnostic system: Perform vehicle handover, read out and erase fault memory→ 0101IN
DIAGNOSTIC SYSTEM: PERFORMING VEHICLE HANDOVER AND CODING
REAR-END ELECTRONICS
Windscreen washer/headlight cleaning system: Check function, fluid level and nozzle
settings; check window cleaner and antifreeze, depending on the season; check wiper
blades → 0X03IN ELECTRICS MAINTENANCE: CHECKING WINDSCREEN WIPER
AND WASHER SYSTEM
Vehicle lights: Check function. All headlights: Check adjustment. Horn and clock: Check
function → 0X03IN ELECTRICS MAINTENANCE: CHECKING THE FUNCTION OF THE
VEHICLE'S LIGHTS
Electrical equipment, warning and indicator lights: Check operation
Mobile roofs: Check operation → 0X01IN MOBILE ROOFS: CHECKING OPERATION
Check engine-oil level → 170117 CHANGING ENGINE OIL AND OIL FILTER
Check comfort tire pressure → 0X03IN RUNNING GEAR MAINTENANCE: TIRES AND
SPARE WHEEL: CHECKING CONDITION AND TIRE PRESSURE
Wheels, tires: Visual inspection for damage → 0X03IN RUNNING GEAR MAINTENANCE:
TIRES AND SPARE WHEEL: CHECKING CONDITION AND TIRE PRESSURE
Check wheel mounting → 440519 REMOVING AND INSTALLING WHEEL
Brake hoses and lines: Visual inspection for damage in wheel area→ 0X03IN RUNNING
GEAR MAINTENANCE: VISUAL INSPECTION - BRAKE LINES/BRAKE PADS/BRAKE
DISCSCheck brake fluid level → 470855 CHANGING BRAKE FLUID
Visual inspection for leaks: oils, fluids
Exterior equipment and paint finish: Visual inspection for damage
Glazing: Visual inspection for damage
Interior equipment: Visual inspection for damage and soiling
Door and lid locks: Check operation → 0X01IN CHECKING LIDS AND DOORS
Alarm system: Check operation of monitoring devices

Complete vehicle and check that all equipment is present → 0X01IN CHECKING
VEHICLE EQUIPMENT FOR COMPLETENESS
(1)
OK = functioning correctly
(2) Not OK = not functioning correctly
OK Not
Test drive (1)
OK (2)
Electric parking brake and foot brake, clutch, steering, cruise control, ParkAssist, heating,
sports exhaust system, air conditioning and instruments: Check function → WM 0X00IN
TEST DRIVE - SALES CHECK
Transmission: Check operation
Check vehicle for unusual handling behaviour, vibrations and noise
Diagnostic system: Read out and erase fault memory
(1)
OK = functioning correctly
(2)
Not OK = not functioning correctly
Stamp of Official Porsche Centre

Service Manual: 09 - PORSCHE SYSTEM COMPONENTS -- 92A CAYENNE
WM 0940IN PORSCHE UNIVERSAL CHARGER (AC) (HIGH-VOLTAGE CHARGING
CABLE) DIAGNOSTICS (FAULT CODES) (CAYENNE S E-HYBRID) > INFORMATION >
GENERAL INFORMATION
WARNING: Working on electric components
Risk of burns
Risk of short circuit or fire.
→ Before replacing the power cable or vehicle cable, always disconnect the power cable from the
electrical socket.
→ Only replace cables in a dry environment.
→ Porsche universal charger (AC) may only be used as a unit comprising power cable, control unit and
vehicle cable.
Fig 1: Identifying Porsche Universal Charger (AC) Components
A. Power cable
B. Power plug (connector for connecting to main power supply)
C. Control unit
D. Vehicle plug (plug connection for the vehicle)
E. Vehicle cable
Information
Risk of damage to charging equipment.
Charging equipment can be operated in a temperature range from -25 °C to +35 °C.
Control unit must not be submerged in water or covered with snow or ice.
Information
Do not expose Porsche universal charger (AC) to direct sunlight over long periods to prevent it from
overheating during operation.
If the temperature in the control unit exceeds 80 °C, the charging process will be interrupted
automatically until the temperature has dropped to the normal range.
WM 0940IN PORSCHE UNIVERSAL CHARGER (AC) (HIGH-VOLTAGE CHARGING

CABLE) DIAGNOSTICS (FAULT CODES) (CAYENNE S E-HYBRID) > FAULT
DESCRIPTION FOR UNIVERSAL CHARGER CONTROL UNIT
Information
A. Power plug (connector for connecting to main power supply)
B. Control unit display
C. Vehicle plug (plug connection for the vehicle)

Fig 1: Identifying Porsche Universal Charger Components (AC)
LED on
Fault
State Symbol in control unit display control Action required
code
unit
Final switch-off due Dry the vehicle

to triggering of the plug. Then reset
110 Flashes red
surge protector in the control unit by
the control unit pressing "OK".
Control unit display
Switch-off due to Continuous

130 Check cable
overload red light
Replace control
Continuous
140 CP signal not valid unit and/or vehicle
red light
cable
Charging current Place control unit

downgraded due to Flashes in the shade or
170
internal green charge in a cooler
overtemperature environment
Place control unit

Switch-off due to
Continuous in the shade or
180 internal
red light charge in a cooler
overtemperature
environment
Continuous Replace control

200 FI self-test failed
red light unit
Protection
210 permanently
red light unit
conductive

Reduced power as
power drop at Continuous Replace control
220
contactor contact is red light unit
too high
Switch-off as power
230 drop at contactor
red light unit
contact is too high
Contactor contact Continuous Replace control

260
cannot be closed red light unit
Measured
temperature outside Continuous Replace control
290
of temperature red light unit
range
Use a different
electrical socket
300 or wait until the
undervoltage red light
power grid has
stabilized

Use a different
electrical socket
310 or wait until the
overvoltage red light
power grid has
stabilized
Insert
Infrastructure cable Continuous
330 infrastructure
not (fully) inserted red light
cable fully
Insert
Vehicle cable not Continuous
340 infrastructure
(fully) inserted red light
cable fully
Get an electrician
Earth resistance for to check domestic
Continuous
370 infrastructure too installation. Use a
red light
high different electrical
socket
Get an electrician
Switch-off as to check the
Continuous
390 voltage drop under infrastructure. Use
red light
load is too high a different
electrical socket

Cycle counter full
410 without load or
red light unit
under load
Plug in vehicle
State A: Vehicle not Continuous
cable. Replace
connected white light
vehicle cable.
State B: Vehicle Continuous

connected green light
State C: Vehicle is
Flashes
ready to charge and Normal operation
green
charging
Connect vehicle to
charge station
State D: Vehicle Continuous
440 with ventilation.
requires ventilation red light
Replace control
unit

Check keypad.
Button continuously Continuous
450 Replace control
pressed red light
unit
Status LED faulty.

460 Control unit not
red light unit
ready for operation

470 Diode 1 short circuit
red light unit
Open circuit in Get an electrician

480 protective earth Flashes red to check domestic
conductor installation.
Error while writing Continuous Replace control

490
memory red light unit

500 Display fault
red light unit
WM 0940IN UPDATING SOFTWARE FOR PORSCHE UNIVERSAL CHARGER (AC)

(HIGH-VOLTAGE CHARGING CABLE)/RESETTING PIN (CAYENNE S E-HYBRID) >
TOOLS
diagnostic cable Special tool 9868

GENERAL INFORMATION
Risk of burns
electrical socket.
vehicle cable.
A. Power cable
B. Power plug (connector for connecting to mains power supply)
C. Control unit
E. Vehicle cable
Information
Information

UPDATING SOFTWARE/RESETTING PIN
Information
The diagnostic software for the Porsche Universal Charger (AC) and user documentation for the
software can be downloaded from the PPN (PPN > Portal > Dr. Ing. h.c. F. Porsche AG > After Sales >
workshop > Workshop Downloads). In the event of download problems, please contact Technical
Support. A Windows PC or Notebook with administrator rights is required for installing the diagnostic
software.
1. Disconnect the Porsche Universal Charger (AC) from the power supply.
2. Unplug the vehicle plug from the vehicle charge port.
3. Unplug the vehicle cable from the control unit as described below.
Information
On some country versions, lever -A- is secured with a screw. If this is the case, loosen the
screw first before releasing the connector.
1. 3.1. Lift up lever -A- .
2. 3.2. Pull out connector -B- until you feel a certain amount of resistance.
3. 3.3. Close lever -A- .
4. 3.4. Carefully pull out connector -B- .

Fig 1: Removing Vehicle Cable From Control Unit

4. Insert Diagnostic Connector Diagnostic Cable 9868 into the control unit as described below.
1. 4.1. Lever -A- is closed.
2. 4.2. Push diagnostic connector -B- into the control unit until you feel a certain
amount of resistance.
4. 4.4. Insert diagnostic connector -B- fully.

Fig 2: Inserting Diagnostic Connector Into Control Unit
Information
On some country versions, lever -A- is secured with a screw. If this is the case,
secure lever -A- with the screw before locking the connector.
Information
To connect the Porsche Universal Charger (AC) to the PC/Notebook, special tool
Diagnostic Cable 9868 and a commercially available USB cable with a USB type-A
connector on one end and a USB type-B connector on the other end are required
(not supplied with Diagnostic Cable 9868 ).
Fig 3: Identifying USB Cable With Connector Type A And B
5. Connect the Porsche Universal Charger (AC) to a PC/Notebook on which the diagnostic
software for the Porsche Universal Charger (AC) is installed using the USB cable.
1. Porsche Universal Charger (AC) control unit
2. Diagnostic Connector (Special Tool Diagnostic Cable 9868 )
3. USB cable
4. Notebook/PC
5. Power cable for Porsche Universal Charger (AC)

Fig 4: Connecting Control Unit To PC
6. Re-connect the Porsche Universal Charger (AC) to the power supply.
7. Switch on the control unit for the charger.
8. Start the diagnostic software on the PC/Notebook and connect to the Porsche Universal
Charger control unit by clicking on the "Connect" button. Once communication has been
established successfully, the display next to the button will turn green.
Information
To protect the charging function from unauthorized access attempts, a four-digit PIN can be set
using the Porsche Universal Charger (AC) control unit. If the user has forgotten the PIN, it can
be reset using the diagnostic software for the Porsche Universal Charger (AC).
9. To reset the PIN, select the "PIN Reset" tab and press [F8].
The text message "PIN successfully reset" appears once the PIN has been reset successfully.
Information
The control unit software can be updated using the "Software Update" tab. The data required
for this comes from the application. The correct data record is selected automatically.
10. To update the software, select the "Software Update" tab and press [F8]. The PIN is reset
automatically during the software update. Confirm the displayed message by pressing [F12].
The text message "Software update successful" appears when programming is completed
successfully.
Information
After the "PIN Reset" or "Software Update" function has been run, the PIN is no longer
activated (in other words: the PIN is reset to the default value "0000"). A new PIN can then be
set on the Porsche Universal Charger control unit, see operating instructions for the Porsche
Universal Charger (AC).
11. When the PIN has been reset/software has been updated successfully, disconnect the
connection between the PC/Notebook and control unit by clicking on the "Disconnect" button.
The display next to the button turns red.
12. Complete the process by pressing the [Esc] key.
13. Switch off the control unit for the charger.
14. Disconnect the Porsche Universal Charger (AC) from the power supply.
15. Disconnect the USB cable.
16. Unplug the diagnostic connector from the control unit. Procedure: see Step → 3.
17. Plug the vehicle cable into the control unit. Procedure: see Step → 4.
WM 0940Z1 DISASSEMBLING AND ASSEMBLING PORSCHE UNIVERSAL CHARGER

(AC) (HIGH-VOLTAGE CHARGING CABLE) (CAYENNE S E-HYBRID) > GENERAL
INFORMATION
Risk of burns
electrical socket.
vehicle cable.
A. Power cable
B. Power plug (connector for connecting to mains power supply)
C. Control unit
E. Vehicle cable
Information
Information

(AC) (HIGH-VOLTAGE CHARGING CABLE) (CAYENNE S E-HYBRID) >
DISASSEMBLING PORSCHE UNIVERSAL CHARGER (AC)
Information
Before disassembly/assembly, the power plug must be disconnected from the electrical socket and the
vehicle plug must be disconnected from the vehicle charge port.
1. Disconnect power cable and vehicle cable.
Information
On some country versions, lever -A- is secured with a screw. If this is the case, loosen the
screw first before releasing the connector.
2. 1.2. Pull out connector -B- until you feel a certain amount of resistance.
4. 1.4. Pull connector -B- out fully.

Fig 1: Disconnecting Power Cable And Vehicle Cable

(AC) (HIGH-VOLTAGE CHARGING CABLE) (CAYENNE S E-HYBRID) > ASSEMBLING
PORSCHE UNIVERSAL CHARGER (AC)
Information
Before disassembly/assembly, the power plug must be disconnected from the electrical socket and the
vehicle plug must be disconnected from the vehicle charge port.
1. Connect power cable and vehicle cable.
1. 1.1. Lever -A- is closed.
2. 1.2. Push connector -B- into the control unit until you feel a certain amount of
resistance.
4. 1.4. Carefully push in connector -B- .
Information
On some country versions, lever -A- is secured with a screw. If this is the case, screw
lever -A- securely to the control unit before locking the connector.
Fig 1: Connecting Power Cable And Vehicle Cable
WM 090595 PORSCHE CD - SPECIAL TOOL FOR CHECKING NOISE AND

VIBRATIONS (ALL MODELS) > TOOLS
Noise and Vibration CD Special tool 9793

VIBRATIONS (ALL MODELS) > GENERAL INFORMATION ON CHECKING
FREQUENCY STIMULATION VIA THE SOUND SYSTEM
Porsche special tool Noise and Vibration CD 9793
The stimulation of frequencies via the sound system can cause loose components or trim panels to
vibrate or rattle. The test must be performed when the vehicle is stationary.
The following areas can be checked using the test procedure that involves stimulating frequencies via
the sound system:
Vibrations and rattling noises (squeak and rattle) at positions where bass loudspeakers are
secured to interior components.
Sound system testing in the event of defective loudspeakers/drivers/diplexers.
Playing track 1, 2 and 11 covers a wide frequency stimulation spectrum.
Tracks 3 to 7 produce high individual frequencies Sinus 40-100 Hz over a longer period of time.
Tracks 8 to 10 produce low individual frequencies Noise 16-125 Hz over a longer period of time.

VIBRATIONS (ALL MODELS) > PROCEDURE
CAUTION: Volume set too high
Risk of hearing damage
→ Check volume adjustment.
→ Start with a low volume.
→ Increase the volume slowly if necessary.
1. Remove all objects from the door panel and adjacent storage boxes.
2. Adjust the bass, treble, balance and fader settings to a medium setting 0 using the sound
controls. Call up the SOUND menu .
3. Switch off Loudness.
4. If you establish that vibrations and rattling noises (squeak and rattle) are coming from a
particular side of the vehicle or from the front or rear, the balance and fader settings of the
sound system can be preset accordingly.
5. Play track No. 1 .
8. If vibrations and rattling noises (squeak and rattle) occur:
Locate the rattling noises by playing the single-frequency tracks 3 to 7 and 8 to 10

Porsche Cayenne
Service Manual: 0X - COMPLETE VEHICLE - GENERAL -- 92A CAYENNE
WM 0X00IN ELIMINATING NOISE SYMPTOMS - OVERVIEW OF MATERIALS FOR
ELIMINATING DISTURBING NOISES (CAYENNE TIP, CAYENNE MAN, CAYENNE S,
CAYENNE TURBO, CAYENNE GTS, CAYENNE S HYBRID, CAYENNE TURBO S,
CAYENNE DIESEL, CAYENNE S DIESEL, CAYENNE TIP (3.0)) > GENERAL
INFORMATION > SYMPTOMS
Disturbing noises, such as rattling, creaking, clicking or squeaking, which occur mainly in the interior of
the vehicle while driving.

CAYENNE DIESEL, CAYENNE S DIESEL, CAYENNE TIP (3.0)) > GENERAL
INFORMATION > CAUSES AND REMEDIAL ACTION
Cause
Noises can occur due to:
the pairing of different materials
component tolerances and relative movements of components while driving or
dust and dirt.
Remedial action
Information
Various materials for different areas of application are listed below for eliminating disturbing noises.
Make sure to have a good stock of materials available, depending on how often various noise
complaints are reported on vehicles .
Before using the material/adhesive tape, clean the affected area of the vehicle to remove any dust and
grease.
WARNING: Non-heat-resistant materials
Risk of fire
→ Avoid contact with hot components or sources of ignition.
The overview is constantly updated with new materials.

CAYENNE DIESEL, CAYENNE S DIESEL, CAYENNE TIP (3.0)) > TOOLS AND
MATERIALS
TOOLS AND MATERIAL DESCRIPTION
Lubricants, Teflon Spray
000.043.204.40 → Silicone compound Spraying can (200 ml

container)
Used on door locks, for example
000.043.206.65 → Krytox, grease Tube (50 ml container)
Used on hardtop latches, for example
000.043.207.56 → Polylub, grease Tube (50 ml container)
Used on the guide mechanism for the panorama roof, for example
000.043.204.21 → Lock cylinder grease Spraying can (25 ml container)
Used on lock cylinders, for example
999.917.557.00 → Special sliding compound, Bottle (30 ml container)

liquid Krytox
Used on seals, for example
000.043.207.16 → Teflon Spray, sliding compound Spraying can (300 ml

container)
Used on running rails/Targa roof air deflector, for example
Acoustic foam , 2 components
999.915.337.40 → Acoustic foam, 2 components Spraying can (200 ml

container)
Used on the body front section ==> body cavities, for example
Felt , self-adhesive
993.555.545.00 → Felt strips 15 mm wide, 2 mm thick, 1,

345 mm long
Used on rear-wall lining, for example
999.551.138.40 → Felt strips (3 pieces) 25 mm wide, 1 mm thick, 25

mm long
Used on protective panel for A-pillar, for example
997.561.509.00 → Felt strips 26 mm wide, 1 mm thick, 62

mm long
Used on convertible top/roof frame, for example

mm long
Used on middle part of seat backrest/roof lining, for example
000.043.207.44 → Felt strips 30 mm wide, 1 mm thick, 5,

000 mm long
Used on convertible top/roof frame, for example
999.551.173.40/New → Felt strips 35 mm wide, 5 mm thick, 22

mm long
Used on side trim panel, for example

mm long
Used on side skirt, for example
Textile fabric , self-adhesive
999.551.169.40 → Textile fabric, damping strips 7 mm wide, 1 mm thick, 1, 000

mm long
Used on the Carrera GT, for example
999.551.170.40 → Textile fabric 15 mm wide, 1 mm thick, 1,

000 mm long
Used on carpet in footwell, for example
999.551.134.40 → Textile fabric 20 mm wide, 1 mm thick, 65

mm long
Used on metal clips for trim panels, for example
Base strap/plastic foam , self-adhesive
999.911.227.40 → Base strap/plastic foam 23 mm wide, 3 mm thick, 10,

000 mm long
Used on the fuel tank cover, for example
999.911.201.40/New → Sealing strap 10 mm wide, 3 mm thick, 1,

000 mm long
Used on door panel, for example
999.911.695.40 → Plastic foam strips, sealing strip 30 mm wide, 10 mm thick, 680

mm long
Used on the front wheel housing liner, for example
997.555.895.00 → Plastic foam strips 15 mm wide, 15 mm thick, 640

mm long
Used for woofer in door panel area, for example
999.911.664.40 → Plastic foam strips 20 mm wide, 15 mm thick, 680

mm long
Used on the front wheel housing liner, for example

993.556.245.00 → Plastic foam strips, sound 36 mm wide, 25 mm thick, 830
absorber mm long
Used on sound absorber for bottom of rear window, for example
Protective film, transparent rubber , self-adhesive
996.537.237.00 → Protective film, transparent 7 mm wide, 1 mm thick, 95 mm

long
Used on rear side section, for example
999.911.738.40 → Adhesive film, black, 3 ea. 10 mm wide, 1 mm thick, 30

mm long
Used on spoiler drive, protects against soiling, for example
Teflon tape , self-adhesive
000.043.207.27 → Teflon tape, 5 strips on roll 4 mm wide, 1, 600 mm long
Used on Targa roof, for example
000.043.204.83 → Teflon tape 19 mm wide, 16, 500 mm long
Used on front/rear trim panel, for example
Double-sided adhesive tape/plastic foam
000.043.206.04 → Double-sided adhesive tape, 8 mm wide, 1 mm thick, 4, 000

1-mm thick plastic foam mm long
Used to secure moulding, for example
000.043.207.26 → Double-sided adhesive tape, 8 mm wide, 1 mm thick, 3, 000

1-mm thick plastic foam mm long
Used on hood compartment lid, for example
000.043.207.63/New → Double-sided adhesive tape, 19 mm wide, 5, 000 mm long

Tesafix 4965, high-temperature
resistant
Used on A-pillar trim, for example
000.043.113.00/New → Double-sided adhesive tape, 19 mm wide, 5, 000 mm long

1-mm thick plastic foam
Used on moulding in sill cover area, for example
WM 0X00IN OVERVIEW OF A, B AND C MARKETS (CAYENNE TIP, CAYENNE MAN,

CAYENNE S, CAYENNE TURBO, CAYENNE GTS, CAYENNE S HYBRID, CAYENNE
TURBO S, CAYENNE DIESEL, CAYENNE S DIESEL, CAYENNE TIP (3.0)) >
INFORMATION > OVERVIEW OF A, B AND C MARKETS
Information
Applies only to the Cayenne (V6) and S Hybrid from model year 2011.
Because of different fuel octane ratings, the change intervals for oil and spark plugs have been adapted
to suit the various markets.
Markets Countries
A markets AndorraBelgiumGermanyDenmarkEstoniaFinland,
FranceGreece, Great BritainIreland, Iceland,
ItalyJapanLatviaLiechtenstein, Lithuania,
LuxembourgMaltaNetherlands, NorwayAustriaPoland,
PortugalSweden, Switzerland, Slovakia, SpainCzech
RepublicHungaryCyprus
B markets Egypt, Algeria, Angola, Argentina, Armenia, Aruba (itc

Caribbean), Azerbaijan, AustraliaBahamas, Bahrain,
Bangladesh, Barbados, Bosnia and Herzegovina, Brazil,
Brunei, BulgariaChile, Costa RicaDominican
RepublicEcuador, El SalvadorFrench Guiana, French
PolynesiaGhana, Guadeloupe, GuatemalaHaiti, Dutch
Antilles, Honduras, Hong KongIndia, Iraq, Iran,
IsraelJamaica (itc Caribbean), Yemen, JordanCameroon,
Canada, Kazakhstan, Qatar, Cayman Islands, Kenya,
Columbia, Croatia, KuwaitLesotho, Lebanon, LibyaMalaysia,
Morocco, Martinique (F), Mauritius, Mexico, Moldova,
MonacoNamibia, New Caledonia, New Zealand, Nigeria,
NicaraguaOmanPakistan, Panama, Paraguay, Peru,
Philippines, Puerto RicoReunion, Romania, RussiaSaudi
Arabia, Serbia and Montenegro, Zimbabwe, Singapore,
Slovenia, Sri Lanka, South Africa, South Korea, Swaziland,
SyriaTaiwan, Thailand, Trinidad and Tobago, Turkey,
TunisiaUkraine, Uruguay, USAUAE (Abu Dhabi, Dubai),
Venezuela, VietnamBelarus, Western Sahara
C markets China, Indonesia
WM 0X00IN TEST DRIVE - MAINTENANCE (CAYENNE TIP, CAYENNE MAN, CAYENNE

S, CAYENNE TURBO, CAYENNE S HYBRID, CAYENNE DIESEL, CAYENNE S DIESEL,
CAYENNE TIP (3.0)) > TEST DRIVE - MAINTENANCE
Information
The following test items are included in the test drive.
Actuate remote control for central locking and check operation.
Seats: check operation of adjustments.
Check electric parking brake and footbrake operation and actuation travel.
Start engine, check operation.
Actuate clutch, check operation.
Actuate steering, check operation.
Shift transmission, check operation.

ParkAssist: select reverse gear and check operation.
Activate cruise control during the test drive and check operation.
Actuate PSM switch during the test drive and check operation.
Check operation of heating adjustment when engine is warm.
Check operation of sports exhaust system.
Check operation of air-conditioning system when engine is running.
Check operation of instruments.
WM 0X00IN TEST DRIVE - SALES CHECK (CAYENNE TIP, CAYENNE MAN, CAYENNE
S, CAYENNE TURBO, CAYENNE S HYBRID, CAYENNE DIESEL, CAYENNE S DIESEL,
CAYENNE TIP (3.0)) > TEST DRIVE - SALES CHECK
Information
The following test items are included in the test drive.
Check electric parking brake and footbrake operation and actuation travel.
Actuate clutch, check operation.
Actuate steering, check operation.
Shift transmission, check operation.
ParkAssist: select reverse gear and check operation.
Activate cruise control during the test drive and check operation.
Check operation of heating adjustment when engine is warm.
Check operation of sports exhaust system.
Check operation of air-conditioning system when engine is running.
Check operation of instruments.
WM 0X01IN ALARM SYSTEM: CHECKING OPERATION OF MONITORING DEVICES

(CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S
E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > ALARM
SYSTEM: CHECKING OPERATION OF MONITORING DEVICES
1. Read out the fault memory and activate systems on the unlocked vehicle (see previous point in
sales check).
2. Lock the vehicle using the remote control (key fob). A warning tone must not be emitted by the
alarm system horn shortly after locking the vehicle (not relevant for USA).
3. If a warning tone is emitted, open and close all doors and outer lids one after the other (not
relevant for USA).
4. As soon as the vehicle is locked, the LED in the driver's door panel must flash quickly for 2
seconds and then start to flash slowly.
Fault indicator:
5. LED flashes quickly for 2 seconds, lights up for 28 seconds and then flashes slowly: Connect
the System Tester and read out the fault memory.
WM 0X01IN CHECKING VEHICLE IDENT. NO. FOR CONFORMITY (CAYENNE,

CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE
TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > CHECKING VEHICLE IDENT. NO.
FOR CONFORMITY
Information
The adhesive label for the on-board literature is included with the vehicle registration documents
and can be found in the glove compartment .
Fig 1: Identifying Vehicle Identification Label
Check that the following vehicle identification numbers are identical. Then stick the vehicle data carrier
sticker provided with the vehicle into the on-board literature (Warranty and Maintenance booklet).
Vehicle identification number on lower left of windscreen.
Vehicle identification number stamped on the bodyshell in the front right footwell.
Vehicle identification number on the vehicle data carrier sticker.

Vehicle identification number in the vehicle registration documents.
WM 0X01IN CHECKING GLAZING (CAYENNE, CAYENNE GTS, CAYENNE TURBO S,

CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL,
CAYENNE (3.0)) > CHECKING GLAZING
Information
The following items can be checked by simple visual inspection, no assembly work required.
1. Check whether transport protection has been completely removed and ensure that no film
remains in the body joints or under seals.
2. Check vehicle glazing for stone damage and scratches.
3. Check surrounds and rubber sections of vehicle glazing for damage and cracks.
WM 0X01IN CHECKING LIDS AND DOORS (CAYENNE, CAYENNE GTS, CAYENNE

TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S
DIESEL, CAYENNE (3.0)) > INFORMATION > CHECKING LID LOCK AT FRONT AND
REAR
Check that the lid locks engage when the lids (front and rear) are closed by engaging the upper
parts of the lock and that they disengage again when the lid openers are actuated.
Clean and grease the lock if it is difficult to move or corroded.

DIESEL, CAYENNE (3.0)) > INFORMATION > FUNCTION TEST ON REAR LID CLOSING
AID
Check that the closing aid automatically pulls the rear lid into the lock when you close the rear lid.

DIESEL, CAYENNE (3.0)) > INFORMATION > FUNCTION TEST ON AUTOMATIC REAR
LID
Information
More detailed information on the opening and closing process can be found in the Driver's Manual. →
"Owner's Manual"
Check that the rear lid can be opened using the remote control and the release options in the
vehicle.
1. Open the rear lid with the remote control.
2. Close the rear lid by pressing the button on the rear lid.
3. Open the rear lid by actuating the switch on the driver's door.
4. Open the rear lid by actuating the release handle on the outside of the rear lid.

DIESEL, CAYENNE (3.0)) > INFORMATION > CHECKING SAFETY HOOK FOR FRONT
LID
Check that the front lid is held down by the safety hook (locking hook) after the lid lock is opened.
Check whether the return spring on the upper part of the lock pulls back the safety hook as far as
the stop.

DIESEL, CAYENNE (3.0)) > INFORMATION > DOOR LOCK FUNCTION TEST
Check that the door locks engage in two stages when the doors are closed and that they
disengage again when the door handles are operated (inside and outside).
Clean and grease the lock if it is difficult to move or corroded.

DIESEL, CAYENNE (3.0)) > INFORMATION > FUNCTION TEST ON TANK CAP LOCK
Lock vehicle.
Check tank cap is locked by the tank cap lock in the closed position.

DIESEL, CAYENNE (3.0)) > MAINTENANCE WORK > GREASING DOOR ARRESTER
1. Lubricate door arrester.
1. 1.1. Open doors completely.
2. 1.2. Evenly apply a thin coating of grease to the door arrester from the top
downwards.
Fig 1: Lubricating Door Arrester
WM 0X01IN CHECKING SEAT BELTS (CAYENNE, CAYENNE GTS, CAYENNE TURBO

S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL,
CAYENNE (3.0)) > WARNING NOTE FOR SEAT BELTS
WARNING: Road tests on public roads
Danger to other people on the roads
→ Perform drive tests on a stretch of road with no traffic.
Information
After any accident, the seat belt system must be checked systematically for signs of damage. If damage
is found, the entire seat belt system must be replaced.

CAYENNE (3.0)) > CHECKING PROCEDURE FOR SEAT BELT
Information
After any accident, the seat belt system must be checked systematically for proper function and damage.
If damage is found according to the test points, the entire seat belt system must be replaced.
Information
In the case of damage which does not occur as the result of an accident, e.g. wear, only the damaged
part needs to be replaced.
Information
The following requirements must be met when fitting the seat belt.
If one of the requirements listed below is not met, the seat belt or seat-belt buckle must be replaced.

CAYENNE (3.0)) > CHECKING BELT STRAP
Pull the belt strap fully out of the automatic belt device.
Check the belt strap for soiling; clean, if necessary, with mild soap suds. When drying, avoid direct
sunshine.
1. Damage type 1
1. 1.1. If one of the damage types shown below -Damage type 1, 2- is found on an
vehicle involved in an accident, the seat belt and seat-belt buckle must be replaced.
Fig 1: Identifying Damage Seat Belt Type 1

2. Damage type 2
1. 2.1. If damage -Damage type 1, 2, 3- is found on a vehicle not involved in an

accident, it is sufficient to replace the damaged seat belt.
3. Damage type 3
1. 3.1. Burn marks from cigarettes or similar.

4. Damage type 4
1. 4.1. The seat-belt pretensioner must always be replaced if it has been triggered. The
seat belt is damaged by the deflector -Damage type 4- .

CAYENNE (3.0)) > CHECKING AUTOMATIC BELT DEVICE (LOCKING EFFECT)
The automatic belt device has two locking functions
The first locking function is triggered by pulling the seat belt out quickly (belt extension
acceleration).
Test
Pull the belt strap out of the automatic belt device with a strong jerk.
If no locking effect occurs, the entire seat belt and belt buckle must be replaced.
In the event of faults in the extension or retraction of the seat belt, check whether the locking lug of the
automatic belt device is engaged correctly in the sheetmetal bracket on the body.
The second locking function is triggered by a change in the sequence of vehicle movement
(vehicle-dependent locking function).
Test

Fasten the seat belt.
Accelerate the vehicle to 20 km/h (12 mph) and then perform an emergency stop with the foot
brake.
If the belt is not locked by the blocking mechanism during the braking phase, the entire seat belt and belt
buckle must be replaced.

CAYENNE (3.0)) > CHECKING LOOK AND OPERATION OF SEAT-BELT BUCKLE
Inspect the belt buckle for crack formation and flaking.
In the case of damage, the entire seat belt and belt buckle must be replaced.
Check belt buckle
Push the belt latch into the seat-belt buckle until it engages with an audible click. Check whether
the lock mechanism has engaged by pulling strongly on the belt strap.
If the belt tongue fails to lock in the belt buckle even just once in at least 5 test procedures, the entire
seat belt and belt buckle must be replaced.
Checking belt buckle release
Release the seat belt by pressing with a finger on the button on the belt buckle.
Carry out the test procedure at least 5 times. If the belt tongue fails to jump out even just once, the entire
seat belt and belt buckle must be replaced.
Information
Lubricants must never be used to eliminate noises or stiffness of the buttons on the seat-belt buckles.

CAYENNE (3.0)) > CHECKING SASH GUIDES
Plastic-coated covers show fine, parallel scores after the belt system has been subjected to stress (seat
belt buckled during accident). On the other hand, wear caused by frequent use is indicated by a
stripe-free, smooth surface.
Inspect the sash guides for distortion, flaking and crack formation.
In the event of scoring and/or damage, the entire seat belt and seat-belt buckle must be replaced.

CAYENNE (3.0)) > CHECKING MOUNTING ELEMENTS AND MOUNTING POINTS
Check the belt buckle strap for distortion.
Check the function of the height adjuster.
Check fastening points (seat, B-pillar, C-pillar, vehicle floor) for distortion or thread damage.
If damage is found on the parts, the entire seat belt and belt buckle must be replaced.
Replace damaged or distorted mounting points.
WM 0X01IN CHECKING VEHICLE EQUIPMENT FOR COMPLETENESS (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > VEHICLE EQUIPMENT
Check that the items listed below are in the vehicle.
Designation Qty. Restrictions Position in the vehicle
Warning triangle 1x Country-specific(1) Rear lid lining
First-aid kit 1x Country-specific(1) Luggage compartment

(storage bin on right-hand
side, vehicles with spare
wheel: in the spare wheel
cover)
On-board folder 1x Standard Glove compartment

containing technical
information(2) Driver's
Manual, PCM/CDR
operating instructions,
Warranty and
Maintenance booklet(3)(4)
Spare wheel 1x Depending on vehicle Internal

equipment (I-no.: 3F4)
Folding wedges 2x Depending on vehicle Luggage compartment

equipment (I-no.: C38) (under the loadspace
floor; Hybrid: on the
loadspace floor)
Spare wheel 1x Depending on vehicle Luggage compartment

equipment (I-no.: 1G1, (under the loadspace
1G4) floor)
Ball head for trailer hitch 1x For vehicles with
removable trailer hitch
(not USA)
Bottle of sealing 1x For vehicles without

compound for tires, Tire emergency wheel or
Fit spare wheel (I-no: 1G8)
Compressor 1x For vehicles with

emergency spare wheel
or Tire Fit (I-no: 1G1,
1G4, 1G8)
Torch and torch holder 1x Japan only Passenger's side at door

entry guard
Front number plate 1x USA and Japan only

carrier, including Stored in luggage
fastening material(5) compartment
Wiper blades, front(6) 2x
(1)
All countries except for USA, Canada, Japan
(2)
Except for German-speaking countries, the on-board folder containing technical information (Driver's
Manual and Guarantee and Maintenance booklet) must be supplied by the dealer or importer .
(3)
The PCM/CDR operating instructions must be supplied by the dealer or importer in all non-German-
speaking countries .
(4)
The navigation CD must be supplied by the dealer or importer in the USA .
(5)
Only in states in the USA that require a number plate at the front of the vehicle and in Japan →
668319 REMOVING AND INSTALLING NUMBER PLATE COVER .
(6)
Replace the one-way wiper blades with the enclosed wiper blades .

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TOOL KIT
Designation Qty. Restrictions Position in the vehicle
Open-ended wrench 1x
Towing lug 1 x(1)
Screwdriver 1x
Standard
Luggage compartment
Socket wrench 1x
(under the loadspace
Socket for security wheel 1x floor)
bolts
Wheel bolt wrench 1x Only for vehicles with

emergency wheel or
Jack 1x
Assembly pin 1x spare wheel (I-no: 1G1,
1G4, 1G8, 3F4)
Puller hook 1x
Allen key for emergency 1x Vehicles with sliding or Dashboard cover (left lid)
operation of roof systems panoramic roof
Emergency operation of 1x
ignition key lock
(1) 2 x in vehicles with Off-Road Technical or Off-Road Design package

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > DRIVER'S KEY
Designation Qty. Restrictions
Key ring 1x Standard
Key tag 1x Standard
Remote control 2x Standard
WM 0101IN DIAGNOSTIC SYSTEM: PERFORMING VEHICLE HANDOVER (CAYENNE

TIP, CAYENNE MAN, CAYENNE S, CAYENNE TURBO, CAYENNE S HYBRID,
CAYENNE DIESEL, CAYENNE S DIESEL, CAYENNE TIP (3.0)) > TOOLS

CAYENNE DIESEL, CAYENNE S DIESEL, CAYENNE TIP (3.0)) > TECHNICAL VALUES

CAYENNE DIESEL, CAYENNE S DIESEL, CAYENNE TIP (3.0)) > INFORMATION >
PERFORMING VEHICLE HANDOVER
NOTE: Voltage drop
battery.
1. PIWIS Tester II 9818 must be connected to the vehicle. Then start the System Tester. Switch
on ignition .
Fig 1: Locating Vehicle Diagnostic Socket
2. Select the vehicle.
3. In the Control unit overview , press [F7] to continue.
4. Select the Vehicle handover function, then press [F12].
5. When Remove transport protection is displayed, press [F12] to continue.

6. Create vehicle handover log , then press [F12].
7. Write service interval, then press [F8] (Yes).
8. Select the individual maintenance intervals for the maintenance interval allocation for each
specific country and engine. [F12].
9. Write maintenance interval , then press [F12].
10. The control units are activated and the status is displayed. Compare the chassis number
displayed on the Tester with the vehicle identification number of the vehicle. Press [F12] to
continue.
11. Conclude vehicle handover and press [F12]. The log you created is saved under the vehicle
identification number.
12. Test-drive the vehicle and read out the fault memory. Check faults after diagnosis if necessary
and erase the fault memory before delivering the vehicle.
WM 0X01IN MOBILE ROOFS: CHECKING OPERATION (CAYENNE TIP, CAYENNE

MAN, CAYENNE S, CAYENNE TURBO, CAYENNE S HYBRID, CAYENNE DIESEL,
CAYENNE S DIESEL, CAYENNE TIP (3.0)) > CHECKING SLIDING ROOF AND
PANORAMA ROOF SYSTEM
1. By operating the control switch, return to original tilting, opening and closing positions. During
operation, check for malfunctions and noises.
2. Fully open and close sliding roof lining by hand. During operation, check for noise and
stiffness.
WM 0X01IN REMOVING TRANSPORT PROTECTION (CAYENNE, CAYENNE GTS,

CAYENNE TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO,
CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING EXTERNAL TRANSPORT
PROTECTION
Installation position: Body
Material: Plastic film
Installation position: Doors
Material: Foam strips with adhesive film
Installation position: Front bumper
Material: Foam strips with adhesive film
Installation position: Wheel rims
Material: Self-adhesive rim protection
Installation position: Mirrors
Material: Plastic bag

WM 0X01IN REMOVING TRANSPORT PROTECTION (CAYENNE, CAYENNE GTS,
CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING INTERNAL TRANSPORT
PROTECTION
Installation position: Seats (front)
Material: Fleece
Installation position: Centre console cover
Material: Fleece
Installation position: Door sill
Installation position: Lower door trim panel
Material: Cardboard protection
Installation position: Inner door handle
Installation position: Footwell
Material: Cardboard protection
WM 0X01IN TRAILER HITCH MAINTENANCE: CHECKING OPERATION (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION > REQUIRED TEST
TOOL
Information
To perform this check, a trailer with no faults in the wiring and lights, or a trailer test cable VAS
1537 A is required.
Please note that if a VAS 1537 A trailer test cable is used, only vehicles with a 13-pin plug can be
checked.
The test cable can be plugged into the trailer socket to locate faults. The plug has 13 pins;
adapters are required for 7-pin sockets. Because of the build-up of heat, ensure that a thermal
circuit breaker is used in the test cable.
Fig 1: Identifying Test Cable (VAS 1537 A)
Item Designation Source Explanation
Socket tester V.A.G.

1537 A

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION > CHECKING
OPERATION OF THE TRAILER HITCH SOCKET
1. Connect the test cable to the trailer hitch socket on the vehicle and lay the cable to the front.
Fig 1: Identifying Vehicle Trailer Hitch Socket And Test Cable

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION > TEST PROCEDURE
Information
The LED for permanent positive -9- is lit for the entire duration of the test .
Fig 1: LED Indicator - System Diagram
1. Switch on the ignition and switch through the following loads in turn:
Switch on left direction indicator light -1- or right direction indicator light -4- - the direction
indicator and the direction indicator pilot light for the trailer in the instrument cluster light up;
press the relevant button -B- for left or -C- for right: now the LEDs -1- or -4- and the direction
indicator in the instrument cluster should not light up.
2. Actuate the brake pedal - LEDs -6- should light up.

3. Switch on the parking light - LEDs -5, 7- should light up.
4. Switch on the parking light and rear fog light - LEDs -5, 7- should light up.
Disconnect the trailer hitch plug. The rear fog light on the vehicle must light up.
5. Switch off the lights and engage reverse gear.
The reversing light on the vehicle must light up.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION > GENERAL
-10- Charge positive
-11- Ground for charge positive
-12- Trailer detection
-13- Depending on the load (heat build-up) on the tester (the more LEDs that light up), the
tester switches off and this is indicated by the fact that this LED lights up. Disconnect the test
equipment and let it cool for at least 20 minutes.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION > CHECKING
ELECTRICALLY EXTENDABLE TRAILER HITCH (AHK)
Information
The swivel action of the ball hitch is interrupted in the one-touch function of the rocker switch if
resistance interferes with the movement sequence. The interruption is indicated by the rapid
flashing of the red LED in the rocker switch.
Overload protection is switched off by pressing the rocker switch for at least two seconds.
WARNING: Risk of injury and damage when retracting and extending the ball hitch.
Make sure that no persons, animals or obstacles are in the movement range of the ball
hitch.
To interrupt the swivel action of the ball hitch in the event of danger, touch the rocker
switch again.
→ Never swivel the ball hitch when a trailer is coupled or when bicycle racks, for example, are mounted
or supported on the ball hitch.
→ Only use the trailer hitch when the ball hitch is extended fully.
→ Never insert tools of any kind into the ball hitch swivel mechanism. This could damage the locking
mechanism; safe operation of the trailer hitch can then no longer be guaranteed.
→ Check that the ball hitch locks into position correctly before every journey.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION > OVERLOAD
PROTECTION
Information
The vehicle must be stationary.
Rear lid or rear window must be open.
The trailer must be unhitched.
Connectors (and any adapters) must be removed from the socket.
There must not be any accessories on the ball hitch (e.g. ball protection cap, bicycle rack, etc.).
1. Swivelling out the trailer coupling
1. 1.1. Prerequisite
Information
1. The vehicle must be stationary.
2. Rear lid or rear window must be open.
2. 1.2.
3. 1.3. To swivel out:
4. 1.4. Touch rocker switch -A- .
5. 1.5. [>>] The ball hitch moves automatically into operating position.
6. 1.6. The red LED in the rocker switch flashes until the operating position is reached.
Fig 1: Identifying Rocker Switch
2. Retracting the trailer hitch
1. 2.1. Prerequisite
Information
1. The vehicle must be stationary.
2. Rear lid or rear window must be open.
3. The trailer must be unhitched.
4. Connectors (and any adapters) must be removed from the socket.
5. There must not be any accessories on the ball hitch (e.g. ball protection cap,
bicycle rack, etc.).
2. 2.2.
3. 2.3. To retract:
4. 2.4. Touch rocker switch -A- .
5. 2.5. [>>] The ball hitch moves automatically into operating position.
6. 2.6. The red LED in the rocker switch flashes until the operating position is reached.
Fig 2: Identifying Rocker Switch
WM 0X03IN CHECKING OPERATION OF ELECTRICAL EQUIPMENT AS WELL AS

WARNING AND INDICATOR LIGHTS (CAYENNE, CAYENNE GTS, CAYENNE TURBO S,
CAYENNE (3.0)) > CHECKING OPERATION OF ELECTRICAL EQUIPMENT AS WELL
AS WARNING AND INDICATOR LIGHTS
Turn ignition key and check function of warning and indicator lights (visual inspection).
Actuate power windows and check that they are working correctly.
Check that rear window heating is working.
Adjust heater blower and fans to high and low and check air-flow rate at the air vents.
Front seats and back seats: check function.
Check audio function.
Check function of exterior mirrors, check adjustment options.
Check function of orientation lights.
Check function of luggage compartment lamps.

Check function of interior lights.
Actuate central locking system and check function.
Operate cigarette lighter and check that it is working.
WM 0X03IN AIR CONDITIONING MAINTENANCE: PARTICLE FILTER - REPLACING

FILTER INSERT (CAYENNE TIP, CAYENNE MAN, CAYENNE S, CAYENNE TURBO,
CAYENNE S HYBRID, CAYENNE DIESEL, CAYENNE S DIESEL, CAYENNE TIP (3.0)) >
PRELIMINARY WORK
Remove cover under dashboard at the passenger's side. → 702219 REMOVING AND INSTALLING
COVER UNDER DASHBOARD

PARTICLE FILTER: REMOVING FILTER ELEMENT
Fig 1: Identifying Particle Filter Installation Position
1. Unclip footwell outlet vent on passenger's side -1- from the bracket -2- and pull it off the air
guide -3- .
Fig 2: Identifying Footwell Outlet Vent
Information
If the locking mechanism -2- breaks off during removal, the cover can -1- be -4- screwed
down. Use the correct fastening screw for this.
Fig 3: Identifying Particle Filter Cover
2. Remove cover -1- for particle filter.

1. 2.1. Removing cover for the first time: Unclip locking mechanism -2- and pull the
cover -1- out of the bracket -3- .
2. 2.2. For repeated removal: Unscrew fastening screw -4- and remove cover -1- from
the bracket -3- .
3. Remove particle filter.

PARTICLE FILTER: INSTALLING FILTER ELEMENT
Information
If the locking mechanism -2- breaks off during removal, the cover can -1- be -4- screwed down. Use
the correct fastening screw for this.
1. Fit particle filter.
2. Install cover -1- for particle filter.

1. 2.1. Fit cover -1- into the bracket -3- .
2. 2.2. Screw in fastening screw -4- .
3. Attach footwell outlet vent -1- to the air guide -3- and clip it into the bracket -2- .
Fig 3: Identifying Footwell Outlet Vent

SUBSEQUENT WORK
Install cover under dashboard at the passenger's side. → 702219 REMOVING AND INSTALLING
WM 0X03IN CREATING VEHICLE ANALYSIS LOG (VAL) (CAYENNE, CAYENNE GTS,

CAYENNE S DIESEL, CAYENNE (3.0)) > TOOLS

PIWIS Tester 2 Special tool 9818
WM 0X03IN CREATING VEHICLE ANALYSIS LOG (VAL) (CAYENNE, CAYENNE GTS,

CAYENNE S DIESEL, CAYENNE (3.0)) > CREATING VEHICLE ANALYSIS LOG (VAL)
Information
When creating the FAP, it is essential to guarantee the power supply for the Porsche System Tester. A
battery charger with a current rating of at least 40 A must be connected to the vehicle battery.
The Porsche System Tester instructions take precedence and in the event of a discrepancy, these are
the instructions that must be followed. Deviations may occur with later software versions.
The procedure described here has been structured in general terms; different text or additions may
appear in the Porsche System Tester.
1. PIWIS Tester 2 9818 must be connected to the vehicle. Then start the Tester.
2. Switch on ignition.
3. Select "Diagnosis" .
4. Select vehicle type.
5. Select "Additional menu" by pressing [F7].
6. Select VAL by pressing [F12].
7. Select AS VAL or OBD VAL . Then press [F8] to start.
8. Check the chassis number and correct it if necessary.
9. If you want to print the data, connect the printer to the PIWIS Tester 2 9818 .
10. Switch on the printer.
11. Press [F10] to display the VAL.
12. If there is a printer connected, the print job can be started using the menu bar.
13. Then save or delete the VAL using the touchpad.
14. Shut down the Tester, switch it off and disconnect it from the vehicle.
WM 0X03IN ELECTRICS MAINTENANCE: CHECKING THE FUNCTION OF THE
VEHICLE'S LIGHTS (CAYENNE TIP, CAYENNE MAN, CAYENNE S, CAYENNE TURBO,
CHECKING OPERATION OF VEHICLE LIGHTS > CHECK LIGHTING
Turn on ignition, switch on all vehicle exterior lights one after another and check that the individual lights
are working.
Lights to be checked:
Main headlights
Fog lights
Direction indicator light, front
Side direction indicator light
Tail light
Number plate light
Additional brake light
WM 0X03IN ELECTRICS MAINTENANCE: CHECKING THE FUNCTION OF THE

VEHICLE'S LIGHTS (CAYENNE TIP, CAYENNE MAN, CAYENNE S, CAYENNE TURBO,
CHECKING OPERATION OF VEHICLE LIGHTS > CHECKING HORN FUNCTION
Press horn actuation on steering wheel and check the function and sound of horn.
Checking Bi-Xenon headlight
Checking LED headlights
Checking rear light
Checking the clock
Adjusting main headlights
1. → 941516 ADJUSTING HEADLIGHTS
WM 0X03IN ELECTRICS MAINTENANCE: CHECKING WINDSCREEN WIPER AND

WASHER SYSTEM > WINDSCREEN WASHER/HEADLIGHT CLEANING SYSTEM:
CHECKING OPERATION, NOZZLE SETTINGS
NOTE: Headlight surface not cleaned properly
Scratches
→ Use only soapy water to clean the exterior lights and the plastic headlight lenses.
→ Never use chemical cleaning agents.
→ To avoid scratches, do not rub with dry or slightly damp cloths, paper towels or insect-removal
sponges.
Information
The headlight washer nozzles are pre-set!
Generally, it is not necessary to adjust them!
Information
Check operation, fluid level indicator and nozzle settings. If the spray nozzle settings for the windscreen
washer system are not OK, the nozzles need to be adjusted:
Insert a sharp object (needle) into the nozzle hole.
Align the spray nozzles using the sharp object.

CHECKING OPERATION, NOZZLE SETTINGS > MIX RATIO OF FLUIDS FOR
WINDSCREEN WASHER SYSTEM
Fluid: Mix ratio:
Water Undiluted
1: 1
Water/isopropanol 2: 1
3: 1
1: 1
Water/ethanol 2: 1
3: 1

CHECKING OPERATION, NOZZLE SETTINGS > CHECKING WIPER BLADES
Check the wiper blades for any deformities and tears.
1. Turn on the ignition, operate the spray nozzles and check the quality of the wipers.
WM 0X03IN RUNNING GEAR MAINTENANCE: TIRES AND SPARE WHEEL:

CHECKING CONDITION AND TYRE PRESSURE (CAYENNE TIP, CAYENNE MAN,
CAYENNE S, CAYENNE TURBO, CAYENNE S HYBRID, CAYENNE DIESEL, CAYENNE
S DIESEL, CAYENNE TIP (3.0)) > CHECKING > CHECKING CONDITION
For vehicles with tyre pressure monitoring (TPM), which can be identified by aluminum valves, the tyre
pressure must be adjusted according to the >> Filling information << on the multi-function display. To do
this, select >> Main menu >> Tyre pressure >> Filling information <<. Adjust the deviation values so that
they range from 0.0 bar to +0.1 bar. Fill the tires according to the display using the tyre-inflating device.
Example: If the tyre pressure display >> Filling information << shows - 0.2 bar, 0.2 bar pressure must be
added.
Fig 1: Display - Tyre Pressure Information Screen
Information
The >> Tyre pressure << display is for information purposes only.
Tyre pressure settings can only be entered according to the values in >> Filling information <<.
The tyre pressure is only displayed when the vehicle is stationary.
Due to the pressure and temperature relationship (approx. 0.1 bar/10° C), the actual pressure values
displayed under >> Tyre pressure << in the multi-function display, or on the pressure gauge of the
tyre-inflating device, can deviate from the required pressure specified at 20° C on the tyre pressure plate
if the air temperature in the tyre is significantly above (higher values) or significantly below 20° C (lower
values). Changes in tyre pressure are displayed after max. 1 minute under >> Filling information << after
switching on the ignition. A series of dashes (-.-) will appear instead of the tyre pressure during this time.
Always use plastic valve caps on vehicles with tyre pressure monitoring (TPM). Plastic valve caps
protect against dust, dirt and humidity, and therefore against damage (corrosion).
Tires are a safety element that fulfil the demands placed on them only if they have the correct air
pressure and a sufficient tread depth.
WARNING: Risk of accidents if the air pressure in the tires falls below the minimum, if the
tread depth is insufficient or if there are foreign bodies, pricks, cracks and bulges in the
sidewall (ply breakage).
Modified handling behavior can cause accidents and major material damage.
→ The air pressure must never fall below the values specified (these are minimum pressures).
→ The tread depth must never fall below the minimum value.
→ A visual inspection of the tires (for cracks, pricks, bulges in the sidewall and/or foreign bodies) must
be carried out.
1. Check condition and tyre pressure.
2. Always screw on valve caps tightly and replace missing valve caps.
Notes
Cold tyre pressures (at approx. 20° C)
Information
The currently applicable air pressure values and comfort tyre pressure values in the individual countries
can be found in the Manufacturer Approval >>Approved wheels and tires<< in the >>Manufacturer
Approvals<<, Group 4.
Tyre pressures apply to all-season, winter and summer tires. They also apply only to tires approved by
Porsche.
Part load: The tyre pressure is specified for a load of up to 3 people + 21 kg of luggage.
The collapsible spare wheel is an optional extra (tyre sealant comes as standard).
WM 0X03IN OVERVIEW OF A, B AND C MARKETS (CAYENNE, CAYENNE GTS,

CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION > OVERVIEW OF A, B AND C
MARKETS
Information
Applies only to the Cayenne (V6) and S Hybrid from model year 2011.
Because of different fuel octane ratings, the change intervals for oil and spark plugs have been adapted
to suit the various markets.
Markets Countries
A markets AndorraBelgiumGermanyDenmarkEstoniaFinland,
FranceGreece, Great BritainIreland, Iceland,
ItalyJapanLatviaLiechtenstein, Lithuania,
LuxembourgMaltaNetherlands, NorwayAustriaPoland,
PortugalSweden, Switzerland, Slovakia, SpainCzech
RepublicHungaryCyprus
B markets Egypt, Algeria, Angola, Argentina, Armenia, Aruba (itc

Caribbean), Azerbaijan, AustraliaBahamas, Bahrain,
Bangladesh, Barbados, Bosnia and Herzegovina, Brazil,
Brunei, BulgariaChile, Costa RicaDominican
RepublicEcuador, El SalvadorFrench Guiana, French
PolynesiaGhana, Guadeloupe, GuatemalaHaiti, Dutch
Antilles, Honduras, Hong KongIndia, Iraq, Iran,
IsraelJamaica (itc Caribbean), Yemen, JordanCameroon,
Canada, Kazakhstan, Qatar, Cayman Islands, Kenya,
Columbia, Croatia, KuwaitLesotho, Lebanon, LibyaMalaysia,
Morocco, Martinique (F), Mauritius, Mexico, Moldova,
MonacoNamibia, New Caledonia, New Zealand, Nigeria,
NicaraguaOmanPakistan, Panama, Paraguay, Peru,
Philippines, Puerto RicoReunion, Romania, RussiaSaudi
Arabia, Serbia and Montenegro, Zimbabwe, Singapore,
Slovenia, Sri Lanka, South Africa, South Korea, Swaziland,
SyriaTaiwan, Thailand, Trinidad and Tobago, Turkey,
TunisiaUkraine, Uruguay, USAUAE (Abu Dhabi, Dubai),
Venezuela, VietnamBelarus, Western Sahara
C markets China, Indonesia
WM 0X03IN RUNNING GEAR MAINTENANCE: TIRES AND SPARE WHEEL:

CHECKING CONDITION AND TYRE PRESSURE (CAYENNE TIP, CAYENNE MAN,
S DIESEL, CAYENNE TIP (3.0)) > CHECKING > CHECKING CONDITION
For vehicles with tyre pressure monitoring (TPM), which can be identified by aluminum valves, the tyre
pressure must be adjusted according to the >> Filling information << on the multi-function display. To do
this, select >> Main menu >> Tyre pressure >> Filling information <<. Adjust the deviation values so that
they range from 0.0 bar to +0.1 bar. Fill the tires according to the display using the tyre-inflating device.
Example: If the tyre pressure display >> Filling information << shows - 0.2 bar, 0.2 bar pressure must be
added.
Fig 1: Display - Tyre Air Filling Information Screen
Information
The >> Tyre pressure << display is for information purposes only.
Tyre pressure settings can only be entered according to the values in >> Filling information <<.
The tyre pressure is only displayed when the vehicle is stationary.
Due to the pressure and temperature relationship (approx. 0.1 bar/10° C), the actual pressure values
displayed under >> Tyre pressure << in the multi-function display, or on the pressure gauge of the
tyre-inflating device, can deviate from the required pressure specified at 20° C on the tyre pressure plate
if the air temperature in the tyre is significantly above (higher values) or significantly below 20° C (lower
values). Changes in tyre pressure are displayed after max. 1 minute under >> Filling information << after
switching on the ignition. A series of dashes (-.-) will appear instead of the tyre pressure during this time.
Always use plastic valve caps on vehicles with tyre pressure monitoring (TPM). Plastic valve caps
protect against dust, dirt and humidity, and therefore against damage (corrosion).
Tires are a safety element that fulfil the demands placed on them only if they have the correct air
pressure and a sufficient tread depth.
WARNING: Risk of accidents if the air pressure in the tires falls below the minimum, if the
tread depth is insufficient or if there are foreign bodies, pricks, cracks and bulges in the
sidewall (ply breakage).
Modified handling behavior can cause accidents and major material damage.
→ The air pressure must never fall below the values specified (these are minimum pressures).
→ The tread depth must never fall below the minimum value.
→ A visual inspection of the tires (for cracks, pricks, bulges in the sidewall and/or foreign bodies) must
be carried out.
1. Check condition and tyre pressure.
2. Always screw on valve caps tightly and replace missing valve caps.
Notes
Cold tyre pressures (at approx. 20° C)
Information
The currently applicable air pressure values and comfort tyre pressure values in the individual countries
can be found in the Manufacturer Approval >>Approved wheels and tires<< in the >>Manufacturer
Approvals<<, Group 4.
Tyre pressures apply to all-season, winter and summer tires. They also apply only to tires approved by
Porsche.
Part load: The tyre pressure is specified for a load of up to 3 people + 21 kg of luggage.
The collapsible spare wheel is an optional extra (tyre sealant comes as standard).
WM 0X03IN RUNNING GEAR MAINTENANCE: AXLE JOINTS/DRIVE SHAFTS/TIE ROD

JOINTS (CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S
DIESEL, CAYENNE (3.0)) > PRELIMINARY WORK
WARNING: Vehicle can fall down
Risk of squashing or crushing
Risk of damage to the vehicle
→ Do not place any solid objects under the raised vehicle.
→ Ensure that the lifting platform is prevented from lowering.
→ Remove solid objects before lowering the vehicle.
→ Raise the vehicle only at the jacking points provided.
→ The outer jacking points should be used primarily.
1. Jack and raise the vehicle at the prescribed jacking points.
→ 4X00IN LIFTING THE VEHICLE

DIESEL, CAYENNE (3.0)) > PRELIMINARY WORK > CHECKING BALL JOINT
1. Check the lower axle joint at the pivot bearing.

Information
Conditions for checking the lower axle joint
The vehicle must be raised in order to check the axle joint of the lower wishbone.
Insert a mounting lever into the pivot bearing housing -top arrow- and lever the ball joint of
the axle joint -2- downwards. See -side arrow- .
There must be no play on the joint.
Fig 1: Checking Lower Axle Joint
2. Check the upper axle joint at the pivot bearing.
Information
Conditions for checking the upper axle joint
Raise the vehicle until there is no weight on the wheels so that only the wheels' own weight is
on the ground.
Hold the top of the wheel and apply pressure to the pivot bearing -1- on alternate sides in the
directions shown -arrows- .
Fig 2: Checking Pivot Bearing
3. Check the tie rod joint.
CAUTION: Turning steering too sharply using the steering wheel.
1. Risk of squashing arms.
→ Only turn the steering wheel as far to the left and right as required in order to check the
amount of play on the tie rod.
Information
Conditions for checking the tie rod joint
The vehicle must be standing on its wheels in order to check the tie rod joint; vehicles with air
suspension must be adjusted to maximum ground clearance.
Fig 3: Checking Tie Rod Joint
1. 3.1. Check that the dust boots, bellows and joints are working perfectly and have no
leaks.
2. 3.2. Check the left tie rod joint.
Turn the wheels to the right and take hold of the tie rod joint -1- . Get a second
worker to turn the steering by moving the steering wheel back and forth slightly.
If you detect a certain amount of play that is not caused by the tie rod joint, the
axial joint between the steering gear and tie rod must be worn.
3. 3.3. Check the right tie rod joint.
Turn the wheels to the left and take hold of the tie rod joint -1- . Get a second worker
to turn the steering by moving the steering wheel back and forth slightly.
If you detect a certain amount of play that is not caused by the tie rod joint, the
axial joint between the steering gear and tie rod must be worn.
DIESEL, CAYENNE (3.0)) > PRELIMINARY WORK > AXLE JOINTS: CHECKING DUST
BOOTS
1. Visually inspect the dust boots for damage.
Information
1. When doing so, the rubber dust boots should be pressed down with the fingers to reveal
hidden cracks.
2. If a rubber dust boot leaks, the corresponding joint or control arm must be replaced,
because any dirt or moisture that seeps in will destroy the joint .
2. Inspect the dust boots of the axle joints on the wheel suspension (front and rear) as follows:
1. Place the vehicle on a lifting platform with the steering lock disengaged.
2. Perform a visual inspection after cleaning.
Information
Over a small area in the vicinity of the brake cover panels, no visual inspection is possible.
Check this area by touch.
The procedure for the front axle is as follows:
Turn the front wheels as far as they will go
Perform a visual inspection of the visible surfaces on the left and right
After turning the front wheels to the other steering stop, check the other half of each rubber dust
boot.

DIESEL, CAYENNE (3.0)) > PRELIMINARY WORK > TIE ROD JOINTS: CHECKING
DUST BOOTS
1. Raise the vehicle → 4X00IN LIFTING THE VEHICLE
Information
1. The rubber dust boots and bellows on the steering gear and on the tie rods can be
damaged by external influences, e.g. stone impact, or during assembly work.
2. If a rubber dust boot leaks, the joint or tie rod must be replaced, because any dirt or
moisture that seeps in will destroy the joint.
2. Check dust boots.

DIESEL, CAYENNE (3.0)) > PRELIMINARY WORK > DRIVE SHAFTS: VISUAL
INSPECTION OF BOOTS
Perform a visual inspection of the boots for leaks and damage.
WM 0X03IN RUNNING GEAR MAINTENANCE: RUNNING GEAR

ADJUSTMENT/STORAGE OF ASSEMBLIES (CAYENNE TIP, CAYENNE MAN,
S DIESEL, CAYENNE TIP (3.0)) > INFORMATION > RUNNING GEAR ADJUSTMENT
(WHEEL ALIGNMENT VALUES)
Check that threaded connections for chassis adjustment (wheel alignment values) at front and
rear are secure.
WM 0X03IN RUNNING GEAR MAINTENANCE: RUNNING GEAR

ADJUSTMENT/STORAGE OF ASSEMBLIES (CAYENNE TIP, CAYENNE MAN,
S DIESEL, CAYENNE TIP (3.0)) > INFORMATION > ANCILLARY UNIT
MOUNTS/CHASSIS
Visual inspection of all rubber mountings for damage.
WM 0X03IN RUNNING GEAR MAINTENANCE: STEERING GEAR - FLUID LEVEL AND

BELLOWS (CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S
DIESEL, CAYENNE (3.0)) > CHECKING > POWER STEERING: CHECKING FLUID
LEVEL
WARNING: Caustic fluids
Danger of chemical burns
→ Avoid contact with caustic fluid.
→ Wear personal protective gear.
→ Ensure that there is good ventilation.
→ If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if
necessary.
NOTE: Aggressive fluids
Risk of damage to components and surfaces

→ Do not spill fluids.
→ In the event of contact, wash the component or surface with water.
→ Replace components that are already damaged.
Information
Overfilling the system can cause Pentosin CHF 202 to overflow onto coolant hoses and other
components. The engine must be run for approx. 20 seconds prior to the fluid level check. Multiple
steering operations change the fluid level in the supply tank. Check the fluid level.
Damage to the power-assisted steering will occur if there is a shortage of oil in the hydraulic system.
Even small leaks can cause the fluid to escape as a result of the high oil pressure present in the
hydraulic circuit and damage the servo pump.
Grunt-like noises that can be heard when the steering is locked, or foam formation in the supply tank
indicate a lack of oil and/or that air has also been sucked in. Before filling the supply tank, any existing
leaks must be eliminated. In this case, the oil level in the supply tank must be checked with the engine
running as well as stopped! If the oil level drops to the bottom of the reservoir or bubbles rise up, there is
air in the hydraulic system. The system must then be bled → 4890IN TEST AND ASSEMBLY WORK ON
POWER STEERING .
The supply tank is located at the front left of the engine compartment -arrow- .
Fig 1: Locating Power-Steering Reservoir
Use only Pentosin CHF 11 S in the reservoir. Pentosin CHF 11 S can be ordered under the following part
number: Quantity supplied 1 litre = 000.043.203.33.
A dipstick with a MIN/MAX marking is mounted on the closure cap of the expansion tank. The marks are
for a fluid level with a cold engine (approx. 20 °C)!
Fig 2: Identifying Dipstick And Power-Steering Reservoir
Information
The MAX mark can be easily exceeded at higher temperatures!
1. Start engine and run it at idle speed for approx. 20 seconds. Switch off engine.
2. Open engine cover and open the lid of the engine compartment cover.
3. Open reservoir cap.
4. Wipe dipstick. Close and then reopen cap. The fluid level must be in the indicated range
(MAX/MIN level at approx. 20 °C). Top up with Pentosin if necessary.
WM 0X03IN RUNNING GEAR MAINTENANCE: STEERING GEAR - FLUID LEVEL AND

BELLOWS (CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S
DIESEL, CAYENNE (3.0)) > CHECKING > CHECKING BELLOWS ON STEERING GEAR
Information
The bellows on the steering gear can be damaged by outside influences, for example by stone
damage or during assembly work.
The steering gear can start to leak if dirt or moisture enters a leaky bellows.
Visually inspect the bellows for damage.
WM 0X03IN RUNNING GEAR MAINTENANCE: VISUAL INSPECTION - BRAKE

LINES/BRAKE PADS/BRAKE DISCS (CAYENNE TIP, CAYENNE MAN, CAYENNE S,
CAYENNE TURBO, CAYENNE S HYBRID, CAYENNE DIESEL, CAYENNE S DIESEL,
CAYENNE TIP (3.0)) > CHECKING > BRAKE HOSES AND LINES
Carry out visual inspection for leaks, damage, routing and corrosion.
WM 0X03IN RUNNING GEAR MAINTENANCE: VISUAL INSPECTION - BRAKE

LINES/BRAKE PADS/BRAKE DISCS (CAYENNE TIP, CAYENNE MAN, CAYENNE S,
CAYENNE TURBO, CAYENNE S HYBRID, CAYENNE DIESEL, CAYENNE S DIESEL,
CAYENNE TIP (3.0)) > CHECKING > BRAKE SYSTEM: VISUAL INSPECTION OF THE
BRAKE PADS AND BRAKE DISCS FOR WEAR
WARNING: Risk of accidents if brake pads and brake discs are not replaced in time.
Injury and material damage due to impaired braking effect.
→ The brake pads must be replaced when the brake pad warning indicator lights up, but no later than
when there is a residual pad thickness of 2 mm.
→ Brake discs must be replaced on reaching the wear limits.
Information
If brake pad wear is indicated by the warning light, the warning contact (sender including wire and
plug connection) must also be replaced.
Replacing the warning contact can be avoided by replacing the brake pads no later than when the
pad thickness is approx. 2.5 mm.
Warning contacts must be replaced if the core of the wire is worn. Worn insulation is not important.
However, if only the plastic part of the warning contact is worn, there is no need to replace it.
1. Visually inspect the brake pads for wear (wear limit: 2 mm).
NOTE: → 463602 CHECKING THICKNESS OF FRONT BRAKE PADS →

463802 CHECKING THICKNESS OF REAR BRAKE PADS
2. Carry out a visual inspection of the brake discs for wear → 4650TW TECHNICAL
DATA/BRAKE WEAR LIMITS
Service Manual: 6X - BODY-EQUIPMENT OUTSIDE - GENERAL -- 92A CAYENNE
WM 6X00IN DISPOSAL OF AIRBAG AND SEAT-BELT PRETENSIONER UNITS
(CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S HYBRID,
CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TOOLS
Detonator Special tool 9257

(ignition
device)
Adapter cable Special tool 9257/4


CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > DISPOSAL OF AIRBAG
AND SEAT-BELT PRETENSIONER UNITS
WARNING: Incorrect handling of airbag units
Triggering of airbag unit.
System faults can occur.
→ Switch off ignition and remove ignition key or remote control (hand-held transmitter).
→ A power supply (e.g. battery charger) must not be connected to the external power supply/jump-lead
starting terminals.
→ Disconnect the battery and insulate the ground strap so that all contact with a ground carrier is
avoided.
→ Wait 1 minute after disconnecting the battery.
→ Only pull off connector on the triggering unit after the waiting time has elapsed.
→ Make sure that no foreign objects are located in front of the airbag unit during installation.
→ Replace damaged parts during removal.
→ Always position airbag units so that the blow-out opening is facing upwards, e.g. crest on driver's
airbag.
→ Do not position anything on the airbag units.
→ If removed for an extended period, the airbag units must be stored in a safe place.
→ Airbag units must not come into contact with grease, oil, detergents, liquids, or similar substances.
→ Do not expose airbag units to temperatures above 90°.
→ Do not remove the short-circuit spring on the plug-in contacts.

→ Ignition and preparations may only be carried out by skilled staff, supervised by a second responsible
person.
→ Before disposal, the airbag unit must be rendered harmless by electrical ignition performed in
accordance with all precautionary measures, thereby preventing it from being used incorrectly.
Information
Country-specific statutory regulations and legislation based on them which go beyond these
instructions must always be observed and take precedence over these instructions!
Information
Airbag units are pyrotechnical items and can pose an environmental hazard!
For this reason, non-ignited airbag units or entire vehicles must not be disposed of as normal
scrap, refuse or in other final storage facilities!
If the vehicle suffered fire damage which caused one or several airbags or belt tensioners to be
triggered, additional ignition with the adapter cable must be carried out in order to ensure that only
parts without pyrotechnical contents are scrapped!
In the case of airbag units which cannot be ignited or if the conditions for safe ignition are
insufficient, always return the airbag units to Porsche or the respective importer in their original
packaging!

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > SAFETY PROCEDURES
WHEN IGNITING AIRBAG UNITS
starting terminals.
avoided.

airbag.
person.
Information
Only ignite airbag units that are securely installed in the vehicle and in the original condition. Use only
the ignition tool intended for this purpose.
Carry out ignition only in suitable, open areas.
First remove all loose objects from the expansion area of the airbag.
Each ignition circuit for all airbag units and seat-belt tensioners must be ignited individually.
Persons possibly affected must be informed of the resulting noise beforehand.
Wear ear protectors. Keep a safe distance by utilizing the entire cable length of the ignition tool.
Connect power source only just prior to igniting.
If ignition fails, wait for approx. 3 minutes before approaching the vehicle.
Allow airbag units to cool down under observation following ignition.
Avoid skin contact with ignited airbag units.

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TOOLS AND MATERIALS
> DETONATOR (IGNITION DEVICE) 9257
A. Ignition device 9257

Fig 1: Overview Of Ignition Device (92570)
Adapter cable 9257/4
A. Purple marking on connector - adapter for knee airbag
B. Marking A - adapter for 1st stage of driver's airbag unit
C. Marking B - adapter for 2nd stage of driver's airbag unit
D. Green marking on connector - adapter not required
E. Adapter for ignition device

Fig 2: Overview Of Adapter Cable (9257/4)
A. Purple marking on connector - adapter not required
B. Blue marking - adapter for 1st stage of driver's airbag unit
C. Black marking on connector - adapter for head airbag
D. Turquoise marking on connector - adapter for 1st stage of passenger's airbag unit
E. Yellow marking on connector - adapter for 2nd stage of passenger's airbag unit and seat-belt
pretensioner
F. Adapter for ignition device


Fig 4: Identifying Adapter Cable (9257/8) For Side Airbag

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > CONNECTING IGNITION
TOOL
starting terminals.
avoided.
airbag.
person.
Information
Only ignite airbag units that are securely installed and in original condition in the vehicle. Allow airbag
units to cool down under observation following ignition.
Use only the ignition tool intended for this purpose. First remove all loose objects from the
expansion area of the airbag.
Every ignition circuit for all airbag units and seat-belt pretensioners must be ignited individually.
Persons who may be affected must be informed of the resulting noise beforehand.
Wear ear protectors.
Keep a safe distance by utilizing the entire cable length of the ignition tool. Do not connect the
voltage source until all other preparations are complete.
Do not allow ignited airbag units to come into contact with the skin.

TOOL > DRIVER'S SIDE
starting terminals.
avoided.
airbag.
person.
Information

B - Marking A - adapter for 1st stage of driver's airbag unit
C - Marking B - adapter for 2nd stage of driver's airbag unit
E - Adapter for ignition device

1. Remove steering column casing. → REMOVING STEERING COLUMN CASING
2. Disconnect connector from the airbag at the steering-column switch and plug in connector -B-
- 1st stage - from the adapter cable 9257/4 first.
3. Connect the ignition device 9257 to the 2-pin connector -E- of the adapter cable 9257/4 .
4. Place ignition device in front of the vehicle through the door gap.
5. After triggering, repeat the step with connector -C- - 2nd stage.
Fig 2: Installing Plug Connector

TOOL > PASSENGER'S SIDE
starting terminals.
avoided.
airbag.
person.
Information
D - Turquoise marking on connector - adapter for 1st stage of passenger's airbag unit.
E - Yellow marking on connector - adapter for 2nd stage of passenger's airbag unit.
F - Adapter for ignition device.

1. Remove glove compartment. → REMOVING GLOVE COMPARTMENT
2. Unplug both connectors at the airbag unit -arrow- and plug in connector -D- - 1st stage - from
adapter cable 9257/7 at the airbag unit first.
Fig 2: Unplugging Connectors On Passenger Airbag Unit
Information
1. This is a two-stage airbag module with a connection for the 1st stage at the left in
direction of travel and a connection for the 2nd stage at the right in direction of travel.
3. Connect the ignition device 9257 to the 2-pin connector -F- of the adapter cable 9257/7 .
5. After the airbag is triggered, repeat the step on the second connection of the airbag unit with
connector -E- - 2nd stage.

TOOL > SIDE AIRBAG ON FRONT SEAT

starting terminals.
avoided.
airbag.
person.
Information

1. Position front seat.
1. 1.1. Driver's side: Move the front seat all the way up and all the way back.
2. 1.2. Passenger's side: Move the front seat all the way up and all the way forward.
2. Release and unplug connector for side airbag in the front seat.
1. 2.1. Driver's side: Release and unplug connector -1- for side airbag in the front
seat.
Fig 2: Identifying Electric Plug Connections For Driver Seat
2. 2.2. Passenger's side: Release and unplug connector -1- for side airbag in the
front seat.
Fig 3: Identifying Electric Plug Connections For Passenger Seat
3. Insert the correct yellow-colored connector for the adapter cable 9257/8 .
4. Connect the ignition device 9257 to the orange-colored 2-pin connector for the adapter
cable 9257/8 .

TOOL > HEAD AIRBAG
starting terminals.
avoided.
airbag.
person.
Information
C - Black marking on connector - adapter for head air↓bag

F - Adapter for ignition device
1. Remove D-pillar trim panel → REMOVING D-PILLAR TRIM PANEL .
2. Unplug connector at the head airbag and insert connector -C- from the adapter cable 9257/7
.
Fig 2: Unplugging Connector At Head Airbag
3. Connect the ignition device 9257 to the 2-pin connector -F- of the adapter cable 9257/7 .

TOOL > SEAT-BELT PRETENSIONERS
starting terminals.
avoided.
airbag.
person.
Information
E - Yellow marking on connector - adapter for seat-belt pretensioner

1. For the front seat-belt pretensioners, remove the B-pillar trim panel → REMOVING B-PILLAR
TRIM .
2. For the rear outer seat-belt pretensioners, remove the C-pillar trim panel and the rear side trim
panel
→ REMOVING SIDE TRIM PANEL FOR REAR LUGGAGE COMPARTMENT .
→ REMOVING SIDE TRIM PANEL FOR REAR LUGGAGE COMPARTMENT
3. Unplug connector -1- at the seat-belt pretensioner and plug in connector -A from adapter
cable 9257/7 .
4. Connect the ignition device 9257 to the 2-pin connector -a- of the adapter cable 9257/7 .
Fig 2: Pulling Off Connector On Seat-Belt Pretensioner

TOOL > KNEE AIRBAG ON DRIVER'S SIDE
starting terminals.
avoided.
airbag.
person.
Information
C - Black marking on connector - adapter for knee airbag

1. Remove cover under dashboard → REMOVING COVER UNDER DASHBOARD .
2. Remove fuse box cover on the outer left of the dashboard.
3. Loosen both fastening screws on the fuse box and press the fuse box aside until you have
easy access to the connector for the knee airbag.
4. Release and unplug connector for ignition module and plug in connector -C- of adapter cable
9257/7 .
5. Connect the ignition device 9257 to the 2-pin connector -A- of the adapter cable 9257/7 .

TOOL > IGNITION

starting terminals.
avoided.
airbag.
person.
Information
If igniti↓on fails, wait for approx. 3 minutes before approaching the vehicle.
Information
Connect ignition device to a separate vehicle battery and press the button.
Fig 1: Connecting Ignition Device Vehicle Battery
WM 6X00IN GENERAL INFORMATION ON REMOVING CAR WINDOWS (ALL

MODELS) > TOOLS
Cutting thread Commercially

available tool
Removal kit Commercially vag 1474 b

for flush available tool
bonded
windows
Removal kit Commercially VAG 1474 B
for flush available tool
bonded
windows

MODELS) > TOOLS AND MATERIALS > TOOLS AND MATERIALS FOR REMOVING
CAR WINDOWS
-A- Removal kit for flush bonded windows vag 1474 b Contains set components A1-A9
-B- Cutting thread
Item Designation
-A1- Guide rail
-A2- Cutting tool (wire holder)
-A3- Spooling device
-A4- Awl
-A5- Guide rail
-A6- Spatula
-A7- Guide roller with brace
-A8- Handle
-A9- Square cutting wire

Fig 1: Identifying Tools And Materials Of Car Windows

MODELS) > REMOVING GLASS USING WIRE FOR CUTTING TOOL
Information
The following instructions describe the general procedure for removing car windows with the glass
separating tool VAG 1474 B.
Information on procedures relating to specific vehicles can be obtained from the instructions in the
corresponding articles in the Technical Service information.
A. Removal kit for flush bonded windows VAG 1474 B 1)
B. Cutting thread
A1 - Guide rail
A2 - Cutting tool (wire holder)
A3 - Spooling device
A4 - Awl
A5 - Guide rail
A6 - Spatula
A7 - Guide roller with brace
A8 - Handle
A9 - Square cutting wire
Fig 1: Identifying Tool Kit For Flush Bonded Windows
1)
Contains set components A1-A9 and protective film for dashboard
Information
It is generally possible to remove the windscreen with the cutting wire and the optional cutting
thread contained in the tool set.
In contrast to cutting threads, however, the cutting wire has the following disadvantages:
Danger of injury when tearing off the cutting wire.
Danger of damage to materials on paint surfaces and interior equipment parts.
For the reasons outlined above we recommend using the cutting thread.
WARNING: Vehicle windows removed and installed incorrectly
Danger of cuts
Risk of eye injuries
→ Always shut off power supply when replacing cutting knife.
NOTE: Windscreen removed incorrectly

Risk of damage to vehicle identification number (VIN) label
Risk of damage to paintwork
→ When cutting out the windscreen, make sure that the label with the vehicle identification number (VIN)
is not damaged.
Information
In order to guarantee an optimum fastening intake grip, it is advisable to clean the inside of the
glass before removal.
1. Clean the inside of the glass
Information
1. The film protects the damping mat against damage when removing the glass.
2. Affix protective film to the dashboard
1. 2.1. Select the appropriate film -1- and push it in between the windscreen and
damping mat.
Fig 2: Fitting Protective Film
Information
1. In order to prevent damage, make sure that the vehicle identification number is
completely covered by the protective film when pushing through the adhesive
bead.
3. Insert cutting thread into the passenger compartment
1. 3.1. Push through adhesive bead on the glass at the edge of the vehicle identification
number -C- with the awl -A4- from the inside to the outside.
2. 3.2. Pass cutting thread -B- through the eyelet on the awl -A4- .
3. 3.3. Pull cutting thread -B- into the passenger compartment.
4. 3.4. Pull cutting thread -B- out of the awl -A4- .
5. 3.5. Pull cutting thread -B- approx. 1 m into the passenger compartment.
Fig 3: Cutting Thread Into Passenger Compartment
Information
1. The cutting thread should be positioned under the rim as far as possible. The
sealing lip must be raised slightly in the upper part of the glass in order to pull
the cutting thread through.
4. Insert cutting thread into the gap in the glass
1. 4.1. Insert cutting thread -B- in direction of arrow into the gap between the glass and
body all the way around. Use a spatula if -A6- necessary.
Fig 4: Inserting Cutting Thread Of Glass
5. Secure cutting thread to the body
1. 5.1. Attach the loose end of the cutting thread -B- firmly at a suitable point on the
body using the fastening screw -2- for a component (e.g. wiper motor mounting). To
do this, loosen the fastening screw, wind the cutting thread -B- once around the
screw and tighten the fastening screw again.
Fig 5: Securing Cutting Thread To Body
6. Attach cutting thread to the spooling device
1. 6.1. Loosen clamping screw -3- .
2. 6.2. Insert cutting thread -B- into the bore on the spooling device -A3- .
3. 6.3. Clamp cutting thread -B- firmly with the clamping screw -3- .
Fig 6: Attaching Cutting Thread To Spooling Device
Information
1. The fastening force can be increased by moistening the fastening intake.
7. Fit spooling device and deflection rollers on the glass
1. 7.1. Position spooling device -A3- diagonally in the center of the glass.
2. 7.2. Press spooling device -A3- firmly against the glass using the suction cups.
3. 7.3. Secure suction cup to the glass by moving the actuating lever.
Fig 7: Fitting Spooling Device On Glass
8. Separate glass as far as P1
1. 8.1. Separate glass by spooling the cutting thread on the spooling device as far as
point -P1- .
Fig 8: Separating Glass
Information
9. Reposition spooling device
1. 9.1. Release spooling device.
2. 9.2. Loosen the lower suction cup on the spooling device.
3. 9.3. Pull cutting thread through onto the other side of the suction cup.
Fig 9: Positioning Spooling Device
Information
10. Separate glass as far as -P2-
1. 10.1. Position deflection roller in the lower right corner.
2. 10.2. Press deflection roller with suction cup firmly against the glass.
4. 10.4. Pass cutting thread over the deflection roller onto the spooling device.
point -P2- .
Information
2. 11.2. Position deflection roller in the upper right corner.
point -P3- .
Information
12. Reposition spooling device
2. 12.2. Loosen the upper suction cup on the spooling device.
3. 12.3. Pull cutting thread through onto the other side of the suction cup.
Fig 12: Positioning Spooling Device
Information
1. 13.1. Position deflection roller in the upper left corner.
point -P4- .
Fig 13: Separating Glass On Spooling Device
Information
2. 14.2. Position deflection roller in the lower left corner.
point -P5- .
point -P6- .
Fig 15: Separating Glass On Spooling Device
16. Remove glass

MODELS) > CUTTING FORCE FOR REMOVING GLASS WITH CUTTING THREAD
Information
The force required for separating the glass is lower when the cutting thread is deflected to its
maximum point. An angle greater than 90° should be avoided.
Unfavourable angle (strong pulling force required)

Fig 1: Identifying High Cutting Force Angle
Favourable angle (average pulling force required)

Fig 2: Identifying Average Cutting Force Angle
Optimum angle (minimum pulling force required)

Fig 3: Identifying Low Cutting Force Angle
WM 6X00IN HANDLING AND REPLACING AIRBAG AND SEAT-BELT PRETENSIONER

UNITS (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S
HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TOOLS
2nd Special tool 9818

generation
PIWIS Tester
HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TOOLS AND
MATERIALS
Use Porsche work clothing.

HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > GENERAL
WARNING NOTES > GENERAL WARNINGS FOR HANDLING AIRBAG AND
SEAT-BELT PRETENSIONER UNITS
CAUTION: Danger of injury and material damage if the airbag unit is not handled
correctly!
Triggering of the airbag unit!
→ The airbag units are pyrotechnical items in hazard class T 1!
→ Handling, transport and storage of these units must conform to hazardous goods regulation and
explosives legislation!
→ The listed statutory requirements Germany. The relevant valid regulations must be observed in all
other countries. Consult the importer for the country concerned!
→ The commencement of work with pyrotechnical items must be reported to the Trade Supervisory
Office (responsible authority) 14 days in advance!
→ The airbag units may only be shipped in transport packaging officially approved for this purpose!
→ Internally and otherwise, they must always be transported in the luggage compartment or loadspace
of a vehicle using the above-mentioned transport packaging!
→ They must never be transported in the passenger compartment!
→ Airbag units must be stored in accordance with the explosives legislation SprengLR 240 - Storage of
airbag and seat-belt pretensioner units!
→ This ordinance stipulates that small quantities of materials and items may be stored at certain
locations without special storage approval!
→ The airbag units must be kept in a locked place!
→ When storing airbag units, ensure that the blow-out opening is facing upwards (risk of injury as a
result of inflation of the airbag units in the event of accidental ignition)!
→ The airbag units must be stored in a dry place and must not be stored together with other hazardous
goods (lacquers, etc.)!
→ Loose airbag units or airbag units in a removed steering wheel must never become the actual
(physical) property of the customer!
→ The possession of loose airbag units not installed in the vehicle is not permitted in the private sector!
→ Airbag units may become the property of the customer only when installed in the vehicle!

HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > GENERAL
WARNING NOTES > WARNINGS ABOUT ASSEMBLY AND STRAIGHTENING WORK
WARNING: Incorrect handling of airbag triggering unit
Malfunction in airbag system
→ Never drive with an untaught or unlocked airbag triggering unit.
→ Teach and lock the airbag triggering unit using the 2nd generation PIWIS Tester 9818 . The warning
light will flash continuously until such a time as you teach and lock the airbag triggering unit.
→ Inspection and assembly work may only be carried out by specialist staff.

HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION
FOR HANDLING AIRBAG AND SEAT-BELT PRETENSIONER UNITS > DANGERS FOR
PERSONS AND THE ENVIRONMENT
Information
Dangers for persons and the environment
Injury caused by incorrect triggering of the installed unit.
Injury caused by spinning away, e.g. of the entire unit.
Burns caused by touching the hot surfaces of a triggered unit.
Damage to hearing due to the explosion when gas is released.
Irritation caused by breathing in fuel particles.
Irritation caused by skin and eye contact with fuel particles.
Airbag/belt tensioner components must not be opened nor repaired; always use only new parts.
Injury caused by incorrect triggering due to tampering with the short circuit bridges.

FOR HANDLING AIRBAG AND SEAT-BELT PRETENSIONER UNITS > PROTECTIVE
MEASURES AND RULES OF BEHAVIOR
Information
Protective measures and rules of behavior
Assembly work only by trained staff.
Carry out tests only using the PIWIS Tester II 9818 diagnosis unit; do not use test lamps, voltmeters or
ohmmeters.
Avoid contact with grease, solvents, cleaning agents or liquids.
Do not expose to temperatures above 90 °C.
Keep the deployment area of the blow-out opening clear; e.g. do not hang test devices over the steering
wheel. When carrying the airbag, hold it with the blow-out opening facing away from the body. Set the
airbag unit down with the blow-out opening facing upwards.
Electrostatic charge: In general, wear appropriate work clothing and footwear.
Do not remove the short-circuit spring of the plug contacts.
An airbag unit must never be connected incorrectly to electrical power sources (danger of ignition). Only
use testers prescribed by the manufacturer.
During installation/removal or work on the vehicle involving vibrations: switch off ignition, disconnect and
cover the negative terminal of the battery, wait 1 minute and only then should you disconnect the plug
connection.
Transport: In transport packaging. Never in the passenger compartment!
Storage in the workshop: Max. 10 kg (=> 100 driver or 50 passenger airbags); protect against theft!
The airbag/seat-belt pretensioner unit must be installed immediately after removal from the transport
container.
If work is interrupted, the airbag/seat-belt pretensioner unit must be stored in the transport container
again.
Never leave the airbag/seat-belt pretensioner unit unattended.

FOR HANDLING AIRBAG AND SEAT-BELT PRETENSIONER UNITS > BEHAVIOR IN
CASES OF MALFUNCTION OR DANGER
Information
Behavior in cases of malfunction or danger
Protect from flames and heat.

In case of fire, inform the fire brigade on arrival about the units present.
Do not install mechanically damaged units or units that have fallen, even from a low height.
Always replace units that are mechanically damaged (bulges, cracks).
Because of the irritating combustion residues, only handle triggered airbags with protective gloves and
goggles.
In the case of contact with combustion residues, wash the affected skin with soap and water.
In the case of eye contact, wash the eyes out with water.

FOR HANDLING AIRBAG AND SEAT-BELT PRETENSIONER UNITS > GENERAL
INFORMATION
Information
Airbags - general information
A period of 10 seconds is required to enable the triggering unit to identify all faults in the system!
In order to guarantee that every possible fault source is checked during the vehicle test, the ignition must
be switched on for at least 10 seconds!
The fault memory must be cleared following a fault in the airbag system and after it has been corrected!
The replacement of a component must be noted in the Guarantee and Maintenance booklet!
To do this, stick or enter the documentation number in a free panel intended for this purpose!
The documentation number is attached to the replacement part as a tear-off sticker or is stored in PIWIS
Tester II 9818 !
Replaced airbag units or airbag modules must be retained by the Porsche Centre or authorized Porsche
dealer and must not be handed over to the customer (customer has no right to keep them). They must
be destroyed or disposed of in accordance with the explosives ordinance and the hazardous materials
ordinance, or returned to the manufacturer!
When the steering wheel is replaced, e.g. in order to install a steering wheel from the Equipment range,
the airbag unit of the replaced steering wheel must be removed and destroyed, disposed of or returned
to the manufacturer before the steering wheel that was replaced is handed over to the customer!
The airbag system is constantly monitored by a diagnosis unit in the triggering unit. Any fault is signalled
by a warning light. The warning light for the airbag system comes on in the event of a fault. The airbag
warning light comes on for approx. 3 seconds after the ignition is switched on and goes off if there is no
fault entered in the fault memory. If it lights up again, this indicates a fault in the system. The fault can be
read out using PIWIS Tester II 9818 .

FOR HANDLING AIRBAG AND SEAT-BELT PRETENSIONER UNITS > COMPONENT
EXCHANGE AFTER AIRBAG/SEAT-BELT PRETENSIONER TRIGGERING
The following components must be removed and replaced after the airbag system is triggered:
Airbag unit, driver's side:
1. Airbag unit on driver's side.
2. Contact unit.
3. Triggering unit after the system is triggered for the third time.
4. Airbag sensors: see below → 1.→ 2.
Airbag unit, passenger's side:
1. Airbag unit, passenger's side.
2. Dashboard.
3. Check dashboard bracket for deformation and replace if necessary.
Side airbag unit, seat:
1. Side airbag unit, seat.
2. Seat covering, deformed seat components.
Head airbag unit:
1. Head airbag unit.
2. Replace roof lining.
Knee airbag on driver's side:
1. Trim panel under dashboard with knee airbag on driver's side.
Airbag sensor:
1. All airbag sensors in damaged/deformed areas of the vehicle must always be replaced.
2. Otherwise (i.e. even if the vehicle was not crashed), the airbag sensors must be replaced if
they show signs of mechanical damage and/or if the airbag control unit detects that the airbag
sensor is defective (use PIWIS Tester II 9818 to read out the fault memory).
Seat-belt pretensioners:
1. All seat-belt pretensioner units.
Because it is difficult to visually determine if one or more seat-belt pretensioners has been
triggered, check the following points:
Use PIWIS Tester II 9818 to read out the fault memory.
Check plug connection on the seat-belt pretensioner for damage.
Pull out the belt strap as far as possible and check for wear.
Perform a function test on the automatic belt device.
WM 6X00IN WORKING WITH PORSCHE 2-COMPONENT WINDOW ADHESIVE

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > PRE-TREATMENT OF
BONDING SURFACES > PRE-TREATING ADHESIVE FLANGES ON VEHICLE
WINDOWS
Information
The table below shows how to use cleaners, primers and activators when preparing the bonding
surfaces.
Preparing vehicle windows for installation
Old glass New glass
(window removed) with preliminary coat (durable primer)
Cleaner ?
Cut back adhesive bead?
Clean rim (ceramic layer and durable primer)?
Activator ? Primer ?
Activate adhesive bead (only necessary after Apply primer from the adhesive kit over the durable
standing times > 24 h)↓ primer on the spare part?
Apply adhesive
Install glass
WM 6X00IN WORKING WITH PORSCHE 2-COMPONENT WINDOW ADHESIVE

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > PRE-TREATMENT OF
BONDING SURFACES > PRE-TREATING BONDED FLANGES ON THE VEHICLE
BODY
Information
The table below shows how to use cleaners, primers and activators when preparing the bonding
surfaces.
Prepare vehicle window flange for installation
Old flange (old paint) New flange (new paint)
Cleaner ?
Clean flange surface?
Activate adhesive bead (only necessary after standing times > 24 h)↓ Prime flange surface?
Apply adhesive
Install glass
WM 6X00IN GAP DIMENSIONS (CAYENNE, CAYENNE GTS, CAYENNE TURBO S,

CAYENNE S, CAYENNE S HYBRID, CAYENNE TURBO, CAYENNE S DIESEL,
CAYENNE (3.0)) > TECHNICAL VALUES
Roof to Roof only Gap dimension 1 mm -1 mm

sliding-roof panel recessed
(D1)
Roof to sliding-roof panel

Sliding-roof Roof only raised Gap dimension 0.8 mm +0.2 mm -0.8 mm
panel to roof
(D2)
Sliding-roof panel to roof
Roof to front lid Gap dimension 10 mm +/-1.2 mm

(D3)
Roof to front lid
Roof to front lid Gap dimension 1.4 mm +/-1 mm

(D4)
Roof to front lid
Front panel to Gap dimension 2 mm +/-0.5 mm

rear panel (D5)
Front panel to rear panel
Front panel to Gap dimension 1 mm +1.2 mm -0.6 mm

rear panel (D6)
Front panel to rear panel
Rear lid to roof gap dimension 10 mm +/-1.2 mm

(D7)
Rear lid to roof
Rear lid to roof Gap dimension 0.8 mm +/-1 mm

(D8)
Rear lid to roof
Wing to door Gap dimension 3.7 mm +/-0.5 mm

(K3)
Wing to door
Wing to door Door only Gap dimension 0 mm -1 mm

(K3b) recessed
Wing to door
Door frame to Gap dimension 5.9 mm +/-2 mm

side panel (T1)
Door frame to side panel
Door frame to Door frame only Gap dimension 0 mm +2 mm

side panel (T1b) recessed
Door frame to side panel
B-pillar trim on Gap dimension 4.2 mm +/-1 mm

front door to
B-pillar trim on
rear door (T2)
B-pillar trim on front door to B-pillar trim on rear door
B-pillar trim on Flush Gap dimension 0 mm +0.5 mm -1.5 mm

front door to
B-pillar trim on
rear door (T2b)
Front door to Gap dimension 4.2 mm +/-0.8 mm

rear door (T3)
Front door to rear door
Front door to Rear door Gap dimension 0 mm -1 mm

rear door (T3b) recessed
Door panel to Gap dimension 4.8 mm +/-1.5 mm

door entry guard
(T4)
Door panel to door entry guard
Door panel to Gap dimension 0.3 mm +0.5 mm -1.5 mm

door entry guard
(T5)
Front door panel Gap dimension 5.7 mm +1.2 mm -1 mm

to rear door
panel (T6)
Front door panel to rear door panel
Front door panel Flush Gap dimension 0 mm +0.5 mm -1.5 mm

to rear door
panel (T6b)
Front apron to Gap dimension 3 mm +/-0.7 mm

front lid (B1)
Front apron to front lid

front lid (B2)
Front lid to Gap dimension 3 mm +/-1 mm

headlights (K1)
Lid to headlights
Rear wing to Gap dimension 3.5 mm +0.7 mm -0.9 mm

front lid (K1)
Lid to wing
Rear wing to Gap dimension 2 mm

front lid (K2)
Lid to wing
Spoiler to roof Gap dimension 5.5 mm +/-1 mm

(R1)
Rear lid to roof
Spoiler to roof Gap dimension 1 mm +/-1 mm

(R2)
Rear lid to roof
Lid to side panel Gap dimension 4 mm +/-1 mm

(R3)
Rear lid to side panel
Lid to rear apron Gap dimension 4 mm +/-1 mm

(R4)
Rear lid to rear apron
→ Gap dimension: 1 mm-1 mm

Fig 1: Identifying Gap Dimension Of Roof To Sliding-Roof Panel
→ Gap dimension: 0.8 mm+0.2 mm-0.8 mm

Fig 2: Identifying Gap Dimension Of Sliding-Roof Panel To Roof

CAYENNE (3.0)) > GAP DIMENSIONS OF PANORAMIC ROOF
→ Gap dimension: 10 mm+/-1.2 mm

Fig 1: Identifying Gap Dimension Of Roof To Front Lid
→ Gap dimension: 1.4 mm+/-1 mm

Fig 2: Identifying Gap Dimension Of Roof To Front Lid

Fig 3: Identifying Gap Dimension Of Front To Rear Panel
→ Gap dimension: 1 mm+1.2 mm-0.6 mm

Fig 4: Identifying Gap Dimension Of Rear To Front Panel
→ gap dimension: 10 mm+/-1.2 mm

Fig 5: Identifying Gap Dimension Of Rear Lid To Roof

Fig 6: Identifying Gap Dimension Of Roof To Rear Lid

CAYENNE (3.0)) > GAP DIMENSIONS OF FRONT DOOR
→ Gap dimension: 3.7 mm+/-0.5 mm

Fig 1: Identifying Gap Dimension Of Wing To Door

Fig 2: Identifying Gap Dimension Of Door To Wing

Fig 3: Identifying Gap Dimension Of Door Frame To Side Panel
→ Gap dimension: 0 mm+2 mm

Fig 4: Identifying Gap Dimension Of Side Panel To Door Frame

Fig 5: Identifying Gap Dimension Of B-Pillar Trim On Front To Rear Door

Fig 6: Identifying Gap Dimension Of B-Pillar Trim On Rear To Front Door

Fig 7: Identifying Gap Dimension Of Front To Rear Door

Fig 8: Identifying Gap Dimension Of Rear To Front Door

Fig 9: Identifying Gap Dimension Of Door Panel To Entry Guard

Fig 10: Identifying Gap Dimension Of Door Entry Guard To Panel
→ Gap dimension: 5.7 mm+1.2 mm-1 mm

Fig 11: Identifying Gap Dimension Of Front To Rear Door Panel

Fig 12: Identifying Gap Dimension Of Rear To Front Door Panel

CAYENNE (3.0)) > GAP DIMENSIONS OF FRONT LID

front lid (B1)

front lid (B2)

headlights (K1)
Lid to headlights

CAYENNE (3.0)) > GAP DIMENSIONS OF FRONT WING

front lid (K1)
Lid to wing

front lid (K2)
Lid to wing

CAYENNE (3.0)) > GAP DIMENSIONS OF REAR LID

(R1)
Rear lid to roof

(R2)
Rear lid to roof
Lid to side Gap dimension 4 mm +/-1 mm

panel (R3)
Lid to rear Gap dimension 4 mm +/-1 mm

apron (R4)

Service Manual: 91 - RADIO, STEREO, TELEPHONE, ON-BOARD COMPUTER -- 92A CAYENNE
WM 911019 REMOVING AND INSTALLING PCM 3.1 DISPLAY AND OPERATOR
CONTROL UNIT (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE
S HYBRID, CAYENNE S E, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) >
TOOLS
PIWIS Tester Special tool 9818

II

TECHNICAL VALUES
Fastening Tightening 7.5 Nm (5.5)

screws for torque
PCM

PRELIMINARY WORK
1. If the PCM system has to be replaced, the values/data must be read out prior to removal using
PIWIS Tester II 9818 . → 911055 REPLACING PCM .
2. Remove center air vent at the left and right. → REMOVING CENTRE AIR VENT

REMOVING PCM 3.1 DISPLAY AND OPERATOR CONTROL UNIT
Information
Always comply with the regulations for handling ESD-sensitive components!
Assembly work may only be carried out if the mechanic is wearing the working clothes and shoes
approved by Porsche .
The new part must only be removed from the ESD (electrostatic discharge) protective packaging
just before installation and at the position at which the part is to be installed .
Never touch the electric pins and plug contacts .

Fig 1: Identifying PCM Position
1. Unscrew four fastening screws -1- .
2. Remove display and operator control unit -2- (-A- ).

Fig 2: Removing PCM
3. Release electric plug connections -1 + 2- (-a- ) and pull them off -arrow- .
Fig 3: Disconnecting Antenna Plug Connections
4. Release electric plug connections -3 + 4- (-a- ) and pull them off -A- .
5. Release clip -1- on electric plug connection -a- and bend it down -A- , then pull off electric
plug connection -B- .
Fig 5: Disconnecting Plug Connection

INSTALLING PCM 3.1 DISPLAY AND OPERATOR CONTROL UNIT
1. The display and operator control unit is installed in reverse order to removal.
2. Tighten four fastening screws -1- on the display and operator control unit -2- to → Tightening
torque: 7.5 Nm (5.5) .
Fig 1: Identifying PCM

SUBSEQUENT WORK
1. If the PCM system was replaced, the values/data must be written into PCM using PIWIS
Tester II 9818 . → 911055 REPLACING PCM .
2. Install center air vent at the left and right. → INSTALLING CENTRE AIR VENT
WM 911019 REMOVING AND INSTALLING PCM DISPLAY AND OPERATOR CONTROL

UNIT (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S HYBRID,
CAYENNE S E, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TOOLS

II

CAYENNE S E, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) >
TECHNICAL VALUES
PCM mounting Tightening 7.5 Nm (5.5

torque ftlb.)

PRELIMINARY WORK
1. When replacing PCM, read out values/data using PIWIS Tester II 9818 before removing the
PCM system. → 911055 REPLACING PCM .
2. Remove center air vents. → REMOVING CENTRE AIR VENT

REMOVING PCM 3.1 DISPLAY AND OPERATOR CONTROL UNIT
Fig 1: Identifying PCM Position
1. Unscrew fastening screws -1- .
2. Remove display and operator control unit -2- (-arrow- ).

Fig 2: Removing PCM
3. Release electric plug connections -1, 2- (-a- ) and disconnect them -arrows- .
4. Release electric plug connections -3, 4- (-a- ) and disconnect them -arrows- .
5. Release clip -1- on electric plug connection -a- and move it down -A- . Then disconnect
electric plug connection -B- .

1. The display and operator control unit -2- is installed in reverse order to removal.
2. Tighten fastening screws -1- on the display and operator control unit -2- . Tightening torque
7.5 Nm (5.5 ftlb.)
Fig 1: Identifying PCM

SUBSEQUENT WORK
1. If PCM was replaced, write values/data to PSM using PIWIS Tester II 9818 . → 911055
REPLACING PCM .
2. Install center air vents. → INSTALLING CENTRE AIR VENT
WM 911055 REPLACING PCM (CAYENNE TIP, CAYENNE MAN, CAYENNE S,

CAYENNE TURBO S, CAYENNE S DIESEL) > TOOLS

II

CAYENNE TURBO S, CAYENNE S DIESEL) > TECHNICAL VALUES

CAYENNE TURBO S, CAYENNE S DIESEL) > READING AND WRITING VALUES
NOTE: Voltage drop
battery.
Information
If a new PCM/CDR is to be installed in a vehicle, the enabling code specified in the PIWIS
information system must be used .
You can get the codes from the PIWIS Infosystem or from your importer by specifying the vehicle
identification number .
During coding, it is essential to guarantee the power supply for the PIWIS Tester II 9818 . A
battery charger with a current rating of at least 40 A must be connected to the vehicle battery .
The PIWIS Tester II 9818 instructions take precedence and in the event of a discrepancy, these
are the instructions that must be followed. Deviations may occur with later software versions .
The procedure described here has been structured in general terms; different text may appear in
the PIWIS Tester II 9818 or additional information/steps may be displayed or required .
Information
If the PCM unit is to be replaced with a new unit, the navigation data must be installed using a Software
Update navigation CD/DVD .
To enable you to actually install the Software Update navigation data , you must read out the
enabling code from the PIWIS information system. Additional enabling codes, e.g. customer has
navigation system for Europe and Russia, or customer has already obtained navigation updates,
must be queried by customer service personnel at the customer site .
The PCM maps software version can be read from the PIWIS information system
(electrics/electronics information)
The required Software Update navigation CD/DVD must be ordered via PET .
The Software Update navigation CD/DVD must not be handed over to the customer. This
CD/DVD can only be used with PIWIS Tester II 9818 .
The Software Update navigation CD/DVD that corresponds to the relevant vehicle model year
must always be used for the required PCM system, e.g. if the vehicle model year is 2010, the
CD/DVD for 2010 must be used. This applies even if CDs/DVDs for 2011 are available .
The model year-based Software Update navigation CD/DVD must always be archived in the
Porsche Centre .
Further changes/supplements to the Software Update navigation CD/DVD can also be obtained.
These will have to be used later for older vehicles. For example, CDs/DVDs for 2011 are already
available, but an error was found on the 2010 version, so the old CD/DVD for 2010 will have to be
replaced with an updated CD/DVD for 2010. This process will be announced in a TI .
Current compatibility with Bluetooth telephones can be checked at http://www.porsche.com

/germany/accessoriesandservices/porscheservice/vehicleinformation/docume
Information
If the PCM system is replaced, the trim panel on the "old" PCM system must be unclipped and then
clipped onto the "new" PCM system.
Fig 1: Identifying PCM Trim Panel
1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on
ignition.
3. Select the required control unit PCM 3.1 in the overview .
4. Select Maintenance/repairs .
5. Select Control unit replacement and press [F12].
6. Select Read data and press [F12].
7. Press [F8] to start reading out data.
8. Check the chassis number and press [F12].
9. Switch off ignition and replace the control unit. → 911019 REMOVING AND INSTALLING PCM
DISPLAY AND OPERATOR CONTROL UNIT .
10. Switch on ignition. Select the Write data menu (procedure described above), press [F12] and
then press [F8] to start installing the data that was read out.
11. The System Tester displays the message Data has been written . Press [F12] to continue.
12. Read out the fault memory and erase it if necessary.
13. Select Function activation in the Maintenance/repairs menu and press [F12].
1. 13.1. The PIWIS Tester displays all the possible enabling codes.
2. 13.2. Using the vehicle-specific codes from the PIWIS information system, click on
the menus, enter the relevant enabling code and press [F8] to start coding.
14. Quit the PCM 3.1 control unit. PCM 3.1 goes out of Service mode.
15. Insert the Software Update navigation CD/DVD into the PCM3.1 unit (see operating
instructions).
16. Confirm the messages on the PCM unit, start the update according to instructions and leave it
running.
17. PCM then displays the message Update to version completed successfully . Confirm this
info on the touchscreen.
18. Check the audio, telephone, TV and navigation functions, depending on vehicle equipment.
Only for equipment variant XM radio
19. Drive the vehicle to a free area outside. Leave the engine switched on.
20. Adjust the radio to Station preview.
21. Contact SiriusXM OEM Call Centre at 1-800-852-9696. Press button 2 for "Other enquiries" in
the selection menu.
22. Give the customer advisor the radio ID/ESN of both the original and new PCM systems.
23. Once you have successfully registered the system, check that all PCM functions are working.
All vehicles
24. Read out the fault memory on the PCM 3.1 system.
WM 911055 REPLACING PCM DISPLAY AND OPERATOR CONTROL UNIT (CAYENNE,

CAYENNE TURBO S, CAYENNE S HYBRID, CAYENNE S, CAYENNE S HYBRID,
CAYENNE TURBO, CAYENNE (3.0)) > TOOLS

II

CAYENNE TURBO, CAYENNE (3.0)) > TECHNICAL VALUES

CAYENNE TURBO, CAYENNE (3.0)) > READING AND WRITING VALUES
NOTE: Voltage drop
battery.
Information
If a new PCM/CDR is to be installed in a vehicle, the enabling code specified in the PIWIS
information system must be used .
You can get the codes from the PIWIS Infosystem or from your importer by specifying the vehicle
identification number .
During coding, it is essential to guarantee the power supply for the PIWIS Tester II 9818 . A
battery charger with a current rating of at least 40 A must be connected to the vehicle battery .
The PIWIS Tester II 9818 instructions take precedence and in the event of a discrepancy, these
are the instructions that must be followed. Deviations may occur with later software versions .
The procedure described here has been structured in general terms; different text may appear in
the PIWIS Tester II 9818 or additional information/steps may be displayed or required .
Information
If the PCM unit is to be replaced with a new unit, the navigation data must be installed using a Software
Update navigation CD/DVD .
To enable you to actually install the Software Update navigation data , you must read out the
enabling code from the PIWIS information system. Additional enabling codes, e.g. customer has
navigation system for Europe and Russia, or customer has already obtained navigation updates,
must be queried by customer service personnel at the customer site .
The PCM maps software version can be read from the PIWIS information system
(electrics/electronics information)
The required Software Update navigation CD/DVD must be ordered via PET .
The Software Update navigation CD/DVD must not be handed over to the customer. This
CD/DVD can only be used with PIWIS Tester II 9818 .
The Software Update navigation CD/DVD that corresponds to the relevant vehicle model year
must always be used for the required PCM system, e.g. if the vehicle model year is 2010, the
CD/DVD for 2010 must be used. This applies even if CDs/DVDs for 2011 are available .
The model year-based Software Update navigation CD/DVD must always be archived in the
Porsche Centre .
Further changes/supplements to the Software Update navigation CD/DVD can also be obtained.
These will have to be used later for older vehicles. For example, CDs/DVDs for 2011 are already
available, but an error was found on the 2010 version, so the old CD/DVD for 2010 will have to be
replaced with an updated CD/DVD for 2010. This process will be announced in a TI .
Current compatibility with Bluetooth telephones can be checked at http://www.porsche.com

/germany/accessoriesandservices/porscheservice/vehicleinformation/docume
Information
If the PCM system is replaced, the trim panel on the "old" PCM system must be unclipped and then
clipped onto the "new" PCM system.
Fig 1: Identifying PCM Trim Panel
1. Connect the Porsche System Tester to the vehicle and start the System Tester.
3. Select the required vehicle type.
4. Select the required control unit PCM 3.1 in the overview .
5. Maintenance/repairs must then be selected.
6. Control unit replacement must now be selected. Then press [F12] to continue.
7. Read data must be selected. Then press [F12] to continue.
9. Check the chassis number and press [F12] to continue.
10. Switch off ignition and replace control unit. → 911019 REMOVING AND INSTALLING PCM
DISPLAY AND OPERATOR CONTROL UNIT .
11. Switch on ignition and switch to the menu (as described above).
12. Select Write data and press [F12] to continue.
13. Press [F8] to start. The data that was read out is installed.
16. Select the Function enable function in the Maintenance/repairs menu and press [F12] to
confirm your selection.
1. 16.1. The PIWIS Tester displays all possible enabling codes.
2. 16.2. Using the vehicle-specific codes from the PIWIS information system, click on
the menus, enter the relevant enabling code and press [F8] to start coding.
17. Exit the PCM 3.1 control unit. PCM 3.1 goes out of Service mode.
18. Insert Navigation software update CD/DVD into PCM 3.1 (see operating instructions).
19. Confirm the messages on the PCM unit, start the update according to instructions and leave it
running.
20. PCM then displays the message Update to version completed successfully . Confirm this
info on the touchscreen.
21. Check the audio, telephone, TV and navigation functions, depending on vehicle equipment.
For equipment variant XM radio
22. Drive the vehicle to a free area outside. Leave the engine switched on.
23. Adjust the radio to Station preview.
24. Contact SiriusXM OEM Call Centre at 1-800-852-9696.
25. Press button 2 for "Other enquiries" in the selection menu.
26. Provide the customer advisor with the radio ID/ESN of the "old" and "new" PCM system.
27. Once you have successfully registered the system, check that the PCM functions are working.
All vehicles
28. Read out the fault memory on the PCM 3.1 system.
WM 911319 REMOVING AND INSTALLING GPS ANTENNA (CAYENNE, CAYENNE

GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S HYBRID, CAYENNE TURBO,
CAYENNE S DIESEL, CAYENNE (3.0)) > PRELIMINARY WORK
1. Remove caps on the rear-view mirror base and remove rear-view mirror from the holder. →
REMOVING INTERIOR REAR-VIEW MIRROR

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING > REMOVING GPS ANTENNA
NOTE: Voltage peaks
Risk of damage to electrical load or to the control unit
Fig 1: Identifying GPS Antenna Position
1. Remove cover on front camera -1- .
1. 1.1. Carefully loosen cover on front camera -1- at the bottom, in the mirror base
area, using a plastic wedge.
2. 1.2. Carefully loosen cover on front camera -1- at the rear left and right sides using a
plastic wedge.
3. 1.3. Pull cover on front camera -1- out of the centering device and remove it -A- .
Fig 2: Removing Front Camera Cover
2. Unclip GPS antenna -1- , release electric plug connection -2- (-a- ) and disconnect it -A- .
Fig 3: Removing GPS Antenna

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING > INSTALLING GPS ANTENNA
1. Installation is performed in reverse order to removal.

CAYENNE S DIESEL, CAYENNE (3.0)) > SUBSEQUENT WORK
1. Install rear-view mirror and clip in rear-view mirror caps. → INSTALLING INTERIOR
REAR-VIEW MIRROR
WM 911719 REMOVING AND INSTALLING TV TUNER (CAYENNE, CAYENNE GTS,

CAYENNE TURBO S, CAYENNE S, CAYENNE S HYBRID, CAYENNE TURBO,
CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION > INSTALLATION POSITION
Fig 1: Identifying TV Tuner Position

1. Switch off ignition and remove ignition key.
2. Remove right side trim panel for luggage compartment. → REMOVING SIDE TRIM PANEL
FOR REAR LUGGAGE COMPARTMENT
3. Remove loudspeaker booster. → 914419 REMOVING AND INSTALLING LOUDSPEAKER

BOOSTER

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING TV TUNER
1. Release electric plug connections from TV tuner -arrow- and disconnect them -arrow a- .
Fig 1: Disconnecting Electric Plug Connections
2. Release electric plug connections from surround view camera control unit -arrow- and
disconnect them -arrow a- .
Fig 2: Releasing Electric Plug Connections
3. Unscrew screw on connector holder -1- and set it aside.

Fig 3: Removing Connector Holder Mounting
4. Release electric plug connections from trailer hitch control unit -arrow- and disconnect them
-arrows A, B, C- .
Fig 4: Removing Trailer Hitch Control Unit Connectors
5. Unscrew screws -2- on the loudspeaker booster -1- .

Fig 5: Removing Loudspeaker Booster Holder Mounting
6. Remove loudspeaker booster holder -1- (-arrows- ).
7. Unscrew screws -2- from holder -1- .

Fig 6: Removing TV Tuner Holder Mounting
8. Remove holder -1- with TV tuner, surround view camera control unit and trailer hitch control
unit -arrow- .
9. Release retaining lug -arrow- and pull surround view camera control unit out of the holder
-arrow a- .
Fig 7: Pulling Control Unit
10. Unscrew screws -2- on trailer hitch control unit -1- .

Fig 8: Removing Trailer Hitch Control Unit Mounting
11. Remove trailer hitch control unit -1- (-arrows- ).
12. Unscrew screws -1- .

Fig 9: Identifying Trailer Hitch Control Unit Screws
13. Remove TV tuner -2- from the holder -3- .

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING TV TUNER
1. The TV tuner is installed in reverse order to removal.
2. Tighten screws for TV tuner.
3. Tighten screws for trailer hitch control unit.
4. Tighten screws for holder for TV tuner, surround view camera control unit and trailer hitch
control unit.↓
5. Tighten screws for loudspeaker booster holder.
6. Tighten screws for connector holder.

1. Install loudspeaker booster. → 914419 REMOVING AND INSTALLING LOUDSPEAKER

BOOSTER
2. Install right side trim panel for luggage compartment. → INSTALLING SIDE TRIM PANEL FOR
REAR LUGGAGE COMPARTMENT
3. If the TV tuner control unit was replaced, the steps "Program TV tuner" → 911755
REPLACING TV TUNER - → 911755 REPLACING TV TUNER must be carried out using the
PIWIS Tester.
WM 911755 REPLACING TV TUNER (CAYENNE, CAYENNE GTS, CAYENNE TURBO S,

CAYENNE (3.0)) > TOOLS

II


CAYENNE (3.0)) > READING AND WRITING VALUES
NOTE: Voltage drop

battery.
Information
The PIWIS Tester II 9818 instructions take precedence since the description may be different with later
Tester releases.
appear in ↓PIWIS Tester II 9818 .
3. Select the vehicle type and start the PIDT.
5. Select TV tuner control unit in the overview and press [F12] to continue.
7. Write data must be selected. Then press [F12] to continue.
8. Switch off ignition.
Information
If a new TV tuner is installed, there must be no signals at the optical waveguide connector
(disconnected optical waveguide connector does not light up).
Given this, the battery must be disconnected before installing a new TV tuner.
9. Disconnect the battery. → LOOSENING GROUND STRAP FOR BATTERY
10. Replace control unit. → 911719 REMOVING AND INSTALLING TV TUNER
11. Connect the battery. → SECURING GROUND STRAP FOR BATTERY
13. Select Write data in the menu (procedure described above), then press [F12] to continue.

17. Carry out a function test on the TV tuner.
WM 912219 REMOVING AND INSTALLING MULTIMEDIA INTERFACE (EXCEPT

CAYENNE TIP "PLATINUM EDITION", CAYENNE, CAYENNE GTS, CAYENNE TURBO
S, CAYENNE S, CAYENNE S HYBRID, CAYENNE TURBO, CAYENNE S DIESEL,
CAYENNE (3.0)) > PRELIMINARY WORK > PRELIMINARY WORK FOR REMOVING
AND INSTALLING MULTIMEDIA INTERFACE
1. Remove oddments tray. → REMOVING ODDMENTS TRAY

CAYENNE (3.0)) > REMOVING MULTIMEDIA INTERFACE
Fig 1: Overview Of Multimedia Interface
1. Unscrew screw -2- for the multimedia interface -3- from the oddments tray -1- .
2. Remove guide lugs -4- for the multimedia interface -3- from the oddments tray -1- (-arrows-
).
3. Remove multimedia interface -3- .

Fig 2: Removing Multimedia Interface

CAYENNE (3.0)) > INSTALLING MULTIMEDIA INTERFACE
1. The multimedia interface is installed in reverse order to removal.

CAYENNE (3.0)) > SUBSEQUENT WORK > SUBSEQUENT WORK FOR REMOVING
AND INSTALLING MULTIMEDIA INTERFACE
1. Install oddments tray. → INSTALLING ODDMENTS TRAY .
WM 912255 REPLACING MULTIMEDIA INTERFACE (CAYENNE, CAYENNE GTS,

CAYENNE (3.0)) > PRELIMINARY WORK
1. Remove oddments tray. → REMOVING ODDMENTS TRAY
2. Remove PCM. → Removing PCM 3.1 Display And Operator Control Unit 911019 REMOVING
AND INSTALLING PCM DISPLAY AND OPERATOR CONTROL UNIT
3. Remove center console. → REMOVING CENTRE CONSOLE

CAYENNE (3.0)) > REPLACING MULTIMEDIA INTERFACE
NOTE: Voltage peaks
Risk of damage to load or to the control unit
→ Remove the ignition key and switch off load before disconnecting or removing load.
Information
The new lines will be secured to the fastening points for the old lines .
The old wire harness remains installed in the vehicle .
The old wire harness will only be disconnected/unplugged directly at the connected components .
Information
When installing the wire harness, make sure the insulation of the line is not damaged .
1. Unclip electric plug connections for USB -1- and AUX -2- (-arrow- ) and disconnect them
-arrow- .
Fig 1: Removing Electric Plug Connections
2. Cut off electric plug connections -1, 2, 3, 4- , isolate them and tie them to the main wire
harness.
Fig 2: Identifying Electric Plug Connections
3. Route new USB and AUX lines along the main wire harness, guide them through the existing
cable ducts and secure them to the main wire harness.

CAYENNE (3.0)) > SUBSEQUENT WORK
1. Install center console. → INSTALLING CENTRE CONSOLE
2. Install PCM. → Installing PCM 3.1 Display And Operator Control Unit 911019 REMOVING
AND INSTALLING PCM DISPLAY AND OPERATOR CONTROL UNIT
3. Install oddments tray. → INSTALLING ODDMENTS TRAY
WM 912419 REMOVING AND INSTALLING CAR RADIO (EXCEPT CAYENNE,

CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S HYBRID, CAYENNE
TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TOOLS

II

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES
Securing CDR Tightening 7.5 Nm (5.5)

torque

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > PRELIMINARY WORK
1. If the CDR has to be replaced, the values/data must be read out prior to removal using PIWIS
2. Remove center air vent at the left and right. → REMOVING CENTRE AIR VENT

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING CAR RADIO
Information

Fig 1: Identifying PCM/CDR Position
1. Unscrew four fastening screws -1- .

Fig 2: Removing PCM/CDR
2. Remove CDR -2- (-A- ).
3. Release electric plug connections -1 + 2- (-a- ) and pull them off -arrow- .
4. Release electric plug connections -3 + 4- (-a- ) and pull them off -A- .
5. Release clip -1- on electric plug connection -a- and bend it down -A- , then pull off electric
plug connection -B- .

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING CAR RADIO
1. The display and operator control unit is installed in reverse order to removal.
2. Tighten four fastening screws -1- on the display and operator control unit -2- to → Tightening
torque: 7.5 Nm (5.5) .
Fig 1: Identifying PCM/CDR

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > SUBSEQUENT WORK
1. If the CDR was replaced, the values/data must be written into the new CDR using PIWIS
2. Install center air vent at the left and right. → INSTALLING CENTRE AIR VENT
WM 912823 INSTALLING ANTENNA LINE (GPS ANTENNA FOR PCM) (CAYENNE,

CAYENNE GTS, CAYENNE TURBO S, CAYENNE S DIESEL, CAYENNE S, CAYENNE S
HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > INFORMATION > OVERVIEW
Fig 1: Identifying Antenna Line Position

HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > PRELIMINARY WORK
1. Remove headliner.
→ REMOVING HEADLINER
2. Remove caps on the rear-view mirror base and remove rear-view mirror from the holder.
→ REMOVING INTERIOR REAR-VIEW MIRROR .
3. Remove dashboard.
→ REMOVING DASHBOARD

HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > INSTALLING ANTENNA LINE (GPS
ANTENNA FOR PCM)
NOTE: Voltage peaks

Information
Information
plastic wedge.
Fig 1: Identifying Front Camera Cover
2. Release electric plug connection -2- on GPS antenna -1- (-a- ) and disconnect it -A- .
Fig 2: Removing GPS Antenna
3. Cut off the connectors on the damaged antenna line, then insulate it and tie it to the main wire
harness.
4. Route the new antenna line along the main wire harness, guide it through the existing cable
ducts and tie it to the main wire harness using tie-wraps.
5. Plug in antenna line -2- at the GPS antenna -1- until it engages securely.

HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > SUBSEQUENT WORK
1. Install headliner.
→ INSTALLING HEADLINER
2. Install dashboard.
→ INSTALLING DASHBOARD
REAR-VIEW MIRROR
WM 912823 INSTALLING ANTENNA LINE (CONNECTION POINT IN ROOF TO TV
TUNER) (GPS ANTENNA FOR PCM) (CAYENNE, CAYENNE GTS, CAYENNE TURBO S,
CAYENNE S DIESEL, CAYENNE S, CAYENNE S HYBRID, CAYENNE TURBO,
CAYENNE (3.0)) > INFORMATION > OVERVIEW OF ANTENNA LINES
1. PCM antenna line to connection point in roof
2. Antenna line from connection point in roof to TV tuner
3. PCM antenna line to GPS/GSM antenna

Fig 1: Overview Of Antenna Lines


BOOSTER
4. Detach headliner and lower it at the rear. → REMOVING HEADLINER

CAYENNE (3.0)) > INSTALLING ANTENNA LINE (CONNECTION POINT IN ROOF TO
TV TUNER)
NOTE: Voltage peaks
Information
Information
1. Disconnect antenna line at the connection point in the roof.
2. Release antenna line (multiple plug connection on the right) from the TV tuner -arrow- and
disconnect it -arrow a- .
3. Cut connector off the damaged antenna line.
4. Insulate antenna line and tie it to the main wire harness.
5. Route new antenna line along the main wire harness, guide it through the existing cable ducts
and tie it to the main wire harness using tie-wraps.
6. Route new antenna line at the connection point in the roof and secure it.
7. Plug in antenna line on the TV tuner and make sure that the locking mechanism engages
securely.

1. Install headliner. → INSTALLING HEADLINER

BOOSTER
WM 912823 INSTALLING ANTENNA LINES (CONNECTION POINT IN ROOF TO PCM)

(CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S DIESEL, CAYENNE S,
CAYENNE S HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > INFORMATION >
OVERVIEW
Fig 1: Overview Of Antenna Line

CAYENNE S HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > PRELIMINARY WORK
→ REMOVING HEADLINER
→ REMOVING DASHBOARD

CAYENNE S HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > INSTALLING ANTENNA
LINE (CONNECTION POINT IN ROOF TO PCM)
NOTE: Voltage peaks
Information
Information
1. Disconnect antenna line at the connection point in roof.
2. Cut off the connectors on the damaged antenna line, then insulate it and tie it to the main wire
harness.
3. Route the new antenna line along the main wire harness, guide it through the existing cable
ducts and tie it to the main wire harness using tie-wraps.
4. Route new antenna line at the connection point in the roof and secure it.

CAYENNE S HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > SUBSEQUENT WORK
1. Install headliner.
→ INSTALLING HEADLINER
2. Install dashboard.
→ INSTALLING DASHBOARD
WM 912824 INSTALLING ANTENNA LINES (CAYENNE, CAYENNE GTS, CAYENNE

TURBO S, CAYENNE S DIESEL, CAYENNE S, CAYENNE S HYBRID, CAYENNE
TURBO, CAYENNE (3.0)) > INFORMATION > OVERVIEW OF ANTENNA LINES
1. PCM antenna line to connection point in roof
2. Antenna line from connection point in roof to TV tuner
3. PCM antenna line to GPS/GSM antenna

Fig 1: Overview Of Antenna Lines

TURBO, CAYENNE (3.0)) > INFORMATION > REPLACING ANTENNA LINE (GPS
ANTENNA TO PCM)
1. The procedure for replacing the antenna line (GPS antenna to PCM) is described under:
→ 912823 INSTALLING ANTENNA LINE (GPS ANTENNA FOR PCM)

TURBO, CAYENNE (3.0)) > INFORMATION > REPLACING ANTENNA LINES
(CONNECTION POINT IN ROOF TO PCM)
1. The procedure for replacing the antenna line (connection point in roof to PCM) is described
under:
→ 912823 INSTALLING ANTENNA LINES (CONNECTION POINT IN ROOF TO PCM)

TURBO, CAYENNE (3.0)) > INFORMATION > REPLACING ANTENNA LINE
(CONNECTION POINT IN ROOF TO TV TUNER)
1. The procedure for replacing the antenna line (connection point in roof to TV tuner) is described
under:
→ 912823 INSTALLING ANTENNA LINE (CONNECTION POINT IN ROOF TO TV TUNER)
WM 913619 REMOVING AND INSTALLING SUBWOOFER (CAYENNE, CAYENNE GTS,

CAYENNE TURBO S, CAYENNE S, CAYENNE TURBO, CAYENNE S DIESEL,
Subwoofer Tightening 2 Nm (1.5 ftlb.)

torque
Subwoofer Tightening 2 Nm (1.5 ftlb.)

torque

CAYENNE (3.0)) > REMOVING SUBWOOFER
NOTE: Incorrect handling of components
Risk of irreparable damage to electric and electronic components
Reduced functionality
→ Switch off the ignition, remove the ignition key and switch off the audio system before removing the
loudspeakers.
Fig 1: Identifying Subwoofer Position
1. Open the cover in the luggage compartment floor.
2. Unscrew four fastening nuts -1- .

Fig 2: Identifying Subwoofer Nuts
3. Release electric plug connection -a- and pull it off -A- .

Fig 3: Removing Subwoofer Connector

CAYENNE (3.0)) > INSTALLING SUBWOOFER
loudspeakers.
1. The subwoofer is installed in reverse order to removal.
2. Tighten one M8 fastening nut to → Tightening torque: 2 Nm (1.5 ftlb.) .
3. Tighten three M6 fastening nuts to → Tightening torque: 2 Nm (1.5 ftlb.) .

WM 913619 REMOVING AND INSTALLING SUBWOOFER (S E-HYBRID) (CAYENNE S
HYBRID) > TECHNICAL VALUES

HYBRID) > PRELIMINARY WORK
1. Remove side trim panel for luggage compartment at the left. → REMOVING SIDE TRIM
PANEL FOR REAR LUGGAGE COMPARTMENT

HYBRID) > REMOVING SUBWOOFER
loudspeakers.
Fig 1: Identifying Subwoofer Installation Position (S E-Hybrid)
1. Unscrew fastening nuts -1- .

Fig 2: Identifying Subwoofer Screws
2. Release and disconnect electric plug connection -1- .

Fig 3: Disconnecting Subwoofer Connector
3. Carefully remove subwoofer.

HYBRID) > INSTALLING SUBWOOFER
loudspeakers.
1. The subwoofer is installed in reverse order to removal.

HYBRID) > SUBSEQUENT WORK
1. Install side trim panel for luggage compartment at the left. → INSTALLING SIDE TRIM PANEL
WM 913819 REMOVING AND INSTALLING SDARS ANTENNA (EXCEPT CAYENNE,

Fastening nut Tightening 6 Nm (4.5 ftlb.) +/-0.9 %

for SDARS torque
antenna

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > SDARS
ANTENNA
2 - SDARS antenna
3 - Fastening nut
1 - Electric plug connection

Fig 1: Identifying SDARS Antenna
Fastening nut Tightening 6 Nm (4.5 ftlb.) +/-0.9 %

for SDARS torque
antenna

1. Remove C-pillar trim panel at the left and right. → REMOVING C-PILLAR TRIM
2. Detach headliner. → REMOVING HEADLINER

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING SDARS ANTENNA
1. Release electric plug connection -1- (-a- ) and disconnect it.

Fig 1: Removing SDARS Antenna
2. Loosen fastening nut -2- and remove SDARS antenna -3- .

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING SDARS ANTENNA
1. Position SDARS antenna -3- and secure with the fastening nut -2- . Tightening torque 6 Nm
(4.5 ftlb.) +/- 0.9 %
Fig 1: Installing SDARS Antenna
2. Connect electric plug connection -1- until the connector engages securely.

1. Secure the headliner. → INSTALLING HEADLINER
2. Install C-pillar trim panel at the left and right. → INSTALLING C-PILLAR TRIM
WM 914019 REMOVING AND INSTALLING FRONT LOUDSPEAKERS (DASHBOARD)

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION >
COMPONENT OVERVIEW
1. Front loudspeakers (dashboard) at the left and right
2. Front center loudspeaker (dashboard)

Fig 1: Identifying Loudspeakers Installation Position

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > PRELIMINARY WORK >
PRELIMINARY WORK FOR FRONT LOUDSPEAKERS (DASHBOARD) AT THE LEFT
AND RIGHT
1. Remove cover for loudspeaker at the left and right. → REMOVING LOUDSPEAKER TRIM
PANEL

PRELIMINARY WORK FOR FRONT CENTRE LOUDSPEAKER (DASHBOARD)
1. Remove cover for center loudspeaker. → REMOVING LOUDSPEAKER TRIM PANEL

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT
LOUDSPEAKERS (DASHBOARD) > REMOVING FRONT LOUDSPEAKERS
(DASHBOARD) AT THE LEFT AND RIGHT
loudspeakers.
Information
Some of the repair illustrations show only one side of the vehicle .
Naturally, some steps also have to be performed on the opposite side of the vehicle as well .
1. Unclip -a- and remove loudspeaker -A- .

Fig 1: Removing Loudspeaker
2. Disconnect electric plug connection -arrow- .

Fig 2: Disconnecting Electric Plug Connection

LOUDSPEAKERS (DASHBOARD) > REMOVING FRONT CENTRE LOUDSPEAKER
(DASHBOARD)
loudspeakers.
1. Unscrew fastening screws -1- on the loudspeaker and remove loudspeaker -arrow- .
Fig 1: Removing Loudspeakers Screws
2. Release electric plug connection -a- and disconnect it -A- .


CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT
LOUDSPEAKERS (DASHBOARD) > INSTALLING FRONT LOUDSPEAKERS
(DASHBOARD) AT THE LEFT AND RIGHT
1. Plug in electric plug connection on the loudspeaker -arrow- until it engages securely.
Fig 1: Installing Front Loudspeakers Electric Plug Connection
2. Clip the loudspeaker into the dashboard -arrow- . Check that the clips are fitted securely.
Fig 2: Pressing Loudspeaker

LOUDSPEAKERS (DASHBOARD) > INSTALLING FRONT CENTRE LOUDSPEAKER
(DASHBOARD)
1. Plug in electric plug connection on loudspeaker -arrow- until it engages securely.

Fig 1: Locating Electric Plug Connection
2. Position the loudspeaker on the dashboard.
3. Tighten fastening screws -1- .

Fig 2: Installing Loudspeaker

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > SUBSEQUENT WORK >
SUBSEQUENT WORK FOR FRONT LOUDSPEAKERS (DASHBOARD) AT THE LEFT
AND RIGHT
1. Install cover for loudspeaker at the left and right. → INSTALLING LOUDSPEAKER TRIM
PANEL

SUBSEQUENT WORK FOR FRONT CENTRE LOUDSPEAKER (DASHBOARD)
1. Remove cover for center loudspeaker. → REMOVING LOUDSPEAKER TRIM PANEL
WM 914119 REMOVING AND INSTALLING FRONT LOUDSPEAKERS (CAYENNE,

Fastening screws Tightening 3.5 Nm (2.5

for woofer torque ftlb.)
Fastening screw Tightening 1.5 Nm (1

for mid-range torque ftlb.)
loudspeaker

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION
Fig 1: Identifying Front Loudspeakers Installation Position

1. Remove front door panel. → REMOVING FRONT DOOR PANEL

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT
LOUDSPEAKERS > REMOVING WOOFER FROM DOOR SUB-FRAME
NOTE: Voltage peaks
→ Switch off ignition and remove remote control before disconnecting or removing load.
Information
1. Release electric plug connection from the woofer -arrows a- and disconnect it -B- .
Fig 1: Releasing Electric Plug Connection
2. Unscrew the six fastening screws -3- .

Fig 2: Removing Woofer Screws
3. Remove woofer.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT
LOUDSPEAKERS > REMOVING MID-RANGE LOUDSPEAKER FROM DOOR PANEL
NOTE: Voltage peaks
Information
1. Unscrew the three fastening screws -4- .
Fig 1: Removing Midrange Loudspeaker Screws
2. Remove mid-range loudspeaker from the door panel.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT
LOUDSPEAKERS
1. The front loudspeakers are installed in reverse order to removal.
2. Tighten the six fastening screws on the woofer. Tightening torque 3.5 Nm (2.5 ftlb.)
3. Tighten the three fastening screws on the mid-range loudspeaker. Tightening torque 1.5 Nm
(1 ftlb.)

1. Install front door panel. → INSTALLING FRONT DOOR PANEL

WM 914219 REMOVING AND INSTALLING REAR LOUDSPEAKERS (CAYENNE,

for woofer torque ftlb.)
Fastening screw Tightening 1.5 Nm (1

for mid-range torque ftlb.)
loudspeaker

for tweeter torque ftlb.)

Information
A. Low-range loudspeaker (woofer)
B. Mid-range loudspeaker
C. High-range loudspeaker (tweeter)
D. High-range loudspeaker (tweeter)

Fig 1: Identifying Rear Loudspeakers Installation Position

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > PRELIMINARY WORK >
PRELIMINARY WORK FOR LOW-RANGE LOUDSPEAKER IN REAR DOOR
Remove rear door panel. → REMOVING REAR DOOR PANEL

PRELIMINARY WORK FOR MID-RANGE LOUDSPEAKER IN REAR DOOR

PRELIMINARY WORK FOR TWEETER IN REAR DOOR

PRELIMINARY WORK FOR TWEETER IN REAR SIDE TRIM PANEL
Remove side trim panel for rear luggage compartment. → REMOVING SIDE TRIM PANEL FOR REAR
LUGGAGE COMPARTMENT

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR LOUDSPEAKERS
> REMOVING LOW-RANGE LOUDSPEAKER IN REAR DOOR
loudspeakers.
1. Release electric plug connection -arrows a- and disconnect it -arrow A- .

Fig 1: Removing Loudspeaker Plug Connection

Fig 2: Identifying Low-Range Loudspeaker Screws

> REMOVING MID-RANGE LOUDSPEAKER IN REAR DOOR
loudspeakers.

Fig 1: Removing Mid-Range Loudspeaker
2. Disconnect electric plug connection -arrow A- .

> REMOVING TWEETER IN REAR DOOR
loudspeakers.
1. If installed:
Remove sun blind. → REMOVING SUN BLIND ON DOOR WINDOW

2. Press the locks outwards -arrows A- and remove the loudspeaker -arrow B- .
Fig 1: Removing Tweeter

> REMOVING TWEETER IN REAR SIDE TRIM PANEL
loudspeakers.

Fig 1: Removing Tweeter (Rear Side Trim Panel)

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR
LOUDSPEAKERS > INSTALLING LOW-RANGE LOUDSPEAKER IN REAR DOOR
1. The low-range loudspeaker in the rear door is installed in reverse order to removal.
2. Tighten fastening screws. Tightening torque 3.5 Nm (2.5 ftlb.)

LOUDSPEAKERS > INSTALLING MID-RANGE LOUDSPEAKER IN REAR DOOR
1. The mid-range loudspeaker in the rear door is installed in reverse order to removal.
2. Tighten fastening screws. Tightening torque 1.5 Nm (1 ftlb.)

LOUDSPEAKERS > INSTALLING TWEETER IN REAR DOOR
1. The tweeter in the rear door is installed in reverse order to removal. During installation, make
sure that the pin of the tweeter is inserted into the cut-out in the door panel.

LOUDSPEAKERS > INSTALLING TWEETER IN REAR SIDE TRIM PANEL
1. The tweeter is installed in the rear side trim panel in reverse order to removal.
2. Tighten fastening screws. Tightening torque 3.5 Nm (2.5 ftlb.)

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > SUBSEQUENT WORK >
SUBSEQUENT WORK FOR WOOFER IN REAR DOOR
1. Install rear door panel. → INSTALLING REAR DOOR PANEL

SUBSEQUENT WORK FOR MID-RANGE LOUDSPEAKER IN REAR DOOR

SUBSEQUENT WORK FOR TWEETER IN REAR DOOR

SUBSEQUENT WORK FOR TWEETER IN REAR SIDE TRIM PANEL
Install side trim panel for rear luggage compartment. → INSTALLING SIDE TRIM PANEL FOR REAR
LUGGAGE COMPARTMENT
WM 914319 REMOVING AND INSTALLING REVERSING CAMERA (CAYENNE,

CAYENNE GTS, CAYENNE TURBO S, CAYENNE TURBO, CAYENNE S DIESEL) >
TOOLS

II

TECHNICAL VALUES
Reversing Tightening 6 Nm (4.5 ftlb.)

camera to rear torque
lid

PRELIMINARY WORK
Information
If the reversing camera has to be removed and installed, the reversing camera must be calibrated using
PIWIS Tester II 9818 . → 9143K2 CALIBRATING REVERSING CAMERA
Information
If the reversing camera has to be replaced, the values/data must be read out of the reversing camera
control unit before removing the reversing camera. → 914355 REPLACING REVERSING CAMERA
1. Remove lower part of tailgate trim panel. → REMOVING TRIM PANEL FOR TAILGATE

REMOVING REVERSING CAMERA
Fig 1: Identifying Reversing Camera Position
1. Unclip electric plug connections -1- -2- .

Fig 2: Removing Reversing Camera Connector
2. Release and disconnect electric plug connections -1 + 2- .

3. Unscrew fastening nuts -1- and remove cover plate -2- .

Fig 4: Removing Cover Plate
4. Disconnect electric plug connection.
5. Press reversing camera -1- outwards at the pins -2- .

Fig 5: Removing Reversing Camera

INSTALLING REVERSING CAMERA
1. The reversing camera is installed in reverse order to removal.
2. Tighten fastening nuts on the reversing camera. Tightening torque 6 Nm (4.5 ftlb.)

SUBSEQUENT WORK
Information
If the reversing camera was replaced, the values/data must be written back into the reversing camera
control unit using PIWIS Tester II 9818 after removing the reversing camera. → 914355 REPLACING
REVERSING CAMERA
Information
If the reversing camera was removed and installed, the reversing camera must be calibrated using
PIWIS Tester II 9818 . → 9143K2 CALIBRATING REVERSING CAMERA
1. Install lower part of tailgate trim panel. → INSTALLING TRIM PANEL FOR TAILGATE
WM 914355 REPLACING REVERSING CAMERA (EXCEPT CAYENNE, CAYENNE GTS,

calibration unit Workshop WE 1368

VAS 6350 equipment
spacing laser Workshop WE 1369

VAS 6350/2 equipment

II

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES

CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION > WHEN DOES REVERSING
CAMERA NEED TO BE CALIBRATED?
The reversing camera must be re-calibrated in the following situations:
When removing and installing or replacing the reversing camera.
When removing and installing or replacing control unit for reversing camera.
When lowering the chassis.
During conversion or repair work on the rear lid, upper part of rear lid lock or rear lid release.

Information
Calibrating the reversing camera balances the tires, chassis tolerances and installation tolerances of the
camera.
The calibration unit VAS 6350 WE 1368 and a spacing laser VAS 6350/2 WE 1369 are needed
for calibration .
During calibration, the control unit for the reversing camera calculates the vehicle-specific
adjustment values (e.g. image rectification) for the camera image .
After the actual calibration process, which takes approx. 2 minutes, the rectified image can be
seen on the vehicle display .
1 and 2 Wheel center support with reflectors.
3 and 8 Stop for distance meter
4 Height-adjustable calibration plate base
5 Line laser
6 Distance measuring unit
7 Spirit level for adjusting calibration plate horizontally in X and Y direction and cut-out for measuring
calibration plate height
9 Calibration pattern
10 Reversing camera
A Height of center of camera lens from floor
B Distance between calibration plate and vehicle, equal on both sides
C Calibration plate height

Fig 1: Overview Of Reversing Camera
Information
Calibration must only be performed on level ground.
On vehicles with air suspension, switch on ignition, close the doors and set the air suspension to
Comfort .
1. Park the vehicle on a level surface and set up the calibration unit VAS 6350 WE 1368 behind
the vehicle in accordance with the operating instructions for VAS 6350.
MP 1 bis 4 - Measuring points
X1 - Distance from calibration plate to right reflector
X2 - Distance from calibration plate to left reflector
Z - Height of camera from floor
K - Calibration plate height
Fig 2: Overview Of Vehicle
2. Fit the wheel nut supports and reflectors on the vehicle in accordance with the operating
instructions for VAS 6350. The reflectors must be hanging freely.
Fig 3: Fitting Reflectors

Fig 4: Identifying VAS (6350)
3. Align the work surface with the middle of the vehicle, adjust the line laser to suit the calibration
plate in accordance with the operating instructions for VAS 6350.

CAYENNE S DIESEL, CAYENNE (3.0)) > CALIBRATING REVERSING CAMERA
The following tools are required:
Calibration unit VAS 6350 WE 1368
Spacing laser VAS 6350/2 WE 1369
NOTE: Voltage drop

battery.
Information
Tester releases.
The procedure described here has been structured in general terms. Different text or additional
information may appear in PIWIS Tester II 9818 .
ignition and press [F12] to continue.
3. Select the Reversing camera control unit in the overview .
4. Select Calibrate reversing camera .
5. Read the warnings displayed on the Tester. The exact adjustment sequence is shown on the
Tester during calibration.
6. The Tester confirms that calibration is complete .
7. Check the function and image quality of the reversing camera.
8. Read out fault memory.
WM 9143K2 CALIBRATING REVERSING CAMERA (CAYENNE, CAYENNE GTS,

calibration unit Workshop WE 1368

VAS 6350 equipment
spacing laser Workshop WE 1369

II


CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION > WHEN DOES REVERSING
CAMERA NEED TO BE CALIBRATED?
The reversing camera must be re-calibrated in the following situations:
When removing and installing the reversing camera.
When changing the height of the chassis.
When removing and installing the rear apron.

Information
Calibrating the reversing camera balances the tires, chassis tolerances and installation tolerances of the
camera.
The calibration unit VAS 6350 WE 1368 and the spacing laser VAS 6350/2 WE 1369 are needed
for calibration .
During calibration, the control unit for the reversing camera calculates the vehicle-specific
adjustment values (e.g. image rectification) for the camera image .
After the actual calibration process, which takes approx. 2 minutes, the rectified image is shown on
the vehicle display .
Information
Calibration must only be performed on level ground.
the vehicle in accordance with the operating instructions.
MP1 - MP4 - Measuring points
X1 - Distance from calibration board to right reflector
X2 - Distance from calibration board to left reflector
Z - Distance from reversing camera to floor
K - Calibration board height
Fig 1: Overview Of Vehicle (911 Carerra)
2. Fit the wheel nut support with the right reflector and the wheel nut support with the left reflector
on the vehicle in accordance with the operating instructions for calibration unit VAS 6350 WE
1368 . The reflectors must be hanging freely.
Fig 2: Installing Reflectors
3. Align the calibration board with the center of the vehicle and adjust the linear laser on the
calibration board in accordance with the operating instructions for calibration unit VAS 6350
WE 1368 .

CAYENNE S DIESEL, CAYENNE (3.0)) > CALIBRATING REVERSING CAMERA
NOTE: Voltage drop
battery.
Information
Tester releases.
Information
When you calibrate the reversing camera by selecting Calibrate reversing camera in the PIWIS Tester,
the reversing camera control unit is then coded automatically. To do this, follow the relevant instructions
on the PIWIS Tester.
1. Wheel center support with right reflector
2. Wheel center support with left reflector
3. Right stop bracket for distance measuring unit
4. Left stop bracket for distance measuring unit
5. Linear laser
6. Distance measuring unit
7. Spirit level for adjusting calibration board in X and Y direction and cut-out for measuring
calibration board height
8. Height-adjustable calibration board base
9. Calibration pattern
10. Reversing camera


Fig 1: Overview Of Vehicle (911 Carerra)
Information
The surface of the calibration board must be clean and free of objects.
1. Align the linear laser -5- .
1. 1.1. Position the distance measuring unit -6- at the right stop bracket -3- of the
calibration board and measure the distance -X1- to the right reflector -1- . The
distance must be approx. 1, 400 mm.
2. 1.2. Position the distance measuring unit -6- at the left stop bracket -4- of the
calibration board and measure the distance -X2- to the left reflector -2- . The
distance must be approx. 1, 400 mm.
3. 1.3. The difference between distance -X1- and distance -X2- can be max. 1 mm!
2. PIWIS Tester II 9818 must be connected to the vehicle before starting PIWIS Tester II 9818 .
Switch on ignition.
3. Start the diagnostic application and select the required vehicle type.
4. Select Reversing camera control unit in the overview .
6. Select Calibrate reversing camera and press [F12] to continue.
7. In the Code control unit phase display, press [F12] to continue.
8. Wait until the Code control unit phase has finished and then press [F12] to continue.
9. Follow the calibration instructions on the Tester, then press [F12].
10. PIWIS Tester II 9818 confirms that the calibration was completed successfully .
11. Check the function and image quality of the reversing camera.
12. Read out the fault memory.
WM 914419 REMOVING AND INSTALLING LOUDSPEAKER AMPLIFIER (CAYENNE,


generation
PIWIS Tester
WM 914419 REMOVING AND INSTALLING LOUDSPEAKER AMPLIFIER (CAYENNE,

1. If the loudspeaker amplifier has to be replaced, the values must be read out prior to removal
using the 2nd generation PIWIS Tester 9818 . → 914455 REPLACING LOUDSPEAKER
AMPLIFIER .
2. Remove rear right luggage compartment side-panel lining. → REMOVING SIDE TRIM PANEL
WM 914455 REPLACING LOUDSPEAKER AMPLIFIER (EXCEPT CAYENNE, CAYENNE

CAYENNE GTS, CAYENNE TURBO S, CAYENNE S DIESEL, CAYENNE (3.0)) > TOOLS

II

CAYENNE GTS, CAYENNE TURBO S, CAYENNE S DIESEL, CAYENNE (3.0)) >
TECHNICAL VALUES

PRELIMINARY WORK
2. Disconnect the battery. → 2X00IN WORK INSTRUCTIONS AFTER DISCONNECTING THE

BATTERY .
3. Replace control unit. → 911719 REMOVING AND INSTALLING TV TUNER .
4. Connect the battery.

PRELIMINARY WORK > READING AND WRITING VALUES
NOTE: Voltage drop
battery.
Information
Tester releases.
appear in PIWIS Tester II 9818 .
ignition.
2. Select the vehicle type and start the diagnostic application.
3. Select the required control unit, e.g. Amplifier in the overview .
4. Programming must now be selected.
5. Automatic programming must now be selected. Then press [F12] to continue.
6. The System Tester displays the message Coding has been completed successfully . Press
[F12] to continue.
8. Carry out a function check on the loudspeaker amplifier.
WM 914719 REMOVING AND INSTALLING MOBILE COMMUNICATION ANTENNA

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > PRELIMINARY WORK
1. Remove caps on the rear-view mirror base and remove rear-view mirror from the holder. →
REMOVING INTERIOR REAR-VIEW MIRROR
CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING MOBILE
COMMUNICATION ANTENNA
NOTE: Voltage peaks
Fig 1: Identifying Mobile Communication Antenna Position
plastic wedge.
Fig 2: Identifying Front Camera Cover
2. Unclip GSM antenna -1- (-a- ) and remove it -A- . Release electric plug connection -2- (-b- )
and disconnect it -B- .
Fig 3: Removing GSM Antenna

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING MOBILE

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > SUBSEQUENT WORK
REAR-VIEW MIRROR
WM 915519 REMOVING AND INSTALLING TELEPHONE HANDSET AND CHARGING

TRAY (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S,
CAYENNE S HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) >
INFORMATION > COMPONENT INFORMATION
Fig 1: Telephone Installation Location

REMOVING TELEPHONE HANDSET AND CHARGING TRAY
1. Lift off handset.

Fig 1: Removing Handset
2. Carefully remove dummy plug -A- .

Fig 2: Identifying Charging Tray Dummy Plug
3. Loosen fastening screws -A- .

Fig 3: Identifying Charging Tray Screws
4. Lift charging tray, turn and carefully disconnect plug connection -A- .
5. Remove charging tray.

INSTALLING TELEPHONE HANDSET AND CHARGING TRAY
1. Installation is performed in reverse order.
WM 915719 REMOVING AND INSTALLING MICROPHONE FOR TELEPHONE

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING AND
INSTALLING MICROPHONE FOR TELEPHONE
1. The microphone for the telephone is integrated in the roof console and cannot be replaced
separately. → 708319 REMOVING AND INSTALLING ROOF CONSOLE
WM 916219 REMOVING AND INSTALLING CONTROL UNIT FOR STEERING WHEEL

ELECTRONICS (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S,
TOOLS

II

TECHNICAL VALUES

PRELIMINARY WORK > PRELIMINARY WORK FOR REMOVING AND INSTALLING
CONTROL UNIT FOR STEERING WHEEL ELECTRONICS
1. Move steering wheel to straight-ahead position and adjust it down and back as far as possible.
2. Remove steering wheel. → REMOVING STEERING WHEEL
3. Remove steering column casing. → REMOVING STEERING COLUMN CASING

REMOVING CONTROL UNIT FOR STEERING WHEEL ELECTRONICS
WARNING: Airbag contact unit not set correctly
Malfunction in driver's airbag unit
→ When removing and installing the steering column switch, turn the steering wheel so that the wheels
are in straight-ahead position. This ensures that the airbag contact unit is locked in the central position.
→ Do not trap the cable of the airbag contact unit.
→ Check that the cable is routed correctly.
1. Release electric plug connections -1- and disconnect them from the steering wheel electronics
control unit -2- .
2. Unscrew fastening screw -3- .

Fig 1: Identifying Steering Wheel Electronics Control Unit
3. Carefully disengage locking mechanisms -1- on the steering wheel electronics control unit -2-
and remove steering wheel electronics control unit from the steering-column switch -3- .
Fig 2: Identifying Steering Wheel Electronics Control Unit

INSTALLING CONTROL UNIT FOR STEERING WHEEL ELECTRONICS
WARNING: Airbag contact unit not set correctly
Malfunction in driver's airbag unit
→ When removing and installing the steering column switch, turn the steering wheel so that the wheels
are in straight-ahead position. This ensures that the airbag contact unit is locked in the central position.
→ Do not trap the cable of the airbag contact unit.
→ Check that the cable is routed correctly.
2. Tighten fastening screw used to secure the steering wheel electronics control unit to the
steering-column switch.

SUBSEQUENT WORK > SUBSEQUENT WORK FOR REMOVING AND INSTALLING
CONTROL UNIT FOR STEERING WHEEL ELECTRONICS
1. Install steering column casing. → 481319 REMOVING AND INSTALLING STEERING

COLUMN CASING
2. Install steering wheel. → INSTALLING STEERING COLUMN CASING
3. After replacing the steering wheel electronics control unit, teach the rear-end electronics
control unit to suit the vehicle again using PIWIS Tester II 9818 .
WM 916255 REPLACING CONTROL UNIT FOR STEERING WHEEL ELECTRONICS


II

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES

1. Replace control unit for steering wheel electronics. → 916219 REMOVING AND INSTALLING
CONTROL UNIT FOR STEERING WHEEL ELECTRONICS .
CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REPLACING CONTROL
UNIT FOR STEERING WHEEL ELECTRONICS
NOTE: Voltage drop
battery.
Information
Tester releases.
Information
On vehicles with the equipment variant multi-function steering wheel, a function enable process must be
carried out after replacing the steering wheel electronics control unit.
1. Connect the PIWIS Tester to the vehicle and start the PIWIS Tester. Switch on ignition.
3. Select the steering wheel electronics control unit in the overview .
4. Codings/adaptations must now be selected.
5. Automatic coding must now be selected. Then press [F12] to continue.
6. The Tester displays the message Coding has been completed successfully . Press [F12] to
continue.
7. Select Steering-angle sensor calibration in the Maintenance/repairs menu.
8. Follow the instructions on the Tester and press [F8] to start.

9. The Tester indicates that the calibration was completed successfully . Press [F12] to
continue.
11. Function test: Perform a test drive.

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > ENABLING FUNCTIONS
Information
On vehicles with the equipment variant heated steering wheel, multi-function steering wheel, cruise
control or on-board computer, a function enable process must be carried out after replacing the steering
wheel electronics control unit.
1. Determine function enabling code in PIWIS.
2. Connect the PIWIS Tester to the vehicle and start the PIWIS Tester. Switch on ignition.
4. Select Steering wheel electronics using the cursor keys and press [F12] to continue.
5. Maintenance/repairs must now be selected.
6. Select Function enable using the cursor keys and press [F12] to continue.
7. Select the function, enter the function enabling code and press [F8] to save your entries.
8. Repeat the process for other functions.

1. Initialize and calibrate the steering-angle sensor. → 456005 INITIALIZING AND CALIBRATING
STEERING-ANGLE SENSOR
WM 916719 REMOVING AND INSTALLING SIDE CAMERA (CAYENNE, CAYENNE GTS,

1. Remove rear-view mirror housing (upper part). → REMOVING REAR-VIEW MIRROR

HOUSING (UPPER PART)
CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING SIDE CAMERA

Fig 1: Identifying Side Camera Screws
2. Remove camera -1- with holder -2- .
3. Release electric plug connection -arrow- and disconnect it -arrow a- .

Fig 2: Removing Camera With Holder
4. Guide camera -1- out of the holder -2- .

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING SIDE CAMERA
Information
Check that the camera is positioned correctly. The camera is designed so that it cannot turn and can
only be installed at one position.
1. The camera is installed in reverse order to removal.

1. Install rear-view mirror housing (upper part). → INSTALLING REAR-VIEW MIRROR HOUSING
(UPPER PART)
2. If a new camera was installed, calibrate surround view cameras. → WM 917219 REMOVING
AND INSTALLING SURROUND VIEW CAMERA CONTROL UNIT
WM 916819 REMOVING AND INSTALLING OUTSIDE TEMPERATURE SENSOR

1. Loosen front wheel housing liner at the right in the lower area on the front apron. →
REMOVING FRONT WHEEL HOUSING LINER

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING OUTSIDE
TEMPERATURE SENSOR
1. Switch off ignition and pull remote control out of ignition lock.
2. Pull outside temperature sensor -1- out of the right cooling-air duct -2- on the front spoiler
-arrow- .
Fig 1: Removing Outside Temperature Sensor
3. Release electric plug connection -1- (-arrow- ) and pull off outside temperature sensor -2- .

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING OUTSIDE
TEMPERATURE SENSOR

1. Secure front wheel housing liner at the right in the lower area to the front apron. →
INSTALLING FRONT WHEEL HOUSING LINER
WM 916919 REMOVING AND INSTALLING FRONT CAMERA (CAYENNE, CAYENNE

Front camera Tightening 3 Nm (2 ftlb.)

holder to torque
radiator grille
Front camera Tightening 1 Nm (0.5 ftlb.)

to holder torque

CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION
Fig 1: Identifying Front Camera Position

1. Remove front apron. → REMOVING FRONT APRON

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT CAMERA
1. Release and disconnect electric plug connection -1- on the front camera -a- .
2. Unscrew fastening screws -2- and remove front camera with housing -3- from the front apron.
Fig 1: Loosening Front Camera From Front Apron
4. Disengage rear half of housing -2- from front half of housing -3- (-a- ) and remove it.
Fig 2: Removing Front Camera
5. Remove front camera -1- from front half of housing -2- .

Fig 3: Removing Front Camera

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT CAMERA
Information
Check installation position: Fit the front camera in the front half of the housing in such a way that the
electric connection is on the right-hand side.
2. Tighten rear fastening screws on front half of front camera housing. Tightening torque 1 Nm
(0.5 ftlb.)
3. Tighten fastening screws securing front camera housing to front apron. Tightening torque 3
Nm (2 ftlb.)

1. Install front apron. → INSTALLING FRONT APRON
2. Clean the front camera lens with a soft, clean cloth.
3. Calibrate front camera. → WM 917219 REMOVING AND INSTALLING SURROUND VIEW

CAMERA CONTROL UNIT
WM 917019 REMOVING AND INSTALLING CONTROL UNIT FOR LANE CHANGE

ASSIST (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S

II

HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL
VALUES
Control unit to Fastening screw Tightening 4 Nm (3 ftlb.)

holder -1- torque

HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > PRELIMINARY
WORK
1. If a Lane Change Assist control unit has to be replaced, the data must be read out prior to
removal using PIWIS Tester II 9818 . → 914355 REPLACING REVERSING CAMERA
Remove rear apron. → REMOVING REAR APRON .

HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING
CONTROL UNIT FOR LANE CHANGE ASSIST
Information
For trouble-free operation, Lane Change Assist must be calibrated after the following work is carried out
on the vehicle:
When one or both Lane Change Assist control units are replaced .
When the installation position of one or both Lane Change Assist control units is changed .
When body repairs are carried out on the rear of the vehicle .
When the rear bumper is removed or moved out of position .
Information
Lane Change Assist has two control units:
The master control unit on the left and
the slave control unit on the right .

Fig 1: Identifying Lane Change Assist Control Units Installation Position
1. Switch off ignition and remove remote control (hand-held transmitter).
2. Unscrew the three fastening screws -1- .

Fig 2: Removing Control Unit
3. Open the retaining clips for the electric connector -a- and disconnect connector -A- from the
control unit.

HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING
CONTROL UNIT FOR LANE CHANGE ASSIST
1. Plug in electric connector on the control unit -A- until it engages securely.
2. Position the control unit on the holder -B- and secure it with the three fastening screws -1- .
→ Tightening torque: 4 Nm (3 ftlb.)
Fig 1: Installing Control Unit

HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > SUBSEQUENT
WORK
1. Install rear apron. → INSTALLING REAR APRON
2. If a Lane Change Assist control unit was replaced, the data must be written back into the
control unit again using PIWIS Tester II 9818 . → 914355 REPLACING REVERSING
CAMERA .
3. The Lane Change Assist control unit must be calibrated whenever the rear apron is
removed/fitted. → 9170K2 CALIBRATING CONTROL UNIT FOR LANE CHANGE ASSIST
WM 917025 PROGRAMMING CONTROL UNIT FOR LANE CHANGE ASSIST

(CAYENNE S, CAYENNE S HYBRID, CAYENNE TURBO, CAYENNE S DIESEL,

Calibration Workshop WE 1368
unit VAS 6350 equipment
Spacing laser Workshop WE 1369


unit for Lane equipment
Change Assist
VAS 6350/4
II


CAYENNE (3.0)) > INFORMATION > WHEN DOES LANE CHANGE ASSIST NEED TO
BE CALIBRATED?
The Lane Change Assist control units must be re-calibrated in the following situations:
When one or both Lane Change Assist control units are replaced.
When the installation position of one or both Lane Change Assist control units is changed.
When body repairs are carried out on the rear of the vehicle.
When the rear bumper/rear apron is removed or moved out of position.

Information
The calibration process sends out radar beams, which the Doppler generator reflects. This simulates a
vehicle.
A certain number of radar beams are expected in a defined time due to the defined position of the
Doppler generator.
Deviations indicate that the control units are not at the correct installation position.
These deviations are displayed on the Porsche System Tester.

Information
The following tools are required for calibration:
Calibration plates and wheel center mountings: Calibration unit VAS 6350 WE 1368 .
Doppler generator: Calibration unit for Lane Change Assist VAS 6350/4 WE 1375
Spacing laser: Spacing laser VAS 6350/2 WE 1369
Information
The following conditions must be observed in order to perform calibration:
Calibration must only be performed on level ground .
The vehicle must be empty .
Wheels must be positioned straight ahead .
Vehicle doors must be closed .
Tires must have the specified air pressure .
On vehicles with air suspension, the chassis must be set to Normal Level and suspension
levelling (air suspension) must be completed .
The retractable trailer hitch must be retracted .
The engine must not be running during calibration .
Check that there is adequate space behind the vehicle and that there are no metal
objects/obstacles within 5 meters of the rear of the vehicle .
Make sure that no objects are moved or no-one moves behind the vehicle during calibration .
There must be no heavy soiling in the sensor area on the rear apron .
There must be no stickers in the sensor area on the rear apron .
The calibration plates, wheel center mountings and the Doppler generators must be fitted,
centered/aligned in accordance with the operating instructions .
Workshop conditions
The system must only be calibrated in a suitable area of the workshop .
This area of the workshop must be sheltered from all environmental influences, such as rain, snow
and swirling dust .
The workshop must be at room temperature .
the vehicle.
MP 1 to 4 - Measuring points

Fig 1: Overview Of Vehicle (Panamera)
2. Fit wheel center mountings and reflectors on the vehicle. The reflectors must be hanging freely.

Fig 3: Installing Wheel Centre Mountings
3. Align the work surface with the center of the vehicle and adjust the line laser to suit the
calibration board.

CAYENNE (3.0)) > CALIBRATING CONTROL UNIT FOR LANE CHANGE ASSIST
NOTE: Voltage drop

battery.
Information
Tester releases.
1. The following tools are required:
1. 1.1. Calibration unit VAS 6350 WE 1368
2. 1.2. Spacing laser VAS 6350/2 WE 1369

3. 1.3. Calibration unit for Lane Change Assist VAS 6350/4 WE 1375
2. PIWIS Tester must be connected to the vehicle before starting it. Switch on ignition and press
[F12] to continue.
4. Select the Lane Change Assist control unit in the overview .
5. Select Calibrate Lane Change Assist .
6. Follow instructions on the Tester.
7. Calibration of the master and slave control unit for Lane Change Assist is menu-driven.
8. Read the information displayed on the Tester and proceed according to instructions.
9. Once you have calibrated Lane Change Assist, carry out a test drive and check the Lane
Change Assist function.
10. After the test, read out the fault memory and erase it if necessary.
WM 917055 REPLACING CONTROL UNIT FOR LANE CHANGE ASSIST (CAYENNE,



Change Assist
VAS 6350/4

II


TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > READING AND WRITING VALUES
NOTE: Voltage drop

battery.
Information
Tester releases.
Information
For trouble-free operation, Lane Change Assist must be calibrated after the following work is carried out
on the vehicle:
When one or both Lane Change Assist control units are replaced .
When the installation position of one or both Lane Change Assist control units is changed .
When body repairs are carried out on the rear of the vehicle .
When the rear bumper is removed or moved out of position .
2. Select the vehicle type and start the Tester.
9. Switch off ignition and replace control unit. → 917019 REMOVING AND INSTALLING
CONTROL UNIT FOR LANE CHANGE ASSIST .
10. Switch on ignition. Select the Write data menu (procedure described above), press [F12] to
continue and then press [F8] to start installing the data that was read out.

If a Lane Change Assist control unit was removed and installed or replaced, the Lane Change Assist
control unit must be re-calibrated on a level surface using the calibration unit Calibration unit for Lane
Change Assist VAS 6350/4 WE 1375 , Calibration unit VAS 6350 WE 1368 , Spacing laser VAS
6350/2 WE 1369 . → 9170K2 CALIBRATING CONTROL UNIT FOR LANE CHANGE ASSIST .
WM 9170K2 CALIBRATING CONTROL UNIT FOR LANE CHANGE ASSIST (EXCEPT

CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S HYBRID,


Change Assist
VAS 6350/4

II


CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION > WHEN
DOES LANE CHANGE ASSIST NEED TO BE CALIBRATED?
The Lane Change Assist control units must be re-calibrated in the following situations:
When one or both Lane Change Assist control units are replaced.
When the installation position of one or both Lane Change Assist control units is changed.
When body repairs are carried out on the rear of the vehicle.
When the rear bumper/rear apron is removed or moved out of position.

Information
The calibration process sends out radar beams, which the Doppler generator reflects. This simulates a
vehicle.
A certain number of radar beams are expected in a defined time due to the defined position of the
Doppler generator.
Deviations indicate that the control units are not at the correct installation position.
These deviations are displayed on the Porsche System Tester.
Information
The following tools are required for calibration:
Calibration plates and wheel center mountings: Calibration unit VAS 6350 WE 1368 .
Doppler generator: Calibration unit for Lane Change Assist VAS 6350/4 WE 1375
Spacing laser: Spacing laser VAS 6350/2 WE 1369
Information
The following conditions must be observed in order to perform calibration:
Calibration must only be performed on level ground .
The vehicle must be empty .
Wheels must be positioned straight ahead .
Vehicle doors must be closed .
Tires must have the specified air pressure .
On vehicles with air suspension, the chassis must be set to Normal Level and suspension
levelling (air suspension) must be completed .
The retractable trailer hitch must be retracted .
The engine must not be running during calibration .
Check that there is adequate space behind the vehicle and that there are no metal
objects/obstacles within 5 meters of the rear of the vehicle .
Make sure that no objects are moved or no-one moves behind the vehicle during calibration .
There must be no heavy soiling in the sensor area on the rear apron .
There must be no stickers in the sensor area on the rear apron .
The calibration plates, wheel center mountings and the Doppler generators must be fitted,
centered/aligned in accordance with the operating instructions .
Workshop conditions
The system must only be calibrated in a suitable area of the workshop .
This area of the workshop must be sheltered from all environmental influences, such as rain, snow
and swirling dust .
The workshop must be at room temperature .
the vehicle.
2. Fit the wheel center mountings and reflectors on the vehicle. The reflectors must be hanging
freely.

Fig 3: Installing Wheel Centre Mountings
3. Align the work surface with the center of the vehicle and adjust the line laser to suit the
calibration plate.

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > CALIBRATING CONTROL
UNIT FOR LANE CHANGE ASSIST
NOTE: Voltage drop

battery.
Information
Tester releases.
1. The following tools are required:
1. 1.1. Calibration unit VAS 6350 WE 1368
2. 1.2. Spacing laser VAS 6350/2 WE 1369
3. 1.3. Calibration unit for Lane Change Assist VAS 6350/4 WE 1375
2. Connect the PIWIS Tester to the vehicle and start it. Switch on ignition and press [F12] to
continue.
5. Select Calibrate Lane Change Assist .
6. Follow instructions on the Tester.
7. Calibration of the master and slave control unit for Lane Change Assist is menu-driven.
8. Read the information displayed on the Tester and proceed according to instructions.
9. Once you have calibrated Lane Change Assist, test-drive the vehicle and check the Lane
Change Assist function.
10. After the test, read out the fault memory. If there are faults stored, correct the faults in
accordance with the fault-finding strategy.
WM 917119 REMOVING AND INSTALLING LANE CHANGE ASSIST DISPLAY

1. Remove mirror glass. → REMOVING MIRROR GLASS

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING LANE
CHANGE ASSIST DISPLAY
1. Remove Lane Change Assist display.
1. 1.1. Press the display out of the housing from the inside -A- .
2. 1.2. Release and disconnect electric plug connection.

Fig 1: Removing Lane Change Assist

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING LANE
CHANGE ASSIST DISPLAY
1. Connect electric plug connection until it engages securely.
2. Clip display into the exterior mirror bracket.
3. Carry out a function test.

1. Install mirror glass. → INSTALLING MIRROR GLASS
WM 917219 REMOVING AND INSTALLING SURROUND VIEW CAMERA CONTROL

UNIT ((CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S
HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0))) > PRELIMINARY
WORK

BOOSTER

HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0))) > REMOVING
SURROUND VIEW CAMERA CONTROL UNIT
1. Release electric plug connections from TV tuner -arrow- and disconnect them -arrow a- .
2. Release electric plug connections -arrow- and disconnect them -arrow a- .

3. Release locking lug -arrow- and pull surround view camera control unit out of the holder
-arrow a- .
Fig 3: Pulling Control Unit

HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0))) > INSTALLING
SURROUND VIEW CAMERA CONTROL UNIT
1. The surround view camera control unit is installed in reverse order to removal.

HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0))) > SUBSEQUENT
WORK

BOOSTER
WM 9172IN ADAPTATION OF CALIBRATION MATS (CAYENNE, CAYENNE GTS,

Calibration system Workshop WE 1606

equipment
WM 9172IN ADAPTATION OF CALIBRATION MATS (CAYENNE, CAYENNE GTS,

CAYENNE S DIESEL, CAYENNE (3.0)) > ADAPTING CALIBRATION MATS
Information
The following tools are required: Calibration system WE 1606
The calibration system must be adapted in order to be able to use it for the Cayenne and Macan.
The adaptation must only be carried out once and does not have to be reset.
Adaptation also ensures that the system can be used for the Panamera.
1. Adapt front and rear calibration mats (VAS 6905/2) from the calibration system WE 1606 as
follows:
1. 1.1. Spread out front and rear calibration mats (VAS 6905/2) on a clean, flat surface.
2. 1.2. At the outer left and right respectively, tape the transverse lines using 38 - 50
mm wide adhesive strips -1- running along the longitudinal axis of the vehicle →
Taping front and rear calibration mats (VAS 6905/2) .
Adhesive strips must be the same color as the calibration mats so as not to
affect the contrast .
Adhesive strips must not change the width of transverse and longitudinal
lines .
The tape must be affixed in the same way at the front and rear.
Fig 1: Identifying Front And Rear Calibration Mats (VAS 6905/2)
2. Adapt calibration mats for left and right side panel (VAS 6905/1) from the calibration system
WE 1606 as follows:
Fig 2: Identifying Calibration Mats For Left And Right Side Panel (VAS 6905/1)
1. 2.1. Spread out calibration mats for left and right side panel (VAS 6905/1) on a clean,
level surface.
2. 2.2. Tape the respective rear transverse line using 38 - 50 mm wide adhesive strips
-2- running along the longitudinal axis of the vehicle.
lines .
The tape must be affixed on the left side as a mirror image of the right side.
3. 2.3. Tape the front transverse lines using 38 - 50 mm wide adhesive strips -3-
running transversely with respect to the longitudinal axis of the vehicle so that they
are distinguished from the longitudinal lines.
lines .
The tape must be affixed on the left side as a mirror image of the right side.
WM 917419 REMOVING AND INSTALLING CONTROL UNIT FOR PARK ASSIST


II

Screw securing ST 4.2 x 16 Tightening 1.5 Nm (1

gateway/PDC torque ftlb.)
control unit to
gateway/PDC
holder
Screw securing M6 Tightening 6 Nm (4.5

holder to module
carrier

1. Read out values and coding using PIWIS Tester II 9818 before installing a new control unit. →
917455 REPLACING CONTROL UNIT FOR PARKASSIST .
2. Remove trim panel under dashboard at the left. → REMOVING TRIM PANEL UNDER
DASHBOARD
3. Loosen fuse box at the front left. → LOOSENING RELAY CARRIER

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING CONTROL
UNIT FOR PARK ASSIST
Information

Fig 1: Identifying Control Unit For Parkassist Installation Position
NOTE: Voltage peaks
2. Remove holder with control units -arrow A- and set them down in the footwell.
Fig 2: Removing Control Unit Holder
3. Release electric plug connections and disconnect them from the ParkAssist control unit
-arrow- .
Fig 3: Removing Control Unit For Parkassist
4. Unscrew fastening screw -2- on control unit for ParkAssist.
5. Pull control unit for ParkAssist out of the bracket -3- (-arrow A- ).
6. Remove control unit for ParkAssist.

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING CONTROL
UNIT FOR PARK ASSIST
Information

1. Position control unit for ParkAssist in the bracket -3- (-arrow B- ).
Fig 1: Installing Control Unit For Parkassist
2. Tighten fastening screw -2- . Tightening torque 1.5 Nm (1 ftlb.)
3. Plug in electric plug connections on control unit for ParkAssist -arrow- until they engage
securely.
4. Position holder on dashboard support -arrow A- and tighten fastening screws -1- .
Tightening torque 6 Nm (4.5 ftlb.)
Fig 2: Installing Control Unit Holder

1. Secure fuse box at the front left. → SECURING RELAY CARRIER
2. Install trim panel under dashboard at the left. → INSTALLING TRIM PANEL UNDER
DASHBOARD
3. If the control unit was replaced, the new control unit must be taught to suit the vehicle using
PIWIS Tester II 9818 . → 917455 REPLACING CONTROL UNIT FOR PARKASSIST .
WM 917455 REPLACING CONTROL UNIT FOR PARK ASSIST (EXCEPT CAYENNE,


II


TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > READING AND WRITING VALUES
NOTE: Voltage drop
battery.
Information
Tester releases.
ignition.
3. Select the ParkAssist control unit in the overview .
CONTROL UNIT FOR PARKASSIST .
13. Function test: manoeuvre the vehicle.
WM 917519 REMOVING AND INSTALLING SENSOR FOR PARK ASSIST (EXCEPT

Remove the front or rear apron as required. → REMOVING FRONT APRON or → REMOVING REAR
APRON

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING SENSOR FOR
PARK ASSIST
Information
If one or more sensors must be replaced or repainted:
Follow the painting specifications in the Paint Information .
1. Pull off connector on sensor for ParkAssist.
1. 1.1. Pull locking lugs apart -arrows A- and remove sensor for ParkAssist -1-
(-arrow B- ).
2. 1.2. Release connector -2- (-arrow C- ) and pull it off sensor for ParkAssist -1-
(-arrow D- ).
Fig 1: Pulling Parkassist Sensor Connector

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING SENSOR
FOR PARK ASSIST
1. Plug in connector on sensor for ParkAssist.
1. 1.1. Plug in connector -2- on sensor for ParkAssist -1- (-arrow A- ) until the
connector -2- engages securely.
2. 1.2. Press sensor for ParkAssist -1- into the mounting in the rear apron -arrow B-
until the locking lugs engage securely.
Fig 1: Locating Parkassist Sensor Connector

Install the front or rear apron as required. → INSTALLING FRONT APRON or → INSTALLING REAR
APRON
WM 917519 REMOVING AND INSTALLING PARKASSIST SENSOR (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > PRELIMINARY WORK FOR FRONT
PARK ASSIST SENSOR
Inner front ParkAssist sensor
Outer front ParkAssist sensor
2. Loosen the lower area of the front air grille. → REMOVING FRONT AIR GRILLE

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > PRELIMINARY WORK FOR REAR
PARK ASSIST SENSOR
1. Remove rear apron. → 635519 REMOVING AND INSTALLING REAR APRON

Fig 1: Identifying Front Parkassist Sensors Position

Fig 2: Identifying Rear Parkassist Sensors Position

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING PARK ASSIST SENSOR
1. Remove ParkAssist sensor -1- .
1. 1.1. Disengage locking mechanisms -2- and take ParkAssist sensor -1- out of the
holder.
2. 1.2. Disengage locking mechanism for electric plug connection by moving it to the
side -3- .
3. 1.3. Press locking mechanism -4- and disconnect electric plug connection at the
ParkAssist sensor -1- .
Fig 1: Removing Parkassist Sensor

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING PARK ASSIST SENSOR
Information
If the cover on the ParkAssist sensor must be painted, read and follow instructions in the Paint
Information!
Installation is performed in reverse order to removal .

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > SUBSEQUENT WORK FOR REAR
PARK ASSIST SENSOR

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > SUBSEQUENT WORK FOR FRONT
PARK ASSIST SENSOR
Outer front ParkAssist sensor
1. Secure front air grille. → INSTALLING FRONT AIR GRILLE
Inner front ParkAssist sensor
WM 917619 REMOVING AND INSTALLING BUZZER FOR PARKING ASSISTANT

FOR BUZZER FOR REAR PARKING ASSISTANT
1. Remove subwoofer. → Removing Subwoofer 913619 REMOVING AND INSTALLING

SUBWOOFER (S E-HYBRID)
2. Disconnect on-board charger from the body and set it aside with lines connected. →
REMOVING HIGH-VOLTAGE CHARGER
Remove side trim panel for rear luggage compartment at the left. → REMOVING SIDE TRIM PANEL

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING BUZZER FOR
REAR PARKING ASSISTANT

Fig 1: Identifying Buzzer

2. Release expansion rivets -2- and pull them out.
Fig 2: Identifying Rear Parking Assistant Buzzer Position
1. Release electric plug connection -1- (-a- ) and disconnect it -A- .

Fig 3: Removing Buzzer For Rear Parking Assistant
2. Release expansion rivets -2- and pull them out.

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING BUZZER
FOR REAR PARKING ASSISTANT
1. The buzzer for the rear parking assistant is installed in reverse order to removal.

FOR BUZZER FOR REAR PARKING ASSISTANT
1. Install on-board charger. → INSTALLING HIGH-VOLTAGE CHARGER
2. Install subwoofer. → Installing Subwoofer
Install side trim panel for rear luggage compartment at the left. → INSTALLING SIDE TRIM PANEL FOR
WM 917619 REMOVING AND INSTALLING BUZZER FOR PARKING AID (EXCEPT
FOR BUZZER FOR REAR PARKING AID
Remove side trim panel for rear left luggage compartment. → REMOVING SIDE TRIM PANEL FOR

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING BUZZER FOR
REAR PARKING AID
Fig 1: Identifying Rear Parking Aid Buzzer Position
1. Release electric plug connection -1- (-a- ) and pull it off -A- .
2. Release three expansion rivets -2- using a screwdriver and pull them out.
Fig 2: Removing Buzzer For Rear Parking Aid

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING BUZZER
FOR REAR PARKING AID
1. The rear parking aid buzzer is installed in reverse order to removal.

FOR BUZZER FOR REAR PARKING AID
Install side trim panel for rear left luggage compartment. → INSTALLING SIDE TRIM PANEL FOR
WM 918419 REMOVING AND INSTALLING ANTENNA AMPLIFIER (CAYENNE,

Antenna Tightening 9 Nm (6.5 ftlb.)

amplifier torque

1. Remove upper part of rear trim panel. → REMOVING TRIM PANEL FOR TAILGATE

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING ANTENNA AMPLIFIER
NOTE: Voltage peaks
Fig 1: Identifying Antenna Amplifier Position
1. Carefully lever out electric plug connection -A- using a small screwdriver and pull it out.
2. Release and pull off three electric plug connections -B- (-a- ).
Fig 2: Pulling Plug Connections
3. Release and pull off electric plug connection -a- .

Fig 3: Pulling Plug Connections
4. Unscrew the fastening screw.
5. Lift up antenna amplifier -A- and remove it -B- .

Fig 4: Releasing Antenna Amplifier

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING ANTENNA AMPLIFIER
1. Insert antenna amplifier into the cut-out -A, B- .

Fig 1: Fitting Antenna Amplifier
2. Screw in fastening screw Tightening torque 9 Nm (6.5 ftlb.) .
3. Plug in electric plug connection until it engages securely.

Fig 2: Installing Plug Connection
4. Plug in three electric plug connections -A- until they engage securely.
5. Plug in electric plug connection -B- .
1. 5.1. Check that the electric plug connection is seated securely.

1. Install upper part of rear trim panel. → INSTALLING TRIM PANEL FOR TAILGATE
WM 918619 REMOVING AND INSTALLING CONTROL UNIT FOR ANTENNA

AMPLIFIER (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE
S HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL
VALUES

S HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > PRELIMINARY
WORK
1. Remove upper trim panel at the rear. → REMOVING TRIM PANEL FOR TAILGATE

S HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING
CONTROL UNIT FOR ANTENNA AMPLIFIER
NOTE: Voltage peaks
Fig 1: Identifying Control Unit For Antenna Amplifier Position
1. Release electric plug connection -A- using a small screwdriver -a- and disconnect it.
2. Release and disconnect electric plug connection -B- (-a- ).
3. Unscrew the fastening screw.
4. Lift up control unit for antenna amplifier -A- and remove it -B- .
Fig 3: Removing Control Unit For Antenna Amplifier

S HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING
1. Insert control unit for antenna amplifier into the cut-out -A, B- .
Fig 1: Installing Control Unit For Antenna Amplifier
2. Fit ground line and secure with the fastening screw.
3. Plug in electric plug connections until they engage securely.

Fig 2: Connecting Plug Connections

S HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > SUBSEQUENT
WORK
1. Install upper part of rear trim panel. → INSTALLING TRIM PANEL FOR TAILGATE
WM 919019 REMOVING AND INSTALLING CONTROL UNIT FOR TELEPHONE

MODULE (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S
WORK
1. Remove PCM display and operator control unit. → Removing PCM 3.1 Display And Operator
Control Unit 911019 REMOVING AND INSTALLING PCM DISPLAY AND OPERATOR
CONTROL UNIT

CONTROL UNIT FOR TELEPHONE MODULE
1. Carefully open the cover on the PCM display and operator control unit using a screwdriver.
Fig 1: Opening Control Unit Cover
2. Unscrew fastening screws -1- and pull telephone control unit up and out.
Fig 2: Identifying Telephone Control Unit Screws

CONTROL UNIT FOR TELEPHONE MODULE

WORK
1. Install PCM display and operator control unit. → Installing PCM 3.1 Display And Operator
Control Unit 911019 REMOVING AND INSTALLING PCM DISPLAY AND OPERATOR
CONTROL UNIT
WM 919125 TEACHING ADDITIONAL/TELEPHONE HANDSET (EXCEPT CAYENNE

DIESEL "PLATINUM EDITION", CAYENNE, CAYENNE GTS, CAYENNE TURBO S,
CAYENNE S, CAYENNE S HYBRID, CAYENNE TURBO, CAYENNE GTS, CAYENNE
TURBO S, CAYENNE S DIESEL, CAYENNE (3.0)) > TOOLS

TURBO S, CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES

TURBO S, CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > TEACHING
ADDITIONAL/TELEPHONE HANDSET
CAUTION: Voltage drop
battery.
Information
Later versions of the software may display slightly different text or require a slightly different procedure.
The instructions you receive from the Tester itself take precedence over this description.
1. PIWIS Tester 9718 must be connected to the vehicle before starting the System Tester.
Switch on ignition. Press [>>] to continue.
2. Select vehicle type. Press [>>] to continue.
3. Select HeadUnit control unit and press [>>].
4. Engage telephone handset in the charging cradle.
5. Select the Drive links/Tests menu.
6. Select the Teach handset function and press [>>].
7. Start the activation process by pressing [F8].
8. Follow the instructions on the Tester. The message Handset has been taught must appear.
Press [<<] to go back.
9. Check the function of the handset.
WM 919155 ADDITIONAL HANDSET FOR TELEPHONE >> REPLACING BATTERY

(EXCEPT CAYENNE DIESEL "PLATINUM EDITION", CAYENNE, CAYENNE GTS,
CAYENNE S DIESEL, CAYENNE (3.0)) > ADDITIONAL HANDSET FOR TELEPHONE >>
REPLACING BATTERY
Information
Make sure not to scrape the cover with the screwdriver.
1. Insert a small screwdriver into the opening -1- on the back of the additional handset and
carefully prise off the cover -2- .
Fig 1: Opening Battery Cover
2. Lift up battery -3- and disconnect electric connector -4- on the additional handset.
Fig 2: Removing Battery
3. Unpack new battery.
4. Plug in electric connector -4- on the additional handset and carefully push the plug connection
on as far as it will go using a small screwdriver if necessary.
Fig 3: Installing Electric Connector On Handset
5. Insert the battery into the additional handset and close the cover until it engages securely.
Service Manual: 92 - WINDSHIELD WIPER AND WASHER SYSTEM -- 92A CAYENNE
WM 921219 REMOVING AND INSTALLING RAIN SENSOR (EXCEPT CAYENNE,
Remove interior rearview mirror. → 682719 REMOVING AND INSTALLING INTERIOR REARVIEW
MIRROR

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING RAIN SENSOR
NOTE: Voltage peaks
Fig 1: Identifying Rain Sensor Installation Position
2. Using a plastic wedge, carefully detach the rain sensor -1- out of the adhesive plate -2- .
Fig 2: Removing Rain Sensor
3. Disconnect electric plug connection -1- .


TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING RAIN SENSOR
Information
Limited rain sensor function if the following points are not observed:
There must be no air trapped between the windscreen and silicone layer on the rain sensor .
The temperature of the windscreen and rain sensor must be approx. 20 °C during assembly.
Carefully heat the windscreen and rain sensor using a hot-air gun if necessary .
The contact surfaces must be free of grease and dirt .
Do not touch silicone layer on the rain sensor .
Do not remove the protection cap from a new rain sensor until immediately before pressing the rain
sensor onto the windscreen .
1. Clean inner area of adhesive plate.

2. Plug in electric plug connection -1- until the connector engages securely.
Fig 1: Connecting Plug Connection
3. Remove the protection cap from the sensor.
4. Position the sensor -1- and insert it into the adhesive plate -2- .
Fig 2: Installing Rain Sensor
5. Check the function of the rain sensor: Use a spray bottle filled with water to moisten the
windscreen (close to the rain sensor) and switch on the windscreen wiper. Subsequent work

Install interior rearview mirror. → 682719 REMOVING AND INSTALLING INTERIOR REARVIEW
MIRROR
WM 921519 REMOVING AND INSTALLING WIPER MOTOR (EXCEPT CAYENNE,

Fastening screw Tightening 9 Nm (6.5 ftlb.)

securing wiper torque
motor to wiper
linkage
Fastening nut -4- Tightening 18 Nm (13
for wiper linkage torque ftlb.)
Fastening screw -3- Tightening 9 Nm (6.5 ftlb.)

on wiper linkage torque
M6 x 30
Fastening screw -2- Tightening 9 Nm (6.5 ftlb.)

on wiper linkage torque
M6 x 35

1. Remove cowl panel cover. → 664419 REMOVING AND INSTALLING COWL PANEL COVER

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING WIPER MOTOR
Information
When the bonnet is open the wiper system is deactivated; only after closing the bonnet and
switching the wiper system off and on again are the wipers reactivated .
The wiper control unit is located in the wiper motor .
Information

Fig 1: Identifying Wiper Motor Installation Position
NOTE: Voltage peaks
1. Unclip engine wire harness from the three clips -1- .

Fig 2: Identifying Engine Wire Harnesses Clips
2. Unscrew fastening screws -2 and 3- .

Fig 3: Removing Fastening Screws
3. Rotate complete wiper linkage at the front upwards and then to the left and remove it in an
upward direction.
4. Release and pull off electric plug connection.

Fig 4: Pulling Off Electric Plug Connection
5. Unscrew fastening nut on the wiper motor -4- .

Fig 5: Removing Fastening Nut On Wiper Motor
6. Mark the drive position of the wiper linkage -5- .

Fig 6: Marking Drive Position Of Wiper Linkage
7. Disengage drive mechanism -arrow- .
8. Unscrew three fastening screws -6- and remove wiper motor.

Fig 7: Removing Fastening Screws On Wiper Motor
9. Remove wiper motor in a downward direction.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING WIPER MOTOR
WARNING: Electrically moved components
Danger of limbs being trapped or severed
→ Switch off electric power to drive motor.
→ Make sure it does not switch on again.
→ Check that there is no electric charge.
Information
If a new wiper motor is being installed, ensure that the correct Porsche original screws are used .
1. Before fitting the wiper motor, connect the wiper motor to the electric plug connection, close
the bonnet, operate one-touch wipe at least once and let the wiper run to the end position.
Disconnect plug connection again.
2. Switch off ignition and remove remote control from ignition lock.
3. Position wiper linkage marked -5- on the wiper shaft -arrow- .

Fig 1: Positioning Wiper Linkage
4. Tighten fastening screws -6- until secure. → Tightening torque: 9 Nm (6.5 ftlb.)
Fig 2: Tightening Fastening Screws On Wiper Motor
5. Tighten fastening nut for the wiper linkage -4- securely. → Tightening torque: 18 Nm (13
ftlb.)
Fig 3: Tightening Fastening Nut For Wiper Linkage

Fig 4: Plugging In Electric Plug Connection
7. Position wiper system -arrow- . Guide in wiper motor with linkage in a downward direction,
slide the wiper linkage to the right, turn it slightly and set it down.
Fig 5: Positioning Wiper Linkage In Engine Compartment
8. Check that the wiper motor is seated correctly.
Information
Observe the sequence of the five fastening screws in direction of travel.
1. 1. Rear left .
2. 2. Rear right .
3. 3. Rear middle .
4. 4. Front right .
5. 5. Front middle .
9. Fit fastening screws -3- for the wiper system and tighten fastening screws. → Tightening
torque: 9 Nm (6.5 ftlb.)
Fig 6: Fitting Fastening Screws For Wiper System
10. Fit fastening screws -2- for the wiper system and tighten fastening screws. → Tightening
11. Clip in engine wire harness.
12. Before fitting wiper arms, the wiper motor must be operated a second time at least once with
one-touch wipe and run to the end position. To do this, close the bonnet.

1. Install cowl panel cover. → 664419 REMOVING AND INSTALLING COWL PANEL COVER
WM 922515 ADJUSTING WIPER ARM ATTACK ANGLE (EXCEPT CAYENNE,


Adjustment Special tool 9737
device

Information
The wiper arm attack angle will need to be checked and adjusted if the customer complains of: rubbing
or hesitation of wiper, noises when wiping or uneven wiping area.
It is important that the wiper blades are inspected for wear and the windscreen is free of contamination.
1. Check the condition of the windscreen and clean it if it is dirty.
2. Remove wiper blade.
3. Check the condition of the wiper blade and replace it if necessary.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > ADJUSTING WIPER ARM ATTACK
ANGLE
NOTE: Voltage peaks

Information
Wiper system must be in the parking position. Before starting work, allow the wiper system to run 2 - 3
times with water spray.
Special tools: Adjustment device 9737
Fig 1: Identifying Tools
A. Angle measuring device
B. Adapter
C. Angle adjusting tool - holder
D. Angle adjusting tool - arm bracket
1. Fit the adapter -B- flush on the wiper arm and secure with the knurled screw.
Fig 2: Screwing Adapter Onto Wiper Arm
2. Fit the angle measuring device -A- on the adapter and secure with the knurled screw.
Fig 3: Fitting Angle Measuring Device On Adapter
3. Read off wiper arm angle of attack using the angle measuring device and compare with the
nominal values.
Wiper position Nominal angle Tolerance
Parking position on driver's + 4° +/- 1°

side
Parking position on + 6° +/- 1°

passenger's side
4. If the nominal values are not achieved, the wiper arm must be adjusted using the two adjusting
tools.
5. Slide the two angle adjusting tools onto the wiper arm and set the angle as required by turning
the front adjusting tool.
Fig 4: Sliding Angle Adjusting Tools Onto Wiper Arm

1. Install wiper blade.
2. Check wiper function of wiper system.
WM 922519 REMOVING AND INSTALLING WIPER ARM (EXCEPT CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING WIPER ARMS

Information
To counteract the deformation of the wiper rubber that occurs when it is at rest, the wiper arm is
alternately moved to two different parked positions. However, the wiper arm may only be removed and
installed in the lower parked position. Before removing or installing the wiper arm, operate the wiper
once and watch whether the wiper is moved up again slightly into the upper parked position after it has
reached the lower parked position. In this case, operate the wiper again so that the wiper arm is moved
into the lower parked position.
Fig 1: Identifying Wiper Arms Installation Position
NOTE: Voltage peaks
1. Open the front lid and pull off caps -1- .

Fig 2: Removing Fastening Nuts
2. Unscrew and remove fastening nuts -2- .
3. Using → VW VAS 6935 Pole terminal puller , pull wiper arms off the linkage and remove wiper
arms.
Fig 3: Removing Wiper Arms
WM 922519 REMOVING AND INSTALLING WIPER ARM (EXCEPT CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING WIPER ARMS
Information
To counteract the deformation of the wiper rubber that occurs when it is at rest, the wiper arm is
alternately moved to two different parked positions. However, the wiper arm may only be removed and
installed in the lower parked position. Before removing or installing the wiper arm, operate the wiper
once and watch whether the wiper is moved up again slightly into the upper parked position after it has
reached the lower parked position. In this case, operate the wiper again so that the wiper arm is moved
into the lower parked position.
1. Fit wiper arms on the wiper linkage.
2. Adjust dimension -a- for the wiper arm on the driver's side -1- .
Fig 1: Adjusting Dimension For Wiper Arm On Driver's Side
3. Adjust dimension -b- for the wiper arm on the passenger's side -2- .
Driver's side Passenger's side
-a- -b-
59 mm 11 mm
4. Hold the wiper arm by pressing lightly on the cone and fit the fastening nut -2- .
Fig 2: Fitting Fastening Nuts
5. Screw on and tighten fastening nut -2- for the wiper arm.
6. Press on the cap -1- .
7. Actuate the wiper motor until it comes to a stop and check the position of the wiper arm again.
WM 923419 REMOVING AND INSTALLING WIPER MOTOR FOR REAR WINDOW

WIPER SYSTEM (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S,
Remove lower part of trim panel for rear lid. → 708719 REMOVING AND INSTALLING TRIM PANEL
FOR REAR LID
Remove wiper arm for rear window wiper system. → 924119 REMOVING AND INSTALLING WIPER
ARM FOR REAR WINDOW WIPER SYSTEM

CAYENNE (3.0)) > REMOVING > REMOVING WIPER MOTOR FOR REAR WIPER
SYSTEM
Fig 1: Identifying Wiper Motor For Rear Wiper System Installation Position
NOTE: Voltage peaks
1. Release electric plug connection -a- for wiper motor -A- and pull it off in direction of arrow -B-
.
Fig 2: Releasing Electric Plug Connection For Wiper Motor
2. Release water spray line -1- using a screwdriver and remove it.
Fig 3: Removing Water Spray Line Using Screwdriver
3. Unscrew fastening nuts -1- and remove wiper motor -2- .

Fig 4: Removing Wiper Motor Fastening Nuts

CAYENNE (3.0)) > INSTALLING > INSTALLING WIPER MOTOR
1. Position wiper motor -2- .

Fig 1: Installing Wiper Motor
2. Screw on fastening nuts -1- and tighten uniformly.
3. Plug in electric plug connection in direction of arrow until it engages securely.

Fig 2: Inserting Plug Connection
4. Attach water spray line -1- and secure it.

Fig 3: Identifying Water Spray Line

Install wiper arm for rear wiper system. → Installing Wiper Arm For Rear Window Wiper System
Install lower part of rear lid trim panel. → 709219 REMOVING AND INSTALLING TRIM PANEL FOR
TAILGATE
WM 924119 REMOVING AND INSTALLING WIPER ARM FOR REAR WINDOW WIPER
SYSTEM (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S,
CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) >
TOOLS
pole terminal puller Workshop WE 1660

equipment
REMOVING WIPER ARM FOR REAR WINDOW WIPER SYSTEM
CAUTION: Electrically moved components
Danger of limbs being trapped
1. Switch off the wiper actuating mechanism at the steering column, switch off ignition and
remove remote control from the ignition lock.
Information
To position the wiper arm for the rear window wiper system correctly during installation, it must
be at its end position (horizontal).
2. Open the cap -1- (-A- ) and pull it up and off -B- .
Fig 1: Removing Cap
3. Lever the spray nozzle -1- off the wiper shaft using a screwdriver -2- .
Fig 2: Removing Spray Nozzle
4. Screw off fastening nut -1- .
5. Pull wiper arm -2- off the wiper shaft using pole terminal puller WE 1660 .
Fig 3: Removing Wiper Arm
INSTALLING > INSTALLING WIPER ARM FOR REAR WINDOW WIPER SYSTEM
1. Fit wiper arm -2- on the wiper shaft.

Fig 1: Fitting Wiper Arm On Wiper Shaft
2. Tighten fastening nut -1- .
3. Fit spray nozzle -1- onto the wiper shaft -2- and press on until it engages securely.
Fig 2: Fitting Spray Nozzle Onto Wiper Shaft
Information
Before fitting the cap, check the retaining lugs of the cap for damage. The cap must be
replaced in the event of damage or if you have any doubts about it.
4. Fit cap -1- and press on in direction of arrow until it engages securely.
Fig 3: Installing Cap
5. Perform function test on rear wiper and spray nozzle for rear wiper.
WM 925619 REMOVING AND INSTALLING PUMP FOR WINDSCREEN WASHER

PRELIMINARY WORK
1. Detach windscreen-washer reservoir. → 926019 REMOVING AND INSTALLING

WINDSCREEN-WASHER RESERVOIR

REMOVING PUMP FOR WINDSCREEN WASHER SYSTEM
Information
Collect windscreen washer system fluid in a suitable container.

Fig 1: Identifying Pump For Windscreen Washer System Installation Position
1. Release and disconnect water line for the headlight cleaning system. → 927819 REMOVING
AND INSTALLING PUMP FOR HEADLIGHT CLEANING SYSTEM
2. Release and pull off electric plug connection for pump for windscreen washer system -2- .
3. Release and disconnect the two water hoses -3- from the pump.
Fig 3: Pulling Off Water Hoses
4. Pull the windscreen-washer pump up out of the reservoir and rubber sleeve.
Fig 4: Pulling Out Pump

INSTALLING PUMP FOR WINDSCREEN WASHER SYSTEM
Information
Check rubber sleeves and clips and replace them if necessary.
1. Press the pump for the windscreen washer system into the rubber sleeve by turning it back
and forward slightly.
Fig 1: Pressing Pump Into Rubber Sleeve
2. Press the water hoses -3- with the clips over the pump connections.
Fig 2: Pressing Water Hoses Over Connections
3. Plug in and lock electric plug connection for pump for windscreen washer system -2- until it
engages securely.
4. Plug in and lock electric plug connection for the fluid level sensor until it engages securely. →
926719 REMOVING AND INSTALLING FLUID LEVEL SENSOR
5. Clip electric line into the guide until it engages securely.

SUBSEQUENT WORK
1. Install windscreen-washer reservoir. → 926019 REMOVING AND INSTALLING

WM 926019 REMOVING AND INSTALLING RESERVOIR FOR WINDSCREEN WASHER

PRELIMINARY WORK
1. Remove front wheel housing liner at the right. → 505619 REMOVING AND INSTALLING
FRONT WHEEL HOUSING LINER
Only when removing the filler tube:
2. Remove cover for lock support. → 703919 REMOVING AND INSTALLING COVER FOR
FRONT LOCK SUPPORT
3. Remove cover at the right. → 700219 REMOVING AND INSTALLING FRONT TRIM PANEL
(ENGINE COMPARTMENT)
4. Remove the right headlight. → 941519 REMOVING AND INSTALLING HEADLIGHTS

REMOVING RESERVOIR FOR WINDSCREEN WASHER SYSTEM
Information
Information
Check rubber sleeves, clips and water reservoir and replace them if necessary.
1. Pull water pipe off the connection on the pump for the headlight cleaning system. → 927819
REMOVING AND INSTALLING PUMP FOR HEADLIGHT CLEANING SYSTEM
2. Collect any emerging fluid in a suitable container.
3. Pull the filler tube out of the reservoir.

Fig 1: Pulling Filler Tube Out Of Reservoir
4. Support the bottom of the reservoir with your hand and unscrew and remove the two fastening
screws on the reservoir -1- .
Fig 2: Removing Fastening Screws On Reservoir
5. Unclip electric line at the reservoir.
6. Release and pull off electric plug connections -1, 2, 3- .

Fig 3: Removing Electric Plug Connections
7. Release and pull water lines off the connections for the windscreen-washer pump. → 925619
REMOVING AND INSTALLING PUMP FOR WINDSCREEN WASHER SYSTEM
8. Disengage the reservoir and remove it sideways.

INSTALLING RESERVOIR FOR WINDSCREEN WASHER SYSTEM
Information
Check rubber sleeves, clips and water reservoir and replace them if necessary.
1. Check that water pipes and electric lines are routed properly.
2. Fit both water lines to the connections for the windscreen-washer pump using clips. →
Installing Pump For Windscreen Washer System
3. Connect water line to the connection for the headlight cleaning system pump using a clip.
4. Plug in electric plug connections -1, 2, 3- until they engage securely.
5. Clip electric line into the reservoir.
6. Engage the reservoir in the body.
7. Secure the reservoir to the body with the two fastening screws -1- .
Fig 2: Installing Fastening Screws On Reservoir
8. Push the filler tube into the reservoir - use soap suds.

SUBSEQUENT WORK
1. Install front wheel housing liner at the right. → 505619 REMOVING AND INSTALLING FRONT
WHEEL HOUSING LINER
Only when installing the filler tube:
2. Install the right headlight. → 941519 REMOVING AND INSTALLING HEADLIGHTS
3. Install cover at the right. → 700219 REMOVING AND INSTALLING FRONT TRIM PANEL
4. Install cover for lock support. → 703919 REMOVING AND INSTALLING COVER FOR FRONT
LOCK SUPPORT
5. Fill the windscreen-washer reservoir with window cleaner or antifreeze, depending on the
season.
6. Actuate the headlight cleaning system and windscreen washer system several times in order
to bleed the hoses and spray nozzles.
WM 926619 REMOVING AND INSTALLING SPRAY NOZZLE (EXCEPT CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING SPRAY NOZZLE
NOTE: Voltage peaks
Fig 1: Identifying Spray Nozzle Installation Position
1. Lever off spray nozzle -1- using a plastic wedge.

Fig 2: Levering Off Spray Nozzle
2. Release electric plug connection for spray nozzle -a- and pull it off.
3. Release washer-fluid hose -A- and pull it off -B- .

Fig 4: Disconnecting Hose
WM 926619 REMOVING AND INSTALLING SPRAY NOZZLE (EXCEPT CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING SPRAY NOZZLE
Information
The installation position ("L" for left and "R" for right) is marked on the inside of the spray nozzles. The
spray nozzles must be installed in the vehicle according to this marking.
1. Slide in locking mechanism on washer-fluid hose -arrow- .

Fig 1: Sliding In Locking Mechanism
2. Attach washer-fluid hose to the spray nozzle until it engages securely -arrow- .
Fig 2: Clipping In Hose
3. Plug in electric plug connection -1- for spray nozzle in direction of arrow until it engages
securely.
Fig 3: Connecting Electric Plug Connection
4. Fit spray nozzle -1- at the top -A- and clip it in at the bottom -B- .
Fig 4: Fitting Spray Nozzle At Top
5. Check spray nozzle setting and spray pattern.
WM 926719 REMOVING AND INSTALLING FLUID LEVEL SENSOR (EXCEPT

CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S
E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > PRELIMINARY
WORK

E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING
FLUID LEVEL SENSOR
Information

Fig 1: Identifying Fluid Level Sensor Installation Position
1. Release and pull off water line for headlight cleaning system. → 927819 REMOVING AND
INSTALLING PUMP FOR HEADLIGHT CLEANING SYSTEM
2. Release and pull off electric plug connection for sensor -1- .
Fig 2: Pulling Off Electric Plug Connection For Sensor
3. Pull the sensor -1- out of the rubber sleeve by turning it back and forward slightly.
Fig 3: Pulling Out Sensor

E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING
FLUID LEVEL SENSOR
Information
1. The fluid level sensor is installed in reverse order to removal.

E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > SUBSEQUENT
WORK
1. Install front wheel housing liner. → 505619 REMOVING AND INSTALLING FRONT WHEEL
HOUSING LINER
WM 927019 REMOVING AND INSTALLING COVER FOR SPRAY NOZZLE (EXCEPT
COVER FOR SPRAY NOZZLE
Information
Fig 1: Identifying Cover For Spray Nozzle Installation Position
1. Disengage cap on nozzle head.
1. 1.1. Front apron installed: Grasp spray nozzle cover at the sides; the nozzle head
-1- must then be pulled out -A- and held.
2. 1.2. Disengage cap -2- at the latches of the nozzle head -1- (-B- ) and remove it.
Fig 2: Disengaging Cap On Nozzle Head
WM 927019 REMOVING AND INSTALLING COVER FOR SPRAY NOZZLE (EXCEPT

COVER FOR SPRAY NOZZLE
Information
If the cover of the spray nozzle has to be replaced, the new part must be painted the same colour as the
front apron.
1. Engage cap on nozzle head.
1. 1.1. Pull nozzle head -1- out of the front apron -A- and hold it.
2. 1.2. Engage cap -2- at the latches on the nozzle head -1- (-B- ).
Fig 1: Engaging Cap On Nozzle Head
2. Slide nozzle head and cover into the locking teeth on the spray nozzle.
3. Release spray nozzle and check the gap to ensure that the spray nozzle cover is positioned
evenly all the way round.
WM 927219 REMOVING AND INSTALLING SPRAY NOZZLE FOR HEADLIGHT

CLEANING SYSTEM (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S,
1. Remove cover on spray nozzle for headlight cleaning system. → 927019 REMOVING AND
INSTALLING COVER FOR SPRAY NOZZLE
2. Remove front apron. → 631519 REMOVING AND INSTALLING FRONT APRON

CAYENNE (3.0)) > REMOVING SPRAY NOZZLE FOR HEADLIGHT CLEANING SYSTEM
Information
These must be carried out as a mirror image of the steps shown .
2. Unclip spray nozzle for headlight cleaning system -2- from the vent guide -3- (-arrow- ) and
remove it.
Fig 1: Removing Spray Nozzle For Headlight Cleaning System

CAYENNE (3.0)) > INSTALLING SPRAY NOZZLE FOR HEADLIGHT CLEANING
SYSTEM
2. Tighten fastening screws securing spray nozzle for headlight cleaning system to the front
apron.

1. Install front apron. → 631519 REMOVING AND INSTALLING FRONT APRON
2. Install cover on spray nozzle for headlight cleaning system. → 927019 REMOVING AND
INSTALLING COVER FOR SPRAY NOZZLE
3. Actuate the headlight cleaning system several times in order to bleed the hoses and spray
nozzles for the headlight cleaning system.
4. Fill the windscreen-washer reservoir with window cleaner or antifreeze, depending on the
season. Only use windscreen cleaning agents and antifreeze approved by Porsche.
WM 927719 REMOVING AND INSTALLING HOSE FOR HEADLIGHT CLEANING

SYSTEM (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S
WORK

WORK
Fig 1: Identifying Hose Installation Position For Headlight Cleaning System

HOSE FOR HEADLIGHT CLEANING SYSTEM
1. Guide open ends of the hose for the headlight cleaning system into a suitable container,
remove hose clamp and drain windscreen-washer reservoir.
Fig 1: Removing Hose Clamp
2. Release hose for headlight cleaning system -1- at the headlight cleaning system pump -a-
and pull it off.
3. Unclip and remove hose for headlight cleaning system -1- at the windscreen-washer reservoir.
Fig 2: Identifying Headlight Cleaning System At Windscreen-Washer Reservoir
4. Check O-ring on the headlight cleaning system pump for damage and make sure that it is
seated correctly.

HOSE FOR HEADLIGHT CLEANING SYSTEM

WORK
2. Install front wheel housing liner at the right. → 505619 REMOVING AND INSTALLING FRONT
WHEEL HOUSING LINER
WM 927819 REMOVING AND INSTALLING PUMP FOR HEADLIGHT CLEANING
PRELIMINARY WORK
1. Loosen reservoir for windscreen washer system. → 926019 REMOVING AND INSTALLING
RESERVOIR FOR WINDSCREEN WASHER SYSTEM

REMOVING PUMP FOR HEADLIGHT CLEANING SYSTEM
Information
Fig 1: Identifying Installation Position Pump For Headlight Cleaning System
1. Unclip electric line.
2. Release and pull off electric plug connection for fluid level sensor. → 926719 REMOVING AND
INSTALLING FLUID LEVEL SENSOR
3. Pull off water hose for headlight cleaning system.

Fig 2: Pulling Off Water Hose For Headlight Cleaning System
4. Release and pull off electric plug connection.

5. Pull the pump out of the rubber sleeve by turning it back and forward slightly.
Fig 4: Pulling Off Pump

INSTALLING PUMP FOR HEADLIGHT CLEANING SYSTEM
Information
1. Press the pump into the rubber sleeve by turning it back and forward slightly.
Fig 1: Pressing In Pump
2. Plug in and lock electric plug connection.

3. Clip electric line into the washer-fluid reservoir.
4. Press water hose for headlight cleaning system with the clip onto the pump connection.
Fig 3: Fitting Water Hose
5. Plug in and lock electric plug connection for fluid level sensor. → 926719 REMOVING AND
INSTALLING FLUID LEVEL SENSOR

SUBSEQUENT WORK
1. Secure reservoir for windscreen washer system. → Installing Reservoir For Windscreen
Washer System
Service Manual: 50 - BODY FRONT -- 92A CAYENNE
WM 501855 REPLACING FRAME HEAD (IMPACT ABSORBER MOUNT) > TOOLS
Hot-air blower,
Workshop
Leister-Electron/VAG WE 1119
Equipment
1416
Body Straightening Workshop

WE 1121
System, Celette Equipment
WE 1122
System, Car Bench Equipment
Special Electric Workshop

WE 1137
Cutter - Fine Equipment
Pneumatic Spotweld
Workshop
Remover, Vario Drill WE 1139
Equipment
WS 90
Cartridge Gun VAG Workshop

WE 1141
1628 Equipment
Body saw VAG Workshop

WE 1347
1523A Equipment
Star gauges for body
Special tool Nr.127-1
gap dimensions
Commercially
Spotweld drill Nr.129
available tool
Commercially
Twist drill Nr.201
available tool
WM 501855 REPLACING FRAME HEAD (IMPACT ABSORBER MOUNT) >

PRELIMINARY WORK > PRELIMINARY WORK FOR BODY REPAIRS WITH
ALIGNMENT BENCH
1. Remove accessories in the repair area.
1. 1.1. Remove accessories in the repair area according to the extent of damage to the
vehicle.
2. Set up straightening bench with straightening set.
1. 2.1. Equip alignment bench with the basic straightening attachments according to the
plans included with the straightening attachments.
3. Set vehicle on straightening bench.

Information
1. As a result of the joint which seals the side member, the vehicle must not be secured to
the straightening bench with quick-acting claws.
1. 3.1. Position vehicle on straightening bench, align according to the reference holes
and bolt firmly with the straightening set.
4. Cover the accessories adjacent to the repair area on the vehicle.
1. 4.1. Cover all accessories remaining on the vehicle and adjacent areas with fire-proof
protective covers.
5. Reshape connection area of the sheetmetal parts to be replaced.
6. Expose welding areas.
1. 6.1. Remove undersealing, paint, etc. from the welding areas of the body with a
hot-air gun or rotary brush.
WM 501855 REPLACING FRAME HEAD (IMPACT ABSORBER MOUNT) > SAFETY

INSTRUCTIONS AND INFORMATION ON QUALITY
CAUTION: Non-observance of safety instructions for body repairs
Danger of injury
→ Read the relevant safety instructions as well as general information and quality instructions → WM
5X00IN SAFETY INSTRUCTIONS (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S,
CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE (3.0))
Tools and metalworking tools for body repairs
WM 501855 REPLACING FRAME HEAD (IMPACT ABSORBER MOUNT) > TOOLS AND
MATERIALS > TOOLS AND MATERIALS FOR BODY REPAIRS
Straightening set 92A Cayenne; see Body Straightening System, Celette WE 1121 Body
Straightening System, Car Bench WE 1122
Resistance spot welder
Metal inert gas (MIG) welder
Pneumatic spotweld remover Pneumatic Spotweld Remover, Vario Drill WS 90 WE 1139 .
Pneumatic body saw Body saw VAG 1523A WE 1347
Oscillating body saw (special electric cutter) Special Electric Cutter - Fine WE 1137 .
Rotary brush
Leister Electron hot-air blower Hot-air blower, Leister-Electron/VAG 1416 WE 1119 .

Cartridge gun Cartridge gun VAG 1628 WE 1141 .
Spotweld drill Spotweld drill .
Twist drill Twist drill Nr.201 .
Star gauge for body gap dimensions Star gauges for body gap dimensions Nr.127-1 .
Support adhesive
Structural adhesive
WM 501855 REPLACING FRAME HEAD (IMPACT ABSORBER MOUNT) > REMOVING

FRAME HEAD (IMPACT ABSORBER MOUNT)
Fig 1: Identifying Frame Head (Impact Absorber Mount)
Information
All straightening work on the body in the connection area of the sheetmetal parts to be replaced
must be completed before the damaged parts are removed.
1. Remove frame head (impact absorber mount).
1. 1.1. Grind down the MIG-welded joints between the frame head (impact absorber
mount) and top side member using the parting grinder → see Fig 2 (areas -A- , -B- ,
-C- , -D- ).
Fig 2: Identifying MIG-Welded Joints Between Frame Head - Impact Absorber Mount
(1 Of 5)
(2 Of 5)

(3 Of 5)

(4 Of 5)

(5 Of 5)
2. Remove frame head (impact absorber mount).

Fig 7: Removing Frame Head (Impact Absorber Mount)
WM 501855 REPLACING FRAME HEAD (IMPACT ABSORBER MOUNT) > PREPARING

FRAME HEAD (IMPACT ABSORBER MOUNT) FOR INSTALLATION
Fig 1: Identifying Frame Head (Impact Absorber Mount) Welding And Sealing Areas
1. Clean welding and sealing areas.
1. 1.1. Grind both sides of the connection flange of the new parts in the marked areas
-F- and -G- until bare using a rotary brush.
WM 501855 REPLACING FRAME HEAD (IMPACT ABSORBER MOUNT) > PREPARING

CONNECTION AREAS OF THE BODY FOR INSTALLING THE FRAME HEAD (IMPACT
ABSORBER MOUNT)
1. 1.1. Clean the body connection flanges of undersealing, adhesive residue and paint
in the marked areas using a hot-air gun or rotary brush. Grind the connection flange
until bare.
Fig 1: Identifying Body Connection Areas (1 Of 2)

Fig 2: Identifying Body Connection Areas (2 Of 2)
2. Coat spot-weld flange areas with zinc powder paint.
1. 2.1. Coat all spot-weld flange areas with zinc powder paint.
WM 501855 REPLACING FRAME HEAD (IMPACT ABSORBER MOUNT) > INSTALLING

FRAME HEAD (IMPACT ABSORBER MOUNT)
1. Fit the frame head (impact absorber mount) to the body.
1. 1.1. Position the frame head (impact absorber mount) against the body and fix in
place with a straightening attachment.
Fig 1: Installing Frame Head (Impact Absorber Mount)
2. 1.2. Fix the frame head (impact absorber mount) to the body with tensioning clamps.
2. Weld the frame head (impact absorber mount) using the inert-gas arc welding process → see
Fig 2.
Fig 2: Identifying Frame Head (Impact Absorber Mount) To Body
1. 2.1. Apply a full weld to the frame head (impact absorber mount) in the areas -A- ,
-B- , -C- and -D- using inert gas.
Fig 3: Identifying Frame Head Welded Areas (1 Of 4)



WM 501855 REPLACING FRAME HEAD (IMPACT ABSORBER MOUNT) >

SUBSEQUENT WORK > SUBSEQUENT WORK FOR BODY REPAIRS
1. Remove vehicle from the alignment bench.
2. Clean welded joints and sheetmetal flanges with a wire brush.
3. Prime flange areas with 2K primer.
4. Restore standard seal with body sealant
5. Restore standard undersealing with underbody sealant
6. Paint repair area and adjacent surfaces, if necessary.
7. Apply cavity preservation to the accessible areas of the repair.
8. Install removed accessories in the repair area.

WM 503819 REMOVING AND INSTALLING LOCK CARRIER > TECHNICAL VALUES
Basic Tolerance
Location Description Type Tolerance 1
value 2
Tightening 12 Nm (9 +/-1 Nm (+/-0.5

Lock carrier to bumper
torque ftlb.) ftlb.)
Lock carrier to upper Tightening 5 Nm (3.5 +/-0.5 Nm (+/-0.5

radiator holder torque ftlb.) ftlb.)
Tightening 8 Nm (6 +/-0.5 Nm (+/-0.5

Lock carrier to upper body
Tightening 9 Nm (6.5 +/-1 Nm (+/-0.5

Lock support to bumper
WM 503819 REMOVING AND INSTALLING LOCK CARRIER > PRELIMINARY WORK

BATTERY
2. Remove front apron. → REMOVING FRONT APRON - section on "Removing"
3. Remove front retaining strips. → REMOVING FRONT RETAINING STRIP - section on

"Removing"
4. Remove lower part of front lid lock. → REMOVING LOWER PART OF FRONT LID LOCK -
section on "Removing"
5. Remove horn. → REMOVING HORN - section on "Removing"
6. Remove distance measuring sensor. → REMOVING CONTROL UNIT FOR DISTANCE

MEASURING SENSOR - section on "Removing"
7. Only With Charge Air Cooler
Detach the charge air cooler at the top of the lock carrier. → REMOVING CHARGE-AIR
COOLER - section on "Removing"
WM 503819 REMOVING AND INSTALLING LOCK CARRIER > REMOVING LOCK

CARRIER
Information
Some of the repair illustrations show only one side of the vehicle.
Naturally, some steps also have to be performed on the opposite side of the vehicle as well.
These must be carried out as a mirror image of the steps shown for the front and rear.
1. Pull air intake pipe (two on the V8) and sound absorber forward out of the lock carrier.
To facilitate removal, first pull out the sound absorber and then pull the air intake pipe out of
the air cleaner housing by turning it.
Fig 1: Removing Air Guide
2. Unscrew fastening screw -1- and remove the lock support in an upward direction.
Fig 2: Identifying Lock Support Fastening Screws
3. Loosen the lock carrier.
1. 3.1. Unscrew fastening screws -2- for the bumper.

Fig 3: Identifying Lock Carrier Fastening Screws
2. 3.2. Unscrew fastening screw -3- for the radiator at the top.
3. 3.3. Unscrew fastening screw -4- for the body.
4. Press the actuating cable -5- for the lid lock at the bottom back through the lock carrier.
Fig 4: Identifying Actuating Cable
5. Disconnect electric plug connections.
1. 5.1. Release and disconnect electric plug connection -6- for the wire harness on the
left side.
Fig 5: Identifying Electric Plug Connections At Left
2. 5.2. Unclip electric plug connections (if additional equipment is fitted) -7- on the left
side from the bracket and release and disconnect them.
3. 5.3. Release and disconnect electric plug connection -8- on the right side.
Fig 6: Identifying Electric Plug Connections On Right
4. 5.4. Unclip temperature sensor from the air guide.
6. Remove lock carrier.
WM 503819 REMOVING AND INSTALLING LOCK CARRIER > INSTALLING LOCK

CARRIER
1. Place lock carrier over the air guide and position it.
2. Press the actuating cable -5- for the lid lock at the bottom front forward through the lock
carrier.
Fig 1: Identifying Actuating Cable
3. Connect electric plug connections.
1. 3.1. Plug in electric plug connections -6- for the wire harness on the left side and
lock them until they engage securely.
Fig 2: Identifying Electric Plug Connections At Left
2. 3.2. Plug in electric plug connections (for additional equipment) -7- on the left side
and lock them until they engage securely.
3. 3.3. Clip electric plug connections (for additional equipment) -7- into the bracket.
4. 3.4. Plug in electric plug connections -8- on the right side and lock them until they
engage securely.
Fig 3: Identifying Electric Plug Connections On Right
5. 3.5. Clip temperature sensor into the air guide.
4. Secure lock carrier.
1. 4.1. Screw in fastening screws -2- , -3- and -4- .

Fig 4: Identifying Lock Carrier With Fastening Screws
2. 4.2. Tighten fastening screws -2- for the bumper to → Tightening torque: 12 Nm (9
ftlb.)+/-1 Nm (+/-0.5 ftlb.) .
3. 4.3. Tighten fastening screw -3- for the radiator to → Tightening torque: 5 Nm (3.5
ftlb.)+/-0.5 Nm (+/-0.5 ftlb.) .
4. 4.4. Tighten fastening screw -4- for the body to → Tightening torque: 8 Nm (6
ftlb.)+/-0.5 Nm (+/-0.5 ftlb.) .
5. Insert lock support and tighten fastening screw -1- to → Tightening torque: 9 Nm (6.5
ftlb.)+/-1 Nm (+/-0.5 ftlb.) .
Fig 5: Identifying Lock Support Screw
6. Insert air intake pipe (two on the V8) and sound absorber into the air cleaner housing through
the lock carrier.
To facilitate fitting, first fit the air intake pipe into the air cleaner housing by turning it and then
insert the sound absorber.
Check that they are seated securely on the air cleaner housing.
Fig 6: Installing Air Guide
WM 503819 REMOVING AND INSTALLING LOCK CARRIER > SUBSEQUENT WORK
1. Only with charge air cooler
Secure the charge air cooler at the top of the lock carrier. → INSTALLING CHARGE-AIR
COOLER - section on "Installing"
2. Install horn. → INSTALLING HORN - section on "Installing"
3. Install distance measuring sensor. → INSTALLING CONTROL UNIT FOR DISTANCE

MEASURING SENSOR - section on "Installing"
4. Install lower part of front lid lock. → INSTALLING LOWER PART OF FRONT LID LOCK -
section on "Installing"
5. Install front retaining strips. → INSTALLING FRONT RETAINING STRIP - section on

"Installing"
6. Install front apron. → INSTALLING FRONT APRON - section on "Installing"
7. Connect the battery. → CONNECTING THE BATTERY
WM 503955 REPLACING SPRING STRUT MOUNT > TOOLS

Hot-air blower,
Workshop
Equipment
1416

WE 1121
WE 1122

WE 1137
Pneumatic Spotweld
Workshop
Equipment
WS 90
Cartridge gun VAG Workshop

WE 1141
1628 Equipment

WE 1347
1523A Equipment
gap dimensions
Commercially
available tool
Commercially
Twist drill Nr.201
available tool
WM 503955 REPLACING SPRING STRUT MOUNT > PRELIMINARY WORK >

PRELIMINARY WORK FOR BODY REPAIRS WITH STRAIGHTENING BENCH
vehicle.
1. 2.1. Equip straightening bench with the straightening attachments according to the
setup plans included with the straightening attachments.
1. 3.1. Position vehicle on the straightening bench, align according to the reference
holes and bolt firmly to the straightening attachments.
protective covers.
1. 6.1. Remove undersealing, paint, etc. from the welding areas of the body.
WM 503955 REPLACING SPRING STRUT MOUNT > SAFETY INSTRUCTIONS AND

INFORMATION ON QUALITY
Danger of injury
→ Read the relevant safety instructions as well as general information and quality instructions
Tools and metalworking tools
WM 503955 REPLACING SPRING STRUT MOUNT > TOOLS AND MATERIALS >
TOOLS AND MATERIALS FOR BODY REPAIRS
Straightening set 92A Cayenne Body Straightening System, Celette WE 1121 Body Straightening
System, Car Bench WE 1122
Rotary brush
Support adhesive
Structural adhesive
WM 503955 REPLACING SPRING STRUT MOUNT > REMOVING SPRING STRUT

MOUNT
1. Grind down spotwelds.

Fig 1: Removing Spring Strut Mount

2. Loosen welded joints.
Fig 2: Identifying Spring Strut Mount Welded Joints
1. 2.1. Grind down spotwelds.
2. 2.2. Grind down MIG seams.

1. 3.1. Grind down spotwelds in the area -A- through two plate thicknesses.


Fig 5: Identifying Spring Strut Mount Spotwelds (Right)
6. Heat connection areas using a hot-air gun.

Fig 6: Identifying Spring Strut Mount Plug Weld (Left)
7. Remove spring strut mount.
WM 503955 REPLACING SPRING STRUT MOUNT > PREPARING SPRING STRUT

MOUNT FOR INSTALLATION
1. Drill out spotwelds using spotweld drill bit and remove plenum panel closing element.
Fig 1: Identifying Spring Strut Mount (Right)
2. Drill holes (Ø 10 mm) for plug welding using inert gas.

Fig 2: Identifying Spring Strut Mount Drill Holes (Right)

Fig 3: Identifying Spring Strut Mount Drill Holes (Left)
3. Grind both sides of connecting flanges of spring strut mount in the marked areas until bare.
Fig 4: Identifying Connecting Flanges Spring Strut Mount (Right)

Fig 5: Identifying Connecting Flanges Spring Strut Mount (Left)
WM 503955 REPLACING SPRING STRUT MOUNT > PREPARING CONNECTION

AREAS OF BODY FOR INSTALLING SPRING STRUT MOUNT

Fig 1: Identifying Body Welding And Sealing Areas
1. 1.1. Clean the body connecting flanges of underbody protection, adhesive residue
and paint in the marked areas.
2. 1.2. Grind the connecting flanges until bare on both sides.
WM 503955 REPLACING SPRING STRUT MOUNT > INSTALLING SPRING STRUT

MOUNT
1. Fit and secure spring strut mount.
2. Weld in spring strut mount.

Fig 1: Installing Spring Strut Mount
1. 2.1. Plug-weld spring strut mount using inert gas.
2. 2.2. Also spot-weld spring strut mount using inert gas.
3. 2.3. Resistance spot-weld spring strut mount in the area -A- .

Fig 2: Identifying Weld In Spring Strut Mount
1. 3.1. Resistance spot-weld spring strut mount.
2. 3.2. Spot-weld spring strut mount using inert gas.


1. 5.1. Resistance spot-weld spring strut mount in the area -A- .

2. 6.2. Spot-weld spring strut mount using inert gas.
WM 503955 REPLACING SPRING STRUT MOUNT > SUBSEQUENT WORK >

SUBSEQUENT WORK FOR BODY REPAIRS

WM 504155 REPLACING WING STRUT > TOOLS
Hot-air blower,
Workshop
Equipment
1416

WE 1121
WE 1122

WE 1137
Pneumatic Spotweld
Workshop
Equipment
WS 90

WE 1141
1628 Equipment

WE 1347
1523A Equipment
gap dimensions
Commercially
available tool
Commercially
Twist drill Nr.201
available tool
WM 504155 REPLACING WING STRUT > PRELIMINARY WORK > PRELIMINARY

WORK FOR BODY REPAIRS (WITHOUT STRAIGHTENING BENCH)
Information
If it can be ensured there has been no deformation of the vehicle structure, the following repair can
be carried out without the need of a straightening bench. In this case, the vehicle must not be
raised when welding the component; it must stand on its wheels on an even surface.
vehicle.

protective covers.
4. Expose joint areas.
1. 4.1. Remove underbody protection, paint, etc. from the joint areas of the body.
WM 504155 REPLACING WING STRUT > SAFETY INSTRUCTIONS AND

Danger of injury
WM 504155 REPLACING WING STRUT > TOOLS AND MATERIALS > TOOLS AND
MATERIALS FOR BODY REPAIRS
Rotary brush
Support adhesive
Structural adhesive
WM 504155 REPLACING WING STRUT > REMOVING WING STRUT
1. Remove lock carrier. → REMOVING LOCK CARRIER - section on "Removing"
2. Remove headlight mounting bracket.
1. 2.1. Unscrew screws -1- and remove bracket -2- .

Fig 1: Identifying Headlight Mounting Bracket Screws
3. Loosen welded joints for wing strut on lower longitudinal member.
Information
Drill out spotweld A through three plate thicknesses.
1. 3.1. Drill out spotweld -A- .

Fig 2: Identifying Drill Out Spotweld On Wing Strut
Information
Drill out spotwelds B on one side only. Do not damage the plate underneath!
2. 3.2. Drill out spotwelds -B- .
3. 3.3. Grind down MIG seams -C- .
4. Loosen welded joints for wing strut on longitudinal member for wheel housing upper section.
1. 4.1. Drill out spotwelds -A- using Spotweld Drill .

Fig 3: Identifying Drill Out Spotweld On Wing Strut
Information
5. Remove wing strut.
WM 504155 REPLACING WING STRUT > PREPARING WING STRUT FOR

INSTALLATION
1. Clean the welding areas.
1. 1.1. Grind both sides of the connecting flanges of the wing strut in the marked areas
until bare.
Fig 1: Identifying Welding Areas Wing Strut
2. 1.2. Drill holes for plug-welding using inert gas on the lower longitudinal member
using an 8.0-mm drill bit.
2. Coat all spot-weld flange areas with zinc powder paint.
WM 504155 REPLACING WING STRUT > PREPARING CONNECTION AREAS OF THE

BODY FOR INSTALLING WING STRUT
1. 1.1. Clean the body connecting flange in the marked areas to remove underbody
protection and paint.
Fig 1: Identifying Drill Holes For Plug-Welding On Wing Strut
2. 1.2. Drill holes -1- for plug-welding using inert gas at the wheel housing using an
8.0-mm drill bit.
3. 1.3. Drill out hole -2- for plug-welding using inert gas on the lower longitudinal
member using an 8.0-mm drill bit.
4. 1.4. Grind connecting flanges until bare on both sides.
WM 504155 REPLACING WING STRUT > INSTALLING WING STRUT
1. Fit and secure the wing strut.
2. Install wing strut on lower longitudinal member.
1. 2.1. Plug-weld the wing strut using inert gas -A- .

Fig 1: Identifying Plug-Weld On Wing Strut
2. 2.2. Spot-weld the wing strut using inert gas -B- .
3. Install wing strut on longitudinal member for wheel housing upper section.
1. 3.1. Resistance spot-weld the wing strut -A- .

Fig 2: Identifying Resistance Spot-Weld Wing Strut
2. 3.2. Plug-weld longitudinal member for wheel housing upper section to the wing strut
-B- using inert gas.
4. Install headlight mounting bracket.
1. 4.1. Insert bracket -2- and screw in and tighten screws -1- .
Fig 3: Identifying Headlight Mounting Bracket Screws
5. Install lock carrier. → INSTALLING LOCK CARRIER - section on "Installing"
WM 504155 REPLACING WING STRUT > SUBSEQUENT WORK > SUBSEQUENT

WORK FOR BODY REPAIRS (WITHOUT STRAIGHTENING SYSTEM)
1. Prime joint areas and sheetmetal flanges with 2K primer.
Also seal the repair area carefully.
4. Apply standard cavity preservation . Also carefully apply cavity preservation to the repair area.
WM 505355 REPLACING CONNECTION PANEL FOR WING > TOOLS

Hot-air blower,
Workshop
Equipment
1416

WE 1121
WE 1122

WE 1137
Pneumatic Spotweld
Workshop
Equipment
WS 90

WE 1141
1628 Equipment

WE 1347
1523A Equipment
gap dimensions
Commercially
available tool
Commercially
Twist drill Nr.201
available tool
WM 505355 REPLACING CONNECTION PANEL FOR WING > SAFETY INSTRUCTIONS

AND INFORMATION ON QUALITY
Danger of injury
WM 505355 REPLACING CONNECTION PANEL FOR WING > TOOLS AND

Rotary brush
Support adhesive
Structural adhesive
WM 505519 REMOVING AND INSTALLING WING > TOOLS
star gauges for body gap Special

NR.127-1
dimensions tool
WM 505519 REMOVING AND INSTALLING WING > TECHNICAL VALUES
Basic Tolerance
value 2
Screw, M6 x 16, Tightening 9 Nm (6.5 +/-1 Nm (+/-0.5
Wing to A-pillar
Item 1 torque ftlb.) ftlb.)
Fastening screws for wing
Top of wing to longitudinal Screw, M6 x 16, Tightening 9 Nm (6.5 +/-1 Nm (+/-0.5

member Item 2 torque ftlb.) ftlb.)
Front side wing to Screw, M6 x 16, Tightening 9 Nm (6.5 +/-1 Nm (+/-0.5

longitudinal member Item 3 torque ftlb.) ftlb.)
Lower part of wing to door Screw, M6 x 16, Tightening 9 Nm (6.5 +/-1 Nm (+/-0.5
sill Item 4 torque ftlb.) ftlb.)
WM 505519 REMOVING AND INSTALLING WING > PRELIMINARY WORK
2. Remove front wheel. → 440519 REMOVING AND INSTALLING WHEEL
3. Remove front wheel housing liner. → 505619 REMOVING AND INSTALLING FRONT WHEEL
HOUSING LINER
4. Remove front wheel cover. → 661919 REMOVING AND INSTALLING FRONT WHEEL
COVER
5. Remove wing trim panel. → 661819 REMOVING AND INSTALLING WING TRIM PANEL
6. Remove headlight. → 941519 REMOVING AND INSTALLING HEADLIGHTS
7. Remove front retaining strip at the sides. → 631719 REMOVING AND INSTALLING FRONT
RETAINING STRIP
9. Right wing: Remove windscreen-washer reservoir. → 926019 REMOVING AND INSTALLING

10. Left wing, for vehicles with auxiliary heating: Remove complete auxiliary heating. → 822019
REMOVING AND INSTALLING COMPLETE AUXILIARY HEATING
WM 505519 REMOVING AND INSTALLING WING > REMOVING WING
Information
1. Unscrew fastening screws -1- securing wing to A-pillar.

Fig 1: Identifying Wing To A-Pillar Fastening Screws
2. Unscrew fastening screws -2- securing top of wing to longitudinal member.

Fig 2: Identifying Wing To A-Pillar Fastening Screws (Top Of Wing To Longitudinal Member)
3. Unscrew fastening screws -3- securing front wing at the side to longitudinal member.
Fig 3: Identifying Wing To A-Pillar Fastening Screws (Side To Longitudinal Member)
4. Loosen door entry guard at the front. → 663119 REMOVING AND INSTALLING DOOR
ENTRY GUARD
5. Press door entry guard down carefully and unscrew fastening screws -4- securing lower part
of wing to door sill.
Fig 4: Identifying Wing To A-Pillar Fastening Screws (Lower Part Of Wing To Door Sill)
6. Carefully separate wing from the sealant on the A-pillar and remove it.
WM 505519 REMOVING AND INSTALLING WING > INSTALLING WING
Information
Set gap dimensions on the lids, doors and covers, or accessories in accordance with the gap
specifications.
Given a clearance in the openings that is too great or too small, the movable body parts or the
accessories must be centred accordingly.
Ensure that the gaps do not run in a wedge-shaped fashion or do not narrow at local points .
You can use star gauges for body gap dimensions NR.127-1 for this.
The given values are guidelines which should be observed as far as possible.
The guidelines apply to repair and assembly work.
1. Remove old sealant from contact surface of wing at the A-pillar.
2. If you intend to re-use the wing, remove old sealant and old expanded sealant from the contact
surface on the wing.
3. Apply new expanded sealant -1- on the wing.
1. 3.1. Clean and degrease the contact surface for the expanded sealant -1- on the
wing.
2. 3.2. Stick new expanded sealant -1- along the cut on the wing.
3. 3.3. Left wing: Trim projecting expanded sealant -1- on the lower edge of the wing.
Fig 1: Identifying Expanded Sealant On Lower Edge Of Wing
4. Carefully fit the wing on the longitudinal member and screw in fastening screws -1, 2, 3, 4-
hand-tight.
Fig 2: Identifying Wing Fastening Screws On Hand-Tight
5. Adjust gap dimensions and offset from wing to adjacent components. → 5X00IN DIAGRAM -
BODY GAP DIMENSIONS
6. Tighten fastening screws -1- securing wing to A-pillar. Tightening torque 9 Nm (6.5 ftlb.) +/-1
Nm (+/-0.5 ftlb.)
Fig 3: Identifying Fastening Screws Wing To A-Pillar
7. Tighten fastening screws -2- securing top of wing to longitudinal member. Tightening torque
9 Nm (6.5 ftlb.) +/-1 Nm (+/-0.5 ftlb.)
Fig 4: Identifying Wing To A-Pillar Fastening Screws (Top Of Wing To Longitudinal Member)
8. Tighten fastening screws -3- securing front wing at the side to longitudinal member.
Tightening torque 9 Nm (6.5 ftlb.) +/-1 Nm (+/-0.5 ftlb.)
Fig 5: Identifying Wing To A-Pillar Fastening Screws (Side To Longitudinal Member)
9. Press door entry guard -1- down carefully and tighten fastening screws -4- securing lower
part of wing to door sill. Tightening torque 9 Nm (6.5 ftlb.) +/-1 Nm (+/-0.5 ftlb.)
Fig 6: Identifying Door Entry Guard Fastening Screws (Lower Part Of Wing To Door Sill)
10. Seal inner wing to A-pillar in the area shown using spray-on sealant.
Fig 7: Identifying Sealant Applying Inner Wing To A-Pillar
WM 505519 REMOVING AND INSTALLING WING > SUBSEQUENT WORK
1. Left wing, for vehicles with auxiliary heating: Install complete auxiliary heating. → 822019
REMOVING AND INSTALLING COMPLETE AUXILIARY HEATING
2. Right wing: Install windscreen-washer reservoir. → 926019 REMOVING AND INSTALLING

4. Install front retaining strip at the sides. → 631719 REMOVING AND INSTALLING FRONT
RETAINING STRIP
5. Install headlight. → 941519 REMOVING AND INSTALLING HEADLIGHTS
6. Install wing trim panel. → 661819 REMOVING AND INSTALLING WING TRIM PANEL
8. Install front wheel cover. → 661919 REMOVING AND INSTALLING FRONT WHEEL COVER
9. Install front wheel housing liner. → 505619 REMOVING AND INSTALLING FRONT WHEEL
HOUSING LINER
10. Fit front wheel. → 440519 REMOVING AND INSTALLING WHEEL
WM 505619 REMOVING AND INSTALLING FRONT WHEEL HOUSING LINER >

REMOVING FRONT WHEEL HOUSING LINER
Information
Fig 1: Identifying Front Wheel Housing Liner Installation Position
2. Unscrew fastening nuts -3- .
3. Unclip and remove wheel housing liner -1- .
WM 505619 REMOVING AND INSTALLING FRONT WHEEL HOUSING LINER >

The front wheel housing liner is installed in reverse order to removal.
WM 507255 REPLACING LONGITUDINAL MEMBER FOR WHEEL HOUSING UPPER

SECTION > TOOLS

Hot-air blower,
Workshop
Equipment
1416

WE 1121
WE 1122

WE 1137
Pneumatic Spotweld
Workshop
Equipment
WS 90

WE 1141
1628 Equipment

WE 1347
1523A Equipment
gap dimensions
Commercially
available tool
Commercially
Twist drill Nr.201
available tool

SECTION > PRELIMINARY WORK > PRELIMINARY WORK FOR BODY REPAIRS
(WITHOUT STRAIGHTENING BENCH)
Information
vehicle.
protective covers.

SECTION > SAFETY INSTRUCTIONS AND INFORMATION ON QUALITY
Danger of injury

SECTION > TOOLS AND MATERIALS > TOOLS AND MATERIALS FOR BODY
REPAIRS
Resistance spot welder; see *** Gr. 3.5; Workshop Equipment Manual.
Rotary brush
Support adhesive
Structural adhesive

SECTION > REMOVING SIDE MEMBER FOR WHEEL HOUSING UPPER SECTION >
REMOVING LONGITUDINAL MEMBER FOR WHEEL HOUSING UPPER SECTION
1. Remove lock carrier. → REMOVING LOCK CARRIER - section on "Removing"
2. Remove headlight mounting bracket.
1. 2.1. Unscrew screws -1- and remove bracket -2- .

Fig 1: Identifying Headlight Mounting Bracket With Screws
3. Remove the wing. → REMOVING WING - section on "Removing"
4. Loosen welded joints on longitudinal member for wheel housing upper section at the wing
strut.
Information
1. 4.1. Drill out spotwelds -B- using Spotweld Drill .

Fig 2: Identifying Drill Out Spotwelds On Wing Strut
5. Remove welded joints on longitudinal member for wheel housing upper section at the wheel
housing.
1. 5.1. Drill out spotwelds -A- using Spotweld Drill .

Fig 3: Identifying Drill Out Spotwelds On Wing Strut
Information

3. 5.3. Grind down MIG seams -C- .
6. Remove longitudinal member for wheel housing upper section.

SECTION > PREPARING SIDE MEMBER FOR INSTALLING WHEEL HOUSING UPPER
SECTION > PREPARING LONGITUDINAL MEMBER FOR WHEEL HOUSING UPPER
SECTION FOR INSTALLATION
1. 1.1. Grind both sides of the connecting flanges of the longitudinal member for the
wheel housing upper section -1- in the marked areas until bare.
Fig 1: Identifying Drill Holes On Longitudinal Member For Wheel Housing Upper
Section
2. 1.2. Drill holes -B- for plug-welding using inert gas at the wing strut using an 8.0 mm
drill bit.

SECTION > PREPARING CONNECTION AREAS OF BODY FOR INSTALLING
LONGITUDINAL MEMBER FOR WHEEL HOUSING UPPER SECTION
1. 1.1. Clean the body connecting flange in the marked areas to remove underbody
protection and paint.
Fig 1: Identifying Welding And Sealing Areas On Wheel Housing Upper Section
2. 1.2. Drill holes -B- for plug-welding using inert gas at the wheel housing using an
8.0-mm drill bit.
3. 1.3. Grind connecting flanges until bare on both sides.

SECTION > INSTALLING SIDE MEMBER FOR WHEEL HOUSING UPPER SECTION >
INSTALLING LONGITUDINAL MEMBER FOR WHEEL HOUSING UPPER SECTION
1. Fit and secure longitudinal member for wheel housing upper section.
2. Install longitudinal member for wheel housing upper section -1- at the wing strut -2- .
1. 2.1. Resistance spot-weld longitudinal member for wheel housing upper section -A- .
Fig 1: Identifying Resistance Spot-Weld Longitudinal Member For Wheel Housing
Upper Section
2. 2.2. Plug-weld longitudinal member for wheel housing upper section to the wing strut
-B- using inert gas.
3. Install longitudinal member for wheel housing upper section -1- at the wheel housing.
1. 3.1. Resistance spot-weld longitudinal member for wheel housing upper section -A- .
Fig 2: Identifying Resistance Spot-Weld Longitudinal Member For Wheel Housing
Upper Section
2. 3.2. Spot-weld longitudinal member for wheel housing upper section -C- using inert
gas.
3. 3.3. Plug-weld wheel housing to longitudinal member for wheel housing upper
section -B- using inert gas.
4. Install wing. → INSTALLING WING - section on "Installing"
5. Install headlight mounting bracket.
1. 5.1. Insert bracket -2- and screw in and tighten screws -1- .
Fig 3: Identifying Headlight Mounting Bracket With Screws
6. Install lock carrier. → INSTALLING LOCK CARRIER - section on "Installing"

SECTION > SUBSEQUENT WORK > SUBSEQUENT WORK FOR BODY REPAIRS
(WITHOUT STRAIGHTENING SYSTEM)
2. Restore standard seal with body sealant .
WM 507455 REPLACING FRONT WHEEL HOUSING > TOOLS
Hot-air blower,
Workshop
Equipment
1416

WE 1121
WE 1122

WE 1137
Pneumatic Spotweld
Workshop
Equipment
WS 90

WE 1141
1628 Equipment

WE 1347
1523A Equipment
gap dimensions
Commercially
available tool
Commercially
Twist drill Nr.201
available tool
WM 507455 REPLACING FRONT WHEEL HOUSING > PRELIMINARY WORK >

PRELIMINARY WORK FOR BODY REPAIRS (WITHOUT STRAIGHTENING BENCH)
Information
vehicle.

protective covers.
WM 507455 REPLACING FRONT WHEEL HOUSING > SAFETY INSTRUCTIONS AND

Danger of injury
WM 507455 REPLACING FRONT WHEEL HOUSING > TOOLS AND MATERIALS >
Rotary brush
Support adhesive
Structural adhesive
WM 507455 REPLACING FRONT WHEEL HOUSING > REMOVING FRONT WHEEL

HOUSING > REMOVING WING MOUNTING POINT
1. Remove connection panel for wing. → 505355 REPLACING WING CONNECTION PANEL -
Information
If it can be ensured there has been no deformation of the side member for the wheel housing
upper section and wing strut, the following repair can be carried out without removing it.
2. Remove side member for wheel housing upper section. → REMOVING SIDE MEMBER FOR
WHEEL HOUSING UPPER SECTION - section on "Removing"
3. Remove strut for wing. → REMOVING WING STRUT - section on "Removing"
4. Drill out spotwelds using Spotweld Drill .

Fig 1: Identifying Drill Out Spotwelds On Wing Mounting
5. Remove the wing mounting point.
WM 507455 REPLACING FRONT WHEEL HOUSING > REMOVING FRONT WHEEL

HOUSING > REMOVING OUTER UPPER SIDE MEMBER

Fig 1: Identifying Welded Joints Outer Upper Side Member
1. 1.1. Drill out spotwelds using spotweld drill .
2. Remove outer upper side member.
WM 507455 REPLACING FRONT WHEEL HOUSING > PREPARING FRONT WHEEL

HOUSING FOR INSTALLATION > PREPARING WING MOUNTING POINT FOR
INSTALLATION
Information
Only drill holes A if the outer upper side member was not removed.
1. Drill holes for plug-welding using inert gas.

Fig 1: Identifying Drill Holes For Plug-Welding On Wing Mounting
2. Grind both sides of the connecting flanges of the wing mounting point in the marked areas until
bare.
Fig 2: Identifying Connecting Flanges Of Wing Mounting Point
WM 507455 REPLACING FRONT WHEEL HOUSING > PREPARING FRONT WHEEL

HOUSING FOR INSTALLATION > PREPARING OUTER UPPER SIDE MEMBER FOR
INSTALLATION
1. Grind both sides of the connecting flanges on the outer upper side member in the marked
areas until bare.
Fig 1: Identifying Outer Upper Side Member
WM 507455 REPLACING FRONT WHEEL HOUSING > PREPARING CONNECTION

AREAS OF BODY FOR INSTALLING FRONT WHEEL HOUSING > PREPARING
CONNECTION AREAS OF THE BODY FOR INSTALLING WING MOUNTING POINT

2. 1.2. Grind the connecting flanges until bare.
WM 507455 REPLACING FRONT WHEEL HOUSING > PREPARING CONNECTION

AREAS OF BODY FOR INSTALLING FRONT WHEEL HOUSING > PREPARING
CONNECTION AREAS OF BODY FOR INSTALLING OUTER UPPER SIDE MEMBER

WM 507455 REPLACING FRONT WHEEL HOUSING > INSTALLING FRONT WHEEL

HOUSING > INSTALLING WING MOUNTING POINT
1. Fit and secure the wing mounting point.
Information
Resistance spot-weld spotwelds A when the outer upper side member is removed.
Plug-weld spotwelds A using inert gas when the outer upper side member is installed.
2. Weld in the wing mounting point.

Fig 1: Identifying Weld In Wing Mounting Point
1. 2.1. Resistance spot-weld the wing mounting point.
2. 2.2. Plug-weld the wing mounting point in area -B- using inert gas.
WM 507455 REPLACING FRONT WHEEL HOUSING > INSTALLING FRONT WHEEL

HOUSING > INSTALLING OUTER UPPER SIDE MEMBER
1. Fit and secure the outer upper side member.
2. Weld in the outer upper side member.

Fig 1: Identifying Weld In Outer Upper Side Member
1. 2.1. Resistance spot-weld the outer upper side member.
2. 2.2. Apply a welded seam to the outer upper side member using inert gas.
3. Install strut for wing. → INSTALLING WING STRUT - section on "Installing"
4. Install side member for wheel housing upper section. → INSTALLING SIDE MEMBER FOR
WHEEL HOUSING UPPER SECTION - section on "Installing"
5. Install the connection panel for the wing. → 505355 REPLACING WING CONNECTION
PANEL - section on "Installing"
WM 507455 REPLACING FRONT WHEEL HOUSING > SUBSEQUENT WORK >

SUBSEQUENT WORK FOR BODY REPAIRS (WITHOUT STRAIGHTENING SYSTEM)

WM 507955 REPLACING FRONT SIDE MEMBER > TOOLS
Hot-air blower,
Workshop
Equipment
1416

WE 1121
WE 1122

WE 1137
Pneumatic Spotweld
Workshop
Equipment
WS 90

WE 1141
1628 Equipment

WE 1347
1523A Equipment
gap dimensions
Commercially
available tool
Commercially
Twist drill Nr.201
available tool
WM 507955 REPLACING FRONT SIDE MEMBER > TECHNICAL VALUES
Dimension A Length 10 mm
Dimension B Length 10 mm
WM 507955 REPLACING FRONT SIDE MEMBER > PRELIMINARY WORK >

vehicle.
protective covers.
WM 507955 REPLACING FRONT SIDE MEMBER > SAFETY INSTRUCTIONS AND

Danger of injury
WM 507955 REPLACING FRONT SIDE MEMBER > TOOLS AND MATERIALS > TOOLS
AND MATERIALS FOR BODY REPAIRS
Rotary brush
Support adhesive
Structural adhesive
WM 507955 REPLACING FRONT SIDE MEMBER > REMOVING FRONT SIDE MEMBER
> REMOVING FRONT SIDE MEMBER
1. Remove side member for wheel housing upper section. → REMOVING SIDE MEMBER FOR
2. Remove wing strut. → REMOVING WING STRUT - section on "Removing"
3. Remove front wheel housing. → REMOVING FRONT WHEEL HOUSING - section on

"Removing"

Fig 1: Removing Front Side Member
5. Drill out and grind down spotwelds using spotweld drill .


1. 6.1. Drill through spotweld -A- fully (Ø 10 mm).

1. 7.1. Drill through spotwelds in the area -A- fully (Ø 10 mm).
8. Separate front side member gusset plate.

Fig 5: Removing Front Side Member Gusset Plate
1. 8.1. Make rough front cut using the body saw.
2. 8.2. Make rough bottom and rear cut.
3. 8.3. Remove front side member gusset plate.
9. Drill through spotwelds (Ø 10 mm).

10. Make cut window (firewall).

1. 10.1. Mark cut window.
→ Length: 10 mm → Length: 10 mm
2. 10.2. Drill holes (Ø 6 mm) at the edge of the marking.

Fig 8: Identifying Drill Holes At Edge Of Front Side Member Marking
3. 10.3. Make cut all around using the body saw.
Use cut plate for re-installation.
11. Grind down MIG seams.

Fig 9: Identifying Front Side Member MIG Seams

Fig 10: Identifying Front Side Member Welded Joints

1. 13.1. Grind down spotwelds in the area -A- through two plate thicknesses.

1. 14.1. Grind down and drill out spotwelds.
15. Heat up connection areas using a hot-air gun.

Fig 13: Identifying Front Side Member MIG Seams
16. Remove front side member.
WM 507955 REPLACING FRONT SIDE MEMBER > PREPARING FRONT SIDE

MEMBER FOR INSTALLATION
1. Drill out spotwelds using spotweld drill bit and remove plenum panel closing element.
Drill out spotwelds so that no holes are made in the new part.
Fig 1: Identifying Front Side Member Drill Out Spotwelds

Fig 2: Identifying Front Side Member Drill Holes For Plug Welding
3. Cut/shorten sheetmetal lugs in marked area -A- using the body saw.
Information
Procedure for grinding down slots:
A. 10 mm
B. 60 mm
Fig 3: Identifying Grinding Down Slots
1. Mark slot to the dimension -A- and -B- .
2. Drill through the end points using a Ø 10 mm drill bit.
3. Grind down connecting line from hole to hole using a parting grinder.
4. Grind down slots for slot welding.

Fig 4: Identifying Grind Down Slots For Slot Welding On Front Side Member
5. Grind both sides of connecting flanges of front side member in the marked areas until bare.
Fig 5: Identifying Connecting Flanges Of Front Side Member
WM 507955 REPLACING FRONT SIDE MEMBER > PREPARING CONNECTION AREAS

OF BODY FOR INSTALLING FRONT SIDE MEMBERS

WM 507955 REPLACING FRONT SIDE MEMBER > INSTALLING FRONT SIDE

MEMBER
1. Fit and secure front side member.
Information
When welding slots, make sure that both edges of the slot are welded through.
Fig 1: Identifying Front Side Member Slot Welding
2. Weld in front side member.

Fig 2: Identifying Weld In Front Side Member
1. 2.1. Slot-weld front side member in the area -A- using inert gas.
2. 2.2. Plug-weld front side member using inert gas.
3. 2.3. Apply a full well to front side member using inert gas.

1. 3.1. Slot-weld front side member in the area -A- using inert gas.

1. 4.1. Resistance spot-weld front side member in the area -A- .

Fig 5: Installing Front Side Member

Fig 6: Identifying Resistance Spot-Weld Front Side Member
1. 6.1. Resistance spot-weld front side member in the area -A und B- .

2. 7.2. Spot-weld front side member using inert gas.

Fig 8: Identifying Front Side Member Spot-Weld
3. 8.3. Also spot-weld front side member using inert gas.
9. Spot-weld front side member using inert gas.

Fig 9: Identifying Front Side Member Spot-Weld
10. Fit cut window and apply a full weld using inert gas.
Fig 10: Installing Front Side Member
11. Plug-weld front side member using inert gas.

Fig 11: Identifying Plug-Weld Front Side Member
12. Install front wheel housing. → INSTALLING FRONT WHEEL HOUSING - section on
"Installing"
13. Install wing strut. → INSTALLING WING STRUT - section on "Installing"
WM 507955 REPLACING FRONT SIDE MEMBER > SUBSEQUENT WORK >


WM 507955 REPLACING FRONT SIDE MEMBER (SECTION) > TOOLS
Hot-air blower,
Workshop
Equipment
1416

WE 1121
WE 1122

WE 1137
Pneumatic Spotweld
Workshop
Equipment
WS 90

WE 1141
1628 Equipment

WE 1347
1523A Equipment
gap dimensions
Commercially
available tool
Commercially
Twist drill Nr.201
available tool
WM 507955 REPLACING FRONT SIDE MEMBER (SECTION) > TECHNICAL VALUES
Inner front side member Cut dimension, old part 263 mm
Outer front side member Cut dimension, old part 400 mm
WM 507955 REPLACING FRONT SIDE MEMBER (SECTION) > PRELIMINARY WORK >
vehicle.
1. 4.1. Cover all accessories remaining on the vehicle and the adjacent areas with
fire-proof protective covers.
WM 507955 REPLACING FRONT SIDE MEMBER (SECTION) > SAFETY

Danger of injury
WM 507955 REPLACING FRONT SIDE MEMBER (SECTION) > TOOLS AND

Pneumatic spotweld remover Pneumatic Spotweld Remover, Vario Drill WS 90 WE 1139
Oscillating body saw (special electric cutter) Special Electric Cutter - Fine WE 1137
Rotary brush
Leister Electron hot-air blower Hot-air blower, Leister-Electron/VAG 1416 WE 1119
Cartridge gun Cartridge gun VAG 1628 WE 1141
Spotweld drill Spotweld drill
Twist drill Twist drill Nr.201
Star gauges for body gap dimensions Star gauges for body gap dimensions Nr.127-1
Support adhesive
Structural adhesive
WM 507955 REPLACING FRONT SIDE MEMBER (SECTION) > REMOVING FRONT

SIDE MEMBER
1. Remove wing strut. → REMOVING WING STRUT - section on "Removing"
Information
If it can be ensured there has been no deformation of the side member for the wheel housing
upper section, the following repair can be carried out without removing it.
2. Remove side member for upper part of wheel housing. → REMOVING SIDE MEMBER FOR
Information
1. All straightening work on the body in the connection area of the sheetmetal parts to be
replaced must be completed before the damaged parts are removed.
3. Mark and make cuts.

Fig 1: Identifying Mark Position Cut Dimension On Inner And Outer Side Member
1. 3.1. Mark position of cut on inner side member at dimension -A- . → Cut
dimension, old part: 263 mm
2. 3.2. Mark position of cut on outer side member at dimension -B- .
→ Cut dimension, old part: 400 mm
3. 3.3. Cut completely through the inner and outer side members in the area marked.
4. Remove front side member.
Information
Only make cuts in the top plate. Make sure not to damage the plate underneath when doing
this.
5. Remove remaining piece of outer side member on the body.

Fig 3: Identifying Outer Front Side Member
1. 5.1. Cut through the outer side member in the area marked.
3. 5.3. Remove remaining piece of outer side member.
WM 507955 REPLACING FRONT SIDE MEMBER (SECTION) > PREPARING FRONT

SIDE MEMBER FOR INSTALLATION
1. Grind both sides of the connecting flanges on the inner side member in the marked areas until
bare.
Fig 1: Identifying Inner Front Side Member For Installation
2. Grind both sides of the connecting flanges on the outer side member in the marked areas until
bare.
Fig 2: Identifying Outer Front Side Member For Installation
WM 507955 REPLACING FRONT SIDE MEMBER (SECTION) > PREPARING

CONNECTION AREAS OF BODY FOR INSTALLING FRONT SIDE MEMBER

Fig 1: Identifying Front Side Member Body Welding And Sealing Areas
WM 507955 REPLACING FRONT SIDE MEMBER (SECTION) > INSTALLING FRONT

SIDE MEMBER
1. Fix front side member to the body.
Information
1. To fit the side member, the frame head (impact absorber mount) and the top side
member support must be secured to the straightening attachments.
1. 1.1. Fix inner side member to the frame head and secure side member for wheel
housing upper section.
2. 1.2. Fix inner side member to the body using tensioning clamps.
3. 1.3. Fix outer side member to inner front side member using tensioning clamps.
2. Apply a full weld to the inner and outer side members using inert gas.
Fig 1: Identifying Front Side Member Weld Areas
3. Remove the frame head (impact absorber mount) and straightening set.
4. Resistance spot-weld the inner and outer side members.

Fig 2: Identifying Resistance Spot-Weld Inner And Outer Side Members
5. Install frame head (impact absorber mount). →INSTALLING FRAME HEAD (IMPACT
ABSORBER MOUNT) - section on "Installing"
7. Install wing strut. → INSTALLING WING STRUT - section on "Installing"
8. Install the connection panel for the wing. → 505355 REPLACING WING CONNECTION
WM 507955 REPLACING FRONT SIDE MEMBER (SECTION) > SUBSEQUENT WORK >

WM 508119 REMOVING AND INSTALLING CROSS PANEL > PRELIMINARY WORK >
PRELIMINARY WORK FOR LEFT CROSS PANEL
1. Remove cowl panel cover. → REMOVING COWL PANEL COVER - section on "Removing"
2. Remove front trim panel (engine compartment) at the left. → REMOVING FRONT TRIM
PANEL (ENGINE COMPARTMENT) - section on "Removing"
WM 508119 REMOVING AND INSTALLING CROSS PANEL > PRELIMINARY WORK >
PRELIMINARY WORK FOR RIGHT CROSS PANEL
1. Remove wind deflector cover. → REMOVING COWL PANEL COVER - section on "Removing"
2. Remove front cover (engine compartment) at the right. → REMOVING FRONT TRIM PANEL
(ENGINE COMPARTMENT) - section on "Removing"
3. Remove DME control unit. → REMOVING DME CONTROL UNIT - section on "Removing"
WM 508119 REMOVING AND INSTALLING CROSS PANEL > REMOVING CROSS

PANEL > REMOVING LEFT CROSS PANEL
1. Unclip plug connections -1- from the bracket.

Fig 1: Identifying Plug Connections From Bracket
2. Unclip wire harness -2- from the bracket.
3. Unscrew three fastening screws -3- .

Fig 2: Removing Left Cross Panel
4. Lift cross panel up and remove it -A- .
WM 508119 REMOVING AND INSTALLING CROSS PANEL > REMOVING CROSS

PANEL > REMOVING RIGHT CROSS PANEL
1. Unclip plug connections -1- from the bracket.

Fig 1: Identifying Right Cross Panel Plug Connections From Bracket
2. Unclip wire harness -2- from the bracket.
3. Open two tie-wraps -1- .

Fig 2: Identifying Tie-Wraps Wire Harness
4. Remove rubber sleeve on cable bushing -1- from the cross panel -A- .
Fig 3: Removing Rubber Sleeve On Cable Bushing From Cross Panel

Fig 4: Removing Right Cross Panel (Left)
6. Lift cross panel up and remove it -A- .
WM 508119 REMOVING AND INSTALLING CROSS PANEL > INSTALLING CROSS

PANEL > INSTALLING LEFT CROSS PANEL
1. Push rubber seal -1- onto the bodyshell flange and centre cross panel -A- . Lightly coat the
rubber seal with sliding compound, e.g. glycerine (to make it easier to refit the cross panel).
Fig 1: Pushing Rubber Seal Onto Bodyshell Flange And Centre Cross Panel
2. Further installation of the left cross panel is performed in reverse order to removal.
WM 508119 REMOVING AND INSTALLING CROSS PANEL > INSTALLING CROSS

PANEL > INSTALLING RIGHT CROSS PANEL
1. Push rubber seal -1- onto the bodyshell flange and centre cross panel -A- . Lightly coat the
rubber seal with sliding compound, e.g. glycerine (to make it easier to refit the cross panel).
Fig 1: Pushing Rubber Seal Onto Bodyshell Flange And Centre Cross Panel
2. Further installation of the left cross panel is performed in reverse order to removal.
WM 508119 REMOVING AND INSTALLING CROSS PANEL > SUBSEQUENT WORK >
SUBSEQUENT WORK FOR LEFT CROSS PANEL
1. Install wind deflector cover. → INSTALLING COWL PANEL COVER - section on "Installing"
2. Install front cover (engine compartment) on the left. → INSTALLING FRONT TRIM PANEL
(ENGINE COMPARTMENT) - section on "Installing"
WM 508119 REMOVING AND INSTALLING CROSS PANEL > SUBSEQUENT WORK >
SUBSEQUENT WORK FOR RIGHT CROSS PANEL
1. Secure DME control unit. → INSTALLING DME CONTROL UNIT - section on "Installing"
2. Install cowl panel cover. → INSTALLING COWL PANEL COVER - section on "Installing"
3. Install front cover (engine compartment) at the right. → INSTALLING FRONT TRIM PANEL
Service Manual: 51 - BODY CENTER, ROOF, FRAME -- 92A CAYENNE
WM 510355 REPLACING ROOF (CAYENNE, CAYENNE GTS, CAYENNE TURBO S,
Hot-air blower, Workshop WE 1119

Leister- equipment
Electron/V.A.G.
1416
Body Workshop WE 1121

Straightening equipment
System, Celette
System, Car
Bench
Special Electric Workshop WE 1137

Cutter - Fine equipment
Pneumatic Workshop WE 1139
Spotweld equipment
Remover, Vario
Drill WS 90
Cartridge gun Workshop WE 1141

V.A.G. 1628 equipment
Body saw V.A.G Workshop WE 1347

1523A equipment
Star gauges for Special tool Nr.127-1
body gap
dimensions
Spotweld drill; Commercially Nr.129

available tool
Twist drill Commercially Nr.201

available tool

Roof cut line Roof outer edge Distance 2 mm +2 mm
Hole diameter Diameter 20 mm

for roof rail

CAYENNE (3.0)) > PRELIMINARY WORK > PRELIMINARY WORK FOR BODY
REPAIRS (WITHOUT STRAIGHTENING BENCH)
Information
vehicle.
protective covers.

CAYENNE (3.0)) > SAFETY INSTRUCTIONS AND INFORMATION ON QUALITY
Danger of injury
Tools and metalworking tools → TOOLS

CAYENNE (3.0)) > TOOLS AND MATERIALS > TOOLS AND MATERIALS FOR BODY
REPAIRS
Resistance spot welder .
Metal inert gas (MIG) welder .

Pneumatic body saw Body saw V.A.G 1523A WE 1347
Rotary brush
Leister Electron hot-air blower Hot-air blower, Leister-Electron/V.A.G. 1416 WE 1119 .
Cartridge gun Cartridge gun V.A.G. 1628 WE 1141 .
Support adhesive
Structural adhesive

CAYENNE (3.0)) > REMOVING ROOF
1. Drill out spotwelds using spotweld drill .

Fig 1: Identifying Roof Spotwelds Area (1 Of 2)

Fig 2: Identifying Roof Spotwelds Area (2 Of 2)
2. Stick on adhesive tape -1- along the edge of the roof on both sides at dimension -X- . →
Distance: 2 mm+2 mm
Adhesive tape serves as cut line.

Fig 3: Removing Roof
Information
this.
3. Make cut on both sides.
4. Heat up connection areas using the hot-air gun.

Fig 4: Identifying Roof Heat Up Connection Areas
5. Remove roof (three people required).
Information
1. During separation make sure that the components beneath are not damaged.
6. Remove remaining pieces of roof.

Fig 5: Removing roof
1. 6.1. Cut off laser soldered joint on the side panels.
2. 6.2. Remove remaining pieces.

CAYENNE (3.0)) > PREPARING ROOF FOR INSTALLATION
1. Grind both sides of connecting flanges of roof in the marked areas until bare.
Fig 1: Preparing Roof
2. Preparing bonding areas (structural adhesive).

Fig 2: Preparing Roof Bonding Areas (Structural Adhesive)
3. Preparing bonding areas (support adhesive).

Fig 3: Preparing Roof Bonding Areas (Support Adhesive)
Information
Do not apply zinc powder paint to the bonding areas.

CAYENNE (3.0)) > PREPARING CONNECTION AREAS OF BODY FOR INSTALLING
ROOF

Fig 1: Preparing Body Connection Areas
2. Preparing bonding areas (structural adhesive).

Fig 2: Preparing Body For Structural Adhesive
3. Preparing bonding areas (support adhesive).

Fig 3: Preparing Body For Support Adhesive
Information
5. Touch up any paint damage in areas that will no longer be accessible later.
CAYENNE (3.0)) > INSTALLING ROOF
1. Apply structural adhesive and support adhesive.

Fig 1: Installing Roof
1. 1.1. Evenly apply structural adhesive to the marked areas.

Working with body structural adhesive → 5X00IN WORKING WITH BODY
STRUCTURAL ADHESIVE
2. 1.2. Apply support adhesive to the marked areas. Apply additional adhesive beads
as shown.
Support adhesive
Fig 2: Installing Roof
2. Place roof on rear roof frame with the help of two people -arrow A- and swivel it in towards
the front -arrows B- .
Fig 3: Positioning Roof On Rear Roof Frame
Information
1. Have this work carried out by an assistant whilst at the same time starting with the
welding work.
3. Clean surface of roof in the side panel area.

Fig 4: Installing Side Panel Roof
1. 3.1. Remove most of the excess adhesive material with a plastic spatula or cloth.
2. 3.2. Finish cleaning visible surfaces with a cloth soaked in cleaning solution.
Fig 5: Removing Excess Adhesive Material With Plastic Spatula/Cloth
4. Weld in front roof.

Fig 6: Identifying Weld In Front Roof
1. 4.1. Resistance spot-weld roof.
2. 4.2. Apply additional welded seams to roof in area of A-pillar using inert gas.
5. Weld in rear roof.

Fig 7: Identifying Weld In Rear Roof
1. 5.1. Resistance spot-weld roof.
2. 5.2. Apply additional welded seams to roof in area of D-pillar using inert gas.

CAYENNE (3.0)) > DRILLING HOLES FOR ROOF RAIL
Information
As a result of different designs (roof), it is not possible to provide a roof with hole pattern for repair work.
In this case, the holes must be drilled subsequently.
Fig 1: Identifying Hole Points For Roof Rail
1. Position roof rail holder -1- on the body, align and screw down with fastening screws -2- .
Holder serves as drilling template.

Fig 2: Identifying Roof Rail Holder On Body
2. Mark holes centered through the holes on the holder -arrows- and carefully drill through from
the inside to the outside using a Ø 6 mm drill bit.
While drilling the holes, remove the drilling chips using a vacuum cleaner.
Fig 3: Identifying Drilling Holes For Roof Rail
3. Check hole spacing by fitting the roof rail and make adjustments if necessary.
4. Remove roof rail holder.
5. Drill out holes to the dimension -A- . → Diameter: 20 mm

Fig 4: Identifying Drilling Holes Dimension For Roof Rail
6. Apply corrosion protection.

CAYENNE (3.0)) > SUBSEQUENT WORK > SUBSEQUENT WORK FOR BODY
REPAIRS (WITHOUT STRAIGHTENING SYSTEM)
WM 510555 REPLACING INNER ROOF PILLAR (CAYENNE, CAYENNE GTS, CAYENNE

TURBO S, CAYENNE S, CAYENNE S HYBRID, CAYENNE TURBO, CAYENNE S
DIESEL, CAYENNE (3.0)) > TOOLS

Leister- equipment
Electron/V.A.G.
1416

System, Celette
System, Car
Bench

Spotweld equipment
Remover, Vario
Drill WS 90


1523A equipment
body gap
dimensions
Spotweld drill Commercially Nr.129

available tool

available tool

DIESEL, CAYENNE (3.0)) > PRELIMINARY WORK > PRELIMINARY WORK FOR BODY
REPAIRS WITH STRAIGHTENING BENCH
vehicle.
protective covers.

DIESEL, CAYENNE (3.0)) > SAFETY INSTRUCTIONS AND INFORMATION ON
QUALITY
Danger of injury

DIESEL, CAYENNE (3.0)) > TOOLS AND MATERIALS > TOOLS AND MATERIALS FOR
BODY REPAIRS
Rotary brush
Spotweld drill .
Support adhesive; material 000 043 204 82; see WORKING WITH ADHESIVES
Structural adhesive; see WORKING WITH ADHESIVES

DIESEL, CAYENNE (3.0)) > REMOVING INNER ROOF PILLAR
1. Remove outer roof pillar. → 510555 REPLACING OUTER ROOF PILLAR

Fig 1: Removing Inner Roof Pillar

3. Grind down the spotwelds.


5. Remove inner roof pillar.

DIESEL, CAYENNE (3.0)) > PREPARING INNER ROOF PILLAR FOR INSTALLATION
Information
A. 10 mm
B. 60 mm
Mark slot to the dimension -A- and -B-.
Drill through the end points using a Ø 10 mm drill bit.
Grind down connecting line from hole to hole using a parting grinder.
1. Grind down slots for slot welding using inert gas.

Fig 2: Identifying Inner Roof Pillar
2. Grind both sides of connecting flanges of inner roof pillar in the marked areas until bare.
Fig 3: Identifying Inner Roof Pillar

DIESEL, CAYENNE (3.0)) > PREPARING INNER ROOF PILLAR FOR INSTALLATION >
PREPARING CONNECTION AREAS OF BODY FOR INSTALLING INNER ROOF
PILLAR

Fig 1: Identifying Connection Areas Of Body For Installing Inner Roof Pillar

DIESEL, CAYENNE (3.0)) > INSTALLING INNER ROOF PILLAR
1. Fit and secure inner roof pillar.
2. Weld in inner roof pillar.

Fig 1: Installing Inner Roof Pillar
1. 2.1. Resistance spot-weld inner roof pillar.
Information
When slot welding hot-formed parts, make sure that both edges of the slot are
welded.
Fig 2: Identifying Slot Welding Hot-Formed Parts
2. 2.2. Slot-weld inner roof pillar using inert gas.
3. 2.3. Spot-weld inner roof pillar in the area -A- using inert gas and then grind down.
3. Resistance spot-weld inner roof pillar.

Fig 3: Identifying Resistance Spot-Weld Inner Roof Pillar
4. Weld in inner roof pillar.

Fig 4: Identifying Weld In Inner Roof Pillar
1. 4.1. Resistance spot-weld inner roof pillar.
2. 4.2. Spot-weld inner roof pillar using inert gas.
5. Install outer roof pillar. → 510555 REPLACING OUTER ROOF PILLAR

DIESEL, CAYENNE (3.0)) > SUBSEQUENT WORK > SUBSEQUENT WORK FOR BODY
REPAIRS
5. Restore standard undersealing with underbody sealant .
7. Apply cavity preservation to the accessible areas of the repair. .
WM 510555 REPLACING OUTER ROOF PILLAR (CAYENNE, CAYENNE GTS,


Leister- equipment
Electron/V.A.G.
1416
System, Celette

System, Car
Bench

Spotweld equipment
Remover, Vario
Drill WS 90

1523A equipment

body gap
dimensions
available tool

available tool

Dimension D Distance 160 mm
Dimension E Distance 100 mm
Dimension A Distance from 40 mm

hole center to
rail
Dimension B Distance from 36 mm

hole center to
rail
Dimension C Distance from 26 mm

hole center to
rail

CAYENNE S DIESEL, CAYENNE (3.0)) > PRELIMINARY WORK > PRELIMINARY
WORK FOR BODY REPAIRS WITH STRAIGHTENING BENCH
vehicle.
protective covers.

CAYENNE S DIESEL, CAYENNE (3.0)) > SAFETY INSTRUCTIONS AND INFORMATION
ON QUALITY
Danger of injury

CAYENNE S DIESEL, CAYENNE (3.0)) > TOOLS AND MATERIALS > TOOLS AND

Rotary brush l
Support adhesive
Structural adhesive

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING OUTER ROOF PILLAR >
REMOVING OUTER UPPER SIDE MEMBER (SECTION)
Information
Only make cuts in the top plate. Make sure not to damage the plate underneath when doing this.
1. Mark and make cut -A- .

Fig 1: Removing Outer Upper Side Member (Section)

REMOVING WING RAIL
1. Drill out spotwelds using spotweld drill bit (two plate thicknesses).
Fig 1: Removing Wing Rail

3. Remove wing rail.

REMOVING OUTER ROOF PILLAR
Information
The side panel can be separated or removed together to repair the outer roof pillar.
The cuts -A, B, C- must be made in accordance with the spare part.
The cuts -D und E- must be made in accordance with the specified dimensions. → Distance:
160 mm → Distance: 100 mm
Fig 1: Identifying Outer Roof Pillar

1. Remove the roof. → 510355 REPLACING ROOF
2. Remove outer B-pillar reinforcement. → 514255 REPLACING OUTER B-PILLAR

REINFORCEMENT
Information
this.
3. Mark and make cut.


Fig 3: Removing Outer Roof Pillar
1. 5.1. Drill out spotwelds.
2. 5.2. Grind down laser-welded seams.

7. Remove front roof cross member (section).
Information
this.
1. 7.1. Mark and make cut.
2. 7.2. Grind down MIG seams in the area -A- .

Fig 5: Removing Front Roof Cross Member (Section)


Fig 7: Removing Outer Roof Pillar (Grind Down MIG Seams)


Fig 9: Removing Outer Roof Pillar (Grind Down MIG Seams)
12. Raise roof cross member slightly in the area of B-pillar and C-pillar -arrows- and support
against lowering.


15. Remove outer side section from A-pillar as far as C-pillar.
1. 16.1. Drill out spotwelds in the area -A- .
3. 16.3. Grind down MIG seam.


Fig 14: Removing Outer Roof Pillar (Grind Down Spotwelds)

Fig 15: Removing Welded Joints Outer Roof Pillar

2. 20.2. Drill out spotwelds in the area -A- (two plate thicknesses).
Fig 17: Identifying Welded Joints Outer Roof Pillar

22. Remove outer roof pillar.

CAYENNE S DIESEL, CAYENNE (3.0)) > PREPARING OUTER ROOF PILLAR FOR
INSTALLATION > PREPARING OUTER UPPER SIDE MEMBER (SECTION) FOR
INSTALLATION
1. Transfer cut from the old part and make cut.

Fig 1: Preparing Outer Upper Side Member (Section)
2. Grind both sides of connecting flanges of outer upper side member (section) in the marked
areas until bare.
Fig 2: Preparing Outer Upper Side Member (Section)

INSTALLATION > PREPARING WING RAIL FOR INSTALLATION
1. Punch holes (Ø 8 mm) for plug welding using inert gas. Maintain spacing between holes as on
the old part.
Fig 1: Identifying Wing Rail
2. Grind both sides of connecting flanges of wing rail in the marked areas until bare.
Fig 2: Identifying Connecting Flanges Of Wing Rail

INSTALLATION > PREPARING OUTER ROOF PILLAR FOR INSTALLATION
Information
Information
A. 10 mm
B. 30-60 mm
Mark slot to the dimension -A- and -B- .
1. Grind down slots for slot welding using inert gas (transition to C-pillar).
2. Grind both sides of connecting flanges of outer roof pillar in the marked areas until bare.
Information
A. 10 mm
B. 30-60 mm

INSTALLATION > PREPARING A-PILLAR FOR INSTALLATION
1. Cut A-pillar at the transitions to the body leaving an overlap of 30 mm.

Fig 1: Identifying A-pillar
2. Drill holes (Ø 8 mm) for plug welding using inert gas. Maintain spacing between holes as on
the old part.
Fig 2: Identifying A-Pillar Holes
3. Grind both sides of connecting flanges of A-pillar in the marked areas until bare.
Fig 3: Identifying A-Pillar
Information

INSTALLATION > PREPARING FRONT ROOF CROSS MEMBER (SECTION) FOR
INSTALLATION

Fig 1: Identifying Front Roof Cross Member For Installation
2. Grind both sides of connecting flanges of front roof cross member (section) in the marked
areas until bare.
Fig 2: Identifying Front Roof Cross Member For Installation

INSTALLATION > PREPARING REAR SIDE SECTION (SECTION) FOR INSTALLATION
1. Cut rear side section (section) at the transitions to the body (C-pillar and D-pillar) leaving an
overlap of 30 mm.
Fig 1: Identifying Rear Side Section
2. Grind both sides of connecting flanges of rear side section (section) in the marked areas until
bare.
Fig 2: Identifying Flanges Rear Side Section

CAYENNE S DIESEL, CAYENNE (3.0)) > PREPARING CONNECTION AREAS OF BODY
FOR INSTALLING OUTER ROOF PILLAR

Fig 1: Identifying Body Sealing Areas
Information

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING OUTER ROOF PILLAR
1. Apply adhesive.
Fig 1: Applying Adhesive On Outer Roof Pillar
1. 1.1. Evenly apply adhesive to the marked areas.

STRUCTURAL ADHESIVE
2. Install sealing element.

Fig 2: Identifying Outer Roof Pillar Sealing Element
1. 2.1. Apply body sealant all around the sealing element.
Body sealant from Wurth Klebt und Dichtet
2. 2.2. Clip sealing element into outer roof pillar.
3. Fit and secure outer roof pillar.

4. Weld in outer roof pillar.
1. 4.1. Resistance spot-weld outer roof pillar.
2. 4.2. Spot-weld outer roof pillar using inert gas and then grind down.
5. Resistance spot-weld outer roof pillar.

Fig 4: Identifying Resistance Spot-Weld Outer Roof Pillar (1 Of 3)


1. 6.1. Plug-weld outer roof pillar using inert gas.
2. 6.2. Apply a full weld to inner roof pillar using inert gas (30-40 mm).
Fig 7: Identifying Weld In Outer Roof Pillar

Fig 8: Identifying Weld In Outer Roof Pillar
1. 7.1. Plug-weld outer roof pillar using inert gas.
Information
Fig 9: Identifying Slot Welding
2. 7.2. Slot-weld outer roof pillar in the area -A- using inert gas.
3. 7.3. Spot-weld outer roof pillar using inert gas.
8. Install outer B-pillar reinforcement. → 514255 REPLACING OUTER B-PILLAR

REINFORCEMENT
9. Evenly apply adhesive to the marked areas.

Fig 10: Applying Adhesive Outer Roof Pillar On Marked Areas
10. Fit and secure outer side sections.
11. Resistance spot-weld outer side section.

Fig 11: Identifying Resistance Spot-Weld Outer Side Section (1 Of 4)



12. Weld in outer side section.

Fig 15: Identifying Weld In Outer Roof Pillar Side Section
1. 12.1. Resistance spot-weld outer side section.
2. 12.2. Spot-weld outer side section using inert gas.
13. Spot-weld outer side section using inert gas.

Fig 16: Installing Outer Roof Pillar
14. Install B-pillar. → Installing B-Pillar
15. Apply a full weld to outer side section using inert gas.
16. Weld in front transverse roof strut (section).
1. 16.1. Fit and secure front transverse roof strut.
2. 16.2. Resistance spot-weld front transverse roof strut.
3. 16.3. Apply a full weld to front transverse roof strut using inert gas.
4. 16.4. Spot-weld front transverse roof strut in the area -A- using inert gas.
17. Weld in center transverse roof strut.
1. 17.1. Remove support.
2. 17.2. Plug-weld center transverse roof strut using inert gas.
3. 17.3. Apply a full weld to center transverse roof strut using inert gas.
Fig 19: Identifying Weld In Centre Transverse Roof Strut
18. Weld in rear transverse roof strut.
2. 18.2. Spot-weld rear transverse roof strut using inert gas.

Fig 20: Identifying Weld In Rear Transverse Roof Strut
19. Install the roof. → Installing Roof

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING WING RAIL
1. Fit and secure wing rail. → Distance from hole center to rail: 40 mm → Distance from hole
center to rail: 36 mm → Distance from hole center to rail: 26 mm
2. Plug-weld wing rail using inert gas (two plate thicknesses).


CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING OUTER UPPER SIDE MEMBER
(SECTION)
1. Fit and secure outer upper side member (front section).

2. 2.2. Apply a full weld to outer upper side member in the area -A- using inert gas.
3. 2.3. Spot-weld outer upper side member using inert gas.

Fig 1: Identifying Outer Upper Side Member (Section)

CAYENNE S DIESEL, CAYENNE (3.0)) > SUBSEQUENT WORK > SUBSEQUENT
WORK FOR BODY REPAIRS

WM 511255 REPLACING A-PILLAR (CAYENNE, CAYENNE GTS, CAYENNE TURBO S,


Leister- equipment
Electron/V.A.G.
1416

System, Celette
System, Car
Bench

Spotweld equipment
Remover, Vario
Drill WS 90


1523A equipment
body gap
dimensions

available tool

available tool

Dimension A Distance 30 mm
Dimension A Distance from 40 mm

hole center to
rail
Dimension B Distance from 36 mm

hole center to
rail
Dimension C Distance from 26 mm
hole center to
rail

Information
vehicle.
protective covers.

Danger of injury
Tools and metalworking tools → TOOLS 5X00IN Tools and metalworking tools for body repairs

REPAIRS
Rotary brush l
Support adhesive
Structural adhesive

CAYENNE (3.0)) > REMOVING A-PILLAR > REMOVING OUTER UPPER SIDE MEMBER
(SECTION)
Information
1. Mark and make cut -A- .

Fig 1: Removing Outer Upper Side Member (Section)

CAYENNE (3.0)) > REMOVING A-PILLAR > REMOVING WING RAIL
1. Drill out spotwelds using spotweld drill bit (two plate thicknesses).
Fig 1: Removing Drill Out Spotwelds On Wing Rail


CAYENNE (3.0)) > REMOVING A-PILLAR > REMOVING A-PILLAR
Information
Mark cut B in accordance with the new part. Make sure to leave an overlap of approx. 3 cm with respect
to the body.
Information
1. Mark and make cuts. → Distance: 30 mm


Fig 2: Identifying A-Pillar Welded Joints

Fig 3: Removing A-pillar
4. Remove A-pillar with outer side member (front section).

CAYENNE (3.0)) > PREPARING A-PILLAR > PREPARING OUTER UPPER SIDE
MEMBER (SECTION) FOR INSTALLATION

2. Grind both sides of connecting flanges of outer upper side member (section) in the marked
areas until bare.

CAYENNE (3.0)) > PREPARING A-PILLAR > PREPARING WING RAIL FOR
INSTALLATION
the old part.

CAYENNE (3.0)) > PREPARING A-PILLAR > PREPARING OUTER SIDE MEMBER
(FRONT SECTION) AND A-PILLAR FOR INSTALLATION
1. Cut outer side member (front section) at the transition to the body (B-pillar) leaving an overlap
of 30 mm.
Fig 1: Identifying Outer Side Member (Front Section)
2. Drill holes (Ø 8 mm) for plug welding using inert gas. Maintain spacing between holes as on
the old part.
3. Grind both sides of connecting flanges of outer side member in the marked areas until bare.
4. Cut A-pillar at the transition to the body (A-pillar) leaving an overlap of 30 mm.
the old part.
Fig 5: Identifying Punch Hole On Plug Welding A-Pillar
6. Grind both sides of connecting flanges of A-pillar in the marked areas until bare.
Fig 6: Identifying Connecting Flanges A-Pillar Punch Hole
7. Fit outer side member and A-pillar.
1. 7.1. Fit outer side member.
2. 7.2. Fit the A-pillar.
3. 7.3. In the area -A, B, C- of the overlaps, make cut through outer side member and
A-pillar.
Observe gap dimensions. → 5X00IN DIAGRAM - BODY GAP DIMENSIONS

Fig 7: Identifying A-Pillar And Outer Side Member
8. Remove outer side member and A-pillar.

THE A-PILLAR


CAYENNE (3.0)) > INSTALLING A-PILLAR
1. Apply adhesive and body sealant.

STRUCTURAL ADHESIVE
2. 1.2. Apply body sealant all around the sealing element in the area -A- .
Body sealant from Wurth glue and seals

2. Fit and secure outer side member (front section) and A-pillar.
3. Weld in A-pillar and outer side member.
1. 3.1. Resistance spot-weld A-pillar and outer side member.

Fig 2: Identifying Resistance Spot-Weld A-Pillar And Outer Side Member
2. 3.2. Plug-weld A-pillar and outer side member using inert gas.
Fig 3: Identifying Plug-Weld A-Pillar And Outer Side Member
3. 3.3. Apply a full weld to A-pillar and outer side member using inert gas.

CAYENNE (3.0)) > INSTALLING A-PILLAR > INSTALLING WING RAIL
1. Fit and secure wing rail. → Distance from hole center to rail: 40 mm → Distance from hole
center to rail: 36 mm → Distance from hole center to rail: 26 mm

Fig 2: Identifying Plug-Weld Wing Rail

CAYENNE (3.0)) > INSTALLING A-PILLAR > REMOVING OUTER UPPER SIDE
MEMBER (SECTION)
1. Fit and secure outer upper side member (front section).

2. 2.2. Apply a full weld to outer upper side member in the area -A- using inert gas.
3. 2.3. Spot-weld outer upper side member using inert gas.

Fig 1: Identifying Weld In Outer Upper Side Member


WM 513855 REPLACING A-PILLAR REINFORCEMENT (CAYENNE, CAYENNE GTS,

Leister- equipment
Electron/V.A.G.
1416

System, Celette
System, Car
Bench

Spotweld equipment
Remover, Vario
Drill WS 90


1523A equipment
body gap
dimensions

available tool

available tool

vehicle.
protective covers.

ON QUALITY
Danger of injury

Rotary brush
Support adhesive
Structural adhesive

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING A-PILLAR REINFORCEMENT
1. Remove A-pillar. → 511255 REPLACING A-PILLAR

Fig 1: Identifying A-Pillar Reinforcement


Fig 3: Removing A-Pillar Reinforcement
5. Remove A-pillar reinforcement.

CAYENNE S DIESEL, CAYENNE (3.0)) > PREPARING A-PILLAR REINFORCEMENT
FOR INSTALLATION
Information
A. 10 mm
B. 30-60 mm

2. Grind both sides of connecting flanges of outer B-pillar reinforcement in the marked areas until
bare.
Fig 3: Preparing Flanges Of Outer B-Pillar Reinforcement
Information

FOR INSTALLING A-PILLAR REINFORCEMENT

Information

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING A-PILLAR REINFORCEMENT
1. Apply adhesive.
Fig 1: Applying Adhesive On A-Pillar Reinforcement

STRUCTURAL ADHESIVE
2. Fit and secure A-pillar reinforcement.

3. Weld in A-pillar reinforcement.
Fig 2: Identifying Weld In A-Pillar Reinforcement
1. 3.1. Resistance spot-weld A-pillar reinforcement.
Information
Fig 3: Identifying Resistance Spot-Weld A-Pillar Reinforcement
2. 3.2. Slot-weld A-pillar reinforcement in the area -A- using inert gas.
3. 3.3. Spot-weld A-pillar reinforcement using inert gas.
4. Install A-pillar. → Installing A-Pillar


WM 514155 REPLACING B-PILLAR (CAYENNE, CAYENNE GTS, CAYENNE TURBO S,


Leister- equipment
Electron/V.A.G.
1416

System, Celette
System, Car
Bench

Spotweld equipment
Remover, Vario
Drill WS 90


1523A equipment
body gap
dimensions

available tool

available tool

Dimension C Distance to 30 mm
edge of roof
Dimension A Distance to 10 mm
upper edge

Information
vehicle.
protective covers.

Danger of injury

REPAIRS

Rotary brush
Support adhesive
Structural adhesive

CAYENNE (3.0)) > REMOVING B-PILLAR
Information
Mark cuts A, B, D and E in accordance with the new part. Make sure to leave an overlap of approx. 3
cm with respect to the body.
Information
→ Distance to edge of roof: 30 mm

Fig 1: Identifying B-pillar (1 Of 2)

Fig 2: Identifying B-Pillar (2 Of 2)
2. Grind down laser-welded seams.

Fig 3: Identifying Grind Down Laser-Welded Seams

Fig 4: Identifying Drill Out Spotwelds B-Pillar

Fig 5: Identifying B-pillar
5. Remove B-pillar.

CAYENNE (3.0)) > PREPARING B-PILLAR FOR INSTALLATION
1. Fit the B-pillar.

Fig 1: Identifying B-Pillar
1. 1.1. Cut B-pillar at the transition to the outer side member and top side section
leaving an overlap of 20 mm.
2. 1.2. Fit the B-pillar.

Fig 2: Preparing B-Pillar
3. 1.3. Make cuts through the outer side member and top side section in the overlap
areas.
2. Remove B-pillar.
3. Drill holes for plug welding using inert gas.
→ Distance to upper edge: 10 mm

Fig 3: Identifying B-Pillar Drill Holes For Plug Welding
4. Grind both sides of connecting flanges of B-pillar in the marked areas until bare.

B-PILLAR

Fig 1: Identifying Welding And Sealing Areas Body

CAYENNE (3.0)) > INSTALLING B-PILLAR


STRUCTURAL ADHESIVE
2. 1.2. Apply body sealant in the area -A- with two 15 mm high adhesive beads on the
B-pillar reinforcement and opposite on the B-pillar.
Body sealant from Wurth glue and seals
2. Fit and secure the B-pillar.
3. Resistance spot-weld B-pillar.

Fig 2: Identifying Resistance Spot-Weld B-Pillar

4. Apply a full weld to B-pillar using inert gas.
5. Plug-weld B-pillar using inert gas.

Fig 4: Identifying Plug-Weld B-Pillar


WM 514255 REPLACING B-PILLAR REINFORCEMENT (CAYENNE, CAYENNE GTS,


Leister- equipment
Electron/V.A.G.
1416

System, Celette
System, Car
Bench

Spotweld equipment
Remover, Vario
Drill WS 90


1523A equipment
body gap
dimensions

available tool

available tool

vehicle.
protective covers.

ON QUALITY
Danger of injury

Rotary brush
Spotweld drill .
Support adhesive
Structural adhesive

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING B-PILLAR REINFORCEMENT
1. Remove B-pillar. →Removing B-Pillar
2. Mark and make cuts on inner B-pillar reinforcement.

Fig 1: Identifying B-Pillar Reinforcement
1. 2.1. Mark cut in lower area.
2. 2.2. Make rough top cut using the cutting disc.
3. 2.3. Make bottom cut in marked area using the body saw.

Fig 2: Identifying Spotwelds B-Pillar Reinforcement

Fig 3: Identifying Grind Down Spotwelds B-Pillar Reinforcement

6. Remove outer B-pillar reinforcement.
7. Separate inner B-pillar reinforcement.

Fig 5: Identifying Inner B-Pillar Reinforcement
3. 7.3. Remove remaining part of inner B-pillar reinforcement.
8. Heat up connection areas with a hot-air gun and remove sealing element.

CAYENNE S DIESEL, CAYENNE (3.0)) > PREPARING B-PILLAR REINFORCEMENT
FOR INSTALLATION > PREPARING INNER B-PILLAR REINFORCEMENT FOR
INSTALLATION
1. Fit inner B-pillar reinforcement.

1. 1.1. Cut inner B-pillar reinforcement at the transition to the body leaving an overlap of
30 mm.
2. 1.2. Fit inner B-pillar reinforcement.

3. 1.3. Make cuts through the inner B-pillar reinforcement and body in the overlap
areas.
Information
A. 10 mm
B. 30-60 mm

Fig 4: Identifying Grind Down Slots Welding Inner B-Pillar Reinforcement
4. Grind both sides of connecting flanges of inner B-pillar reinforcement in the marked areas until
bare.
Preparing outer B-pillar reinforcement for installation
Information

A. 10 mm
B. 30-60 mm

Fig 7: Identifying Grind Down Slots For Slot Welding Outer B-Pillar Reinforcement
bare.
Fig 8: Identifying Connecting Flanges Of Outer B-Pillar Reinforcement

FOR INSTALLING B-PILLAR REINFORCEMENT
Fig 1: Identifying Body Welding And Sealing Areas (1 Of 2)

Fig 2: Identifying Body Welding And Sealing Areas (2 Of 2)

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING B-PILLAR REINFORCEMENT >
INSTALLING INNER B-PILLAR REINFORCEMENT
1. Fit and secure inner B-pillar reinforcement.
2. Resistance spot-weld inner B-pillar reinforcement.

Fig 1: Identifying Resistance Spot-Weld Inner B-Pillar Reinforcement
3. Apply a full weld to inner B-pillar reinforcement using inert gas.

Fig 2: Identifying Inner B-Pillar Reinforcement Weld Area
Information
When welding the inner B-pillar reinforcement at the roof cross member, make sure that the
heat does not damage the outer roof panel.
1. Perform a welding sample before applying a full weld and set the correct parameters
(wire feed, welding level/welding current).
2. Cool the outer roof panel using a moist cloth and if necessary insert a copper plate
between the roof and roof cross member.
4. Weld in inner B-pillar reinforcement.

Fig 3: Identifying Weld In Inner B-Pillar Reinforcement
1. 4.1. Spot weld inner B-pillar reinforcement using inert gas.
Information
Fig 4: Identifying Slot Welding
2. 4.2. Slot-weld inner B-pillar reinforcement in the area -A- using inert gas.
3. 4.3. Plug-weld inner B-pillar reinforcement using inert gas.

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING B-PILLAR REINFORCEMENT >
INSTALLING OUTER B-PILLAR REINFORCEMENT
1. Fit and secure outer B-pillar reinforcement.
2. Resistance spot-weld outer B-pillar reinforcement.

Fig 1: Identifying Resistance Spot-Weld Outer B-Pillar Reinforcement
3. Weld in outer B-pillar reinforcement.

Fig 2: Identifying Weld In Outer B-Pillar Reinforcement
1. 3.1. Spot-weld outer B-pillar reinforcement using inert gas.
Information
Fig 3: Identifying B-Pillar Reinforcement Slot Welding
2. 3.2. Slot-weld outer B-pillar reinforcement in the area -A- using inert gas.
4. Spot-weld outer B-pillar reinforcement using inert gas.

Fig 4: Installing outer B-pillar reinforcement
5. Fill outer B-pillar reinforcement with foam.

Fig 5: Filling Outer B-Pillar Reinforcement With Foam
1. 5.1. Fill outer B-pillar reinforcement with foam from the inside in the marked area. →
5X00IN PROCESSING BODY FOAM FILLER

WM 514255 REPLACING OUTER B-PILLAR REINFORCEMENT (CAYENNE, CAYENNE


Leister- equipment
Electron/V.A.G.
1416
System, Celette

System, Car
Bench

Spotweld equipment
Remover, Vario
Drill WS 90

1523A equipment

body gap
dimensions
available tool

available tool

vehicle.
protective covers.


ON QUALITY
Danger of injury

Rotary brush
Spotweld drill .
Support adhesive
Structural adhesive
CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING OUTER B-PILLAR
REINFORCEMENT
1. Remove B-pillar. → Removing B-Pillar

Fig 1: Removing Outer B-Pillar Reinforcement

Fig 2: Identifying Outer B-Pillar Reinforcement
2. 3.2. Grind down MIG seam in the area -A- .

Fig 3: Removing Outer B-Pillar Reinforcement
5. Remove outer B-pillar reinforcement.
Fig 4: Identifying Outer B-Pillar Reinforcement

CAYENNE S DIESEL, CAYENNE (3.0)) > PREPARING OUTER B-PILLAR
REINFORCEMENT FOR INSTALLATION
Information
A. 10 mm
B. 30-60 mm
Fig 1: Identifying Grinding Down Slots On Outer B-Pillar Reinforcement

Fig 2: Identifying Grind Down Slots For Slot Welding Outer B-Pillar Reinforcement
bare.
Fig 3: Removing connecting flanges of outer B-pillar reinforcement

FOR INSTALLING OUTER B-PILLAR REINFORCEMENT

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING OUTER B-PILLAR
REINFORCEMENT
1. Fit and secure outer B-pillar reinforcement.
2. Resistance spot-weld outer B-pillar reinforcement.

Fig 1: Identifying Resistance Spot-Weld Outer B-Pillar Reinforcement

3. Weld in outer B-pillar reinforcement.
Fig 2: Identifying Weld In Outer B-Pillar Reinforcement
1. 3.1. Spot-weld outer B-pillar reinforcement using inert gas.
Information
2. 3.2. Slot-weld outer B-pillar reinforcement in the area -A- using inert gas.
Fig 3: Identifying Spot-Weld Outer B-Pillar Reinforcement
4. Spot-weld outer B-pillar reinforcement using inert gas.

Fig 4: Identifying Spot-Weld Outer B-Pillar Reinforcement
5. Fill outer B-pillar reinforcement with foam.
1. 5.1. Fill outer B-pillar reinforcement with foam from the inside in the marked area. →
Fig 5: Filling Outer B-Pillar Reinforcement With Foam


WM 514555 REPLACING OUTER SIDE MEMBER (CAYENNE, CAYENNE GTS,


Leister- equipment
Electron/V.A.G.
1416
System, Celette

System, Car
Bench

Spotweld equipment
Remover, Vario
Drill WS 90

1523A equipment

body gap
dimensions
available tool

available tool


lower edge of
rail
upper edge

Information
vehicle.
protective covers.

ON QUALITY
Danger of injury

Rotary brush

Support adhesive
Structural adhesive

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING OUTER SIDE MEMBER >
POSSIBLE SEPARATION POINTS
Information
Cuts can be made in the defined areas in the outer side member due to the parts dimensions. The
purpose of the different cuts is to keep the repair area as small as possible in the event of damage.
The diagram should help you to determine the correct position of cuts.
A-B-C - Cuts for replacing outer side member.
A-E or D-E - Cuts for replacing outer side member (front section).
C-F - Cuts for replacing outer side member (rear section).
E-F - Cuts for replacing B-pillar.

Fig 1: Identifying Separation Points On Outer Side Member

REMOVING WING RAIL
Information
1. Mark and make cut for wing rail. → Distance to lower edge of rail: 275 mm
Fig 1: Identifying Distance To Lower Edge Of Rail

Fig 2: Identifying Drill Out Spotwelds Wing Rail


REMOVING OUTER SIDE MEMBER
Information
Mark cuts A, B and C in accordance with the new part. Make sure to leave an overlap of approx. 3 cm
with respect to the body.
Information

Fig 1: Identifying Outer Side Member

Fig 2: Identifying Drill Out Spotwelds Outer Side Member
3. Grind down laser-welded seams.

Fig 3: Identifying Laser-Welded Seams Outer Side Member
A. A-pillar sealing element
B. B-pillar sealing element
C. Rear wheel housing sealing element

Fig 4: Identifying Rear Wheel Housing Sealing Element
5. Remove outer side member.

CAYENNE S DIESEL, CAYENNE (3.0)) > PREPARING OUTER SIDE MEMBER FOR
INSTALLATION
1. Fit outer side member.

Fig 1: Preparing Outer Side Member For Installation
1. 1.1. Cut outer side member at the transitions to the body leaving an overlap of 30
mm.
2. 1.2. Fit outer side member.

3. 1.3. Make cuts through the outer side member and body in the overlap areas.
2. Remove outer side member.
In the area of the A-pillar, maintain spacing between the holes as on the old part.
→ Distance to upper edge: 10 mm

Fig 3: Identifying Drill Holes For Plug Welding Outer Side Member
4. Grind both sides of connecting flanges of outer side member in the marked areas until bare.

CAYENNE S DIESEL, CAYENNE (3.0)) > PREPARING OUTER SIDE MEMBER FOR
INSTALLATION > PREPARING WING RAIL FOR INSTALLATION

2. Drill holes for plug welding using inert gas. Maintain spacing between holes as on the old part.
Fig 2: Identifying Drill Holes For Plug Welding On Wing Rail
Fig 3: Identifying Connecting Flanges Of Wing Rail

FOR INSTALLING OUTER SIDE MEMBER


CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING OUTER SIDE MEMBER

Fig 1: Applying Adhesive And Body Sealant On Outer Side Member

STRUCTURAL ADHESIVE
2. 1.2. Apply support adhesive to a height of 15 mm all around the sealing elements in
the areas -A und C- .
Apply support adhesive in the area -B- with two 15 mm high adhesive beads on the
B-pillar and opposite on the side member.
Support adhesive
Fig 2: Applying Support Adhesive On Outer Side Member
2. Fit and secure outer side member.
3. Weld in outer side member.

Fig 3: Identifying Weld In Outer Side Member
1. 3.1. Resistance spot-weld outer side member.
2. 3.2. Apply a full weld to outer side member using inert gas.
Fig 4: Identifying Resistance Spot-Weld Outer Side Member
3. 3.3. Plug-weld outer side member using inert gas.

Fig 5: Identifying Plug-Weld Outer Side Member

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING OUTER SIDE MEMBER >
INSTALLING WING RAIL
1. Fit and secure wing rail.

Fig 1: Identifying Plug-Weld Wing Rail

WM 514955 REPLACING SIDE MEMBER REINFORCEMENT (CAYENNE, CAYENNE


Leister- equipment
Electron/V.A.G.
1416

System, Celette
System, Car
Bench

Spotweld equipment
Remover, Vario
Drill WS 90


1523A equipment
body gap
dimensions

available tool

available tool

vehicle.
protective covers.

ON QUALITY
Danger of injury
Tools and metalworking tools TOOLS

Rotary brush
Support adhesive
Structural adhesive

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING SIDE MEMBER
REINFORCEMENT
1. Remove outer side member. → Removing Outer Side Member
2. Remove A-pillar reinforcement. → Removing A-Pillar Reinforcement 513855 REPLACING

A-PILLAR REINFORCEMENT
3. Remove outer B-pillar reinforcement. → Installing B-Pillar Reinforcement 514255 REPLACING

B-PILLAR REINFORCEMENT
Fig 1: Identifying Side Member Reinforcement

Fig 2: Identifying Welded Joints On Side Member Reinforcement

Fig 3: Identifying Welded Joints On Side Member Reinforcement

Fig 4: Removing Spotwelds On Side Member Reinforcement

Fig 5: Identifying Side Member Reinforcement
9. Remove lower side member reinforcement.

CAYENNE S DIESEL, CAYENNE (3.0)) > PREPARING SIDE MEMBER

Fig 1: Identifying Drill Holes For Plug Welding On Side Member Reinforcement
2. Grind both sides of connecting flanges of side member reinforcement in the marked areas until
bare.
Fig 2: Identifying Connecting Flanges Side Member Reinforcement
Information

CAYENNE S DIESEL, CAYENNE (3.0)) > PREPARING CONNECTION AREAS OF THE
BODY FOR INSTALLING SIDE MEMBER REINFORCEMENT

1. 1.1. Clean body connecting flanges of underbody protection, adhesive residue and
paint in the marked areas.
Information

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING OUTER B-PILLAR
REINFORCEMENT > INSTALLING SIDE MEMBER REINFORCEMENT
1. Apply adhesive.
Fig 1: Applying Adhesive On Side Member Reinforcement

STRUCTURAL ADHESIVE
2. Fit and secure side member reinforcement.
3. Resistance spot-weld side member reinforcement.

Fig 2: Identifying Resistance Spot-Weld Side Member Reinforcement
4. Weld in side member reinforcement.

Fig 3: Identifying Weld In Side Member Reinforcement
1. 4.1. Resistance spot-weld side member reinforcement.
2. 4.2. Spot-weld side member reinforcement using inert gas.
5. Plug-weld side member reinforcement using inert gas.

Fig 4: Identifying Plug-Weld Side Member Reinforcement
6. Install outer B-pillar reinforcement. → Installing B-Pillar Reinforcement 514255 REPLACING

B-PILLAR REINFORCEMENT
7. Install A-pillar reinforcement. → Installing A-Pillar Reinforcement 513855 REPLACING

A-PILLAR REINFORCEMENT
8. Install outer side member. → Installing Outer Side Member 514555 REPLACING OUTER
SIDE MEMBER
WM 516819 REMOVING AND INSTALLING DASHBOARD BRACKET (CAYENNE,

Fastening nut Item 3 Tightening 20 Nm (15

securing torque ftlb.)
dashboard bracket
to body at the left
Fastening nuts for dashboard bracket at the left
Fastening nut Item 3 Tightening 20 Nm (15

dashboard bracket
to body at the right
Fastening nut for dashboard bracket at the right
Fastening screw Item 2 Tightening 20 Nm (15

securing bracket to torque ftlb.)
center tunnel
Fastening screws securing dashboard to center tunnel
Fastening screw Tightening 20 Nm (15

securing engine torque ftlb.)
compartment to
dashboard bracket
Fastening screws securing engine compartment to bracket
Fastening screw Tightening 10 Nm (7.5

under main cable torque ftlb.)
duct
Fastening screw on main cable duct

dashboard bracket
to plenum panel
Fastening screw securing dashboard to plenum panel

1. Remove dashboard. → REMOVING DASHBOARD
2. Loosen steering column at the bracket. → REMOVING STEERING COLUMN
3. Detach wiper linkage. → REMOVING WIPER ARMS

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING DASHBOARD SUPPORT
> REMOVING DASHBOARD BRACKET
Information
The number of fastening screws, fixing clips, plug connections, holders and trim panels can vary
depending on equipment.
The illustrations for removing and installing the drive mechanism are shown only on one equipment
variant and may differ from the actual equipment variant.
Some steps must be carried out automatically.
Information
Due to the large number of cable attachments, not all cable attachments can be described and
illustrated.
Information
When removing the dashboard support, make sure that wires or plug connections are not damaged.
Fig 1: Identifying Dashboard Bracket Installation Position
1. Unscrew and remove the fastening screws -1- for the fuse box at the left and right and leave
the fuse box hanging at the lines.
Fig 2: Removing Bracket For Fuse Box At Left And Right
2. Screw off fastening nut on driver's side -arrow - and remove ground cable.
Fig 3: Locating Ground Cable Fastening Nut (Driver's Side)
3. Screw off fastening nut on passenger's side -arrow- and remove ground cable.
Fig 4: Locating Ground Cable Fastening Nut (Passenger's Side)
4. Release and unplug four electric plug connections for the front-end electronics control unit on
the driver's side. → REMOVING CONTROL UNIT FOR FRONT-END ELECTRONICS
5. Release and unplug electric plug connection for the voltage transformer for Start/Stop on the
passenger's side. → REMOVING VOLTAGE CONVERTER FOR START/STOP
6. Loosen tie-wraps -arrows- and remove wire harness from the dashboard bracket.
Fig 5: Locating Tie-Wraps
7. Unclip wire harness along the dashboard bracket -arrows- .

Fig 6: Locating Wire Harness
8. Unclip main cable duct from the heater/air-conditioning unit -arrow- .

Fig 7: Locating Main Cable Duct
9. Release electric plug connection at the headlight control unit and disconnect it. → REMOVING
HEADLIGHT CONTROL UNIT
10. Release electric plug connection for KESSY antenna and disconnect it. → REMOVING
KESSY ANTENNA
11. Remove dashboard bracket.
1. 11.1. Unscrew and remove fastening screw for dashboard bracket in the engine
compartment -arrow- .
Fig 8: Locating Engine Compartment To Bracket Fastening Screws
2. 11.2. Lift up main cable duct and unscrew and remove the fastening screw -arrow-
under the main cable duct.
Fig 9: Locating Fastening Screw On Main Cable Duct
3. 11.3. Unscrew and remove fastening screw for dashboard bracket at the plenum
panel -arrow- .
Fig 10: Locating Plenum Panel Fastening Screw
4. 11.4. Unscrew and remove four fastening screws used to secure the dashboard
bracket to the center tunnel at the left and right.
Fig 11: Identifying Dashboard To Centre Tunnel Fastening Screws
5. 11.5. Unscrew two fastening nuts -3- used to secure the dashboard bracket to the
body at the left.
Fig 12: Identifying Dashboard Bracket Fastening Nuts
6. 11.6. Unscrew one fastening nut -3- used to secure the dashboard bracket to the
body at the right.
Fig 13: Identifying Dashboard Bracket Fastening Nut (Right)
12. Guide dashboard bracket out of the wire harness and remove it.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING DASHBOARD
SUPPORT > INSTALLING DASHBOARD BRACKET
Information
illustrated.
Information
When positioning the dashboard support, make sure that wires or plug connections are not jammed.
Information
Before securing the dashboard support, make sure that all lines and plug connections are routed
correctly.
1. Get another mechanic to help you position the dashboard bracket in such a way that the wire
harnesses can be clipped in.
2. Install dashboard bracket.

1. 2.1. Tighten two fastening nuts at the left used to secure the dashboard bracket to
the body -3- to Tightening torque 20 Nm (15 ftlb.) .
Fig 1: Identifying Dashboard Bracket Fastening Nut (Left)
2. 2.2. Tighten one fastening nut -3- at the right used to secure the dashboard bracket
to the body to Tightening torque 20 Nm (15 ftlb.) .
Fig 2: Identifying Dashboard Bracket Fastening Nut (Right)
3. 2.3. Tighten four fastening screws on the center tunnel -2- to Tightening torque 20
Nm (15 ftlb.) .
Fig 3: Identifying Centre Tunnel Fastening Screws
4. 2.4. Tighten fastening screw used to secure engine compartment to dashboard

bracket -arrow- to Tightening torque 20 Nm (15 ftlb.) .
Fig 4: Locating Engine Compartment To Bracket Fastening Screws
5. 2.5. Tighten fastening screw under the main cable duct -arrow- to Tightening
torque 10 Nm (7.5 ftlb.) .
Fig 5: Locating Main Cable Duct Fastening Screw
6. 2.6. Tighten fastening screw used to secure the dashboard bracket to the plenum
panel -arrow- to Tightening torque 10 Nm (7.5 ftlb.) .
Fig 6: Locating Dashboard To Plenum Panel Fastening Screw
3. Clip in main cable duct at the heater/air-conditioning unit -arrow- .

Fig 7: Locating Clipping In Main Cable Duct
4. Clip in wire harness along the dashboard bracket -arrows- .

Fig 8: Locating Clipping In Wire Harness
5. Secure wire harness on the dashboard bracket with new tie-wraps -arrows- .
6. Connect ground cable to ground pin.
7. Attach ground cable to the stud and screw on fastening nut on driver's side -arrow- .
Fig 10: Locating Ground Cable Point On Driver's Side
8. Attach ground cable to the stud and screw on fastening nut on passenger's side -arrow- .
Fig 11: Locating Ground Cable Point On Passenger's Side
9. Plug in and lock electric plug connection on headlight control unit. → INSTALLING
HEADLIGHT CONTROL UNIT
10. Plug in and lock electric plug connection for KESSY antenna. → INSTALLING KESSY
ANTENNA
11. Plug in and lock four electric plug connections for the front-end electronics control unit. →
INSTALLING CONTROL UNIT FOR FRONT-END ELECTRONICS
12. Plug in and lock electric plug connection for voltage transformer for Start/Stop. → INSTALLING
VOLTAGE CONVERTER FOR START/STOP
13. Position fuse box at the left and right and secure with the two fastening screws -1- .
Fig 12: Identifying Fuse Box Fastening Screws (Left And Right)

1. Secure the steering column at the bracket. → INSTALLING STEERING COLUMN (CENTRE)
2. Install dashboard. → INSTALLING DASHBOARD
3. Secure the wiper linkage. → INSTALLING WIPER ARMS
WM 516819 REMOVING AND INSTALLING DASHBOARD SUPPORT (EXCEPT

Fastening nut Tightening 20 Nm (15

dashboard support
to body at the left
dashboard support
to body at the right
Fastening screw Tightening 20 Nm (15 +/-15 %

securing support to torque ftlb.)
center tunnel
Fastening screw Tightening 20 Nm (15 +/-15 %

securing engine torque ftlb.)
compartment to
dashboard support
Fastening screw Tightening 10 Nm (7.5 +/-15 %

under main cable torque ftlb.)
duct
Fastening screw Tightening 10 Nm (7.5 +/-15 %

dashboard support
to plenum panel

1. Remove the dashboard. → REMOVING DASHBOARD
2. Detach the steering column at the bracket. → REMOVING STEERING COLUMN
3. Detach the wiper linkage. → REMOVING WIPER ARMS

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING DASHBOARD
SUPPORT
Information
illustrated.
Information
When removing the dashboard support, make sure that wires or plug connections are not damaged.
Fig 1: Identifying Dashboard Support Installation Position
1. Unscrew the fastening screws -1- for the fuse box at the left and right and leave the fuse box
hanging at the wires.
Fig 2: Removing Bracket For Fuse Box At Left And Right
2. Screw off fastening nut on driver's side -arrow - and remove the ground cable.
3. Screw off fastening nut on passenger's side -arrow- and remove the ground cable.
4. Release and unplug four electric plug connections for the control unit for front-end electronics
on the driver's side. → REMOVING CONTROL UNIT FOR FRONT-END ELECTRONICS
5. Release and unplug electric plug connection for the voltage transformer for Start/Stop on the
passenger's side. → REMOVING VOLTAGE CONVERTER FOR START/STOP
6. Remove tie-wraps -arrows- and remove the wire harness from the dashboard support.
7. Unclip the wire harness along the dashboard support -arrows- .

Fig 6: Locating Wire Harness
8. Unclip the main cable duct from the heater/air-conditioning unit -arrow- .
Fig 7: Locating Main Cable Duct
9. Remove dashboard support.
1. 9.1. Unscrew fastening screw for the dashboard support in the engine compartment
-arrow- .
Fig 8: Locating Engine Compartment Fastening Screws
2. 9.2. Lift up the main cable duct and unscrew the fastening screw -arrow- under the
main cable duct.
3. 9.3. Unscrew fastening screw for the dashboard support at the plenum panel
-arrow- .
4. 9.4. Unscrew four fastening screws used to secure the dashboard support to the
center tunnel.
5. 9.5. Unscrew two fastening nuts -3- used to secure the dashboard support to the
body at the left.
Fig 12: Identifying Dashboard Support Fastening Nuts (Left)
6. 9.6. Unscrew one fastening nut -3- used to secure the dashboard support to the
body at the right.
Fig 13: Identifying Dashboard Support Fastening Nuts (Right)
10. Guide the dashboard support out of the wire harness and remove it.

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING
DASHBOARD SUPPORT
Information
illustrated.
Information
When positioning the dashboard support, make sure that wires or plug connections are not jammed.
Information
Before securing the dashboard support, make sure that all lines and plug connections are routed
correctly.
1. Get another mechanic to help you position the dashboard support in such a way that the wire
harnesses can be clipped in.
2. Install dashboard support.

1. 2.1. Tighten two fastening nuts at the left for securing the dashboard support to the
body -3- to → Tightening torque: 20 Nm (15 ftlb.) .
Fig 1: Identifying Dashboard Support Fastening Nuts (Left)
2. 2.2. Tighten one fastening nut -3- at the right for securing the dashboard support to
the body to → Tightening torque: 20 Nm (15 ftlb.) .
Fig 2: Identifying Dashboard Support Fastening Nuts (Right)
3. 2.3. Tighten four fastening screws on the center tunnel -2- to → Tightening torque:
20 Nm (15 ftlb.)+/-15 % .
4. 2.4. Tighten fastening screw securing engine compartment to dashboard support

-arrow- to → Tightening torque: 20 Nm (15 ftlb.)+/-15 % .
Fig 4: Locating Engine Compartment Fastening Screws
5. 2.5. Tighten fastening screw under the main cable duct -arrow- to → Tightening
torque: 10 Nm (7.5 ftlb.)+/-15 % .
6. 2.6. Tighten fastening screw securing dashboard support to plenum panel -arrow- to
→ Tightening torque: 10 Nm (7.5 ftlb.)+/- 15 % .
3. Clip in the main cable duct at the heater/air-conditioning unit -arrow- .

Fig 7: Locating Clipping In Main Cable Duct
4. Clip in wire harness along the dashboard support -arrows- .

Fig 8: Locating Clip In Wire Harness
5. Secure the wire harness on the dashboard support with new tie-wraps -arrows- .
6. Connect ground cable to ground pin.
7. Attach the ground cable to the stud and screw on fastening nut on driver's side -arrow- .
8. Attach the ground cable to the stud and screw on fastening nut on passenger's side -arrow- .
9. Plug in and lock four electric plug connections for the control unit for front-end electronics on
the driver's side. → INSTALLING CONTROL UNIT FOR FRONT-END ELECTRONICS
10. Plug in and lock electric plug connection on control unit at the passenger's side.
11. Position fuse box at the left and right and secure with the two fastening screws -1- .
Fig 12: Installing Bracket For Fuse Box At Left And Right

1. Secure the steering column at the bracket. → INSTALLING STEERING COLUMN (CENTRE)
2. Install the dashboard. → INSTALLING DASHBOARD
3. Secure the wiper linkage. → INSTALLING WIPER ARMS
WM 517055 REPLACING THREADED BUSH FOR SEAT CONNECTION (CAYENNE,


conical shell Commercially Nr.128
reaming drill available tool
spotweld drill Commercially Nr.129

available tool

PRELIMINARY WORK FOR BODY REPAIRS (WITHOUT STRAIGHTENING SYSTEM)
1. 1.1. Remove accessories in the repair area according to the extent of damage on the
vehicle.
2. Cover accessories adjacent to the repair area on the vehicle.
protective covers.
3. Reshape connection area of the sheetmetal parts to be replaced. Note: Information on

aluminum repairs
1. 4.1. Remove underbody protection, paint, etc. from the joint areas of the body using
a hot-air gun or rotary brush.

Designation Dimension Note
Diameter of outlet -x- 30 mm

hole

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING THREADED BUSH FOR
SEAT CONNECTION
Fig 1: Identifying Threaded Bush For Seat Connection
1. Drill out drain hole.
1. 1.1. On the seat cross member extension, use a conical shell reaming drill Nr.128
to drill out the diameter of the drain hole to the dimension -A- = 30 mm.
Fig 2: Identifying Drain Hole Dimension
2. Remove burrs from cut edges.

Fig 3: Identifying Cut Edges
3. Separate welded joints
1. 3.1. Drill out the joints between the seat cross member and threaded insert using a
spotweld drill Nr.129 .
Fig 4: Identifying Welded Joints
4. Remove threaded bush.
1. 4.1. Remove the old threaded bush -1- through the widened opening.
Fig 5: Identifying Threaded Bush

Fig 6: Removing Threaded Bush

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING THREADED BUSH FOR
SEAT CONNECTION
Fig 1: Identifying Threaded Bush For Seat Connection
1. Prepare threaded bush for installation.

Fig 2: Identifying Threaded Bush For Installation
1. 1.1. Grind the threaded bush -1- bright on the contact surface with the seat cross
member.
Fig 3: Installing Threaded Bush On Contact Surface With Seat Cross Member
2. Inserting threaded bush.
1. 2.1. Insert a new threaded bush -1- fully into the seat cross member from below.
2. 2.2. Set the threaded bush -1- at a slight angle.
3. 2.3. Insert an M8 x 120 bolt -2- into the seat cross member from above.
4. 2.4. Screw the bolt -2- approx. three turns into the threaded bush -1- .
5. 2.5. Pull the threaded bush -1- with the bolt -2- up to the seat cross member.
Fig 4: Inserting Threaded Bush
3. Position the threaded bush and weld it into place.
1. 3.1. Align the threaded bush -2- in the middle.
2. 3.2. Weld the threaded -1- insert into the existing holes using MIG welding.
Fig 5: Identifying Threaded MIG Welding (1 Of 2)

Fig 6: Identifying Threaded MIG Welding (2 Of 2)
4. Grinding the spot welds flat
1. 4.1. Unscrew the bolt and grind the spot welds flat.
5. Clean spot-welded joints and sheetmetal flanges with a wire brush.
6. Prime welds and unpainted areas of the body with 2K primer.
7. Sealing flange areas with body sealant.
8. Add cavity preservation inside the seat cross member → Cavity preservation .
9. Closing the drain hole.
1. 9.1. Close off the drain hole from below using a stopper with a diameter of 30 mm
-3- .
Fig 7: Identifying Drain Hole And Stopper
10. Restore standard seal with body sealant → Seam seal
11. Restore standard underbody protection with underbody sealing compound → underseal .
WM 518941 REPAIRING THREADED BUSH FOR CHASSIS SUBFRAME MOUNT


Time-Sert Special tool Nr.122-1
thread repair
set
Spot facer for Special tool Nr.122-2

Time-Sert
thread repair
set
Spot facer for Commercially NR.122-2

Time-Sert available tool
thread repair
set

Milling depth Dimension X Test and 10 mm

for threaded (measured from adjustment
bush outer edge of value
sheet)
Thread depth Dimension Y Test and 40 mm

(measured from adjustment
outer edge of value
sheet)

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TOOLS AND MATERIALS
Fig 1: Identifying Thread Repair Set
Information
To mill the required shoulder, the tool with the designation Spot facer for Time-Sert thread repair
set NR.122-2 must be used. The tool provided with the complete set supplied must not be used in
this case!
Item Tool
-1- Time-Sert thread repair set Nr.122-1
-A- Threaded bush
-B- Drill bit
-C- Spot facer for Time-Sert thread repair set Nr.122-2
-D- Thread cutter
-E- Screw-in tool

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REPAIR
THREADED BUSH
NOTE: Modified chassis jacking points on rear axle
Incorrectly screwed joints on chassis parts following thread repair.
→ Always secure the rear axle using the → HEXAGON-HEAD BOLT N.909.763.02 following repairs to
the chassis bush.
→ Always replace fastening screws.

Fig 1: Identifying Threaded Bush

Fig 2: Replacing Fastening Screws
Information
The repair bush must be installed recessed. To mill the required shoulder, the tool with the
designation Spot facer for Time-Sert thread repair set NR.122-2 must be used. The tool provided
with the complete set supplied must not be used in this case!
1. Drill out thread.
1. 1.1. Drill out the old thread with a drill to the root of the thread.
Fig 3: Drilling Out Thread
2. Mill shoulder.
1. 2.1. Use a spot facer -C- to mill out the bore hole to dimension -X- . → Test and
adjustment value: 10 mm Milling in can only be performed using the tool Spot
facer for Time-Sert thread repair kit Nr.122-2 ! Use an electronically controlled
power drill set to a speed of approx. 250 RPM for milling in .
Fig 4: Cutting Thread Using Cutting Tool
3. Cut thread.
1. 3.1. Cut thread using a cutting tool -D- up to dimension -Y- in the chassis bush. →
Test and adjustment value: 40 mm Clean the thread on the chassis bush (blow it
out).
Fig 5: Identifying Threaded Bush Onto Screw-In Tool
4. Position threaded bush on screw-in tool.
1. 4.1. Clean thread on bush and on screw-in tool.
2. 4.2. Oil the screw-in tool -E- .
3. 4.3. Screw the threaded bush -A- onto the screw-in tool -E- by hand.
Fig 6: Screwing Threaded Bush Onto Screw-In Tool
5. Screw in threaded bush.
1. 5.1. Fully screw in the threaded bush using the screw-in tool -E- .
Fig 7: Screwing Threaded Bush Using Screw-In Tool
Information
1. While pressing in the base thread, a noticeably larger amount of force on the screw-in
tool is required to form the internal thread. Pressing is finished when the screw-in tool
can be turned further more easily.
6. Press threaded bush.
1. 6.1. Form and press the threaded bush by turning further with the screw-in tool -E- in
the base thread.
Fig 8: Pressing Threaded Bush
7. Unscrew the screw-in tool -E- from the threaded bush.

Fig 9: Unscrewing Screw-In Tool From Threaded Bush
WM 519319 REMOVING AND INSTALLING COVER FOR CENTRE UNDERBODY

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING COVER FOR
CENTRE UNDERBODY
Information
1. Loosen the rear fastening screws -1- for the front wheel housing liner.
Fig 1: Releasing Front Wheel Housing Liner
2. Loosen the front fastening screw -1- for the rear wheel housing liner.
Fig 2: Removing Rear Wheel Housing Liner

Fig 3: Detaching Centre Underbody Panelling
4. Remove cover for center underbody.
WM 519319 REMOVING AND INSTALLING COVER FOR CENTRE UNDERBODY

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING COVER FOR
CENTRE UNDERBODY
1. The underbody cover is installed in reverse order to removal.

Service Manual: 53 - BODY REAR -- 92A CAYENNE
WM 530555 REPLACING REAR CLOSING PANEL > TOOLS
Hot-Air Blower,
Workshop
Leister- WE 1119
Equipment
Electron/VAG 1416

WE 1121
WE 1122

WE 1137
Pneumatic Spotweld
Workshop
Equipment
WS 90

WE 1141
1628 Equipment
Body Saw VAG Workshop

WE 1347
1523A equipment
Star Gauges For
Body Gap Special Tool Nr. 127-1
Dimensions
Commercially
Spotweld Drill Nr. 129
Available Tool
Commercially
Twist Drill Nr. 201
Available Tool
WM 530555 REPLACING REAR CLOSING PANEL > PRELIMINARY WORK >

PRELIMINARY WORK FOR BODY REPAIRS
Information
1. Removing accessories in the repair area.
vehicle.

1. 2.1. Set up straightening bench with the straightening set according to the set-up
drawings included with the straightening set.
Information
1. 3.1. Position vehicle on straightening bench, align to the reference holes and firmly
bolt using the straightening set.
1. 4.1. Cover all accessories remaining on the vehicle and the neighboring areas with
fire-proof, protective covers.
6. Exposing welding areas.
WM 530555 REPLACING REAR CLOSING PANEL > SAFETY INSTRUCTIONS AND

Danger of injury
→ Read the relevant safety instructions as well as general information and quality instructions →
SAFETY INSTRUCTIONS Safety instructions
WM 530555 REPLACING REAR CLOSING PANEL > TOOLS AND MATERIALS >
Pneumatic body saw Body Saw VAG 1523A WE 1347
Rotary brush
Cartridge gun Cartridge Gun VAG 1628 WE 1141 .
Spotweld drill Spotweld Drill Nr. 129 .
Twist drill Twist Drill Nr. 201 .
Star gauge for body gap dimensions Star Gauges For Body Gap Dimensions Nr. 127-1 .
Support adhesive
Structural adhesive
WM 530555 REPLACING REAR CLOSING PANEL > REMOVING CLOSING PANEL >
CLOSING PANEL REMOVAL
Fig 1: Identifying Closing Panel
Information
1. Cut off closing panel.
1. 1.1. Cut the welded joint on the closing panel with the spotweld cutter (areas -A, B-
and -C, D- ). Cut the MIG seams at the top of the closing panel with a parting grinder
(area -E- ).
Fig 2: Identifying Welded Joint On Closing Panel (1 Of 7)






2. Remove the closing panel.
WM 530555 REPLACING REAR CLOSING PANEL > FITTING CLOSING PANEL AND
PREPARING FOR INSTALLATION
Fig 1: Identifying Closing Panel Welding And Sealing Areas
1. 1.1. Grind both sides of the connection flange of the closing panel in the marked
areas -A, B- , -C, D- , -E until bare using a rotary brush.
Fig 2: Identifying Connection Flange Of Closing Panel Welding Areas (1 Of 4)



1. 2.1. Coat all spot-weld flange areas with zinc powder paint (areas -A, B- , -C, D- ).
WM 530555 REPLACING REAR CLOSING PANEL > PREPARING CONNECTION

AREAS OF BODY FOR INSTALLING THE CLOSING PANEL
Fig 1: Identifying Closing Panel Connection Areas Of Body
1. 1.1. Clean the body connection flanges of undersealing, adhesive residue and paint
in the marked areas using a hot-air gun or rotary brush. Grind the connection flange
until bare.
Fig 2: Identifying Body Connection Welding And Sealing Areas (1 Of 3)


WM 530555 REPLACING REAR CLOSING PANEL > INSTALLING CLOSING PANEL

Fig 1: Identifying Closing Panel
1. Fit the closing panel to the body.
1. 1.1. Position the closing panel on the body and fix in place with tensioning clamps.
Ensure that the closing panel is positioned flat at the connection point for the bumper.
2. Resistance spot-weld the closing panel.
1. 2.1. Resistance spot-weld the closing panel in areas -A, B- (-A, B- ) and -C, D- .
Fig 2: Identifying Resistance Spot-Weld On Closing Panel Areas (1 Of 4)



3. Inert gas arc weld the closing panel.
1. 3.1. Inset gas arc weld the closing panel in the area -E- (-E- ) with a full weld.
WM 530555 REPLACING REAR CLOSING PANEL > SUBSEQUENT WORK >


7. Apply cavity preservation to the accessible areas of the repair
WM 530955 REPLACING LOCK CARRIER > TOOLS
Hot-Air Blower,
Workshop
Leister- WE 1119
Equipment
Electron/VAG 1416

WE 1121
WE 1122

WE 1137
Pneumatic Spotweld
Workshop
Equipment
WS 90

WE 1141
1628 Equipment

WE 1347
1523A Equipment
Star Gauges For
Dimensions
Commercially
Available Tool
Commercially
Twist Drill Nr. 201
available tool
WM 530955 REPLACING LOCK CARRIER > PRELIMINARY WORK > PRELIMINARY

Information
1. Removing accessories in the repair area.
vehicle.

1. 2.1. Set up straightening bench with the straightening set according to the set-up
drawings included with the straightening set.
Information
1. 3.1. Position vehicle on straightening bench, align to the reference holes and firmly
bolt using the straightening set.
1. 4.1. Cover all accessories remaining on the vehicle and the neighboring areas with
fire-proof, protective covers.
6. Exposing welding areas.
WM 530955 REPLACING LOCK CARRIER > SAFETY INSTRUCTIONS AND

Danger of injury
WM 530955 REPLACING LOCK CARRIER > TOOLS AND MATERIALS > TOOLS AND
Resistance spot welder.
Rotary brush
Leister Electron hot-air blower Hot-Air Blower, Leister-Electron/VAG 1416 WE 1119 .
Spotweld Drill Spotweld Drill .
Support adhesive
Structural adhesive
WM 530955 REPLACING LOCK CARRIER > REMOVING LOCK CARRIER
Information
Fig 1: Identifying Lock Carrier Components
1. Lock carrier
2. D-pillar gusset plate, right
3. D-pillar gusset plate, left
1. Remove end plate. → REMOVING CLOSING PANEL

Fig 2: Overview Of Lock Carrier From Inside
2. Cut off D-pillar gusset plates.
1. 2.1. Mill off welded joints on the D-pillar gusset plates using the spotweld cutter
(areas -A- ).
Fig 3: Identifying Welded Joints On Left D-Pillar Gusset Plate

Fig 4: Identifying Welded Joints On Right D-Pillar Gusset Plate
2. 2.2. Grind off MIG seams on the D-pillar gusset plates using a parting grinder (areas
-B- ).
3. Remove D-pillar gusset plates.

Fig 5: Identifying D-Pillar Gusset Plates Working Area
4. Cut off outer lock carrier.
1. 4.1. Mill off welded joints on the lock carrier using the spotweld cutter (areas -C- ).
Fig 6: Identifying Mill Off Welded Joints On Lock Carrier (Areas C)
2. 4.2. Grind off MIG seams on the lock carrier using a parting grinder (area -D- ).
3. 4.3. Mill off welded joints on the lock carrier using the spotweld cutter (area -E- ).
Fig 7: Identifying Mill Off Welded Joints On Lock Carrier (Areas E)
4. 4.4. Mill off welded joints on the lock carrier using the spotweld cutter (areas -F- ).
Fig 8: Identifying Mill Off Welded Joints On Lock Carrier (Areas F)
5. 4.5. Grind off MIG seams on the lock carrier using a parting grinder (area -G- ).
Fig 9: Identifying MIG Seams On Lock Carrier
5. Cut off inner lock carrier.

1. 5.1. Grind off MIG seams on the lock carrier using a parting grinder (area -H- ).
Fig 10: Grinding Off MIG Seams On Lock Carrier Using Parting Grinder
2. 5.2. Mill off welded joints on the lock carrier using the spotweld cutter (area -I- ).
3. 5.3. Grind off MIG seams on the lock carrier using a parting grinder (area -J- ).
Fig 11: Grinding Off MIG Seams On Lock Carrier Using Parting Grinder (Area J)
4. 5.4. Mill off welded joints on the lock carrier using the spotweld cutter (area -K- ).
6. Remove lock carrier.
WM 530955 REPLACING LOCK CARRIER > FITTING LOCK CARRIER AND

PREPARING FOR INSTALLATION > FITTING IN LOCK CARRIER AND PREPARING
FOR INSTALLATION
Fig 1: Identifying Connection Areas On Lock Carrier And D-Pillar Gusset Plates
1. 1.1. Grind both sides of the connecting flanges of the lock carrier in the marked areas
until bare using a rotary brush.
Fig 2: Identifying Contact Area Of Lock Carrier For Installation
2. 1.2. Grind both sides of the connecting flanges of the D-pillar gusset plates in the
marked areas until bare using a rotary brush.
Fig 3: Identifying Contact Area Of D-Pillar Gusset Plates For Installation
WM 530955 REPLACING LOCK CARRIER > PREPARING CONNECTION AREAS OF

BODY FOR INSTALLING THE LOCK CARRIER
Fig 1: Identifying Connection Areas For Lock Carrier
1. 1.1. Clean undersealing, adhesive residue and paint off the connecting flanges of the
body in the marked areas using a hot-air gun or rotary brush. Grind the connecting
flanges until bare.
Fig 2: Identifying Connection Areas On Inner Left Side

Fig 3: Identifying Connection Areas On Spare-Wheel Well And On Left Side Member

Fig 4: Identifying Connection Areas On Inner Right Side

Fig 5: Identifying Connection Areas On Spare-Wheel Well (Right Side Member)
WM 530955 REPLACING LOCK CARRIER > INSTALLING LOCK CARRIER

Fig 1: Identifying Lock Carrier Installation Position
1. Lock carrier
2. D-pillar gusset plate, right
3. D-pillar gusset plate, left
1. Fit lock carrier to the body.
1. 1.1. Position the lock carrier on the body and fix in place with tensioning clamps.
Fig 2: Identifying Lock Carrier On Body (Inside)
2. Weld in inner lock carrier in area of D-pillar reinforcement and right side floor section.
1. 2.1. Weld the lock carrier in areas -A and B- using inert gas.
Fig 3: Identifying Welded Joints On Right Inner Lock Carrier

2. 2.2. Plug-weld the lock carrier in area -C- using inert gas.
3. Weld in inner lock carrier in area of D-pillar reinforcement and left side floor section.
1. 3.1. Weld the lock carrier in areas -D and E- using inert gas.
Fig 4: Identifying Welded Joints On Inner Left Lock Carrier
2. 3.2. Plug-weld the lock carrier in area -F- using inert gas.
Fig 5: Identifying Lock Carrier Working Area
4. Weld in outer lock carrier in right side member area.
1. 4.1. Resistance spot-weld the lock carrier in areas -G- .

Fig 6: Identifying Welded Joints On Right Outer Lock Carrier
2. 4.2. Weld lock carrier in area -H- using inert gas.

Fig 7: Identifying Weld Lock Carrier Working Area
5. Weld in lock carrier in spare-wheel well area.
1. 5.1. Resistance spot-weld the lock carrier in area -I- .

Fig 8: Identifying Welded Joints On Outer Lock Carrier

Fig 9: Identifying Outer Lock Carrier Working Area
6. Weld in outer lock carrier in left side member area.
1. 6.1. Resistance spot-weld the lock carrier in areas -J- .

Fig 10: Identifying Welded Joints On Left Outer Lock Carrier
2. 6.2. Weld lock carrier in area -K- using inert gas.
7. Fit D-pillar gusset plates on the body.
1. 7.1. Position D-pillar gusset plates on the body and fix in place with tensioning
clamps. Ensure that the D-pillar gusset plates are positioned flat at the connection
point for the end plate.
Fig 11: Overview From Inside D-Pillar Gusset Plates
8. Weld in D-pillar gusset plates.
1. 8.1. Weld D-pillar gusset plates in areas -L- and -N- using inert gas.
Fig 12: Identifying Welded Joints On Right D-Pillar Gusset Plate

Fig 13: Identifying Welded Joints On Left D-Pillar Gusset Plate
2. 8.2. Resistance spot-weld the D-pillar gusset plates in areas -M- and -O- .
9. Install end plate. → INSTALLING CLOSING PANEL
WM 530955 REPLACING LOCK CARRIER > SUBSEQUENT WORK > SUBSEQUENT

7. Apply cavity preservation to the accessible areas of the repair .
WM 532455 REPLACING REAR TRUNK FLOOR PANEL > TOOLS

Hot-Air Blower,
Workshop
Leister- WE 1119
Equipment
Electron/VAG 1416

WE 1121
WE 1122

WE 1137
Pneumatic Spotweld
Workshop
Equipment
WS 90

WE 1141
1628 Equipment

WE 1347
1523A Equipment
Star Gauges For
Dimensions
Commercially
Available Tool
Commercially
Twist Drill Nr. 201
Available Tool
WM 532455 REPLACING REAR TRUNK FLOOR PANEL > PRELIMINARY WORK >
vehicle.
protective covers.
WM 532455 REPLACING REAR TRUNK FLOOR PANEL > SAFETY INSTRUCTIONS

Danger of injury
WM 532455 REPLACING REAR TRUNK FLOOR PANEL > TOOLS AND MATERIALS >
Rotary brush
Spotweld drill Spotweld Drill .
Support adhesive
Structural adhesive
WM 532455 REPLACING REAR TRUNK FLOOR PANEL > REMOVING REAR TRUNK
FLOOR PANEL > REMOVING SPARE-WHEEL WELL AND SIDE FLOOR SECTION
Information
1. Remove lock carrier. → 530955 REPLACING LOCK CARRIER - section on "Removing"
2. Separate spare-wheel well and side floor section using rough cuts.
Fig 1: Identifying Rear Trunk Floor Panel
3. Detaching right and left floor section.

Fig 2: Identifying Rear Trunk Floor Panel (Right And Left Floor Section)
1. 3.1. Drill out spotwelds using Spotweld Drill .
2. 3.2. Grind down MIG seams in area -A- .
3. 3.3. Remove right and left floor section.
4. Detach spare-wheel well.

Fig 3: Removing Rear Trunk Floor Panel
2. 4.2. Heat up connection areas using a hot-air gun.

Fig 4: Identifying Rear Trunk Floor Panel Heat Connection Areas
3. 4.3. Remove spare-wheel well.
WM 532455 REPLACING REAR TRUNK FLOOR PANEL > REMOVING REAR TRUNK
FLOOR PANEL > REMOVING TOP INNER REAR AXLE CROSS MEMBER

Fig 1: Identifying Rear Trunk Floor Panel MIG Seams

Fig 2: Identifying Rear Trunk Floor Panel Drill Out Spotwelds
3. Drill out spotwelds through two plate thicknesses.

4. Drill out spotwelds.


Fig 5: Identifying Rear Trunk Floor Panel Heat Up Connection Areas
6. Remove top inner rear axle cross member.
WM 532455 REPLACING REAR TRUNK FLOOR PANEL > PREPARING REAR TRUNK
FLOOR PANEL FOR INSTALLATION > PREPARING SPARE-WHEEL WELL FOR
INSTALLATION
1. Make holes for plug-welding using inert gas using a body hole punch.
Fig 1: Identifying Spare-Wheel Holes For Plug-Welding
1. 2.1. Grind both sides of the connecting flanges of the spare-wheel well in the marked
areas until bare.
Fig 2: Identifying Connecting Flanges Of Spare-Wheel Well For Installation
FLOOR PANEL FOR INSTALLATION > PREPARING RIGHT AND LEFT FLOOR
SECTION FOR INSTALLATION
1. Make holes for plug-welding using inert gas with a body hole punch.
Fig 1: Identifying Right And Left Floor Section Plug-Welding Hole
1. 2.1. Grind both sides of the connecting flanges of the floor section in the marked
areas until bare.
Fig 2: Identifying Connecting Flanges Of Right And Left Floor Section
FLOOR PANEL FOR INSTALLATION > PREPARING TOP INNER REAR AXLE CROSS
1. Drill holes with a diameter of 10 mm for plug-welding using inert gas. Maintain spacing
between the bores as on the old part.
Fig 1: Identifying Inner Rear Axle Cross Member Plug-Welding Hole
1. 2.1. Grind both sides of the connecting flanges of the floor section in the marked
areas until bare.
Fig 2: Identifying Connecting Flanges Of Top Inner Rear Axle Cross Member
WM 532455 REPLACING REAR TRUNK FLOOR PANEL > PREPARING CONNECTION

AREAS OF THE BODY FOR INSTALLING REAR TRUNK FLOOR PANEL

Fig 1: Identifying Connection Areas Of Body For Installing Rear Trunk Floor Panel

WM 532455 REPLACING REAR TRUNK FLOOR PANEL > INSTALLING REAR TRUNK
FLOOR PANEL > INSTALLING TOP INNER REAR AXLE CROSS MEMBER
1. Fit and secure the top inner rear axle cross member.
2. Resistance spot-weld the top inner rear axle cross member.

Fig 1: Identifying Resistance Spot-Weld Top Inner Rear Axle Cross Member
3. Weld in the top inner rear axle cross member.

Fig 2: Identifying Weld In Top Inner Rear Axle Cross Member
1. 3.1. Plug-weld the top inner rear axle cross member through two plate thicknesses
using inert gas.
2. 3.2. Apply a welded seam to the top inner rear axle cross member in area -A- using
inert gas.
4. Plug-weld the top inner rear axle cross member using inert gas.
WM 532455 REPLACING REAR TRUNK FLOOR PANEL > INSTALLING REAR TRUNK
FLOOR PANEL > INSTALLING SPARE-WHEEL WELL AND SIDE FLOOR SECTION
1. Fit and secure spare-wheel well and side floor section.
2. Weld in the right and left floor section.

Fig 1: Identifying Weld In Right And Left Floor Section
1. 2.1. Plug-weld the floor section using inert gas.
2. 2.2. Apply a welded seam to the floor section in area -A- using inert gas.
3. 2.3. Resistance spot-weld the floor section in area -B- .
3. Weld in the spare-wheel well.

Fig 2: Identifying Resistance Spot-Weld Floor Section
1. 3.1. Resistance spot-weld the spare-wheel well.
2. 3.2. Plug-weld the spare-wheel well using inert gas.

Fig 3: Identifying Resistance Spot-Weld On Rear Trunk Floor Panel
4. Install lock carrier. → 530955 REPLACING LOCK CARRIER - section on "Installing"
WM 532455 REPLACING REAR TRUNK FLOOR PANEL > SUBSEQUENT WORK >
WM 532955 REPLACING C-PILLAR REINFORCEMENT > TOOLS

Hot-Air Blower,
Workshop
Leister- WE 1119
Equipment
Electron/VAG 1416

WE 1121
WE 1122

WE 1137
Pneumatic Spotweld
Workshop
Equipment
WS 90

WE 1141
1628 Equipment

WE 1347
1523A Equipment
Star Gauges For
Dimensions
Commercially
Available Tool
Commercially
Twist Drill Nr. 201
Available Tool
WM 532955 REPLACING C-PILLAR REINFORCEMENT > PRELIMINARY WORK >

vehicle.
protective covers.
WM 532955 REPLACING C-PILLAR REINFORCEMENT > SAFETY INSTRUCTIONS

Danger of injury
WM 532955 REPLACING C-PILLAR REINFORCEMENT > TOOLS AND MATERIALS >

Rotary brush
Twist drill Twist drill Nr. 201 .
Star gauge for body gap dimensions Star gauges for body gap dimensions Nr. 127-1 .
Support adhesive
Structural adhesive
WM 532955 REPLACING C-PILLAR REINFORCEMENT > REMOVING C-PILLAR

REINFORCEMENT
1. Remove rear side section (roof removed). → 535555 REPLACING REAR SIDE SECTION
(ROOF REMOVED) - section on "Removing"
2. Remove outer side member (rear section). → 514555 REPLACING OUTER SIDE MEMBER -
3. Remove closing panel. → 530555 REPLACING REAR CLOSING PANEL - section on

"Removing"

Fig 1: Identifying D-Pillar Gusset Plate MIG Seams
5. Remove D-pillar gusset plate.

Fig 2: Identifying C-Pillar Reinforcement

Fig 3: Identifying C-Pillar Reinforcement MIG Seams

Fig 4: Identifying Welded Joints C-Pillar Reinforcement

Fig 5: Identifying MIG Seams C-Pillar Reinforcement

Fig 6: Identifying C-Pillar Reinforcement Drill Out Spotwelds
Information
Drill out spotwelds A and B through two plate thicknesses.


Fig 8: Identifying C-Pillar Reinforcement Welded Joints

Fig 9: Identifying Welded Joints C-Pillar Reinforcement
1. 13.1. Drill out spotweld from outside.
14. Grind down spotwelds from outside.


16. Grind down and drill out spotwelds.

Fig 12: Removing C-Pillar Reinforcement Drill Out Spotwelds


Fig 14: Identifying C-Pillar Reinforcement Heat Up Connection Areas (1 Of 2)

19. Remove C-pillar reinforcement.
WM 532955 REPLACING C-PILLAR REINFORCEMENT > PREPARING C-PILLAR

1. Drill holes (Ø 8 mm) for plug welding.

Fig 1: Identifying C-Pillar Reinforcement Drill Holes For Plug Welding
2. Grind both sides of connecting flanges of C-pillar reinforcement in the marked areas until bare.
Fig 2: Identifying Connecting Flanges Of C-Pillar Reinforcement
Information
WM 532955 REPLACING C-PILLAR REINFORCEMENT > PREPARING CONNECTION

AREAS OF BODY FOR INSTALLING C-PILLAR REINFORCEMENT


Information
WM 532955 REPLACING C-PILLAR REINFORCEMENT > INSTALLING C-PILLAR

REINFORCEMENT
1. Apply adhesive.
Fig 1: Applying Adhesive To C-Pillar Reinforcement

STRUCTURAL ADHESIVE
2. Fit and secure C-pillar reinforcement.
3. Weld in C-pillar reinforcement.

Fig 2: Identifying Weld In C-Pillar Reinforcement
1. 3.1. Resistance spot-weld C-pillar reinforcement.
2. 3.2. Spot-weld C-pillar reinforcement using inert gas.
4. Resistance spot-weld C-pillar reinforcement.

Fig 3: Identifying Resistance Spot-Weld C-Pillar Reinforcement


7. Spot-weld C-pillar reinforcement using inert gas.

Fig 6: Identifying Spot-Weld C-Pillar Reinforcement


10. Install outer D-pillar reinforcement. → 533055 REPLACING REINFORCEMENT FOR

D-PILLAR - chapter on "Installing"
11. Install rear side section (roof removed). → 535555 REPLACING REAR SIDE SECTION
(ROOF REMOVED) - section on "Installing"
12. Install outer side member (rear section). → 514555 REPLACING OUTER SIDE MEMBER -
WM 532955 REPLACING C-PILLAR REINFORCEMENT > SUBSEQUENT WORK >


WM 532955 REPLACING C-PILLAR REINFORCEMENT (SECTION) > TOOLS
Hot-Air Blower,
Workshop
Leister- WE 1119
Equipment
Electron/VAG 1416

WE 1121
WE 1122

WE 1137
Pneumatic Spotweld
Workshop
Equipment
WS 90

WE 1141
1628 Equipment

WE 1347
1523A Equipment
Star Gauges For
Dimensions
Commercially
Available Tool
Commercially
Twist Drill Nr. 201
Available Tool
WM 532955 REPLACING C-PILLAR REINFORCEMENT (SECTION) > TECHNICAL

VALUES
Dimension A Distance To Hole (Centre) 65 mm
WM 532955 REPLACING C-PILLAR REINFORCEMENT (SECTION) > PRELIMINARY

WORK > PRELIMINARY WORK FOR BODY REPAIRS WITH STRAIGHTENING BENCH
vehicle.
protective covers.
WM 532955 REPLACING C-PILLAR REINFORCEMENT (SECTION) > SAFETY

Danger of injury
WM 532955 REPLACING C-PILLAR REINFORCEMENT (SECTION) > TOOLS AND

Resistance Spot Welder .
Metal Inert Gas (MIG) Welder .
Pneumatic Spotweld Remover Pneumatic Spotweld Remover, Vario Drill WS 90 WE 1139 .
Pneumatic Body Saw Body Saw VAG 1523A WE 1347
Oscillating Body Saw (Special Electric Cutter) Special Electric Cutter - Fine WE 1137 .
Rotary Brush
Leister Electron Hot-Air Blower Hot-Air Blower, Leister-Electron/VAG 1416 WE 1119 .

Cartridge Gun Cartridge Gun VAG 1628 WE 1141 .
Twist Drill Twist Drill Nr. 201 .
Star Gauge For Body Gap Dimensions Star Gauges For Body Gap Dimensions Nr. 127-1 .
Support Adhesive
Structural Adhesive
WM 532955 REPLACING C-PILLAR REINFORCEMENT (SECTION) > REMOVING

C-PILLAR REINFORCEMENT (SECTION)
1. Remove rear side section. → 535555 REPLACING REAR SIDE SECTION - section on
"Removing"
Information
this.
3. Mark and make cut. → Distance to hole (center): 65 mm

Fig 1: Identifying Distance To Hole (Centre) On C-Pillar Reinforcement
Information
Drill out spotweld A through two plate thicknesses.


Fig 3: Identifying C-Pillar Reinforcement Welded Joints
1. 5.1. Drill out spotweld from outside.
6. Grind down spotwelds from outside.






WM 532955 REPLACING C-PILLAR REINFORCEMENT (SECTION) > PREPARING

C-PILLAR REINFORCEMENT (SECTION) FOR INSTALLATION
1. Fit C-pillar reinforcement.
1. 1.1. Cut C-pillar reinforcement at the transition to the body in the area -A- leaving an
overlap of 30 mm.
Fig 1: Identifying C-Pillar Reinforcement Drill Out Spotwelds Area
2. 1.2. Drill out spotwelds in the area -B- so that no holes are made in the new part.
3. 1.3. Drill through spotwelds in the area -C- .
4. 1.4. Remove inner part of D-pillar reinforcement.
5. 1.5. Fit C-pillar reinforcement.

6. 1.6. Make cut through the C-pillar reinforcement and body in the overlap area.
3. Grind both sides of connecting flanges of C-pillar reinforcement in the marked areas until bare.
Fig 3: Identifying Connecting Flanges Of C-Pillar Reinforcement
Information
WM 532955 REPLACING C-PILLAR REINFORCEMENT (SECTION) > PREPARING

CONNECTION AREAS OF BODY FOR INSTALLING C-PILLAR REINFORCEMENT
(SECTION)

Fig 1: Identifying C-Pillar Reinforcement Body Welding And Sealing Areas
Information
WM 532955 REPLACING C-PILLAR REINFORCEMENT (SECTION) > INSTALLING

C-PILLAR REINFORCEMENT (SECTION)
1. Apply adhesive.
Fig 1: Applying Adhesive To C-Pillar Reinforcement
1. 1.1. Evenly apply adhesive to the marked areas (-A- on the inside).

STRUCTURAL ADHESIVE
2. Fit and secure C-pillar reinforcement.

2. 3.2. Plug-weld C-pillar reinforcement in the area -A- using inert gas.
4. Apply a full weld to C-pillar reinforcement using inert gas.

Fig 3: Identifying Plug-Weld C-Pillar Reinforcement Area


2. 6.2. Plug-weld C-pillar reinforcement using inert gas.
7. Spot-weld C-pillar reinforcement using inert gas.

Fig 6: Identifying Spot-Weld C-Pillar Reinforcement


10. Install rear side section. → 535555 REPLACING REAR SIDE SECTION - section on
"Installing"
WM 532955 REPLACING C-PILLAR REINFORCEMENT (SECTION) > SUBSEQUENT

WORK > SUBSEQUENT WORK FOR BODY REPAIRS

WM 533055 REPLACING D-PILLAR REINFORCEMENT > TOOLS
Hot-Air Blower,
Workshop
Leister- WE 1119
Equipment
Electron/VAG 1416

WE 1121
WE 1122

WE 1137
Pneumatic Spotweld
Workshop
Equipment
WS 90

WE 1141
1628 Equipment

WE 1347
1523A Equipment
Star Gauges For
Dimensions
Commercially
Available Tool
Commercially
Twist Drill Nr. 201
Available Tool
WM 533055 REPLACING D-PILLAR REINFORCEMENT > PRELIMINARY WORK >

vehicle.
protective covers.
WM 533055 REPLACING D-PILLAR REINFORCEMENT > SAFETY INSTRUCTIONS

Danger of injury
WM 533055 REPLACING D-PILLAR REINFORCEMENT > TOOLS AND MATERIALS >

Rotary brush
Cartridge Gun Cartridge Gun Vag 1628 We 1141 .
Support Adhesive
Structural Adhesive
WM 533055 REPLACING D-PILLAR REINFORCEMENT > REMOVING D-PILLAR

REINFORCEMENT
1. Remove rear side section (roof removed). → 535555 REPLACING REAR SIDE SECTION
(ROOF REMOVED) - section on "Removing"

"Removing"

Fig 1: Identifying D-Pillar Gusset Plate Welded Joints

Fig 2: Identifying D-Pillar Gusset Plate MIG Seams

Fig 3: Identifying D-Pillar Reinforcement MIG Seams
7. Drill out and grind down spotwelds.

Fig 4: Identifying D-Pillar Reinforcement Spotwelds

Fig 5: Identifying D-Pillar Reinforcement Welded Joints
Information
Drill out spotwelds A, B, C, D through two plate thicknesses.




Fig 9: Identifying D-Pillar Reinforcement Heat Up Connection Areas (1 Of 2)

Fig 10: Identifying D-Pillar Reinforcement Heat Up Connection Areas (2 Of 2)
13. Remove D-pillar reinforcement.
WM 533055 REPLACING D-PILLAR REINFORCEMENT > PREPARING D-PILLAR

REINFORCEMENT FOR INSTALLATION > PREPARING OUTER AND INNER D-PILLAR
REINFORCEMENT AND D-PILLAR REINFORCEMENTS FOR INSTALLATION
1. Prepare outer D-pillar reinforcement.

Fig 1: Identifying Outer D-Pillar Reinforcement
1. 1.1. Drill holes (Ø 8 mm) for plug welding.
2. 1.2. Grind both sides of connecting flanges of outer D-pillar reinforcement in the
marked areas until bare.
Fig 2: Identifying Connecting Flanges Of Outer D-Pillar Reinforcement
2. Prepare inner D-pillar reinforcement.

Fig 3: Identifying Inner D-Pillar Reinforcement Drill Holes For Plug Welding
2. 2.2. Grind both sides of connecting flanges of inner D-pillar reinforcement in the
Fig 4: Identifying Connecting Flanges Of Inner D-Pillar Reinforcement
3. Prepare D-pillar corner piece.

Fig 5: Identifying D-Pillar Corner Piece
1. 3.1. Grind both sides of connecting flanges of D-pillar corner piece in the marked
areas until bare.
4. Prepare lower D-pillar corner reinforcement.

Fig 6: Identifying Lower D-Pillar Corner Reinforcement
1. 4.1. Grind both sides of connecting flanges of lower D-pillar corner reinforcement in
the marked areas until bare.
5. Prepare gusset piece.

Fig 7: Identifying Gusset Piece
1. 5.1. Grind both sides of connecting flanges of gusset piece in the marked areas until
bare.
Information
WM 533055 REPLACING D-PILLAR REINFORCEMENT > PREPARING CONNECTION

AREAS OF BODY FOR INSTALLING D-PILLAR REINFORCEMENT

Fig 1: Identifying D-Pillar Reinforcement Welding And Sealing Areas (1 Of 2)

Fig 2: Identifying D-Pillar Reinforcement Welding And Sealing Areas (2 Of 2)
Information
WM 533055 REPLACING D-PILLAR REINFORCEMENT > INSTALLING D-PILLAR

REINFORCEMENT
1. Apply adhesive.
Fig 1: Applying Adhesive To D-Pillar Reinforcement

STRUCTURAL ADHESIVE
2. Fit and secure inner D-pillar reinforcement together with D-pillar corner piece and D-pillar
corner reinforcement.
3. Resistance spot-weld D-pillar reinforcement.

Fig 2: Identifying Resistance Spot-Weld D-Pillar Reinforcement


Fig 4: Applying Adhesive To D-Pillar Reinforcement Marked Areas (1 Of 2)

Fig 5: Applying Adhesive To D-Pillar Reinforcement Marked Areas (2 Of 2)


8. Weld in D-pillar reinforcement.

Fig 8: Identifying Weld In D-Pillar Reinforcement
1. 8.1. Plug-weld D-pillar reinforcement using inert gas.
2. 8.2. Spot-weld D-pillar reinforcement using inert gas.

Fig 9: Identifying Spot-Weld D-Pillar Reinforcement
10. Spot-weld D-pillar reinforcement using inert gas.

11. Weld in lower D-pillar corner reinforcement.

Fig 11: Identifying Weld In Lower D-Pillar Corner Reinforcement
1. 11.1. Resistance spot-weld lower D-pillar corner reinforcement in the area -A- .
2. 11.2. Plug-weld lower D-pillar corner reinforcement using inert gas.
3. 11.3. Spot-weld lower D-pillar corner reinforcement using inert gas.
12. Weld in gusset piece.

Fig 12: Identifying Weld In Gusset Piece
1. 12.1. Resistance spot-weld gusset piece.
2. 12.2. Spot-weld gusset piece using inert gas.
13. Fill D-pillar reinforcement with foam.

Fig 13: Filling D-Pillar Reinforcement With Foam
1. 13.1. Fill D-pillar reinforcement with foam from the inside in the marked area. →
14. Install rear side section (roof removed). → 535555 REPLACING REAR SIDE SECTION
(ROOF REMOVED) - section on "Installing"
15. Install rear closing panel. → 530555 REPLACING REAR CLOSING PANEL - section on
"Installing"
WM 533055 REPLACING D-PILLAR REINFORCEMENT > SUBSEQUENT WORK >
WM 533055 REPLACING D-PILLAR REINFORCEMENT (SECTION) > TOOLS
Hot-Air Blower,
Workshop
Leister- WE 1119
Equipment
Electron/VAG 1416
WE 1121

WE 1122
WE 1137
Pneumatic Spotweld
Workshop
Equipment
WS 90
WE 1141
1628 Equipment

WE 1347
1523A Equipment
Star Gauges For

Dimensions
Commercially
Available Tool
Commercially
Twist Drill Nr. 201
Available Tool
WM 533055 REPLACING D-PILLAR REINFORCEMENT (SECTION) > PRELIMINARY

WORK > PRELIMINARY WORK FOR BODY REPAIRS WITH STRAIGHTENING BENCH
vehicle.
protective covers.
WM 533055 REPLACING D-PILLAR REINFORCEMENT (SECTION) > SAFETY
Danger of injury
WM 533055 REPLACING D-PILLAR REINFORCEMENT (SECTION) > TOOLS AND

Rotary Brush
Leister Electron hot-air blower Hot-Air Blower, Leister-Electron/VAG 1416 WE 1119 .
Support Adhesive
Structural Adhesive
WM 533055 REPLACING D-PILLAR REINFORCEMENT (SECTION) > REMOVING

D-PILLAR REINFORCEMENT (SECTION)
"Removing"

"Removing"

Fig 1: Identifying D-Pillar Gusset Plate Welded Joints
Information
Drill out spotwelds A and B through two plate thicknesses.



8. Drill out and grind down spotwelds.

Fig 5: Identifying D-Pillar Reinforcement Spotwelds Area



Fig 8: Identifying D-Pillar Reinforcement Heat Up Connection Areas
12. Remove D-pillar reinforcement.
WM 533055 REPLACING D-PILLAR REINFORCEMENT (SECTION) > PREPARING

OUTER AND INNER D-PILLAR REINFORCEMENT AND D-PILLAR REINFORCEMENTS
FOR INSTALLATION
1. Prepare outer D-pillar reinforcement.

Fig 1: Identifying Outer D-Pillar Reinforcement
1. 1.1. Drill out spotwelds between upper and lower part.
Drill out spotwelds so that no holes are made in the new part.

Fig 2: Identifying Outer D-Pillar Reinforcement Drill Holes For Plug Welding
3. 1.3. Grind both sides of connecting flanges of outer D-pillar reinforcement in the
Fig 3: Identifying Connecting Flanges Of Outer D-Pillar Reinforcement
2. Prepare inner D-pillar reinforcement.

Fig 4: Identifying Inner D-Pillar Reinforcement Plug Welded Area
2. 2.2. Grind both sides of connecting flanges of inner D-pillar reinforcement in the
Fig 5: Identifying Connecting Flanges Of Inner D-Pillar Reinforcement
3. Prepare D-pillar corner piece.

Fig 6: Identifying D-Pillar Corner Piece
1. 3.1. Grind both sides of connecting flanges of D-pillar corner piece in the marked
areas until bare.
4. Prepare lower D-pillar corner reinforcement.

Fig 7: Identifying Lower D-Pillar Corner Reinforcement
1. 4.1. Grind both sides of connecting flanges of lower D-pillar corner reinforcement in
the marked areas until bare.
5. Prepare gusset piece.

Fig 8: Identifying Gusset Piece
1. 5.1. Grind both sides of connecting flanges of gusset piece in the marked areas until
bare.
Information
WM 533055 REPLACING D-PILLAR REINFORCEMENT (SECTION) > PREPARING

CONNECTION AREAS OF BODY FOR INSTALLING D-PILLAR REINFORCEMENT
(SECTION)

Fig 1: Identifying D-Pillar Reinforcement Welding And Sealing Areas
Information

WM 533055 REPLACING D-PILLAR REINFORCEMENT (SECTION) > INSTALLING

D-PILLAR REINFORCEMENT (SECTION)
1. Apply adhesive.
Fig 1: Applying Adhesive To D-Pillar Reinforcement

STRUCTURAL ADHESIVE
2. Fit and secure inner D-pillar reinforcement together with D-pillar corner piece and D-pillar
corner reinforcement.



Fig 4: Applying Adhesive To D-Pillar Reinforcement Marked Areas

7. Plug-weld D-pillar reinforcement using inert gas.

Fig 6: Identifying Plug-Weld D-Pillar Reinforcement

Fig 7: Identifying Weld In D-Pillar Reinforcement
9. Spot-weld D-pillar reinforcement using inert gas.

10. Weld in lower D-pillar corner reinforcement.

Fig 9: Identifying Weld In Lower D-Pillar Corner Reinforcement
1. 10.1. Resistance spot-weld lower D-pillar corner reinforcement in the area -A- .
2. 10.2. Plug-weld lower D-pillar corner reinforcement using inert gas.
3. 10.3. Spot-weld lower D-pillar corner reinforcement using inert gas.
11. Weld in gusset piece.

Fig 10: Identifying Weld In Gusset Plate
1. 11.1. Resistance spot-weld gusset piece.
2. 11.2. Spot-weld gusset piece using inert gas.
12. Fill D-pillar reinforcement with foam.

Fig 11: Filling D-Pillar Reinforcement With Foam
1. 12.1. Fill D-pillar reinforcement with foam from the inside in the marked area. →
"Installing"
14. Install rear closing panel. → 530555 REPLACING REAR CLOSING PANEL - section on
"Installing"
WM 533055 REPLACING D-PILLAR REINFORCEMENT (SECTION) > SUBSEQUENT
WORK > SUBSEQUENT WORK FOR BODY REPAIRS
WM 534855 REPLACING REAR SIDE MEMBER > TOOLS
Hot-Air Blower,
Workshop
Leister- WE 1119
Equipment
Electron/VAG 1416
WE 1121

WE 1122
WE 1137
Pneumatic Spotweld
Workshop
Equipment
WS 90
WE 1141
1628 Equipment

WE 1347
1523A Equipment
Star Gauges For

Dimensions
Commercially
Available Tool
Commercially
Twist Drill Nr. 201
Available Tool
WM 534855 REPLACING REAR SIDE MEMBER > TECHNICAL VALUES
Dimension B Distance 385 mm
Dimension C Distance 245 mm
WM 534855 REPLACING REAR SIDE MEMBER > PRELIMINARY WORK >

vehicle.
protective covers.
WM 534855 REPLACING REAR SIDE MEMBER > SAFETY INSTRUCTIONS AND

Danger of injury
WM 534855 REPLACING REAR SIDE MEMBER > TOOLS AND MATERIALS > TOOLS
Rotary brush
Support Adhesive
Structural Adhesive
WM 534855 REPLACING REAR SIDE MEMBER > REMOVING REAR SIDE MEMBER
1. Remove boot floor plate. → 532455 REPLACING REAR TRUNK FLOOR PANEL - section on
"Removing"
2. Remove D-pillar reinforcement (section). → 533055 REPLACING REINFORCEMENT FOR

D-PILLAR (SECTION) - chapter on "Removing"
3. Remove (inner) rear wheel housing. → 536855 REPLACING (INNER) REAR WHEEL
HOUSING - section on "Removing"
4. Separate rear floor section.

Fig 1: Identifying Rear Side Member Spotweld Area
2. 4.2. Make rough cut using the body saw.
3. 4.3. Remove rear floor section.
5. Remove rear wheel housing reinforcement.

Fig 2: Identifying Rear Wheel Housing Reinforcement Spotwelds Area

Fig 3: Identifying Rear Side Member Welded Joints


Fig 5: Identifying Rear Side Member Spotwelds Area
Information

Fig 6: Identifying Rear Side Member Spotweld Area

Fig 7: Identifying Rear Side Member Spotwelds
Information

Fig 8: Identifying Rear Side Member Spotweld Joints


14. Separate center floor section.

Fig 11: Identifying Rear Side Member MIG Seams
1. 14.1. Mark cut. → Distance: 260 mm → Distance: 385 mm → Distance: 245 mm
2. 14.2. Make cut using the body saw.

Fig 12: Identifying Rear Side Member Spotwelds
5. 14.5. Heat up connection areas using a hot-air gun.

Fig 13: Identifying Rear Side Member Heat Up Connection Areas
6. 14.6. Remove center floor section.

Fig 14: Identifying Rear Side Member MIG Seams

Fig 15: Identifying Rear Side Member Heat Up Connection Areas
17. Remove rear side member.
WM 534855 REPLACING REAR SIDE MEMBER > PREPARING REAR SIDE MEMBER
AND REINFORCEMENTS FOR INSTALLATION
1. Prepare center floor section.
1. 1.1. Make cut according to distance dimensions of old part.

Fig 1: Identifying Centre Floor Section
2. 1.2. Punch holes for plug welding using inert gas.

Fig 2: Identifying Centre Floor Section Punch Holes For Plug Welding
3. 1.3. Grind both sides of connecting flanges of center floor section in the marked
areas until bare.
2. Prepare wheel housing reinforcement.

Fig 3: Identifying Connecting Flanges Of Centre Floor Section
1. 2.1. Drill holes for plug welding using inert gas.
2. 2.2. Grind both sides of connecting flanges of reinforcement in the marked areas until
bare.
3. Prepare rear floor section.

Fig 4: Identifying Connecting Flanges Of Rear Floor Section
1. 3.1. Punch holes for plug welding using inert gas.
2. 3.2. Grind both sides of connecting flanges of rear floor section in the marked areas
until bare.
4. Prepare bulkhead part of center floor side member.

Fig 5: Identifying Bulkhead Part Of Centre Floor Side Member
1. 4.1. Grind both sides of connecting flanges of bulkhead part in the marked areas until
bare.
Information
A. 10 mm
B. 60 mm
5. Prepare rear side member.
1. 5.1. Grind down slots for slot welding.

Fig 7: Identifying Rear Side Member Slot Welding Areas
2. 5.2. Grind down slots for slot welding.

Fig 8: Identifying Rear Side Member Slot Welding
3. 5.3. Drill holes for plug welding using inert gas.
4. 5.4. Grind both sides of connecting flanges of rear side member in the marked areas
until bare.
Fig 9: Identifying Connecting Flanges Of Rear Side Member
5. 5.5. Fit and secure bulkhead part on rear side member at dimension -A- .
→ Distance: 100 mm
Fig 10: Identifying Bulkhead Part Dimension On Rear Side Member
6. 5.6. Resistance spot-weld bulkhead part.
7. 5.7. Spot-weld bulkhead part using inert gas.
Information
WM 534855 REPLACING REAR SIDE MEMBER > PREPARING CONNECTION AREAS

OF BODY FOR INSTALLING REAR SIDE MEMBER
Fig 1: Identifying Connection Areas Of Rear Side Member Body (1 Of 2)

Fig 2: Identifying Connection Areas Of Rear Side Member Body (2 Of 2)
Information
WM 534855 REPLACING REAR SIDE MEMBER > INSTALLING REAR SIDE MEMBER
1. Apply adhesive.
Fig 1: Applying Adhesive To Rear Side Member

STRUCTURAL ADHESIVE
2. Fit and secure rear side member.
3. Spot-weld rear side member using inert gas.

Fig 2: Identifying Spot-Weld Rear Side Member Area
4. Apply adhesive.
5. Weld in center floor section.

Fig 4: Identifying Weld In Centre Floor Section
1. 5.1. Resistance spot-weld center floor section.
2. 5.2. Plug-weld center floor section in the area -A- using inert gas.
3. 5.3. Spot-weld center floor section in the area -B- using inert gas.
4. 5.4. Slot-weld center floor section in the area -C- using inert gas.
5. 5.5. Apply a full weld to center floor section using inert gas.
Fig 5: Identifying Slot-Weld Centre Floor Section
Information
Fig 6: Identifying Slot Welding Rear Side Member
6. Slot-weld rear side member using inert gas.

Fig 7: Identifying Slot Welding Rear Side Member (1 Of 2)

Fig 8: Identifying Slot Welding Rear Side Member (2 Of 2)
7. Weld in rear side member.

Fig 9: Identifying Weld In Rear Side Member
1. 7.1. Resistance spot-weld rear side member.
2. 7.2. Plug-weld rear side member using inert gas.
3. 7.3. Spot-weld rear side member using inert gas.

Fig 10: Identifying Plug-Weld Rear Side Member
1. 8.1. Plug-weld rear side member using inert gas.
2. 8.2. Resistance spot-weld rear side member in the area -A- .

Fig 11: Identifying Resistance Spot-Weld Rear Side Member
1. 9.1. Slot-weld rear side member using inert gas.
2. 9.2. Spot-weld rear side member in the area -A and B- using inert gas.
10. Resistance spot-weld rear side member.

Fig 12: Identifying Resistance Spot-Weld Rear Side Member

Fig 13: Identifying Weld In Rear Side Member

Fig 14: Identifying Spot-Weld In Rear Side Member
13. Weld in wheel housing reinforcement.

Fig 15: Identifying Weld In Wheel Housing Reinforcement
1. 13.1. Fit and secure wheel housing reinforcement at dimension -A- .
2. 13.2. Resistance spot-weld wheel housing reinforcement.

Fig 16: Identifying Resistance Spot-Weld Wheel Housing Reinforcement
3. 13.3. Plug-weld wheel housing reinforcement in the area -A- using inert gas.
4. 13.4. Spot-weld wheel housing reinforcement using inert gas.
14. Apply adhesive.

15. Weld in rear floor section.

Fig 18: Identifying Weld In Rear Floor Section
1. 15.1. Resistance spot-weld rear floor section.
2. 15.2. Plug-weld rear floor section in the area -A- using inert gas.
16. Install boot floor plate. → 532455 REPLACING REAR TRUNK FLOOR PANEL - section on
"Installing"
17. Install (inner) rear wheel housing. → 536855 REPLACING (INNER) REAR WHEEL HOUSING
- section on "Installing"
18. Install D-pillar reinforcement (section). → 533055 REPLACING REINFORCEMENT FOR

D-PILLAR (SECTION) - chapter on "Installing"
19. Fill rear side member with foam.

Fig 19: Filling Rear Side Member With Foam
1. 19.1. Fill rear side member with foam through the opening in the side member, in
marked area -A- . → 5X00IN PROCESSING BODY FOAM FILLER
WM 534855 REPLACING REAR SIDE MEMBER > SUBSEQUENT WORK >


WM 534855 REPLACING REAR SIDE MEMBER (SECTION) > TOOLS
Hot-Air Blower,
Workshop
Leister- WE 1119
Equipment
Electron/VAG 1416

WE 1121
WE 1122

WE 1137
Pneumatic Spotweld
Workshop
Equipment
WS 90

WE 1141
1628 Equipment

WE 1347
1523A Equipment
Star Gauges For
Dimensions
Commercially
Available Tool
Commercially
Twist Drill Nr. 201
Available Tool
WM 534855 REPLACING REAR SIDE MEMBER (SECTION) > PRELIMINARY WORK >
vehicle.
protective covers.
WM 534855 REPLACING REAR SIDE MEMBER (SECTION) > SAFETY INSTRUCTIONS

Danger of injury
WM 534855 REPLACING REAR SIDE MEMBER (SECTION) > TOOLS AND MATERIALS
> TOOLS AND MATERIALS FOR BODY REPAIRS
Rotary Brush
Support Adhesive
Structural Adhesive
WM 534855 REPLACING REAR SIDE MEMBER (SECTION) > REMOVING REAR SIDE
MEMBER (SECTION)
Information
The illustrations shown are for the previous model and consequently may differ slightly.
Information
Fig 1: Identifying Installation Position Of Rear Side Member
1. Rear side member (section)
2. Floor section, left
3. Support
1. Remove the spare-wheel well and side floor section. → 532455 REPLACING REAR TRUNK
FLOOR PANEL - section on "Removing"
2. Separate floor section.
1. 2.1. Grind off welded joints on the floor section using a parting grinder (area -A- ).
Fig 2: Grinding Off Welded Joints On Floor Section Using Parting Grinder
2. 2.2. Mill off welded joints on the floor section using the spotweld cutter (areas -A and
B- ).
Fig 3: Milling Off Welded Joints On Floor Section Using Spotweld Cutter
3. 2.3. Heat up sealing areas on the floor section uniformly using a hot-air blower (areas
-A- ).
Fig 4: Identifying Heating Up Sealing Areas On Floor Section
4. 2.4. Heat up bonding area of seal uniformly using a hot-air blower (area -B- ).
3. Remove floor section.
4. Separate rear side member at the bottom of the D-pillar.
1. 4.1. Grind off MIG seams on the D-pillar using a parting grinder (area -A- ).
Fig 5: Grinding Off MIG Seams On D-Pillar Using Parting Grinder
5. Cut through rear side member.
1. 5.1. Cut through the rear side member at the "tailored blank" welded seam -A- using
the body saw.
Fig 6: Cutting Through Rear Side Member Welded Seam Using Body Saw
6. Separate rear side member at the bottom of the D-pillar from the outside.
1. 6.1. Separate the rear side member from the bottom of the D-pillar by making a
rough cut in area -A- using the body saw.
Fig 7: Separating Rear Side Member From D-Pillar Using Body Saw
7. Remove rear side member.
8. Separate remaining part of side member on the bottom of the D-pillar.
1. 8.1. Mill off welded joints at the bottom of the D-pillar using the spotweld cutter (area
-A- ).
Fig 8: Milling Off Welded Joints At Bottom Of D-Pillar Using Spotweld Cutter
9. Remove remaining piece of side member.
WM 534855 REPLACING REAR SIDE MEMBER (SECTION) > PREPARING REAR SIDE
1. Prepare rear side member and clean welding and sealing areas.
1. 1.1. Grind both sides of the connecting flanges on the rear side member in the
Fig 1: Identifying Contact Area Of Rear Side Member For Installation

Fig 2: Identifying Contact Area Of Rear Side Member For Installation (Inside View)

Fig 3: Identifying Contact Area Of Rear Side Member For Installation (Outside View)
2. Prepare floor section and clean welding and sealing areas.
1. 2.1. Grind the connecting flanges of the floor section in the marked areas until bare.
Fig 4: Identifying Floor Section And Clean Welding And Sealing Areas
2. 2.2. Punch 7-mm holes in the fastening flanges of the floor section using a hole
punch (area -A- ). Maintain spacing as on the old part.
3. 2.3. Drill 7-mm holes in the fastening flanges of the floor section (area -B- ). Maintain
spacing as on the old part.
Information
WM 534855 REPLACING REAR SIDE MEMBER (SECTION) > PREPARING

CONNECTION AREAS OF THE BODY FOR INSTALLING REAR SIDE MEMBER
Fig 1: Identifying Connection Areas On Body
Information
WM 534855 REPLACING REAR SIDE MEMBER (SECTION) > INSTALLING REAR SIDE
MEMBER (SECTION)
To fit the rear side member, the frame head (impact absorber mount) must be secured to the
straightening set.
1. Fit rear side member to the body.
1. 1.1. Secure the frame head of the rear side member to the straightening set.
2. 1.2. Fix rear side member to the body using tensioning clamps.
2. Weld in rear side member on the inside and at the bottom.
1. 2.1. Use an inert-gas arc welder to weld the side member to the inside and underside
of the carrier in areas -A- .
Fig 1: Identifying Welded Joints On Inside And Underside Of Side Member
3. Weld in rear side member on the outside.
1. 3.1. Apply a full weld to secure the side member in area -A- to the outside of the
carrier using inert gas.
Fig 2: Identifying Welded Joints On Outside Of Side Member
2. 3.2. Resistance spot-weld the side member in area -B- .
Information
Never grind MIG seams on load-bearing body parts. However, a partial flat-grind may be
required for subsequent installation of body parts.
4. The MIG seam on the upper side member flange must be ground down in order to
accommodate the floor section.
1. 4.1. Grind down MIG seam in areas -A and B- .

Fig 3: Grinding Down MIG Seam On Upper Side Member
5. Weld in rear side member at the bottom of the D-pillar.
1. 5.1. Weld side member in area -A- using inert gas.

Fig 4: Identifying Welded Joints On Rear Side Member
6. Apply adhesive.
1. 6.1. Evenly apply structural adhesive to the marked areas -A and B- .
7. Fit the floor section on the body and weld it in.
1. 7.1. Fix the floor section to the body with tensioning clamps.
2. 7.2. Resistance spot-weld the floor section in areas -A and B- .

Fig 6: Identifying Welded Joints On Floor Section
3. 7.3. Plug-weld the floor section in area -A- using inert gas.
Fig 7: Identifying Plug-Weld On Floor Section
8. Fill rear side member with foam.
1. 8.1. Fill the rear side member with foam from behind through the opening on the
frame head -arrow- close to the seal -A- . → WM 5X00IN PROCESSING BODY
FOAM FILLER (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S,
Fig 8: Filling Rear Side Member With Foam
9. Install spare-wheel well and side floor section. → 532455 REPLACING REAR TRUNK FLOOR
WM 534855 REPLACING REAR SIDE MEMBER (SECTION) > SUBSEQUENT WORK >

WM 535555 REPLACING REAR SIDE PANEL > TOOLS
Hot-Air Blower,
Workshop
Leister- WE 1119
Equipment
Electron/VAG 1416

WE 1121
WE 1122

WE 1137
Pneumatic Spotweld
Workshop
Equipment
WS 90

WE 1141
1628 Equipment

WE 1347
1523A Equipment
Star Gauges For
Dimensions
Commercially
Available Tool
Commercially
Twist Drill Nr. 201
Available Tool
WM 535555 REPLACING REAR SIDE PANEL > TECHNICAL VALUES
Basic Tolerance Tolerance

Location Description Type
value 1 2
Dimension B Distance 160 mm
Dimension C Distance 400 mm
Lower Bolting
Dimension D Distance 146 mm
Point
Dimension A (Horizontal From

Distance A 57.8 mm
Edge Of Holder)
Dimension B (Vertical From Edge
Distance B 17.9 mm
Of Side Panel)
Torque
Spacing Plate To Tail Light Holder 45°
angle
Rear Side Panel Bore A 8 mm
Rear Side Panel Bore B 20 mm
WM 535555 REPLACING REAR SIDE PANEL > PRELIMINARY WORK > PRELIMINARY
Information
vehicle.
protective covers.
WM 535555 REPLACING REAR SIDE PANEL > SAFETY INSTRUCTIONS AND

Danger of injury
WM 535555 REPLACING REAR SIDE PANEL > TOOLS AND MATERIALS > TOOLS
Rotary Brush
Support Adhesive
Structural Adhesive
WM 535555 REPLACING REAR SIDE PANEL > REMOVING REAR SIDE PANEL
Information
Information
Mark cut A in accordance with the new part. Make sure to leave an overlap of approx. 3 cm with respect
to the body.
1. Mark and make cuts in rear side panel.

Fig 1: Identifying Mark And Make Cuts Dimension In Rear Side Panel
1. 1.1. Mark cut in rear side panel at the C-pillar at dimension B. → Distance: 160 mm
2. 1.2. Mark cut in rear side panel at the D-pillar (window aperture) at dimension C. →
Distance: 400 mm
3. 1.3. Mark cut in rear side panel at the D-pillar (water drain channel) at dimension D.
Information
Only make cuts in the top plate. Make sure not to damage the plate underneath
when doing this.
4. 1.4. Cut through the rear side panel in the area marked.
Fig 2: Identifying Rear Side Panel Cutting Area
Information

Fig 3: Identifying Rear Side Panel Spotwelds

Fig 4: Identifying Rear Side Panel Welded Joints
4. Grind down the spot welds.

Fig 5: Identifying Rear Side Panel Spot Welds

Fig 6: Identifying Rear Side Panel Heat Up Connection Areas

Fig 7: Identifying Rear Side Panel Heat Up Connection Areas
7. Remove side panel.
WM 535555 REPLACING REAR SIDE PANEL > PREPARING REAR SIDE PANEL FOR
INSTALLATION
1. Fit rear side panel.
1. 1.1. Cut rear side panel at the transitions to the body leaving an overlap of 30 mm.
Fig 1: Identifying Rear Side Panel For Installation
2. 1.2. Fit rear side panel.

Fig 2: Identifying Rear Side Panel For Installation
3. 1.3. Make cuts through the rear side panel and body in the overlap areas.
Fig 3: Identifying Holes For Plug-Welding
3. Grind both sides of the connecting flanges of the rear side panel in the marked areas until
bare.
Fig 4: Identifying Connecting Flanges Of Rear Side Panel
Information
WM 535555 REPLACING REAR SIDE PANEL > PREPARING CONNECTION AREAS OF

BODY FOR INSTALLING REAR SIDE PANEL

Fig 1: Identifying Rear Side Panel Body Welding And Sealing Areas
Information
WM 535555 REPLACING REAR SIDE PANEL > INSTALLING REAR SIDE PANEL
1. Apply adhesive.

STRUCTURAL ADHESIVE
2. Fit and secure the rear side panel.
3. Resistance spot-weld the rear side panel.

Fig 2: Identifying Resistance Spot-Weld Rear Side Panel
4. Resistance spot-weld the rear side panel.

Fig 3: Identifying Resistance Spot-Weld Rear Side Panel
5. Weld in rear side panel.

Fig 4: Identifying Weld In Rear Side Panel
1. 5.1. Resistance spot-weld rear side panel.
2. 5.2. Apply a welded seam to the rear side panel using inert gas.
3. 5.3. Plug-weld the rear side panel in area -A- using inert gas.
6. Apply a full butt weld one in front of the other to the rear side panel using inert gas.
Fig 5: Identifying Butt Weld In Front Of Rear Side Panel
WM 535555 REPLACING REAR SIDE PANEL > INSTALLING REAR SIDE PANEL >
ADJUSTING CONNECTION POINT FOR TAIL LIGHT
Information
Due to technical issues, it is not possible to provide a side panel with a tail light holder with hole
pattern for repair work. In this case, the bore must be drilled afterwards.
1. Mark center drill hole on the holder.
Fig 1: Adjusting Position Of Connection Point For Tail Light
1. 1.1. Mark drill hole.
→ Distance A: 57.8 mm → Distance B: 17.9 mm
2. Mark drill holes on the holder.

Fig 2: Adjusting Connection Point For Tail Light
1. 2.1. Put spacing plate -1- in position and align it. → Torque angle: 45°
2. 2.2. Mark the center of the holes with a marking tool.
3. Drill holes in the holder.

1. 3.1. Drill the holes → Bore A: 8 mm
2. 3.2. Drill the hole. → Bore B: 20 mm
3. 3.3. File out the transitions between the holes.
4. Fit retainer plate.

Fig 4: Identifying Retainer Plate
WM 535555 REPLACING REAR SIDE PANEL > SUBSEQUENT WORK > SUBSEQUENT
WORK FOR BODY REPAIRS (WITHOUT STRAIGHTENING SYSTEM)
WM 535555 REPLACING REAR SIDE SECTION (ROOF REMOVED) > TOOLS

Hot-Air Blower,
Workshop
Leister- WE 1119
Equipment
Electron/VAG 1416

WE 1121
WE 1122

WE 1137
Pneumatic Spotweld
Workshop
Equipment
WS 90

WE 1141
1628 Equipment

WE 1347
1523A Equipment
Star Gauges For
Dimensions
Commercially
Available Tool
Commercially
Twist Drill Nr. 201
Available Tool
WM 535555 REPLACING REAR SIDE SECTION (ROOF REMOVED) > TECHNICAL

VALUES

value 1 2
Dimension A (Horizontal From Edge Of

Distance A 57.8 mm
Holder)
Dimension B (Vertical From Edge Of

Distance B 17.9 mm
Side Panel)
Torque
Spacing Plate To Tail Light Holder 45°
angle
Rear Side Panel Bore A 8 mm
Rear Side Panel Bore B 20 mm
WM 535555 REPLACING REAR SIDE SECTION (ROOF REMOVED) > PRELIMINARY

WORK > PRELIMINARY WORK FOR BODY REPAIRS (WITHOUT STRAIGHTENING
BENCH)
Information
vehicle.
protective covers.
WM 535555 REPLACING REAR SIDE SECTION (ROOF REMOVED) > SAFETY

Danger of injury
WM 535555 REPLACING REAR SIDE SECTION (ROOF REMOVED) > TOOLS AND

Oscillating Body Saw (special Electric Cutter) Special Electric Cutter - Fine WE 1137 .
Rotary Brush
Support Adhesive
Structural Adhesive
WM 535555 REPLACING REAR SIDE SECTION (ROOF REMOVED) > REMOVING

REAR SIDE SECTION (ROOF REMOVED)
Information
Information
Mark cuts in accordance with the new part. Make sure to leave an overlap of approx. 3 cm with respect
to the body.
Information
1. Mark and make cuts in rear side section.

Fig 1: Identifying Mark And Cuts In Rear Side Section

Fig 2: Identifying Rear Side Section Welded Joints
Information

Fig 3: Identifying Rear Side Section Welded Joints

Fig 4: Identifying Rear Side Section Spotwelds Area

Fig 5: Identifying Rear Side Section MIG Seams
6. Loosen rear transverse roof struts and support against lowering.

Fig 6: Identifying Welded Joints On Rear Side Section

Fig 7: Identifying Rear Side Section Heat Up Connection Areas (1 Of 2)

Fig 8: Identifying Rear Side Section Heat Up Connection Areas (2 Of 2)
9. Remove rear side section.
WM 535555 REPLACING REAR SIDE SECTION (ROOF REMOVED) > PREPARING

REAR SIDE SECTION FOR INSTALLATION (ROOF REMOVED)
1. Fit rear side section.
1. 1.1. Cut rear side section at the transitions to the body leaving an overlap of 30 mm.
Fig 1: Identifying Rear Side Section For Installation (Roof Removed)
2. 1.2. Fit rear side section.

Fig 2: Identifying Rear Side Section Body Gap Dimensions
3. 1.3. Make cuts through the rear side section and body in the overlap areas.
2. Make holes for plug welding using inert gas with a body hole punch.
Fig 3: Identifying Holes For Plug Welding On Rear Side Section
3. Grind both sides of the connecting flanges of the rear side section in the marked areas until
bare.
Fig 4: Identifying Connecting Flanges Of Rear Side Section
Information
WM 535555 REPLACING REAR SIDE SECTION (ROOF REMOVED) > PREPARING

CONNECTION AREAS OF BODY FOR INSTALLING REAR SIDE PANEL > PREPARING
CONNECTION AREAS OF BODY FOR INSTALLING REAR SIDE SECTION (ROOF
REMOVED)

Fig 1: Identifying Rear Side Panel Body Welding And Sealing Areas
Information
WM 535555 REPLACING REAR SIDE SECTION (ROOF REMOVED) > INSTALLING

REAR SIDE SECTION > INSTALLING REAR SIDE SECTION (ROOF REMOVED)
1. Apply adhesive.
Fig 1: Applying Adhesive To Rear Side Section

STRUCTURAL ADHESIVE
2. Fit and secure rear side section.
3. Resistance spot-weld the rear side section.

Fig 2: Identifying Resistance Spot-Weld Rear Side Section
4. Resistance spot-weld the rear side section.

Fig 3: Identifying Resistance Spot-Weld Rear Side Section
5. Weld in rear side section.

Fig 4: Identifying Weld In Rear Side Section
1. 5.1. Resistance spot-weld rear side section.
2. 5.2. Apply a welded seam to the rear side section using inert gas.
6. Weld in rear side section.

Fig 5: Identifying Weld In Rear Side Section
1. 6.1. Resistance spot-weld rear side section.
2. 6.2. Apply a welded seam to the rear side section using inert gas.
3. 6.3. Plug-weld rear side section in the area -A- using inert gas.
7. Apply a full butt weld one in front of the other to the rear side section using inert gas.
Fig 6: Identifying Welded Seam To Rear Side Section
8. Weld in rear transverse roof strut.

Fig 7: Identifying Weld In Rear Transverse Roof Strut
2. 8.2. Spot-weld rear transverse roof strut using inert gas.
WM 535555 REPLACING REAR SIDE SECTION (ROOF REMOVED) > INSTALLING

REAR SIDE SECTION > ADJUSTING CONNECTION POINT FOR TAIL LIGHT
Information




WM 535555 REPLACING REAR SIDE SECTION (ROOF REMOVED) > SUBSEQUENT

WORK > SUBSEQUENT WORK FOR BODY REPAIRS (WITHOUT STRAIGHTENING
SYSTEM)
WM 535655 REPLACING SIDE PANEL BOTTOM SECTION > TOOLS

Hot-Air Blower,
Workshop
Leister- WE 1119
Equipment
Electron/VAG 1416

WE 1121
WE 1122

WE 1137
Pneumatic Spotweld
Workshop
Equipment
WS 90

WE 1141
1628 Equipment

WE 1347
1523A Equipment
Star Gauges For
Dimensions
Commercially
Available Tool
Commercially
Twist Drill Nr. 201
Available Tool
WM 535655 REPLACING SIDE PANEL BOTTOM SECTION > TECHNICAL VALUES

value 1 2
Dimension A (horizontal from edge of

Distance A 57.8 mm
holder)
Dimension B (vertical from edge of

Distance B 17.9 mm
side panel)
Torque
Spacing plate to tail light holder 45°
angle
Rear side panel Bore A 8 mm

Rear side panel Bore B 20 mm
WM 535655 REPLACING SIDE PANEL BOTTOM SECTION > PRELIMINARY WORK >
Information
vehicle.
protective covers.
WM 535655 REPLACING SIDE PANEL BOTTOM SECTION > SAFETY INSTRUCTIONS

Danger of injury
WM 535655 REPLACING SIDE PANEL BOTTOM SECTION > TOOLS AND MATERIALS
> TOOLS AND MATERIALS FOR BODY REPAIRS

Rotary Brush
Cartridge Gun Cartridge gun VAG 1628 WE 1141 .
Support Adhesive
Structural Adhesive
WM 535655 REPLACING SIDE PANEL BOTTOM SECTION > REPLACING SIDE PANEL
BOTTOM SECTION
Information
1. Remove spotwelds.
Fig 1: Identifying Side Panel Bottom Section Spotwelds Area
Information
2. 1.2. Grind down the spot welds in area -B- .

Fig 2: Identifying Side Panel Bottom Section MIG Seams Area

Fig 3: Identifying Side Panel Bottom Section Heat Up Connection Areas
4. Remove side panel bottom section.
WM 535655 REPLACING SIDE PANEL BOTTOM SECTION > PREPARING SIDE PANEL
BOTTOM SECTION FOR INSTALLATION
1. Make holes for plug-welding with inert gas using a body hole punch.
Fig 1: Identifying Side Panel Bottom Section Holes For Plug-Welding
2. Grind both sides of the connecting flanges of the side panel bottom section in the marked
areas until bare.
Fig 2: Identifying Connecting Flanges Of Side Panel Bottom Section
Information
WM 535655 REPLACING SIDE PANEL BOTTOM SECTION > PREPARING

CONNECTION AREAS OF BODY FOR INSTALLING SIDE PANEL BOTTOM SECTION
1. Weld bore in the side section.

Fig 1: Identifying Weld Bore In Side Section
1. 1.1. Hold a copper plate between the side section and wheel housing and plug-weld
the bore in the side section using inert gas.
2. 1.2. Grind the spot weld flat.

Fig 2: Identifying Side Panel Bottom Section Body Welding And Sealing Areas
Information
WM 535655 REPLACING SIDE PANEL BOTTOM SECTION > INSTALLING SIDE PANEL
BOTTOM SECTION
1. Apply adhesive.
Fig 1: Applying Adhesive To Side Panel Bottom Section

STRUCTURAL ADHESIVE
2. Fit and secure the side panel bottom section.
3. Resistance spot-weld the side panel bottom section.

Fig 2: Identifying Resistance Spot-Weld Side Panel Bottom Section
4. Weld in side panel bottom section.
1. 4.1. Apply a welded seam to the side panel bottom section using inert gas.
Fig 3: Identifying Weld In Side Panel Bottom Section
2. 4.2. Plug-weld the side panel bottom section using inert gas.
WM 535655 REPLACING SIDE PANEL BOTTOM SECTION > INSTALLING SIDE PANEL
BOTTOM SECTION > ADJUSTING CONNECTION POINT FOR TAIL LIGHT
Information




WM 535655 REPLACING SIDE PANEL BOTTOM SECTION > SUBSEQUENT WORK >
WM 536855 REPLACING (INNER) REAR WHEEL HOUSING > TOOLS

Hot-Air Blower,
Workshop
Leister- WE 1119
Equipment
Electron/VAG 1416

WE 1121
WE 1122

WE 1137
Pneumatic Spotweld
Workshop
Equipment
WS 90

WE 1141
1628 Equipment

WE 1347
1523A Equipment
Star Gauges For
Dimensions
Commercially
Available Tool
Commercially
Twist Drill Nr. 201
Available Tool
WM 536855 REPLACING (INNER) REAR WHEEL HOUSING > PRELIMINARY WORK >
vehicle.
protective covers.
WM 536855 REPLACING (INNER) REAR WHEEL HOUSING > SAFETY INSTRUCTIONS

Danger of injury
WM 536855 REPLACING (INNER) REAR WHEEL HOUSING > TOOLS AND

Rotary brush
Support Adhesive
Structural Adhesive
WM 536855 REPLACING (INNER) REAR WHEEL HOUSING > REMOVING (INNER)

REAR WHEEL HOUSING
1. Remove (outer) rear wheel housing. → 536855 REPLACING (OUTER) REAR WHEEL
HOUSING - section on "Removing"

Fig 1: Identifying (Inner) Rear Wheel Housing MIG Seams Area

Fig 2: Identifying (Inner) Rear Wheel Housing Welded Joints
4. Remove (inner) rear wheel housing.
WM 536855 REPLACING (INNER) REAR WHEEL HOUSING > PREPARING (INNER)

REAR WHEEL HOUSING FOR INSTALLATION
1. Grind both sides of connecting flanges of (inner) rear wheel housing in the marked areas until
bare.
Fig 1: Identifying Connecting Flanges Of (Inner) Rear Wheel Housing
WM 536855 REPLACING (INNER) REAR WHEEL HOUSING > PREPARING

CONNECTION AREAS OF BODY FOR INSTALLING (INNER) REAR WHEEL HOUSING

Fig 1: Identifying Rear Wheel Housing Body Welding And Sealing Areas
WM 536855 REPLACING (INNER) REAR WHEEL HOUSING > INSTALLING (INNER)

REAR WHEEL HOUSING
1. Fit and secure (inner) rear wheel housing.
2. Weld in (inner) rear wheel housing.

Fig 1: Identifying Weld In (Inner) Rear Wheel Housing
1. 2.1. Resistance spot-weld (inner) rear wheel housing.
2. 2.2. Spot-weld (inner) rear wheel housing using inert gas.
3. Spot-weld (inner) rear wheel housing using inert gas.

Fig 2: Identifying Spot-Weld (Inner) Rear Wheel Housing
4. Install (outer) rear wheel housing. → 536855 REPLACING (OUTER) REAR WHEEL
HOUSING - section on "Installing"
WM 536855 REPLACING (INNER) REAR WHEEL HOUSING > SUBSEQUENT WORK >
7. Apply cavity preservation to the accessible areas of the repair .

WM 536855 REPLACING (OUTER) REAR WHEEL HOUSING > TOOLS
Hot-Air Blower,
Workshop
Leister- WE 1119
Equipment
Electron/VAG 1416

WE 1121
WE 1122

WE 1137
Pneumatic Spotweld
Workshop
Equipment
WS 90

WE 1141
1628 Equipment

WE 1347
1523A Equipment
Star Gauges For
Dimensions
Commercially
Available Tool
Commercially
Twist Drill Nr. 201
Available Tool
WM 536855 REPLACING (OUTER) REAR WHEEL HOUSING > PRELIMINARY WORK >
vehicle.
protective covers.
WM 536855 REPLACING (OUTER) REAR WHEEL HOUSING > SAFETY

Danger of injury
WM 536855 REPLACING (OUTER) REAR WHEEL HOUSING > TOOLS AND

Rotary brush
Support Adhesive
Structural Adhesive
WM 536855 REPLACING (OUTER) REAR WHEEL HOUSING > REMOVING (OUTER)

REAR WHEEL HOUSING
"Removing"

Fig 1: Identifying Rear Wheel Housing (Outer) Welded Joints
2. 3.2. Grind down spotwelds in the area -A- .

Fig 2: Identifying Rear Wheel Housing (Outer) Welded Joints
1. 4.1. Grind down spotwelds from outside.

Fig 3: Identifying Rear Wheel Housing (Outer) Spotwelds

Fig 4: Identifying Rear Wheel Housing (Outer) MIG Seams

Fig 5: Identifying (Outer) Rear Wheel Housing Heat Up Connection Areas
8. Remove (outer) rear wheel housing.
WM 536855 REPLACING (OUTER) REAR WHEEL HOUSING > PREPARING (OUTER)

REAR WHEEL HOUSING FOR INSTALLATION

Fig 1: Identifying (Outer) Rear Wheel Housing Drill Holes For Plug Welding
2. Grind both sides of connecting flanges of (outer) rear wheel housing in the marked areas until
bare.
Fig 2: Identifying Connecting Flanges Of (Outer) Rear Wheel Housing
Information
WM 536855 REPLACING (OUTER) REAR WHEEL HOUSING > PREPARING

CONNECTION AREAS OF BODY FOR INSTALLING (OUTER) REAR WHEEL HOUSING

Fig 1: Identifying Rear Wheel Housing (Outer) Body Welding And Sealing Areas
Information
WM 536855 REPLACING (OUTER) REAR WHEEL HOUSING > INSTALLING (OUTER)

REAR WHEEL HOUSING
1. Apply adhesive.
Fig 1: Applying Adhesive To (Outer) Rear Wheel Housing

STRUCTURAL ADHESIVE
2. Fit and secure (outer) rear wheel housing.
3. Resistance spot-weld the (outer) rear wheel housing.

Fig 2: Identifying Resistance Spot-Weld (Outer) Rear Wheel Housing
4. Weld in (outer) rear wheel housing.

Fig 3: Identifying Weld In (Outer) Rear Wheel Housing
1. 4.1. Resistance spot-weld (outer) rear wheel housing.
2. 4.2. Spot-weld (outer) rear wheel housing using inert gas.
5. Spot-weld (outer) rear wheel housing using inert gas.

Fig 4: Identifying Spot-Weld (Outer) Rear Wheel Housing
6. Weld in (outer) rear wheel housing.

Fig 5: Identifying Weld In (Outer) Rear Wheel Housing
1. 6.1. Resistance spot-weld (outer) rear wheel housing.
2. 6.2. Plug-weld (outer) rear wheel housing in the area -A- using inert gas.
"Installing"
WM 536855 REPLACING (OUTER) REAR WHEEL HOUSING > SUBSEQUENT WORK >
WM 536919 REMOVING AND INSTALLING REAR WHEEL HOUSING LINER >

REMOVING REAR WHEEL HOUSING LINER
Information
Rear left wheel housing liner:

Fig 1: Identifying Rear Left Wheel Housing Liner With Screws
1. Rear wheel housing liner
2. Fastening screws
3. Fastening nuts
3. Unclip and remove rear wheel housing liner -1- .
Rear right wheel housing liner:

Fig 2: Identifying Rear Right Wheel Housing Liner With Screws
1. Front wheel housing liner
2. Fastening screws
3. Fastening nuts
6. Unclip and remove rear wheel housing liner -1- .
WM 536919 REMOVING AND INSTALLING REAR WHEEL HOUSING LINER >

INSTALLING REAR WHEEL HOUSING LINER
The rear wheel housing liner is installed in reverse order to removal.
WM 538055 REPLACING SPARE-WHEEL WELL > TOOLS

Hot-Air Blower,
Workshop
Leister- WE 1119
Equipment
Electron/VAG 1416

WE 1121
WE 1122

WE 1137
Pneumatic Spotweld
Workshop
Equipment
WS 90

WE 1141
1628 Equipment

WE 1347
1523A equipment
Star Gauges For
Dimensions
Commercially
Available Tool
Commercially
Twist Drill Nr. 201
Available Tool
WM 538055 REPLACING SPARE-WHEEL WELL > PRELIMINARY WORK >

Information
vehicle.

protective covers.
WM 538055 REPLACING SPARE-WHEEL WELL > SAFETY INSTRUCTIONS AND

Danger of injury
WM 538055 REPLACING SPARE-WHEEL WELL > TOOLS AND MATERIALS > TOOLS
Rotary brush
Support Adhesive
Structural adhesive
WM 538055 REPLACING SPARE-WHEEL WELL > REMOVING SPARE-WHEEL WELL
Information
1. Remove lock carrier. → 530955 REPLACING LOCK CARRIER - section on "Removing"

Fig 1: Identifying Spare-Wheel Well Drill Out Spotwelds

Fig 2: Identifying Spare-Wheel Well Heat Up Connection Areas
4. Remove spare-wheel well.
WM 538055 REPLACING SPARE-WHEEL WELL > PREPARING SPARE-WHEEL WELL

FOR INSTALLATION
Fig 1: Identifying Spare-Wheel Well Holes For Plug-Welding
1. 2.1. Grind both sides of the connecting flanges of the spare-wheel well in the marked
areas until bare.
Fig 2: Identifying Connecting Flanges Of Spare-Wheel
WM 538055 REPLACING SPARE-WHEEL WELL > PREPARING CONNECTION AREAS

OF BODY FOR INSTALLING SPARE-WHEEL WELL

Fig 1: Identifying Spare-Wheel Well Body Welding And Sealing Areas For Installation
1. 1.1. Clean the body connecting flange of underbody protection and paint in the
marked areas.
WM 538055 REPLACING SPARE-WHEEL WELL > INSTALLING SPARE-WHEEL WELL
1. Fit and secure the spare-wheel well.
2. Weld in the spare-wheel well.

Fig 1: Identifying Weld In Spare-Wheel Well
1. 2.1. Resistance spot-weld the spare-wheel well.
2. 2.2. Plug-weld the spare-wheel well using inert gas.

Fig 2: Identifying Spare-Wheel Well Plug-Weld
3. Install lock carrier. → 530955 REPLACING LOCK CARRIER - section on "Installing"
WM 538055 REPLACING SPARE-WHEEL WELL > SUBSEQUENT WORK >

WM 538219 REMOVING AND INSTALLING REAR CROSS MEMBER > TECHNICAL

VALUES
Rear Cross Member Tightening Torque 45 Nm (33 ft. lb.)

WM 538219 REMOVING AND INSTALLING REAR CROSS MEMBER > PRELIMINARY
WORK
1. Remove rear closing panel. → 530555 REPLACING REAR CLOSING PANEL - section on
"Removing"
WM 538219 REMOVING AND INSTALLING REAR CROSS MEMBER > REMOVING

REAR CROSS MEMBER
Fig 1: Identifying Rear Cross Member
1. Remove rear cross member.
Information
The screws on the rear cross member are micro-self-locking and must be replaced!
1. 1.1. Unscrew and remove screws -1- .

Fig 2: Identifying Rear Cross Member With Screws
2. 1.2. Remove rear cross member -2- .
WM 538219 REMOVING AND INSTALLING REAR CROSS MEMBER > INSTALLING

REAR CROSS MEMBER
1. 1.1. Tighten screws on rear cross member to → Tightening torque: 45 Nm (33 ft.
lb.) .
WM 538219 REMOVING AND INSTALLING REAR CROSS MEMBER > SUBSEQUENT

WORK
1. Install closing panel. → 530555 REPLACING REAR CLOSING PANEL - section on "Installing"
Service Manual: 55 - LIDS, FLAPS -- 92A CAYENNE
WM 551019 REMOVING AND INSTALLING RELEASE FOR FRONT LID (CAYENNE,
Fastening screw Tightening 12 Nm (9 ftlb.) +/-1 Nm (+/- 0.5

for lower part of torque ftlb.)
lid lock
Loosening lid lock

PRELIMINARY WORK FOR RELEASE MECHANISM TO SEPARATING COUPLING
1. Remove inner door sill trim. → 680519 REMOVING AND INSTALLING INNER DOOR SILL
TRIM
2. Remove front trim panel (engine compartment). → 700219 REMOVING AND INSTALLING
FRONT TRIM PANEL (ENGINE COMPARTMENT)

PRELIMINARY WORK FOR SEPARATING COUPLING TO LID LOCK
1. Remove cover for front lock support. → 703919 REMOVING AND INSTALLING COVER FOR
FRONT LOCK SUPPORT
2. Remove front trim panel (engine compartment). → 700219 REMOVING AND INSTALLING

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION > COMPONENT
INFORMATION
Fig 1: Identifying Installation Position Of Front Lid Release
1. Front lid release
2. Clips
3. Lid release cable to separating coupling
4. Rubber sleeve
5. Separating coupling
6. Separating coupling cable to lid lock
7. Lid lock

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING RELEASE FOR FRONT
LID > REMOVING FROM RELEASE MECHANISM TO SEPARATING COUPLING
1. Disconnect cable for front lid at the release mechanism.

Fig 1: Disconnecting Cable For Lid Release
1. 1.1. Unclip guide tube at the release mechanism and swivel the cable out -A- .
2. 1.2. Guide cable out of the mounting -B- .
2. Loosen release mechanism for front lid.
1. 2.1. Swivel release mechanism down and out.

Fig 2: Removing Release Mechanism
3. Pull out expansion rivets -1- and swivel insulating mat -2- aside.
Fig 3: Identifying Expansion Rivets And Swivel Insulating Mat
4. Unclip cable -3- from the fixing clips -2- .

Fig 4: Identifying Cable From Fixing Clips
5. Disconnect cable at the separating coupling.
1. 5.1. Unclip separating coupling from the body.
2. 5.2. Pull cable for lid lock -6- out of the separating coupling -5- .
Fig 5: Pulling Cable For Lid Lock
3. 5.3. Open separating coupling.

Fig 6: Opening Separating Coupling
4. 5.4. Remove cable from the mounting.

Fig 7: Removing Cable From Mounting
6. Pull complete cable out towards the separating coupling.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING RELEASE FOR FRONT
LID > REMOVING FROM SEPARATING COUPLING TO LID LOCK
1. Disconnect cable at the separating coupling.
1. 1.1. Unclip separating coupling from the body.
2. 1.2. Pull cable for lid lock -6- out of the separating coupling -5- .
Fig 1: Pulling Cable For Lid Lock
3. 1.3. Open separating coupling.

Fig 2: Opening Separating Coupling
4. 1.4. Remove cable from the mounting.

Fig 3: Removing Cable From Mounting
2. Unclip cable for front lid at the lid lock. → 551719 REMOVING AND INSTALLING LOWER
PART OF FRONT LID LOCK
1. 2.1. Unscrew fastening screws -9- on lid lock.

Fig 4: Loosening Lid Lock
2. 2.2. Lift up lid lock.
3. 2.3. Disengage cable from the mounting.

Fig 5: Disengage Cable From Mounting
3. Disengage complete cable from separating coupling to lid lock at the brackets and guide it out.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING RELEASE FOR FRONT
LID > INSTALLING FRONT LID RELEASE
Information
Check rubber sleeves for damage and replace if necessary.
Re-insert removed rubber sleeves.
The front lid release is installed in reverse order to removal.
1. Tighten fastening screws on lower part of lid lock to Tightening torque 12 Nm (9 ftlb.) +/-1
Nm (+/- 0.5 ftlb.) .

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > CHECKING FRONT LID LOCK >
FUNCTION TEST ON FRONT LID LOCK
Information
The lid lock does not have an emergency release.
When working close to the front apron and on the various parts of the lock, carry out the following
function test before closing the lid:
1. Check that the release cable is clipped fully into the brackets provided.
2. Lock lower part of lid lock using a screwdriver.
3. Release the lid lock using the lever in the passenger compartment.
4. Perform a visual inspection to check that the lock releases correctly.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > CHECKING FRONT LID LOCK >
CHECKING CLOSING FUNCTION OF LID LOCK
1. Check closing function of lid lock.

Fig 1: Checking Closing Function Of Lid Lock
1. 1.1. Close the lid fully.

2. 1.2. Release the lid.
3. 1.3. Check that the hook -3- holds the lid down.
4. 1.4. Release the hook until the bolt on the lower part of the lock -4- is free.

SUBSEQUENT WORK FOR SEPARATING COUPLING TO LID LOCK
1. Install cover for front lock support. → 703919 REMOVING AND INSTALLING COVER FOR
FRONT LOCK SUPPORT
2. Install front trim panel (engine compartment). → 700219 REMOVING AND INSTALLING

SUBSEQUENT WORK FOR RELEASE MECHANISM TO SEPARATING COUPLING
1. Install inner door sill trim. → Installing Inner Door Entry Guard
2. Install front trim panel (engine compartment). → 700219 REMOVING AND INSTALLING
WM 551719 REMOVING AND INSTALLING LOWER PART OF FRONT LID LOCK

E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL
VALUES

lid lock
Loosening lid lock

WORK
REAR LOCK SUPPORT

LOWER PART OF FRONT LID LOCK
1. Unscrew fastening screws -9- on lid lock.

Fig 1: Loosening Lid Lock
2. Pull up lid lock.
3. Unclip actuating cable from the mounting.

Fig 2: Pulling Up Lid Lock
4. Release microswitch from the lid lock. → 558519 REMOVING AND INSTALLING
MICROSWITCH FOR FRONT LID LOCK

LOWER PART OF FRONT LID LOCK
1. The lower part of the front lid lock is installed in reverse order to removal.
2. Lower the lid slowly until the clip for the upper part of the lock -1- is touching the lower part of
the lock. The clip must be centered flush with the slit in the lower part of the lock -2- .
Fig 1: Identifying Fastening Screws On Lower Part Of Lid Lock
3. Tighten fastening screws on lower part of lid lock to Tightening torque 12 Nm (9 ftlb.) +/-1
Nm (+/- 0.5 ftlb.) .

LOWER PART OF FRONT LID LOCK > FUNCTION TEST ON FRONT LID LOCK
Information

LOWER PART OF FRONT LID LOCK > CHECKING CLOSING FUNCTION OF LID LOCK


WORK
REAR LOCK SUPPORT
WM 551819 REMOVING AND INSTALLING UPPER PART OF FRONT LID LOCK

VALUES
Fastening nuts Tightening 12 Nm (9 ftlb.)

on upper part of torque
lid lock

UPPER PART OF FRONT LID LOCK
Information
Use a marking pen to mark the position of accessories with respect to each other before removal in
order to reduce the amount of adjustment work required for gaps and joints.
1. Open the front lid.
2. Unscrew fastening nuts -1- and remove upper part of lid lock -2- .
Fig 1: Removing Upper Part Of Front Lid Lock

UPPER PART OF FRONT LID LOCK
Information
The self-locking nuts and screws must always be replaced.
1. Roughly position upper part of lock -2- .

Fig 1: Installing Upper Part Of Front Lid Lock
2. Fit fastening nuts -1- so that the upper part of the lock -2- can still be moved.
3. Lower the lid slowly until the bar for the upper part of the lock -1- is touching the lower part of
the lock. The bar must be centered flush with the slit in the lower part of the lock -2- .
Fig 2: Identifying Upper Part Of Lock Components
4. Open the lid.
5. Tighten fastening nuts to the specified tightening torque → Tightening torque: 12 Nm (9

ftlb.) .

UPPER PART OF FRONT LID LOCK > CHECKING CLOSING FUNCTION OF LID LOCK

WM 552215 ADJUSTING FRONT LID (CAYENNE, CAYENNE GTS, CAYENNE TURBO


Star gauges for Special tool NR.127-1
body gap
dimensions


front lid (B1)

front lid (B2)

headlights (K1)
Lid to headlights

front lid (K1)
Lid to wing

front lid (K2)
Lid to wing

for front lid torque ftlb.)
Front lid

securing lid torque ftlb.)
hinge to body
Loosening mounting for lid hinge
Mounting head Tightening 20 Nm (15

for pneumatic torque ftlb.)
spring to front lid
Ball joint for pneumatic spring

lid lock
Loosening lid lock
Fastening nut Item 1 Tightening 12 Nm (9 ftlb.)

lid lock
Adjusting front lid

1. Remove both cover flaps of the cowl panel cover. → 664419 REMOVING AND INSTALLING
COWL PANEL COVER

CAYENNE (3.0)) > TECHNICAL VALUES > GAP DIMENSIONS OF FRONT LID

front lid (B1)

front lid (B2)

headlights (K1)
Lid to headlights

CAYENNE (3.0)) > TECHNICAL VALUES > GAP DIMENSIONS OF FRONT WING

front lid (K1)
Lid to wing

front lid (K2)
Lid to wing

CAYENNE (3.0)) > TECHNICAL VALUES -55- FRONT LID

Front lid

hinge to body

spring to front lid

lid lock
Loosening lid lock

lid lock
Adjusting front lid

CAYENNE (3.0)) > ADJUSTING FRONT LID > ADJUSTING FRONT LID GAP
DIMENSIONS
Information
Set gap dimensions on lid and accessories in accordance with the gap specifications.
Given a clearance in the opening that is too great or too small, the accessories must be centered
Ensure that the gaps do not run in a wedge-shaped fashion or do not narrow at local points.
The given values are guidelines, which should be observed as far as possible.
Use star gauges to check the gap dimensions. Star gauges for body gap dimensions NR.127-1
Fig 1: Adjusting Front Lid
No. Component Function Procedure
1. Fastening nuts on upper Locking mechanism for Loosen.

part of lid lock -1- front lid
2. Fastening nuts securing Adjusting gap dimensions Loosen.

lid hinge to lid -2- in X and Y direction
3. Front lid -3- Set gap dimensions in X

and Y direction by
moving the lid.
4. Fastening nuts securing Adjusting gap dimensions Tighten fastening nuts to

lid hinge to lid -2- in X and Y direction Tightening torque 20
Nm (15 ftlb.) .
5. Fastening nuts on upper Locking mechanism for Tighten fastening nuts to

part of lid lock -1- front lid Tightening torque 12
Nm (9 ftlb.) .
6. Fastening screws Adjusting gap dimensions Loosen.

securing lid hinge to body in Z direction, rear
-4-
7. Front lid -3- Set gap dimensions in Z

direction at the rear by
moving the lid.
8. Fastening screws Adjusting gap dimensions Tighten fastening screws

securing lid hinge to body in Z direction, rear to Tightening torque 20
-4- Nm (15 ftlb.) .
9. Rubber stop -5- Adjusting gap dimensions Set gap dimensions and
in Z direction, front inclination by turning the
rubber stops. There must
be slight preload on the
lid as a result of setting
the rubber stops.

CAYENNE (3.0)) > CHECKING FRONT LID LOCK > FUNCTION TEST ON FRONT LID
LOCK
Information
WM 552219 REMOVING AND INSTALLING FRONT LID (CAYENNE, CAYENNE GTS,


Front lid

1. Remove spray nozzles. → 926619 REMOVING AND INSTALLING SPRAY NOZZLE

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT LID
Information
Some of the repair illustrations show only one side of the vehicle. Naturally, some steps also have to be
performed on the opposite side of the vehicle as well. These must be carried out as a mirror image of
the steps shown.
Information
Fig 1: Identifying Front Lid Installation Position
1. Remove wire harness for front lid.
1. 1.1. Unclip sleeve for wire harness from the cut-out in a downward direction -arrow-
using a suitable tool.
Fig 2: Removing Wire Harness For Front Lid
2. 1.2. Pull wire harness out of the lid.
2. Unclip cover -1- for wire harness on the hinge in a downward direction.
Fig 3: Identifying Cover For Wire Harness
1. 2.1. Remove cover for wire harness.
3. Remove front lid.
1. 3.1. Loosen upper mounting for pneumatic springs for front lid, pull pneumatic
springs forward and set them down. → 553119 REMOVING AND INSTALLING
FRONT PNEUMATIC SPRING
2. 3.2. Screw off fastening nuts -1- on the front lid.

Fig 4: Identifying Front Lid Fastening Nuts
3. 3.3. Pull the lid up and off.

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT LID
1. The lid is installed in reverse order to removal.
2. Adjust the front lid as required. → 552215 ADJUSTING FRONT LID
3. Tighten the fastening nuts to Tightening torque 20 Nm (15 ftlb.).

1. Install spray nozzle. → 926619 REMOVING AND INSTALLING SPRAY NOZZLE
WM 552237 DISASSEMBLING AND ASSEMBLING FRONT LID (CAYENNE, CAYENNE

GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO,

spring to front lid

1. Remove front lid. → 552219 REMOVING AND INSTALLING FRONT LID
2. Remove upper part of front lid lock. → 551819 REMOVING AND INSTALLING UPPER PART
OF FRONT LID LOCK
3. Remove logo. → 660719 REMOVING AND INSTALLING FRONT LOGO
4. Remove insulation for front lid. → 700419 REMOVING AND INSTALLING INSULATION FOR
FRONT LID

CAYENNE S DIESEL, CAYENNE (3.0)) > DISASSEMBLING FRONT LID
1. Unscrew ball joints for pneumatic springs -2- .

Fig 1: Identifying Ball Joint For Pneumatic Spring
2. Remove rubber sleeves at the left and right -1- .

Fig 2: Identifying Rubber Sleeves

CAYENNE S DIESEL, CAYENNE (3.0)) > DISASSEMBLING FRONT LID >
ASSEMBLING LID
1. Assembly is performed in reverse order to disassembly.
2. Tighten ball joint for pneumatic spring to Tightening torque 20 Nm (15 ftlb.).

CAYENNE S DIESEL, CAYENNE (3.0)) > CHECKING FRONT LID LOCK > FUNCTION
TEST ON FRONT LID LOCK
Information
1. Check that the release cable is clipped fully into the bracket provided.

1. Install front lid. → Installing Front Lid
2. Install upper part of front lid lock. → 551819 REMOVING AND INSTALLING UPPER PART OF
FRONT LID LOCK 1
3. Fit logo. → 660719 REMOVING AND INSTALLING FRONT LOGO
4. Install insulation for front lid. → 700419 REMOVING AND INSTALLING INSULATION FOR
FRONT LID
5. Adjust the front lid. → 552215 ADJUSTING FRONT LID
WM 552519 REMOVING AND INSTALLING FRONT LID HINGE (CAYENNE, CAYENNE


hinge to body

1. Remove front lid. → 552219 REMOVING AND INSTALLING FRONT LID
2. Tighten rear profile seal for front lid on both sides. → 553319 REMOVING AND INSTALLING
SEAL FOR FRONT LID
3. Remove both cover flaps of the cowl panel cover. → 664419 REMOVING AND INSTALLING
COWL PANEL COVER

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT LID HINGE
Information
Information
1. Unscrew fastening screws -2- for lid hinge on front lid.

Fig 1: Loosening Mounting For Lid Hinge
2. Remove lid hinge -1- .
3. Unclip cable clip -3- from the lid hinge.

Fig 2: Identifying Cable Clip From Lid Hinge

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT LID HINGE
Information
2. Fit lid hinge at the previously marked position.
3. Tighten fastening screws for lid hinge to Tightening torque 20 Nm (15 ftlb.).

1. Install front lid. → Installing Front Lid

2. Adjust the front lid. → 552215 ADJUSTING FRONT LID
3. Install both cover flaps of the cowl panel cover. → 664419 REMOVING AND INSTALLING
COWL PANEL COVER
4. Install rear profile seal for front lid on both sides. → 553319 REMOVING AND INSTALLING
SEAL FOR FRONT LID
WM 553119 REMOVING AND INSTALLING FRONT PNEUMATIC SPRING (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT PNEUMATIC
SPRING > REMOVING FRONT PNEUMATIC SPRING (ON LID SIDE)
CAUTION: Incorrect handling of gas-filled shock absorbers
Gas-filled shock absorbers can burst
Risk of bruising
→ Gas-filled shock absorbers must be in idle state before removal.
→ Open the lid.
→ Secure the lid to prevent it from closing accidentally following removal of the gas-filled shock
absorbers.
→ Do not use force to open the gas-filled shock absorbers because of their high internal pressure.
2. Insert a screwdriver between the head of the pneumatic spring -1- and the safety clip.
Fig 1: Inserting Screwdriver Between Head Of Pneumatic Spring And Safety Clip
3. Release the safety clip by levering -A- the screwdriver towards the pneumatic spring -2- . The
safety clip remains at the head of the pneumatic spring.
4. Pull the pneumatic spring off the ball pin. -B-

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT PNEUMATIC
SPRING > LOOSENING PNEUMATIC SPRING (ON BODY SIDE)
1. Insert a screwdriver between the safety clip -1- and the head of the pneumatic spring -2- .
Fig 1: Inserting Screwdriver Between Safety Clip And Head Of Pneumatic Spring
2. Loosen the safety clip -1- by levering -A- the screwdriver -2- up and down. The safety clip
-1- remains at the head of the sleeve.
3. Pull pneumatic spring -2- off the ball pin. -B-
4. Pull out the screwdriver.
5. Remove pneumatic spring.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT PNEUMATIC
SPRING
2. The safety clip on the pneumatic spring must lock with an audible click.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > FUNCTION TEST ON PNEUMATIC
SPRING
1. Close and open the lid several times to check that the pneumatic springs are working properly
and were fitted correctly.
2. Open the lid fully. The two fitted pneumatic springs must hold the lid open.
3. Close the lid.
WM 553319 REMOVING AND INSTALLING FRONT LID SEAL (CAYENNE, CAYENNE

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT LID SEAL
Information
During removal, the seal must not come into contact with hot engine components or adjacent units.
This can cause damage to the seal.
1. Open the lid.
2. Remove front profile seal -1- .

Fig 1: Removing Front Profile Seal

1. 2.1. Carefully pull the front profile seal -1- up off the retaining flange.
3. Pull off rear profile seal -2- and -3- .
1. 3.1. Carefully pull the rear profile seals at the sides -2- up and forward off the
retaining flange.
Fig 2: Pulling Off Rear Profile Seal At Side
2. 3.2. Carefully pull the rear profile seal on the inside -3- forward off the retaining
flange.
Fig 3: Pulling Off Rear Profile Seal On Inside
WM 553319 REMOVING AND INSTALLING FRONT LID SEAL (CAYENNE, CAYENNE

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT LID SEAL
Information
Before replacing, check the existing seal for signs of damage (areas torn, crushed, etc.). If there
are signs of damage, the seal must be replaced.
The seal is pressed onto the flange without any additional sealants.
During installation, the seal must not come into contact with hot engine components or adjacent
units. This can cause damage to the seal.
1. The front lid seal is installed in reverse order to removal.
WM 553719 REMOVING AND INSTALLING FILLER FLAP (CAYENNE, CAYENNE GTS,

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING OUTER PART OF FILLER FLAP
1. Open the filler flap.
2. Remove outer part of filler flap -1- .

Fig 1: Removing Outer Part Of Filler Flap
1. 2.1. Insert a screwdriver into the cut-out -A- and disengage the catch -2- .
2. 2.2. Pull off outer part of filler flap -1- (-B- ).
WM 553719 REMOVING AND INSTALLING FILLER FLAP (CAYENNE, CAYENNE GTS,

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING OUTER PART OF FILLER FLAP
Information
Checking for secure fit includes manually moving one component with respect to the other.
1. Position outer part of filler flap and engage it securely
WM 553755 REPLACING FILLER FLAP (CAYENNE, CAYENNE GTS, CAYENNE TURBO


hook VW tool 3370

CAYENNE (3.0)) > REPLACING FILLER FLAP
Information
The filler flap housing will be damaged during removal and must be replaced during installation.
2. Remove outer part of filler flap -1- .

Fig 1: Pulling Off Outer Part Of Filler Flap
1. 2.1. Insert a screwdriver into the cut-out -A- and disengage the catch -2- .
2. 2.2. Pull off outer part of filler flap -1- (-B- ).
3. Disengage retaining strap -1- using a screwdriver.
4. Open the fuel tank cap -2- (-a- ) and remove it.
Fig 2: Removing Fuel Tank Cap
5. Unscrew fastening screw -1- for filler flap actuator.

Fig 3: Loosening Mounting For Filler Flap Actuator
6. Use a screwdriver to puncture the four depressions and release the catches -arrow- .
Fig 4: Releasing Catches
7. Pull out inner part of filler flap using hook 3370 (-arrow A- ).
Fig 5: Removing Inner Part Of Filler Flap
8. Pull drain hose (1) off inner part of filler flap (2) and remove inner part of filler flap (2).
Fig 6: Identifying Drain Hose From Inner Part Of Filler Flap

CAYENNE (3.0)) > INSTALLING FILLER FLAP
Information
1. Checking for secure fit includes manually moving one component with respect to the
other.
2. Position outer part of filler flap and engage it securely
WM 553819 REMOVING AND INSTALLING ACTUATOR FOR FILLER FLAP (CAYENNE,

1. Remove filler flap. → 553755 REPLACING FILLER FLAP

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING ACTUATOR FOR FILLER
FLAP
1. Remove filler flap actuator from the guide -arrow- .

Fig 1: Removing Filler Flap Actuator From Guide
2. Release electric plug connection -a- , disconnect it and remove filler flap actuator.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING ACTUATOR FOR
FILLER FLAP
Installation is performed in reverse order to removal.

1. Install filler flap. → 553755 REPLACING FILLER FLAP
WM 555719 REMOVING AND INSTALLING REAR LID RELEASE (CAYENNE,


Fastening nut Tightening 6 Nm (4.5 ftlb.)
for rear lid torque
release
Removing cover plate

1. Remove trim panel for rear lid. → 708719 REMOVING AND INSTALLING TRIM PANEL FOR
REAR LID

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR LID RELEASE
NOTE: Voltage peaks
1. Release electric plug connections and disconnect connectors.
2. Unscrew fastening nuts -1- on the rear cover plate.
1. 2.1. Unclip cover plate from the catch -2- and remove it.
Fig 1: Removing Cover Plate
3. Press rear lid release -1- outwards at the bolts -2- .

Fig 2: Pressing Rear Lid Release

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR LID RELEASE
1. The rear lid release is installed in reverse order to removal.
2. Tighten the fastening nuts for the rear lid release to Tightening torque 6 Nm (4.5 ftlb.) .

1. Install trim panel for rear lid. → Installing Trim Panel For Rear Lid
WM 555719 REMOVING AND INSTALLING RELEASE FOR REAR LID (EXCEPT

VALUES
Fastening nuts Tightening 6 Nm (4.5 ftlb.)

securing torque
release to rear
lid

WORK
1. Remove lower part of rear trim panel. → 709219 REMOVING AND INSTALLING TRIM PANEL
FOR TAILGATE

RELEASE FOR REAR LID
NOTE: Voltage peaks
1. Screw off fastening nuts -1- for release for rear lid -A- .
Fig 1: Removing Release For Rear Lid
2. Unplug electric plug connection -B- .
3. Press rear lid release at the pins -1- outwards -A- .
Removing rear lid release

RELEASE FOR REAR LID
1. Installation of release for rear lid is performed in reverse order to removal.
2. Tighten the fastening nuts for the release for the rear lid to → Tightening torque: 6 Nm (4.5
ftlb.) .

WORK
1. Install lower part of rear trim panel. → 709219 REMOVING AND INSTALLING TRIM PANEL
FOR TAILGATE
WM 556819 REMOVING AND INSTALLING CONTROL UNIT FOR REAR LID (CAYENNE
TIP, CAYENNE MAN, CAYENNE S, CAYENNE TURBO, CAYENNE GTS, CAYENNE S
HYBRID, CAYENNE TURBO S, CAYENNE DIESEL, CAYENNE S DIESEL, CAYENNE
TIP (3.0)) > TOOLS
2nd generation Special tool 9818

PIWIS Tester
TIP (3.0)) > PRELIMINARY WORK
1. If a new control unit has to be installed, the values and coding must be read out using the 2nd
generation PIWIS Tester 9818 prior to removing the "old" control unit for rear lid. → 556855
REPLACING CONTROL UNIT FOR REAR LID .
FOR TAILGATE
TIP (3.0)) > REMOVING CONTROL UNIT FOR REAR LID
Fig 1: Identifying Installation Position Of Control Unit For Rear Lid
NOTE: Voltage peaks
Information
approved by Porsche.
just before installation and at the position at which the part is to be installed.
Never touch the electric pins and plug contacts.
1. Release electric plug connection -1 and 2- from control unit for rear lid and pull it off -A- .
Fig 2: Pulling Off Plug Connections
2. Release electric plug connection -3- (-a- ) and turn release element -4- 90° anti-clockwise
-B- . Pull electric plug connection off control unit for rear lid.
3. Release the two clips -1- (-A- ) and remove control unit for rear lid by swivelling it -B- out of
the opening in the holder -C- .
Fig 3: Removing Control Unit For Rear Lid
TIP (3.0)) > INSTALLING CONTROL UNIT FOR REAR LID
Information
1. Insert control unit for rear lid with the lower edge into the opening in the holder -A- and swivel
it in -B- until the two clips -1- engage securely.
Fig 1: Positioning Control Unit For Rear Lid
2. Fit electric plug connection -3- on control unit for rear lid and turn release element -4- 90°
clockwise until it engages securely.
Fig 2: Fitting Electric Plug Connection On Control Unit For Rear Lid
3. Plug in electric plug connections -1 and 2- on control unit for rear lid until they engage
securely.
TIP (3.0)) > SUBSEQUENT WORK
1. If the control unit was replaced, the control unit must be adapted to the vehicle using the 2nd
generation PIWIS Tester 9818 . → 556855 REPLACING CONTROL UNIT FOR REAR LID .
FOR TAILGATE
WM 556855 REPLACING CONTROL UNIT FOR REAR LID (CAYENNE TIP, CAYENNE
MAN, CAYENNE S, CAYENNE TURBO, CAYENNE GTS, CAYENNE S HYBRID,
CAYENNE TURBO S, CAYENNE DIESEL, CAYENNE S DIESEL, CAYENNE TIP (3.0)) >
TOOLS
TECHNICAL VALUES
READING AND WRITING VALUES
NOTE: Voltage drop
battery.
Information
Tester releases.
ignition. [F12] to continue.
3. Select the required control unit, e.g. Rear lid in the overview and press [F12] to continue.
CONTROL UNIT FOR REAR LID .
10. The rear lid remains open.
CAUTION: When you start the calibration/teaching process, the tailgate moves
to its limit stops. Mechanical force limitation is not guaranteed during this process.
1. Danger of pinching and squashing body parts.
2. Incorrect values for the control unit, resulting in malfunctions.
→ Take precautions to ensure that no body parts and objects can get caught in the tailgate.
13. Select Calibration in the Maintenance/repairs menu and press [F12].
14. Read the warnings, press [F12] and then press [F8] to start the calibration process.
15. Actuate the "Close rear lid" switch. The rear lid closes.
16. Actuate the "Open rear lid" switch. The rear lid opens.
17. You may have to open and close the tailgate again. Once the teaching process has been
completed successfully, an acoustic signal will be issued.
18. Fault memory must be selected and erased if necessary.
WM 557319 REMOVING AND INSTALLING ACTUATING CYLINDER FOR REAR LID

WORK
REAR LID

ACTUATING CYLINDER FOR REAR LID
CAUTION: Incorrect handling of actuating cylinders
Actuating cylinders can burst
Risk of bruising
→ The actuating cylinders must be in idle state in order to remove them.
→ Open the lid.
→ Secure the lid after removing the actuating cylinders to prevent it from closing accidentally.
→ Do not use force when opening the actuating cylinders due to the high internal pressure.
Information
1. Release electric plug connection -a- and disconnect it.

2. Secure the wire at the connector to make it easier to guide it in during installation.
1. 2.1. Pull rubber sleeve out of the rear lid.
2. 2.2. Guide out the connector.
3. A second person should hold the rear lid to prevent it from closing accidentally.
4. Insert a screwdriver between the actuating cylinder -2- and safety clip -1- .
Fig 2: Inserting Screwdriver Between Actuating Cylinder And Safety Clip
5. Lift up the safety clip by levering it up with the screwdriver -A- . The safety clip remains on the
actuating cylinder.
6. Pull actuating cylinder off the ball joint -B- .

ACTUATING CYLINDER FOR REAR LID
2. Position the actuating cylinder on the ball head and press it in -arrow- . The actuating cylinder
must engage audibly.
Fig 1: Locating Actuating Cylinder For Rear Lid
3. Check that the safety clip is engaged at the exact position required. The safety clip must be
directly at the head of the actuating cylinder.

WORK

E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > FUNCTION
TEST ON ACTUATING CYLINDER FOR REAR LID
1. Open and close the lid several times to check that the actuating cylinders retract correctly and
are fitted correctly.
2. Open the lid fully. The two fitted actuating cylinders must secure the lid in open position.
3. Close the lid. The lid must engage in the initial catch of the closing aid and the closing aid must
then close the lid securely.
WM 558019 REMOVING AND INSTALLING REAR LID BUZZER (CAYENNE S,

PRELIMINARY WORK
FOR TAILGATE

REMOVING REAR LID BUZZER
NOTE: Voltage peaks
Fig 1: Identifying Rear Lid Buzzer
1. Unscrew fastening screw -1- and remove buzzer from the rear lid trim panel -arrow A- .
Fig 2: Removing Buzzer From Rear Lid Trim Panel
2. Pull electric plug connection off the buzzer -arrow B- .

INSTALLING REAR LID BUZZER
1. Plug in electric plug connection on the buzzer until it engages securely -arrow B- .
Fig 1: Installing Rear Lid Buzzer
2. Position buzzer on the rear lid trim panel -arrow A- and secure with the fastening screw -1- .

SUBSEQUENT WORK
FOR TAILGATE
WM 558219 REMOVING AND INSTALLING REAR LID RELEASE SWITCH (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR LID RELEASE
SWITCH
1. Lever rear lid release switch -1- out of the trim panel using a plastic wedge.
2. Release and disconnect electric plug connection -2- from rear lid release switch.
Fig 1: Identifying Rear Lid Release Switch
WM 558219 REMOVING AND INSTALLING REAR LID RELEASE SWITCH (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR LID RELEASE
SWITCH

WM 558519 REMOVING AND INSTALLING MICROSWITCH FOR FRONT LID LOCK
WORK
1. Remove lower part of front lid lock. → 551719 REMOVING AND INSTALLING LOWER PART
OF FRONT LID LOCK

1. Unclip electric plug connection -1- from the lock support.

Fig 1: Removing Plug Connection
2. Release electric plug connection for the microswitch -A- and disconnect it.
Fig 2: Removing Electric Plug Connection For Microswitch
3. Pull lid lock up between the lock carrier and lock support and remove it.
4. Insert a screwdriver into the cut-out in the lower part of the lid lock -A- and detach the
microswitch -1- (-B- ).
Fig 3: Inserting Screwdriver Into Cut-Out In Lower Part Of Lid Lock
5. Remove microswitch.

The microswitch for the front lid lock is installed in reverse order to removal.

WORK
1. Install lower part of front lid lock. → 551719 REMOVING AND INSTALLING LOWER PART OF
FRONT LID LOCK
WM 558619 REMOVING AND INSTALLING LOWER PART OF REAR LID LOCK

VALUES

for rear lid lock torque ftlb.)
Installing lower part of lid lock

WORK
Remove cover for rear lock support. → 703919 REMOVING AND INSTALLING COVER FOR REAR
LOCK SUPPORT

LOWER PART OF REAR LID LOCK
1. Mark installation position of lower part of rear lid lock -1- .

Fig 1: Removing Lower Part Of Lid Lock
2. Unscrew fastening screws -2- for lower part of lid lock -1- .
3. Remove lower part of lid lock.

E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING >
INSTALLING LOWER PART OF REAR LID LOCK
1. Position lower part of lid lock -1- in line with the markings.
Fig 1: Installing Lower Part Of Lid Lock
2. Screw in fastening screws -2- and tighten to Tightening torque 18 Nm (13 ftlb.) until secure.
3. Check adjustment of rear lid and re-adjust if necessary. → 559015 ADJUSTING REAR LID

WORK
Install cover for rear lock support. → 703919 REMOVING AND INSTALLING COVER FOR REAR LOCK
SUPPORT
WM 558719 REMOVING AND INSTALLING UPPER PART OF REAR LID LOCK

VALUES

Fastening screw Item 1 Tightening 12 Nm (9 ftlb.)
securing upper torque
part of lid lock to
rear lid
Unscrewing fastening screws

WORK
REAR LID

UPPER PART OF REAR LID LOCK
NOTE: Voltage peaks
Fig 1: Identifying Installation Position Of Upper Part Of Lid Lock
1. Unscrew fastening screws for upper part of rear lid lock -1- .
Fig 2: Loosening Upper Part Of Lid Lock
2. Remove upper part of lid lock from the rear lid.



UPPER PART OF REAR LID LOCK
1. The upper part of the rear lid lock is installed in reverse order to removal.
2. Tighten fastening screws for upper part of lid lock to Tightening torque 12 Nm (9 ftlb.).

WORK
WM 559015 ADJUSTING REAR LID (CAYENNE, CAYENNE GTS, CAYENNE TURBO S,

Star gauges for Special tool NR.127-1

body gap
dimensions


for rear lid hinge torque ftlb.)
Screw for hinge

on rear lid torque ftlb.)
Rear lid mounting


part of lid lock to
rear lid

for rear lid torque
release
Fastening screw Item 6 Tightening 6 Nm (4.5 ftlb.)

for lid adjusting torque
elements, side
Adjusting rear lid

(R1)
Rear lid to roof

(R2)
Rear lid to roof

(R3)

apron (R4)

CAYENNE (3.0)) > TECHNICAL VALUES > REAR LID

Screw for hinge

Rear lid mounting


part of lid lock to
rear lid

for rear lid torque
release

for lid adjusting torque
elements, side
Adjusting rear lid

CAYENNE (3.0)) > TECHNICAL VALUES > GAP DIMENSIONS OF REAR LID

(R1)
Rear lid to roof

(R2)
Rear lid to roof

(R3)

apron (R4)

CAYENNE (3.0)) > ADJUSTING REAR LID > ADJUSTING GAP DIMENSIONS OF REAR
LID
Information
Set gap dimensions on lid and accessories in accordance with the gap specifications.
Given a clearance in the opening that is too great or too small, the accessories must be centered
The given values are guidelines, which should be observed as far as possible.
Use star gauges to check the gap dimensions. Star gauges for body gap dimensions NR.127-1
Fig 1: Adjusting Gap Dimensions Of Rear Lid
1. Fastening screws -7- for Locking mechanism for Loosen.

catch bar -8- rear lid
2. Fastening screws -1- for Adjusting gap dimensions Loosen.

lid hinge -2- in Y and Z direction
3. Rear lid -3- Set gap dimensions in Y

and Z direction by moving
the lid.
4. Fastening screws -1- Adjusting gap dimensions Tighten fastening screws

securing lid hinge -2- to in Y and Z direction -1- to Tightening torque
rear lid 10 Nm (7.5 ftlb.) .
5. Fastening screws -4- Adjusting gap dimensions Loosen.

securing lid hinge to body. in X direction, rear
If adjustments are
needed, detach the rear
roof trim panel.→ 708419
REMOVING AND
INSTALLING
HEADLINER
6. Fastening screws -4- Adjusting gap dimensions Tighten fastening screws

securing lid hinge to body. in X direction, rear -4- to Tightening torque
If adjustments are 23 Nm (17 ftlb.) .
needed, detach the rear
roof trim panel.→ 708419
REMOVING AND
INSTALLING
HEADLINER
7. Fastening screws -6- for Correcting gap dimension Tighten fastening screws
adjusting elements -5- at with respect to the body -6- to Tightening torque
the sides of the lid 6 Nm (4.5 ftlb.) .
8. Catch bar -8- Locking mechanism for Adjust latch by moving

rear lid the catch bar.
9. Fastening screws -7- for Locking mechanism for Tighten fastening screws
catch bar -8- rear lid -8- to Tightening torque
18 Nm (13 ftlb.) .
10. Rubber stop -9- Adjusting gap dimensions Set gap dimensions and
and preload inclination by turning the
rubber stops -9- . There
must be slight preload on
the lid as a result of
setting the rubber stops
-9- .

CAYENNE (3.0)) > CHECKING REAR LID LOCK > FUNCTION TEST ON REAR LID
LOCK
1. Check the function of the rear lid lock.
1. 1.1. Lock the lid lock using a screwdriver and then unlock it again using the lid
release.
The lock must swivel out freely.
2. 1.2. Check that the rear lid stays open automatically in the upper positions.
3. 1.3. From the middle position, the rear lid must fall into the lock automatically and
lock fully. (Only with gas-filled shock absorbers)
4. 1.4. Perform a visual inspection to check that the lock releases again correctly.
2. Check electric operation of rear lid lock.
1. 2.1. Open the lock using the electric release or remote control.
3. Check electric tailgate drive mechanism.
1. 3.1. Check opening and closing function using the outer handle on the rear lid, the
remote control and the switch in the driver's door.
2. 3.2. It must be possible to stop rear lid operation at any time using all actuators.
3. 3.3. Check the obstacle detection function.
Simulate an obstacle while opening and closing the lid by holding it firmly.
WM 559019 REMOVING AND INSTALLING REAR LID (CAYENNE, CAYENNE GTS,

Rear lid mounting

REAR LID
2. Remove rear spoiler. → 665819 REMOVING AND INSTALLING REAR SPOILER
3. Remove trim panel for rear lid (handle strip). → 664819 REMOVING AND INSTALLING TRIM
PANEL FOR REAR LID (HANDLE STRIP)
4. Disconnect wire harness for rear lid without touching the area in the headliner. → 972719
REMOVING AND INSTALLING WIRE HARNESS FOR TAILGATE

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR LID

Risk of bruising
→ Open the lid.
absorbers.
Information
Only remove the wiring harness from the rear lid as far as the lid hinge.
Only for vehicles with Power Lift Tailgate
2. Remove actuating cylinder for rear lid at the top of the rear lid. → 557319 REMOVING AND
INSTALLING ACTUATING CYLINDER FOR REAR LID
Only for vehicles without Power Lift Tailgate
3. Remove gas-filled shock absorber for rear lid at the top of the rear lid. → 559319 REMOVING
AND INSTALLING REAR PNEUMATIC SPRING
4. Unscrew fastening screws securing rear lid to lid hinges.

Fig 1: Identifying Rear Lid
5. Remove rear lid.

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR LID

2. Tighten fastening screws for rear lid to Tightening torque 10 Nm (7.5 ftlb.) .
Only for vehicles with Power Lift Tailgate
3. Secure actuating cylinder for rear lid at the top of the rear lid. → Installing Actuating Cylinder
For Rear Lid
Only for vehicles without Power Lift Tailgate

4. Secure gas-filled shock absorber for rear lid at the top of the rear lid. → 559319 REMOVING
AND INSTALLING REAR PNEUMATIC SPRING

1. Install wire harness for rear lid. → Installing
2. Install rear spoiler. → 665819 REMOVING AND INSTALLING REAR SPOILER
3. Install trim panel for rear lid (handle strip). → 664819 REMOVING AND INSTALLING TRIM
PANEL FOR REAR LID (HANDLE STRIP)
WM 559037 DISASSEMBLING AND ASSEMBLING REAR LID (EXCEPT CAYENNE,

Hand riveting Commercially Nr.124-1

tool available tool Pos.1

Adjusting Tightening 6 Nm (4.5 ftlb.)

element on rear torque
lid
Bracket for Tightening 10 Nm (7.5

pneumatic torque ftlb.)
spring to rear lid

1. Remove upper part of lid lock. → 558719 REMOVING AND INSTALLING UPPER PART OF
REAR LID LOCK
2. Remove wiper motor for rear window wiper system. → 923419 REMOVING AND INSTALLING
WIPER MOTOR FOR REAR WINDOW WIPER SYSTEM
3. Remove rear window. → 648619 REMOVING AND INSTALLING REAR WINDOW
4. Replace rear lid molding. → 664755 REPLACING REAR LID MOLDING
5. Remove rear lid. → 559019 REMOVING AND INSTALLING REAR LID
6. Remove electrical components (depending on equipment).
1. 6.1. Remove antenna amplifier. → 918419 REMOVING AND INSTALLING

ANTENNA AMPLIFIER
2. 6.2. Remove control unit for antenna amplifier. → 918619 REMOVING AND
INSTALLING CONTROL UNIT FOR ANTENNA AMPLIFIER "
3. 6.3. Remove control unit for rear lid. → 556819 REMOVING AND INSTALLING
CONTROL UNIT FOR REAR LID

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > DISASSEMBLING REAR LID
Information
These must be carried out as a mirror image of the steps shown.
1. Loosen supports for rubber stop at the sides by turning them 90° with a screwdriver and
remove them.
Fig 1: Removing Rubber Stop
2. Unclip water drains at the bottom -1- .

Fig 2: Identifying Water Drain
3. Remove adjusting elements.
1. 3.1. Mark the position of both parts of the adjusting element -1 - 2- with respect to
each other.
Fig 3: Identifying Adjusting Elements With Screws
2. 3.2. Loosen fastening screws -3- and remove adjusting element.
4. Unclip brackets for wire harness -1- at the locking mechanisms -2- using a screwdriver and
remove them.
Fig 4: Removing Bracket For Wire Harness For Rear Lid
5. Pull brackets for wire harness out of the two locking mechanisms -A, B- .
Fig 5: Pulling Brackets For Wire Harness Out Of Locking Mechanisms
6. Unscrew fastening screws -2- on the bracket for the pneumatic spring -1- .
Fig 6: Identifying Bracket For Pneumatic Spring With Screws
7. Remove number plate bracket if necessary.
8. Drill out blind rivets -2- on bracket for rear spoiler -1- .
Fig 7: Identifying Blind Rivets On Bracket For Rear Spoiler
9. Unclip guides for wire harness -1- using a screwdriver -2- .

Fig 8: Removing Guide For Wire Harness

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > ASSEMBLING REAR LID
Information
1. Fit supports for rubber stop at the sides and screw them in by turning them 90° with a
screwdriver.
Fig 1: Installing Rubber Stop
2. Fit water drains with arrow -1- inwards.

Fig 2: Identifying Water Drain
3. Install adjusting elements.
1. 3.1. Fit adjusting elements -1 - 2- at the marked position.

Fig 3: Identifying Adjusting Elements With Screws
2. 3.2. Tighten fastening screws -3- to → Tightening torque: 6 Nm (4.5 ftlb.) .
4. Press in brackets for wire harness -1- at the locking mechanisms -2- .
Fig 4: Installing Bracket For Wire Harness For Rear Lid
Information
The bracket for the wire harness must be replaced during assembly.
Fig 5: Installing Bracket For Wire Harness For Rear Lid
5. Guide in brackets for wire harness -A- and press in locking mechanism -B- .
Fig 6: Identifying Bracket For Wire Harness For Rear Lid
6. Tighten fastening screws -2- for bracket for pneumatic spring -1- to → Tightening torque: 10
Nm (7.5 ftlb.) .
Fig 7: Identifying Bracket For Pneumatic Spring And Screws
7. Install number plate bracket if necessary.
8. Rivet bracket for rear spoiler -1- to the rear lid with blind rivets -2- . Hand riveting tool
Nr.124-1 Pos.1
Fig 8: Identifying Rear Spoiler To Rear Lid With Blind Rivets
9. Clip in guides for wire harness -1- .

Fig 9: Installing Guide For Wire Harness

1. Install rear lid. → Installing Rear Lid
2. Install control unit for rear lid. → Installing Control Unit For Rear Lid
3. Install control unit for antenna amplifier. → 918619 REMOVING AND INSTALLING CONTROL
UNIT FOR ANTENNA AMPLIFIER
4. Install antenna amplifier. → Installing Antenna Amplifier
5. Replace rear lid molding. → 664755 REPLACING REAR LID MOLDING
6. Install upper part of lid lock. → 558719 REMOVING AND INSTALLING UPPER PART OF
REAR LID LOCK
7. Install wiper motor for rear window wiper system. → 923419 REMOVING AND INSTALLING
WIPER MOTOR FOR REAR WINDOW WIPER SYSTEM
8. Install rear window. → Installing Rear Window

WM 559119 REMOVING AND INSTALLING REAR LID HINGE (CAYENNE, CAYENNE

Screw for hinge

Rear lid mounting

1. Detach the headliner from behind as far as the B-pillar. → 708419 REMOVING AND
INSTALLING HEADLINER
2. Remove rear lid-hinge cover. → 709119 REMOVING AND INSTALLING LID-HINGE COVER
CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR LID HINGE
Information
1. Two people are needed to replace the rear lid hinges.
1. 1.1. One person to support the rear lid.
2. 1.2. Another person to replace the hinges.
2. Unscrew and remove screws on the rear lid hinge.

3. Unscrew and remove the screw -1- on the rear lid hinge.
4. Guide the hinge out through the hinge opening in the bodyshell.
Fig 2: Identifying Hinge

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR LID HINGE > INSTALLING
REAR LID HINGE
Information
1. Tighten fastening screw -1- on the hinge to Tightening torque 23 Nm (17 ftlb.) .
Fig 1: Identifying Rear Lid Hinge
2. Tighten fastening screws for rear lid to Tightening torque 10 Nm (7.5 ftlb.) .
Fig 2: Identifying Rear Lid Hinge Screw

WORK FOR REMOVING AND INSTALLING REAR LID HINGE
1. Adjust the rear lid. → 559015 ADJUSTING REAR LID

2. Secure the headliner. → Installing Headliner
3. Install lid-hinge cover. → 709119 REMOVING AND INSTALLING LID-HINGE COVER
WM 559319 REMOVING AND INSTALLING REAR PNEUMATIC SPRING (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > LOOSENING REAR PNEUMATIC
SPRING
Risk of bruising
→ Open the lid.
absorbers.
Information
1. Open the rear lid.
2. Loosen pneumatic spring.

Fig 1: Removing Pneumatic Spring
1. 2.1. A second person should hold the rear lid to prevent it from closing accidentally.
2. 2.2. Insert a screwdriver between the head of the pneumatic spring -1- and the
safety clip.
3. 2.3. Lift up the safety clip by levering the screwdriver towards the rear -A- . The
safety clip remains on the head of the pneumatic spring -1- .
4. 2.4. Pull pneumatic spring off the ball joint -B- .
5. 2.5. Remove screwdriver.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > SECURING REAR PNEUMATIC
SPRING
1. The rear pneumatic spring is installed in reverse order to removal.
2. Check that the safety clips have engaged correctly. The safety clip must be directly on the
head of the pneumatic spring.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > FUNCTION TEST ON REAR
PNEUMATIC SPRINGS
1. Close and open the lid several times to check that the pneumatic springs are working properly
and were fitted correctly.
2. Open the lid fully. The two fitted pneumatic springs must hold the lid open.
3. Close the lid.
WM 559419 REMOVING AND INSTALLING REAR LID SEAL (CAYENNE, CAYENNE

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR LID SEAL
1. Pull rear lid seal -1- off the sheetmetal flange.

Fig 1: Removing Rear Lid Seal
2. Remove all the old sealant from the sheetmetal flange.
WM 559419 REMOVING AND INSTALLING REAR LID SEAL (CAYENNE, CAYENNE

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR LID SEAL
1. Place rear lid seal -1- in installation position.

Fig 1: Installing Rear Lid Seal

Fig 2: Placing Rear Lid Seal In Installation Position
1. 1.1. Fit seal with the vent holes facing outwards on the sheetmetal flange.
2. 1.2. Position gap in the seal -2- close to the left tail light -arrow A- .
2. Press rear lid seal -1- onto the sheetmetal flange.
3. Check that the seal is fitted securely and is flush, especially in the rounded areas.
Service Manual: 57 - DOOR FRONT, CENTRAL LOCKING SYSTEM -- 92A CAYENNE
WM 570919 REMOVING AND INSTALLING LOCK CYLINDER (CAYENNE, CAYENNE
Fastening screw Item 3 Tightening 3.5 Nm (2.5

for lock cylinder torque ftlb.)
Tightening fastening screws

for locking torque ftlb.)
mechanism

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING LOCK CYLINDER
1. Open the driver's door.
2. Insert emergency release key from below (do not turn) and remove cap -1- from the lock
cylinder.
Fig 1: Removing Cap
3. Unclip cap -2- .
5. Only loosen fastening screw -4- until the screw is blocked.
6. Press fastening screw -4- forward using a screwdriver to release the lock cylinder.
Fig 2: Loosening Lock Cylinder
7. Pull out lock cylinder -5- .

Fig 3: Removing Lock Cylinder

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING LOCK CYLINDER
1. Insert and position lock cylinder -5- .

Fig 1: Installing Lock Cylinder
2. Tighten fastening screw -4- to Tightening torque 3.5 Nm (2.5 ftlb.) .
4. Clip in cap -2- .

Fig 2: Securing Lock Cylinder
5. Insert and clip in cap -1- at the right side of the lock cylinder using the locking tab.
Fig 3: Inserting Clip In Cap At Right Side
WM 571119 REMOVING AND INSTALLING FRONT DOOR HANDLE (CAYENNE,

removal and VW tool T10389

assembly tool



mechanism

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT DOOR HANDLE
> REMOVING DOOR HANDLE ON FRONT DRIVER'S SIDE
1. Open the driver's door.
2. Insert emergency release key from below (do not turn) and unclip door handle cover -1- from
lock cylinder.
Fig 1: Removing Door Handle Cover
3. Remove cap -2- on the door.
5. Unscrew fastening screw -4- as far as it will go and press it forward with a screwdriver to
release the lock cylinder.
Fig 2: Removing Cap On Door
6. Pull door handle up slightly and remove the lock cylinder -5- .
7. Remove door handle on front driver's side.
1. 7.1. Pull door handle on front driver's side -6- to the rear and unhook it.
2. 7.2. Swivel door handle out by 90° -A- and pull it out of the inner part -B- .
3. 7.3. Remove rubber base -7- .

Fig 4: Removing Door Handle On Front Driver's Side
8. Vehicles with Kessy: Release electric plug connection -8- (-a- ) and disconnect it.
Fig 5: Disconnecting Connector For Kessy

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT DOOR HANDLE
> REMOVING DOOR HANDLE ON FRONT PASSENGER'S SIDE
1. Pull off cover.

Fig 1: Pulling Off Cover
2. Insert removal and assembly tool T10389 -1- into the passenger's door and pull the locking
clip -2- to the rear.
Fig 2: Pulling Locking Clip To Rear
3. Unclip door handle cover on passenger's side -3- by pulling it outwards.

Fig 3: Removing Door Handle Cover
4. Remove door handle on front passenger's side.
1. 4.1. Pull door handle on front passenger's side -6- to the rear and unhook it.
2. 4.2. Swivel door handle out by 90° -A- and pull it out of the inner part -B- .
3. 4.3. Remove rubber base -7- .

Fig 4: Removing Door Handle On Front Passenger's Side
5. Vehicles with Kessy: Release electric plug connection for Kessy -8- (-a- ) and disconnect it.
Fig 5: Disconnecting Connector For Kessy

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT DOOR HANDLE
> INSTALLING DOOR HANDLE ON FRONT DRIVER'S SIDE
1. Vehicles with Kessy: Plug in electric plug connection for Kessy -8- and lock it -a- .
Fig 1: Connecting Connector For Kessy
2. Install door handle on front driver's side.
1. 2.1. Position rubber base -7- .
2. 2.2. Insert door handle on front driver's side -6- into the inner part -B- .
3. 2.3. Swivel door handle on front driver's side in by 90° -A- and hook in the clip.
Make sure that the rubber lip is at the correct position during installation.
4. 2.4. Check operation of door handle.

Fig 2: Installing Door Handle On Front Driver's Side
3. Pull the door handle up slightly and insert the lock cylinder -5- .
Fig 3: Inserting Lock Cylinder
6. Fit cap -2- .

Fig 4: Tightening Fastening Screws
7. Attach door handle cover -1- to the side of the lock cylinder by means of the locking tab and
then clip it in.
Fig 5: Attaching Door Handle Cover To Side Of Lock Cylinder

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT DOOR HANDLE
> INSTALLING DOOR HANDLE ON FRONT PASSENGER'S SIDE
2. Install door handle on front passenger's side.
2. 2.2. Insert door handle on front passenger's side into the inner part -B- .

Fig 2: Installing Door Handle On Front Passenger's Side
3. Fit door handle cover on passenger's side -3- .

Fig 3: Fitting Door Handle Cover
4. Press the locking clip forward using a blunt tool (e.g. Torx 30) until it engages.
Fig 4: Pressing Locking Clip Forward Using Blunt Tool
5. Fit cap.
Fig 5: Fitting Cap
WM 571119 REMOVING AND INSTALLING FRONT DOOR HANDLE (INNER PART)



mechanism

PRELIMINARY WORK FOR REMOVING INNER PART OF FRONT DOOR HANDLE
1. Remove door sub-frame. → Removing Front Door Sub-Frame 573019 REMOVING AND
INSTALLING FRONT DOOR SUB-FRAME

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT DOOR
HANDLE (INNER PART) > REMOVING INNER PART OF FRONT DOOR HANDLE
1. Disconnect inner part of door handle from door lock.
2. Disengage bowden cable from the door lock at the inner part of the door handle.
1. 2.1. Unclip bowden cable housing using a suitable tool -a- and take it up out of the
bracket.
Fig 1: Removing Bowden Cable Housing
2. 2.2. Turn bowden cable catch 90°.
3. 2.3. Disengage bowden cable catch by pulling it upwards -A- and remove it -B- .
Fig 2: Disengaging Bowden Cable Catch

DOOR HANDLE (INNER PART) > INSTALLING DOOR HANDLE ON FRONT DRIVER'S
SIDE
2. Install door handle on front driver's side.
2. 2.2. Insert door handle on front driver's side -6- into the inner part -B- .

Fig 2: Installing Door Handle On Front Driver's Side
3. Pull the door handle up slightly and insert the lock cylinder -5- .
Fig 3: Inserting Lock Cylinder
6. Fit cap -2- .

Fig 4: Tightening Fastening Screws
7. Attach door handle cover -1- to the side of the lock cylinder by means of the locking tab and
then clip it in.
Fig 5: Attaching Door Handle Cover To Side Of Lock Cylinder

SUBSEQUENT WORK FOR INSTALLING INNER PART OF FRONT DOOR HANDLE
1. Install door sub-frame. → Installing Front Door Sub-Frame 573019 REMOVING AND
WM 571719 REMOVING AND INSTALLING DOOR LOCK (CAYENNE, CAYENNE GTS,

1. Remove door sub-frame. → Removing Front Door Sub-Frame

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING DOOR LOCK
Information
1. Disconnect electric plug connections from the door lock.

Fig 1: Disconnecting Electric Plug Connection For Door Lock
2. Unclip mounting bracket from the door lock.
3. Disengage bowden cable in the door lock from the door lock to the inner part of the door
handle.
1. 3.1. Release bowden cable bracket -3- (-a- ) and unclip it -A- .
2. 3.2. Turn bowden cable bracket 90° -B- and disengage the catch -4- .
Fig 2: Disengaging Bowden Cable From Inner Part Of Door Handle
4. Disengage bowden cable for inner actuating mechanism on the door lock. → Removing Inner
Actuating Mechanism For Door Lock
5. Disengage bowden cable for closing aid on the door lock.
1. 5.1. Unclip bowden cable bracket -1- from the door lock.
2. 5.2. Pull on the bowden cable until the catch -2- is accessible.
3. 5.3. Guide the catch -2- out of the door lock.

Fig 3: Identifying Bowden Cable For Closing Aid

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING DOOR LOCK
1. Engage bowden cable for closing aid on the door lock.
1. 1.1. Guide the catch -2- into the door lock.
2. 1.2. Pull on the bowden cable and clip in bowden cable bracket -1- on the door lock.
Fig 1: Identifying Bowden Cable For Closing Aid
2. Engage actuating mechanism for bowden cable at the door lock. → Removing Inner Actuating
Mechanism For Door Lock
3. Engage bowden cable in the door lock from the inner part of the door handle to the door lock.
1. 3.1. Engage the catch -4- and turn the bowden cable bracket by 90° -C- .
2. 3.2. Press the bowden cable bracket -3- downwards -D- and clip it in -a- .
Fig 2: Engaging Bowden Cable From Inner Part Of Door Handle
4. Clip the mounting bracket into the door lock.
5. Plug in electric plug connection at the door lock until it engages securely.
Fig 3: Plugging In Electric Plug Connection At Door Lock

1. Install door sub-frame. → Removing Front Door Sub-Frame
WM 572619 REMOVING AND INSTALLING FRONT STRIKER PIN (CAYENNE,


slide hammer Commercially Nr.168
kit available tool

Fastening Item 2 Tightening 25 Nm (19

screws for lock torque ftlb.)
peg
Installing lock peg

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT LOCK PEG
(STRIKER PIN)
1. Unscrew fastening screws -2- and remove lock peg -1- .

Fig 1: Removing Front Lock Peg (Striker Pin)

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT STRIKER PIN >
INSTALLING FRONT LOCK PEG (STRIKER PIN)
1. Screw in fastening screws -2- .

Fig 1: Installing Front Lock Peg (Striker Pin)
2. Carefully close the door and check that the lock peg is positioned correctly with respect to the
lock.
3. Adjust the lock peg to suit the lock as required.
4. Tighten fastening screws -2- to Tightening torque 25 Nm (19 ftlb.) .
5. Check position of door and adjust if necessary. → 575115 ADJUSTING FRONT DOOR

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > ADJUSTING STRIKER PIN >
ADJUSTING LOCK PEG (STRIKER PIN)
Information
The striker pin can be adjusted by changing the plasticity of the adjusting element in the B-pillar.
The setting is retained when the striker pin is removed.

Fig 1: Adjusting Element For Striker Pin
1. Loosen fastening screws -2- .
2. Move lock peg outwards.
1. 2.1. Move the lock peg -1- outwards (if necessary) using slide hammer kit Nr.168 .
Fig 2: Moving Lock Peg Outwards
3. Adjust the lock peg back/down/up (if necessary).
1. 3.1. Move catch bar -1- to the required position using a plastic hammer.
2. 3.2. Carefully close the door and check adjustment.
4. Tighten fastening screws -2- to → Tightening torque: 25 Nm (19 ftlb) .

Fig 3: Adjusting Lock Peg
WM 573019 REMOVING AND INSTALLING FRONT DOOR SUB-FRAME (CAYENNE,

Front door Adjustment 160 mm +/-2 mm

window opening value
Guiding down front door window
Fastening Item 7 Tightening 8 Nm (6 ftlb.)

screws for power torque
windows
mechanism
Installing door sub-frame

on door torque
sub-frame
Installing door sub-frame

screws securing torque ftlb.)
door to door lock
Screwing in fastening screws on door lock
Fastening Item 4. Important: Tightening 6 Nm (4.5

screws for Left thread! torque ftlb.)
mounting pieces
Loosening fastening screws for mounting pieces

Information
Guide front door window Adjustment value 160 mm +/-2 mm down from the upper edge of the door.
Fig 1: Identifying Front Door Window
2. Remove front door handle. → Removing Front Door Handle 571119 REMOVING AND
INSTALLING FRONT DOOR HANDLE

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT DOOR
SUB-FRAME
Information
1. Open vehicle door.
2. Detach rubber cover.
1. 2.1. Press unlocking lug -arrow A- .
2. 2.2. Pull back rubber cover -1- on the wiring harness.

Fig 1: Pulling Back Rubber Cover On Wiring Harness
3. Disconnect electric plug connection -1- between the body and door.
1. 3.1. Turn retaining bar -2- down by 90° -arrow A- .
2. 3.2. Disconnect electric plug connection -1- .

4. Push wiring harness with electric connector through the opening into the vehicle door.
5. Release electric plug connection for rear-view mirror -a- and disconnect it -A- .
Fig 3: Releasing Electric Plug Connection For Rear-View Mirror
6. Guide rubber sleeve on the wire harness for rear-view mirror out of the door sub-frame.
-arrow- .
Fig 4: Pulling Rubber Sleeve Out Of Rear-View Mirror
7. Loosen door window glass.
1. 7.1. Remove stopper -3- .

Fig 5: Identifying Door Window Glass Stopper
Loosen left-thread fastening screws by turning them clockwise.
2. 7.2. Loosen fastening screws -4- for mounting pieces.

Fig 6: Identifying Fastening Screws For Mounting Pieces
3. 7.3. Pull door window out of the mounting pieces and fix in place in the upper
position using adhesive tape.
Fig 7: Pulling Door Window Out Of Mounting Pieces
8. Remove front door sub-frame.
1. 8.1. Remove fabric tape -5- from the holes.

Fig 8: Identifying Front Door Sub-Frame Screw
2. 8.2. Unscrew fastening screw -1- on inner part of door handle.

Fig 9: Removing Fastening Screw Inner Part Of Door Handle
3. 8.3. Unscrew fastening screws -2- used to secure the door to the door lock.
Fig 10: Removing Fastening Screws On Door Lock
4. 8.4. Unscrew and remove fastening screws -7- for the window lifter.
5. 8.5. Unscrew and remove twelve fastening screws from the door sub-frame -8- to
the vehicle door.
Fig 11: Removing Sub-Frame
6. 8.6. Pull the door sub-frame down a little.
7. 8.7. Unhook inner part of door handle.

Fig 12: Removing Inner Part Of Door Handle
8. 8.8. Pull A-pillar wiring harness through the opening into the vehicle door.
9. 8.9. Remove door sub-frame by guiding out the door lock with mounting bracket
-arrow A- .

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT DOOR
SUB-FRAME
1. Install door sub-frame.
1. 1.1. Push wiring harness through the vehicle door to the A-pillar.
2. 1.2. Guide in door lock with mounting bracket -arrow A- and move door sub-frame
into installation position.
3. 1.3. Position inner part of door handle.
1. 1.3.1. Guide locking hooks of inner part of door handle through the door
aperture and press inner part of door handle forward -arrows- .
Fig 1: Installing Front Door Sub-Frame
4. 1.4. Tighten twelve fastening screws from the door sub-frame -8- to the vehicle door
to Tightening torque 8 Nm (6 ftlb.) .
5. 1.5. Screw in fastening screws on window lifter -7- and tighten to Tightening torque
8 Nm (6 ftlb.) .
Fig 2: Installing Door Sub-Frame
6. 1.6. Screw in fastening screws -2- on the door lock and tighten to Tightening
torque 20 Nm (15 ftlb.) .
Fig 3: Screwing In Fastening Screws On Door Lock
7. 1.7. Replace fabric tape -5- and affix over the holes.
Fig 4: Identifying Covering Holes
2. Secure the door window.
1. 2.1. Insert door window glass into the mounting pieces and position centered
between the guide rails.
2. 2.2. Tighten fastening screws on the mounting pieces to Tightening torque 6 Nm

(4.5 ftlb.) , working from the left .
Fig 5: Identifying Mounting Pieces For Door Window
3. 2.3. Insert stopper.

Fig 6: Identifying Stopper
3. Connect electric plug connection -1- between the body and door.
1. 3.1. Plug in electric plug connection -1- .
2. 3.2. Turn retaining bar -2- up by 90° -B- .

3. 3.3. Pull rubber sleeve for the wiring harness at the A-pillar over the electric plug
connection and clip it in.

1. Install door panel. → INSTALLING FRONT DOOR PANEL
2. Remove front door handle. → Removing Front Door Handle 571119 REMOVING AND
INSTALLING FRONT DOOR HANDLE
WM 573055 REPLACING FRONT DOOR SUB-FRAME (CAYENNE, CAYENNE GTS,

1. Remove front door sub-frame. → Removing Front Door Sub-Frame 573019 REMOVING AND

CAYENNE S DIESEL, CAYENNE (3.0)) > DISASSEMBLING FRONT DOOR SUB-FRAME
Information
1. Remove wire harness for front door sub-frame. → REMOVING WIRE HARNESS FOR DOOR
2. Remove woofer from door sub-frame. → REMOVING FRONT LOUDSPEAKERS
3. Remove front pressure sensor. → REMOVING FRONT PRESSURE SENSOR
4. Remove front power window motor. →
5. Remove control unit for front door. → 577319 REMOVING AND INSTALLING FRONT DOOR
CONTROL UNIT Removing Control Unit For Front Door
6. Remove motor for closing aid. → Removing Motor For Closing Aid 577219 REMOVING AND
INSTALLING MOTOR FOR CLOSING AID

CAYENNE S DIESEL, CAYENNE (3.0)) > ASSEMBLING FRONT DOOR SUB-FRAME
1. Install motor for closing aid. → Installing Motor For Closing Aid 577219 REMOVING AND
INSTALLING MOTOR FOR CLOSING AID
2. Install control unit for front door. → Installing Control Unit For Front Door 577319 REMOVING
AND INSTALLING FRONT DOOR CONTROL UNIT
3. Install front power window motor. →
4. Install front pressure sensor. → INSTALLING FRONT PRESSURE SENSOR
5. Install woofer in door sub-frame. → INSTALLING FRONT LOUDSPEAKERS
6. Install wire harness for front door sub-frame. → INSTALLING WIRE HARNESS FOR DOOR

Install front door sub-frame. → Installing Front Door Sub-Frame 573019 REMOVING AND INSTALLING
FRONT DOOR SUB-FRAME
WM 573719 REMOVING AND INSTALLING INNER ACTUATING MECHANISM FOR

DOOR LOCK (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S,
PRELIMINARY WORK
1. Remove front door lock. → Removing Door Lock 571719 REMOVING AND INSTALLING
DOOR LOCK

REMOVING INNER ACTUATING MECHANISM FOR DOOR LOCK > REMOVING INNER
DOOR RELEASE
Information
1. Detach inner door release -1- at the door lock.
1. 1.1. Turn bowden cable clip 90° -A- and remove it from the bracket -B- .
Fig 1: Detaching Inner Door Release At Door Lock
2. Disengage actuator for inner door release.
1. 2.1. Turn inner door release -A- until the actuator in the mounting is released.
2. 2.2. Remove actuator for inner door release -1- from the mounting -B- .
Fig 2: Disengaging Inner Door Release

INSTALLING INNER ACTUATING MECHANISM FOR DOOR LOCK > INSTALLING
INNER DOOR RELEASE
1. The inner door release is installed in reverse order to removal.

SUBSEQUENT WORK
1. Install front door lock. → Installing Door Lock 571719 REMOVING AND INSTALLING DOOR
LOCK
WM 574519 REMOVING AND INSTALLING DOOR OPENER (CAYENNE, CAYENNE

Fastening Item 1 Tightening 1.6 Nm (1 ftlb.)

screw for door torque
opener
Removing door opener


CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING DOOR OPENER
Information
1. Swivel insulating mat for door panel aside.
2. Turn holder with door opener light anti-clockwise as far as it will go -A- and remove it from the
door handle -B- .
Fig 1: Removing Door Opener Light
3. Remove cover on door opener. → REMOVING SWITCH FOR MEMORY SEAT ADJUSTMENT
4. Unscrew and remove five fastening screws -1- on the door opener.
5. Remove door opener -C- .

Fig 2: Identifying Fastening Screw On Door Opener

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING DOOR OPENER
Installation is performed in reverse order. Pay particular attention to the following:
1. Tighten fastening screws to Tightening torque 1.6 Nm (1 ftlb.) .
2. When replacing the door opener, the switch for the central locking system must be converted.
→ 577819 REMOVING AND INSTALLING SWITCH FOR CENTRAL LOCKING SYSTEM

WM 575115 ADJUSTING FRONT DOOR (CAYENNE, CAYENNE GTS, CAYENNE

star gauges Special tool NR.127-1

for body gap
dimensions

DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES

peg
Installing lock peg

screw securing torque ftlb.)
door hinge to
door
Front door hinge

door hinge to
outer A-pillar
Door hinge on body side, outer

door hinge to
inner A-pillar
Loosening rear door hinge on body side at the inside

DIESEL, CAYENNE (3.0)) > ADJUSTING FRONT DOOR
WARNING: Incorrect handling of safety bolts
Danger of injury
Loss of torque
→ Always use new fastening screws and nuts following removal.
→ Observe specified tightening torques.
→ Carry out a visual inspection of all re-used parts.
Information
Only tighten the fastening screws on the door hinges hand-tight from the inside until the doors are set
correctly.
Information
specifications.
accessories must be centered accordingly.
Information
The door hinge must be aligned after installing the door.
Loosen fastening screws for door hinge at the door and fastening screws for door hinge at the
A-pillar so that the threaded connections can be moved.
Information
1. Adjust front door with door hinge at the door.

Fig 1: Identifying Front Door Hinge On Door Side
1. Fastening screw -1- Adjustment of gap Loosen.

securing door hinge dimensions in Y and Z
-2- to front door direction
2. Front door Adjust gap dimensions

in Y and Z direction by
moving the door.
3. Fastening screw -1- Adjustment of gap Tighten fastening

securing door hinge dimensions in Y and Z screw -1- securing
-2- to front door direction door hinge -2- to front
door to Tightening
torque 50 Nm (37
ftlb.) .
2. Adjust front door with door hinge at the body.

Fig 2: Identifying Front Door Hinge On Body Side (Inside)

Fig 3: Identifying Front Door Hinge On Body Side (Outside)
1. Tighten fastening Adjustment of gap Loosen.

screw securing door dimensions in X and Z
hinge to body on direction
outside -2- and inside
-1- .

in X and Z direction by
moving the rear door.
3. Fastening screw Adjustment of gap Tighten fastening

securing door hinge to dimensions in X and Z screws securing door
body on outside -2- direction hinge to body on
and inside -1- → outside -2- to
Installing Front Door Tightening torque 50
Hinge Nm (37 ftlb.) and
inside to Tightening
torque 50 Nm (37
ftlb.) .
3. Adjust front door at the lock peg (striker pin).
Fig 4: Adjusting Front Door At Lock Peg (Striker Pin)
1. Fastening screws -2- Locking mechanism Loosen.

for lock peg -1- at the for front door
front

in Y and Z direction at
the rear by moving the
front door.
3. Fastening screws -2- Adjust gap dimensions Tighten fastening

for lock peg -1- at the in Z direction at the screws -2- for lock
front rear by moving the peg -1- at the front to
front door. Tightening torque 25
Nm (19 ftlb.) .

DIESEL, CAYENNE (3.0)) > CHECKING FRONT DOOR LOCK
1. Check the function of the front door lock.
2. Check closing and opening forces and compare with the other doors.
If these forces differ, re-adjust the door.
WM 575119 REMOVING AND INSTALLING FRONT DOOR (CAYENNE, CAYENNE GTS,


screw for door torque ftlb.)
hinge
Loosening fastening screws for hinge connection

door arrester
to A-pillar
Unscrewing fastening screw on door arrester

1. Loosen battery ground strap. → LOOSENING GROUND STRAP FOR BATTERY

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT DOOR
2. Detach rubber cover -1- .
2. 2.2. Swivel rubber cover -1- down -arrow B- .

Fig 1: Removing Rubber Cover

1. 3.1. Turn retaining bar -2- down by 90° -A- .
2. 3.2. Disconnect electric plug connection -1- by pulling it outwards.

Fig 2: Disconnecting Electric Plug Connection Between Body And Door
4. Unscrew and remove fastening screw on the door arrester -4- at the vehicle door.
Fig 3: Removing Fastening Screw On Door Arrester
5. Pull plastic caps -3- off the hinge screws at the top and bottom hinge joints -6- .
Fig 4: Identifying Caps On Hinge Screws
6. Loosen fastening screws -5- on the upper and lower hinge joint -6- .
Fig 5: Loosening Fastening Screws On Upper And Lower Hinge Joint
7. Get another person to hold the vehicle door.
8. Lift the vehicle door up slightly until the hinge bolts come out of the hinge halves on the door
side.
Fig 6: Lifting Vehicle Door
9. Remove vehicle door.

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT DOOR
1. The front door is installed in reverse order to removal.
2. Tighten fastening screw on door hinge to Tightening torque 23 Nm (17 ftlb.) .
3. Tighten fastening screw for door arrester to Tightening torque 30 Nm (22 ftlb.) .

1. Secure battery ground strap. → SECURING GROUND STRAP FOR BATTERY
WM 575137 DISASSEMBLING AND ASSEMBLING FRONT DOOR (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > DISASSEMBLING FRONT DOOR
Information
1. Remove front door. → 575119 REMOVING AND INSTALLING FRONT DOOR
2. Remove front door sub-frame. → 573019 REMOVING AND INSTALLING FRONT DOOR
SUB-FRAME
3. Remove rear-view mirror. → REMOVING REARVIEW MIRROR
4. Remove front corner window pane. → REMOVING FRONT CORNER WINDOW PANE
5. Remove front door lock. → Removing Door Lock 571719 REMOVING AND INSTALLING
DOOR LOCK
6. Remove cover for front door. → 662219 REMOVING AND INSTALLING COVER FOR FRONT
DOOR
7. Remove front door arrester. → Removing Door Arrester 575919 REMOVING AND
INSTALLING FRONT DOOR ARRESTER
WM 575137 DISASSEMBLING AND ASSEMBLING FRONT DOOR (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > ASSEMBLING FRONT DOOR
Information
1. Install front door arrester. → Installing Door Arrester 575919 REMOVING AND INSTALLING
FRONT DOOR ARRESTER
2. Install cover for front door. → INSTALLING COVER FOR FRONT DOOR
3. Install front door lock. → Installing Door Lock 571719 REMOVING AND INSTALLING DOOR
LOCK
4. Install front corner window pane. → INSTALLING FRONT CORNER WINDOW PANE
5. Install rear-view mirror. → INSTALLING REARVIEW MIRROR
6. Install front door sub-frame. → Installing Front Door Sub-Frame 573019 REMOVING AND
7. Install rubber seal for front door. → Installing Rubber Seal For Front Door 576319 REMOVING
AND INSTALLING RUBBER SEAL FOR FRONT DOOR
8. Install front door. → Installing Front Door 575119 REMOVING AND INSTALLING FRONT
DOOR
WM 575319 REMOVING AND INSTALLING FRONT DOOR HINGE (CAYENNE,

door hinge to
door
Front door hinge

door hinge to
outer A-pillar
Door hinge on body side, outer

door hinge to
inner A-pillar
Loosening rear door hinge on body side at the inside

PRELIMINARY WORK FOR FRONT DOOR HINGE ON DOOR SIDE
1. Remove front door. → Removing Front Door 575119 REMOVING AND INSTALLING FRONT
DOOR

PRELIMINARY WORK FOR FRONT DOOR HINGE ON BODY SIDE
Upper left door hinge:
1. Remove trim panel under dashboard. → REMOVING TRIM PANEL UNDER DASHBOARD
2. Loosen bracket for gateway control unit and leave it hanging at the wiring harness. → 903519
REMOVING AND INSTALLING GATEWAY CONTROL UNIT
Upper right door hinge:
3. Remove glove compartment. → REMOVING GLOVE COMPARTMENT
Lower left and right door hinge:
4. Remove inner door sill trim. → REMOVING INNER DOOR ENTRY GUARD

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT DOOR HINGE >
REMOVING FRONT DOOR HINGE ON DOOR SIDE
Information
Fig 1: Identifying Front Door Hinge Position
1. Place the door on a secure, padded surface and make sure that it cannot fall.
2. Unscrew fastening screws -1- from both door hinges -2- .


TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT DOOR HINGE >
REMOVING FRONT DOOR HINGE ON BODY SIDE
Information
Fig 1: Identifying Front Door Hinge Position
1. Detach insulating mat on the inside of the A-pillar.
2. Unscrew and remove fastening screws -2- from both hinges -3- at the outside.
Fig 2: Identifying Front Door Hinge On Body Side (Outside)
3. Unscrew and remove fastening screws -1- from the A-pillar at the inside.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT DOOR HINGE >
INSTALLING FRONT DOOR HINGE ON DOOR SIDE
Danger of injury
Loss of torque
Information
1. Tighten fastening screws -1- on both hinges -2- to Tightening torque 50 Nm (37 ftlb.) until
secure.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT DOOR HINGE >
INSTALLING FRONT DOOR HINGE ON BODY SIDE
Danger of injury
Loss of torque

Information
1. Tighten fastening screws -2- on both hinges -3- at the outside to Tightening torque 50 Nm
(37 ftlb.) until secure.
Fig 1: Identifying Rear Door Hinge On Body Side (Outside)
Information
Only tighten the fastening screws on the door hinges hand-tight from the inside until the doors
are set correctly.
2. Tighten fastening screws -1- on both hinges at the inside to Tightening torque 50 Nm (37
ftlb.) until secure.

SUBSEQUENT WORK FOR FRONT DOOR HINGE ON DOOR SIDE
1. Install front door. → Installing Front Door 575119 REMOVING AND INSTALLING FRONT
DOOR
2. Adjust the front door. → 575115 ADJUSTING FRONT DOOR

SUBSEQUENT WORK FOR FRONT DOOR HINGE ON BODY SIDE
Upper left door hinge:
1. Secure bracket for gateway control unit. → INSTALLING GATEWAY CONTROL UNIT
2. Install trim panel under dashboard. → INSTALLING TRIM PANEL UNDER DASHBOARD
Upper right door hinge:
3. Install glove compartment. → INSTALLING GLOVE COMPARTMENT
Lower left and right door hinge:
4. Install inner door sill trim. → INSTALLING INNER DOOR ENTRY GUARD
5. Adjust the front door. → 575115 ADJUSTING FRONT DOOR
WM 575919 REMOVING AND INSTALLING FRONT DOOR ARRESTER (CAYENNE,


door arrester
to A-pillar
Unscrewing fastening screw on door arrester
Fastening Item 2 Tightening 9 Nm (6.5 ftlb.)

screw securing torque
door arrester
to door
Fastening screws for door

1. Remove front door sub-frame. → Removing Front Door Sub-Frame

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING DOOR ARRESTER
Information
1. Unscrew and remove fastening screw for A-pillar -1- .

Fig 1: Removing Fastening Screw For A-Pillar
2. Unscrew and remove fastening screws for door -2- .

Fig 2: Removing Fastening Screws For Door
3. Remove door arrester by moving it inwards.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING DOOR ARRESTER
Information
1. Position door arrester.
2. Tighten fastening screws for door -2- to Tightening torque 9 Nm (6.5 ftlb.) .
Fig 1: Identifying Door Arrester Fastening Screws
3. Tighten fastening screw for A-pillar -1- to Tightening torque 30 Nm (22 ftlb.) .
Fig 2: Securing Door Arrester

WM 576319 REMOVING AND INSTALLING RUBBER SEAL FOR FRONT DOOR

(EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S
WORK
1. Remove A-pillar trim. → REMOVING A-PILLAR TRIM
2. Remove front side section trim. → REMOVING FRONT SIDE SECTION TRIM
3. Remove front and rear inner door entry guard. → REMOVING INNER DOOR ENTRY GUARD
4. Remove B-pillar trim but not the seat belt. → REMOVING B-PILLAR TRIM
5. Remove front grab handle. → REMOVING FRONT HANDLE

RUBBER SEAL FOR FRONT DOOR
1. Carefully detach roof lining -1- out of the rubber seal for the front door -2- . Do not kink roof
lining.
Fig 1: Detaching Roof Lining
2. Pull off rubber seal all around the sheetmetal flange.

Fig 2: Removing Rubber Seal For Front Door

1. Fit vulcanization point of rubber seal -1- close to the door arrester on the sheetmetal flange.
Fig 1: Identifying Rubber Seal For Front Door
The air vents in the seal must be facing the outside of the vehicle.
2. Press rubber seal onto the sheetmetal flange all the way around.
Fig 2: Pressing On Rubber Seal For Front Door
3. Check that the seal is installed correctly.
1. 3.1. Pay particular attention to the areas near the tight roundings for correct
installation; there must be no deformation or stretching.
2. 3.2. Check the air vents; they must not be closed or covered.
4. Carefully insert roof lining -1- into the rubber seal -2- . Do not kink roof lining.
Fig 3: Inserting Roof Lining Into Rubber Seal For Front Door

WORK
1. Install A-pillar trim. → INSTALLING A-PILLAR TRIM PANEL
2. Install front side section trim. → INSTALLING FRONT SIDE SECTION TRIM PANEL
3. Install front inner door entry guard. → INSTALLING INNER DOOR ENTRY GUARD
4. Install B-pillar trim. → INSTALLING B-PILLAR TRIM
5. Install front grab handle. → INSTALLING FRONT GRAB HANDLES
WM 576555 REPLACING OUTER RUBBER SEAL FOR FRONT DOOR (EXCEPT


Rubber seal to Contact force 40 N
door
Installing rubber seal

1. Detach door arrester at the A-pillar. → Removing Door Arrester 575919 REMOVING AND

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REPLACING OUTER
Information
1. Unclip window frame cover -1- with a plastic wedge, starting at the top.
Fig 1: Removing Window Frame Cover
2. Mark the position of the rubber seal in the lower area of the door with adhesive strips.
3. Pull off rubber seal.

Fig 2: Pulling Off Rubber Seal
Information
1. Immediately before sticking on, wash off the areas on which you intend to stick the seal
using isopropanol to ensure that all traces of silicone, grease and oil are completely
removed.
4. Fit new rubber seal -2- .
1. 4.1. Fit new rubber seal -2- with the vulcanization point -3- centered between the
top and bottom door hinge at the front. The air vents in the rubber seal must be
facing towards the outside of the vehicle.
2. 4.2. Position rubber seal on the sheetmetal flange and on the adhesive strips all the
way around.
3. 4.3. Pull out protective film from under the seal.
4. 4.4. Press rubber seal onto the sheetmetal flange using press-on roller and Contact
force 40 N .
Fig 3: Fitting Rubber Seal
5. Remove strips of adhesive tape.
6. Fit window frame cover at the front and rear between the door panel and window frame, then
clip it into the window guide -1- .
Fig 4: Installing Window Frame Cover

1. Secure door arrester at the A-pillar. → Installing Door Arrester 575919 REMOVING AND
WM 577219 REMOVING AND INSTALLING MOTOR FOR CLOSING AID (CAYENNE,

1. Remove front door sub-frame. → Removing Front Door Sub-Frame 573019 REMOVING AND

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING MOTOR FOR CLOSING
AID
Information
1. Remove cover -1- .

Fig 1: Identifying Cover
3. Remove bracket -2- for bowden cable at the closing aid motor -6- .
4. Disengage ball joint -3- for bowden cable at the closing aid motor -6- .
5. Guide out rubber seals -4- .
6. Route electric line and set bowden cable aside.

8. Lift closing aid motor -6- up and remove it.

Fig 2: Identifying Motor For Closing Aid, Seal And Fastening Screws

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING MOTOR FOR CLOSING
AID
Installation is performed in reverse order.

WM 577319 REMOVING AND INSTALLING CONTROL UNIT FOR FRONT DOOR

WORK

CONTROL UNIT FOR FRONT DOOR
NOTE: Voltage peaks
Fig 1: Identifying Control Unit For Front Door Position
1. Release electric plug connection -a- and pull it off the control unit.
2. Release the locks on the electric plug connections -b- and pull both connectors off the door
control unit.
Fig 2: Removing Electric Plug Connections On Control Unit For Front Door
Information
The door control unit is fitted into the door sub-frame -1- and engaged in the door sub-frame
with a locking lug -2- .
If you are unclipping the door control unit for the first time, greater force will be required in
order to release the locking lug -2- from the door sub-frame.
Press the control unit back against the door sub-frame while you are releasing it.
Fig 3: Releasing Locking Lug From Door Sub-Frame
3. Release the catch -A- on the control unit and remove in direction of arrow -B- .
Fig 4: Releasing Catch On Control Unit

1. Engage control unit for front door in the door sub-frame and clip it in.
Fig 1: Installing Control Unit For Front Door
2. Plug in electric plug connections on the door control unit and press in the locks -a- .
Fig 2: Plugging In Electric Plug Connections

WORK
1. Install front door panel → INSTALLING FRONT DOOR PANEL
WM 577819 REMOVING AND INSTALLING SWITCH FOR CENTRAL LOCKING

HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > COMPONENT
INFORMATION > INSTALLATION POSITION OF SWITCH FOR CENTRAL LOCKING
SYSTEM
Fig 1: Identifying Switch For Central Locking System Installation Position

WORK

SWITCH FOR CENTRAL LOCKING SYSTEM
NOTE: Voltage peaks
Information
1. Release and disconnect electric plug connection -1- on switch for central locking system -2- .
2. Disengage switch for central locking system -2- from the spring clamps -3- and remove it -A-
.
Fig 1: Removing Switch For Central Locking System

SWITCH FOR CENTRAL LOCKING SYSTEM
1. Fit switch for central locking system -2- into the door panel.
2. Press switch -2- in carefully until the spring clamps engage securely.
Fig 1: Identifying Central Locking System Into Door Panel

WORK
WM 577819 SWITCH FOR CENTRAL LOCKING SYSTEM (EXCEPT CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > COMPONENT INFORMATION >
INSTALLATION POSITION OF SWITCH FOR CENTRAL LOCKING SYSTEM
Fig 1: Identifying Switch For Central Locking System Position

1. Remove front door trim. → REMOVING ARMREST FOR FRONT DOOR PANEL

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING SWITCH FOR CENTRAL
LOCKING SYSTEM
NOTE: Voltage peaks
Information
1. Release and disconnect electric plug connection -1- on switch for central locking system -2- .
2. Disengage switch for central locking system -2- from the spring clamps -3- and remove it -A-
.
Fig 1: Removing Switch For Central Locking System

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING SWITCH FOR CENTRAL
LOCKING SYSTEM
1. Fit switch for central locking system -2- into the door panel.
2. Press switch -2- in carefully until the spring clamps engage securely.
Fig 1: Identifying Central Locking System Into Door Panel

1. Install front door trim. → INSTALLING ARMREST FOR FRONT DOOR PANEL
WM 578919 REMOVING AND INSTALLING CONTROL UNIT FOR REAR LID


II

1. If the control unit will be replaced, the old control unit must first be read out using PIWIS Tester
II 9818 . → 556855 REPLACING CONTROL UNIT FOR REAR LID .
2. Remove lower part of rear trim panel. → REMOVING TRIM PANEL FOR TAILGATE

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING CONTROL
UNIT FOR REAR LID
Fig 1: Identifying Control Unit For Rear Lid Position

NOTE: Voltage peaks
Information
1. Release electric plug connection -1 and 2- from control unit for rear lid and disconnect it -A- .
2. Release electric plug connection -3- (-a- ) and turn release element -4- 90° anti-clockwise
-B- . Disconnect electric plug connection from control unit for rear lid.
Fig 2: Disconnecting Plug Connections

3. Pull both buttons -1- towards each other. Push control unit -2- to the right and remove it from
the lid.
Fig 3: Removing Control Unit For Rear Lid

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING CONTROL
UNIT FOR REAR LID
Information
1. Position control unit -1- in the mounting points and push it to the right until both buttons
engage securely.
Fig 1: Positioning Control Unit For Rear Lid
2. Fit electric plug connection -3- on control unit for rear lid and turn release element -4- 90°
clockwise until it engages securely.
3. Connect electric plug connections -1 and 2- on control unit for rear lid until they engage
securely.

1. If the control unit was replaced, the "new" control unit must be taught to suit the vehicle using
PIWIS Tester II 9818 . → 556855 REPLACING CONTROL UNIT FOR REAR LID .
2. Install lower part of rear trim panel. → INSTALLING TRIM PANEL FOR TAILGATE
WM 578919 REMOVING AND INSTALLING CONTROL UNIT FOR REAR-END

ELECTRONICS (CAYENNE S, CAYENNE S HYBRID, CAYENNE TURBO, CAYENNE S

II

1. If the control unit for rear-end electronics has to be replaced, the values/coding must be read
out prior to removal using PIWIS Tester II 9818 . → 578955 REPLACING CONTROL UNIT
FOR REAR-END ELECTRONICS .
2. Remove side trim panel for rear luggage compartment at the right. → REMOVING SIDE TRIM

DIESEL, CAYENNE (3.0)) > REMOVING CONTROL UNIT FOR REAR-END
ELECTRONICS
Fig 1: Identifying Control Unit For Rear-End Electronics Position
NOTE: Voltage peaks
1. Release four electric plug connections -1- (-a- ) and disconnect them.
2. Lift control unit for rear-end electronics up out of the bracket and remove it -arrow A- .
Fig 2: Removing Control Unit For Rear-End Electronics

DIESEL, CAYENNE (3.0)) > INSTALLING CONTROL UNIT FOR REAR-END
ELECTRONICS
1. Slide control unit for rear-end electronics into the bracket -arrow B- .
2. Plug in and lock four electric plug connections -1- until they engage securely.
Fig 1: Installing Control Unit For Rear-End Electronics

DIESEL, CAYENNE (3.0)) > SUBSEQUENT WORK
1. Install side trim panel for rear luggage compartment at the right. → INSTALLING SIDE TRIM
2. If the control unit for rear-end electronics was replaced, the values/coding must be written back
into the control unit again. → 578955 REPLACING CONTROL UNIT FOR REAR-END
ELECTRONICS .
WM 578955 REPLACING CONTROL UNIT FOR REAR-END ELECTRONICS (CAYENNE

TIP "PLATINUM EDITION", CAYENNE TIP (3.0) "PLATINUM EDITION", CAYENNE
DIESEL "PLATINUM EDITION", CAYENNE TIP, CAYENNE MAN, CAYENNE S,
CAYENNE TURBO, CAYENNE GTS, CAYENNE S HYBRID, CAYENNE TURBO S) >
TOOLS

II

TECHNICAL VALUES

Information
All remote controls (keys) are required for teaching a DME, front-end electronics (front BCM), rear-end
electronics (rear BCM), electronic steering lock (ELV) control unit or remote controls (keys) for example.
Remote controls (keys) that are not taught during this teaching procedure will no longer be recognized
by the vehicle.
NOTE: Voltage drop

battery.
Information
Tester releases.
ignition.
3. Select the Rear-end electronics control unit in the overview .
4. Select Rear-end electronics control unit.
CONTROL UNIT FOR REAR-END ELECTRONICS
11. Go back to the Start page on the Tester.
12. To activate the control units, switch on the hazard warning lights.
13. Select the Online teaching function menu on the Start page.
14. Select Vehicle and press [>>]. Vehicle data will be read out.
15. The vehicle identification number (VIN) is displayed. Adapt the vehicle identification number if
necessary.
16. Enter the repair order number and press [>>].
17. Enter the PPN user name and password and press [>>].
18. Login is performed.
19. The Tester displays the message Login successful . Press [>>].
20. Follow the instructions on the Tester to select the required menu.
21. Once the teaching process is completed successfully, the Tester shows the following status, for
example:
2 keys taught
Front BCM: taught
ELV: taught
Rear BCM: taught
DME: taught
Overall vehicle status: taught
22. [>>].
23. Press [EXIT] to exit the Online teaching function and select the vehicle type on the Start
page.
24. Press [F7] Read all fault memories and erase if required and delete all faults.
25. Select Rear-end electronics using the cursor keys and press [>>].
26. Select Control unit replacement with the cursor keys and press the [>>] key.
Re-install the data that was read out by selecting Write values .
28. Function test: Lock, open and start the vehicle using all remote controls.

Service Manual: 58 - REAR DOOR, CENTRAL LOCKING -- 92A CAYENNE
WM 581119 REMOVING AND INSTALLING REAR DOOR HANDLE (CAYENNE,
removal and VW tool T10389

assembly tool

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR DOOR HANDLE
1. Pull off cover.

Fig 1: Pulling Off Cover
2. Insert removal and assembly tool T10389 -1- into the rear door and pull the locking clip -2-
to the rear.
Fig 2: Releasing Clip
3. Unclip rear door handle cover -3- by pulling it outwards.

Fig 3: Unclipping Door Handle Cover
4. Remove rear door handle.
1. 4.1. Unhook rear door handle -6- (-B- ) and swivel it out by 90° -A- .
2. 4.2. Remove rubber base -7- and rear door handle -6- .
Fig 4: Removing Rear Door Handle
5. Vehicles with KESSY: Release electric plug connection for KESSY -8- (-a- ) and disconnect
it.
Fig 5: Disconnecting Connector For KESSY

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR DOOR HANDLE
1. Vehicles with KESSY: Plug in electric plug connection for KESSY -8- and lock it -a- .
Fig 1: Installing Connector
2. Install rear door handle.
2. 2.2. Hook in rear door handle -B- and swivel it inwards by 90° -A- .
3. 2.3. Make sure that the rubber lip is at the correct position during installation.
Fig 2: Installing Door Handle
3. Fit rear door handle cover -3- .

Fig 3: Fitting Door Handle Cover
4. Lock the supporting bow using a blunt tool (e.g. Torx 30).
Fig 4: Locking Support Bow
5. Fit the cover.

Fig 5: Fitting Cover
WM 581119 REMOVING AND INSTALLING REAR DOOR HANDLE (INNER PART)

WORK
1. Remove rear door sub-frame. → Removing Rear Door Sub-Frame

REAR DOOR HANDLE (INNER PART)
1. Remove inner part of door handle at the mounting bracket.

Fig 1: Removing Mounting Bracket
2. Disengage bowden cable from the door lock at the inner part of the door handle.
1. 2.1. Unclip bowden cable housing using a suitable tool -a- and take it up out of the
bracket.
Fig 2: Unclipping Bowden Cable Housing
2. 2.2. Turn bowden cable catch through 90°.
3. 2.3. Disengage bowden cable catch by pulling it upwards -A- and remove it -B- .
Fig 3: Disengaging Bowden Cable Catch

REAR DOOR HANDLE (INNER PART)
1. Engage bowden cable from the door lock at the inner part of the door handle.
1. 1.1. Engage bowden cable catch in the guide -C- and slide it fully to the right -D- .
Fig 1: Engaging Bowden Cable Catch
2. 1.2. Push bowden cable catch to the rear.
3. 1.3. Press bowden cable housing into the bracket and clip it in -a- .
Fig 2: Clipping In Bowden Cable Housing
2. Attach inner part of door handle with mounting bracket.

Fig 3: Attaching Mounting Bracket

WORK
1. Install rear door sub-frame. → Installing Rear Door Sub-Frame
WM 581719 REMOVING AND INSTALLING REAR DOOR LOCK (CAYENNE, CAYENNE


CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR DOOR LOCK
Information
1. Unclip mounting bracket for door lock from the door sub-frame.
2. Release electric plug connection -1- and disconnect connector.

3. Disengage bowden cable in the door lock from the door lock to the inner part of the door
handle.
1. 3.1. Release bowden cable bracket -3- (-a- ) and unclip it -A- .
2. 3.2. Turn bowden cable bracket by 90° -B- and disengage the catch -4- .
Fig 2: Disengaging Bowden Cable From Inner Part Of Door Handle
4. Disengage bowden cable for inner actuating mechanism on the door lock. → Removing Inner
Actuating Mechanism For Door Lock
5. On vehicles with Softclose (closing aid)
6. Remove cover on Softclose motor -1- using a suitable tool.

Fig 3: Removing Cover On Softclose Motor
7. Pull rubber sleeve for bowden cable -1- out of the lower cover.
1. 7.1. Release locking lug -2- and unclip clip from the guide.
Fig 4: Pulling Rubber Sleeve For Bowden Cable
8. Guide out bowden cable -1- and disengage it.

Fig 5: Disengaging Bowden Cable
9. Remove door lock.

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR DOOR LOCK

WM 582619 REMOVING AND INSTALLING STRIKER PIN (CAYENNE, CAYENNE GTS,


slide hammer Commercially Nr.168
kit available tool

Fastening Tightening 20 Nm (15

screw for lock torque ftlb.)
peg (striker
pin)

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING STRIKER PIN > REMOVING
LOCK PEG
Information
1. Unscrew fastening screws -2- and remove lock peg (striker pin) -1- .
Fig 1: Removing Lock Peg

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING STRIKER PIN > INSTALLING
LOCK PEG
Information
1. Position lock peg (striker pin) and screw in the fastening screws -2- .
Fig 1: Installing Lock Peg
2. Carefully close vehicle door and check that the lock peg is positioned correctly with respect to
the lock.
3. Adjust the lock peg to suit the lock as required.
4. Tighten fastening screws -2- to Tightening torque 20 Nm (15 ftlb.) .
5. Check adjustment of vehicle door and adjust it if necessary. → 585115 ADJUSTING REAR
DOOR

CAYENNE S DIESEL, CAYENNE (3.0)) > ADJUSTING STRIKER PIN > ADJUSTING
LOCK PEG (STRIKER PIN)
Information
The striker pin can be adjusted by changing the plasticity of the adjusting element in the C-pillar.
The setting is retained when the striker pin is removed.

Fig 1: Adjusting Element For Striker Pin
1. Loosen the fastening screws -2- .
2. Adjust the lock peg.

Fig 2: Moving Lock Peg (Striker Pin)
1. 2.1. Move the lock peg -1- outwards (if necessary) using a slide hammer kit Nr.168
.
3. Adjust the lock peg back/down/up (if necessary).
1. 3.1. Move catch bar -1- to the required position using a plastic hammer.
2. 3.2. Carefully close vehicle door and check adjustment.
4. Screw in fastening screws -2- and tighten to Tightening torque 20 Nm (15 ftlb.).
WM 583019 REMOVING AND INSTALLING REAR DOOR SUB-FRAME (CAYENNE,


for mounting torque ftlb.)
pieces for door
window
Loosening mounting pieces for window glass

for power torque
windows
mechanism
Installing sub-frame

securing door torque ftlb.)
lock to door
Screwing in fastening screws on door lock
Rear door Adjustment 205 mm +/-2 mm

window opening value
Guiding down rear door window

Information
Guide rear door window Adjustment value 205 mm +/-2 mm down from the upper edge of the C-pillar
for the door.
Fig 1: Identifying Rear Door Window Position
1. Remove rear door panel. → REMOVING REAR DOOR PANEL
2. Remove rear door handle. → Removing Rear Door Handle 581119 REMOVING AND
INSTALLING REAR DOOR HANDLE

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR DOOR
SUB-FRAME
1. 1.1. Unclip rubber cover for the wire harness at the B-pillar and pull it back.

2. Push wire harness with connector through the opening into the vehicle door.
3. Loosen door window glass.
1. 3.1. Remove stoppers and wiring harness -3- .

Fig 2: Identifying Stoppers
Information
2. 3.2. Loosen fastening screws on the mounting pieces -4- .

Fig 3: Loosening Mounting Pieces For Door Window
3. 3.3. Pull door window out of the mounting pieces and fix in place in the upper
position using adhesive tape.
Fig 4: Fixing Door Window In Position
4. Remove front door sub-frame.
1. 4.1. Remove fabric tape -5- from the holes.

Fig 5: Identifying Fabric Tape
2. 4.2. Unscrew fastening screw -1- on inner part of door handle.

Fig 6: Removing Screw On Inner Part Of Door Handle
3. 4.3. Unscrew fastening screws -2- on door lock.

Fig 7: Removing Screws On Door Lock
4. 4.4. Unscrew and remove fastening screws -7- for the window lifter.
Fig 8: Removing Sub-Frame
5. 4.5. On vehicles with sun blind, pull up guide tube for push rod.
6. 4.6. Turn clips by 90° and pull them out of the door sub-frame -8- to the vehicle door.
7. 4.7. Pull door sub-frame outwards and then inwards.
8. 4.8. Unhook inner part of door handle.

Fig 9: Unclipping Inner Part Of Door Handle
9. 4.9. Pull wiring harness for B-pillar through the opening into the vehicle door.
10. 4.10. Remove door sub-frame by guiding out the door lock with mounting bracket
-arrow A- .

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR DOOR
SUB-FRAME
1. Install door sub-frame.
1. 1.1. Push wiring harness through the vehicle door to the B-pillar.
2. 1.2. Guide in door lock with mounting bracket -arrow A- and move door sub-frame
3. 1.3. Position inner part of door handle.

Fig 1: Positioning Inner Part Of Door Handle
1. 1.3.1. Guide locking hooks of inner part of door handle through the door
aperture and press inner part of door handle forward -arrows- .
4. 1.4. Fit clips from the door sub-frame -8- to the vehicle door and turn them by 90°.
5. 1.5. Screw in fastening screws on window lifter -7- and tighten to Tightening torque
8 Nm (6 ftlb.) .
Fig 2: Installing Sub-Frame
6. 1.6. Screw in fastening screws -2- on the door lock and tighten to Tightening
torque 20 Nm (15 ftlb.) .
Fig 3: Installing Screws On Door Lock
7. 1.7. Replace fabric tape -5- and affix over the holes.
Fig 4: Identifying Fabric Tape
2. Secure the door window.
1. 2.1. Guide the door window into the mounting pieces and check that the window is
parallel at the window guide in the B-pillar area.
2. 2.2. Tighten fastening screws on the mounting pieces -4- to Tightening torque 6
Nm (4.5 ftlb.) , working from the left .
Fig 5: Tightening Mounting Pieces For Door Window
3. 2.3. Insert stoppers -3- .

3. Connect electric plug connection -1- between the body and doors.
1. 3.1. Plug in electric plug connection -1- .
2. 3.2. Twist retaining bar -2- up by 90° -B- .
3. 3.3. Pull rubber sleeve for the wiring harness at the B-pillar over the electric plug
connection and clip it in.

WM 583055 REPLACING REAR DOOR SUB-FRAME (CAYENNE, CAYENNE GTS,

Diameter of Diameter 29 mm +/-0.4 mm

hole in
sunblind


CAYENNE S DIESEL, CAYENNE (3.0)) > DISASSEMBLING REAR DOOR SUB-FRAME
1. Remove wire harness for rear door sub-frame. → REMOVING WIRE HARNESS FOR DOOR
2. Remove woofer in rear door. → REMOVING REAR LOUDSPEAKERS
3. Remove rear power window motor. → REMOVING REAR POWER WINDOW MOTOR
4. Remove control unit for rear door. → Removing Rear Door Control Unit

CAYENNE S DIESEL, CAYENNE (3.0)) > ASSEMBLING REAR DOOR SUB-FRAME
Information
Information
On vehicles with optional electric sunblind:
Drill a hole in the center of the notch in the new door sub-frame using a small drill bit.
Then using an antenna drill bit, carefully drill out the hole -arrow- until it measures → Diameter: 29
mm+/-0.4 mm .
Fig 1: Opening Sunblind Rail
1. Install control unit for rear door. → Installing Rear Door Control Unit
2. Install rear power window motor. → INSTALLING REAR POWER WINDOW MOTOR
3. Install woofer in rear door. → INSTALLING REAR LOUDSPEAKERS
4. Install wire harness for rear door sub-frame. → INSTALLING WIRE HARNESS FOR DOOR
WM 583719 REMOVING AND INSTALLING INNER DOOR RELEASE (CAYENNE,

1. Remove rear door lock. → Removing Rear Door Lock

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING INNER DOOR RELEASE
Information
1. Detach inner actuating mechanism -1- from door lock.
1. 1.1. Turn bowden cable clip 90° -A- and remove it from the bracket -B- .
Fig 1: Loosening Inner Door
2. Disengage driver for inner door release.
1. 2.1. Turn inner actuating mechanism -A- until the actuator in the mounting is
released.
2. 2.2. Remove actuator for inner door release -1- from the mounting -B- .
Fig 2: Disengaging Inner Door

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING INNER DOOR RELEASE
1. The inner door release is installed in reverse order to removal.

1. Install rear door lock. → Installing Rear Door Lock

DOOR LOCK (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S,
PRELIMINARY WORK

REMOVING INNER ACTUATING MECHANISM FOR DOOR LOCK
Information
1. Detach inner actuating mechanism -1- from door lock.
1. 1.1. Turn bowden cable clip by 90° -A- and remove from the bracket -B- .
Fig 1: Detaching Inner Actuating Mechanism
2. Detach actuator for inner actuating mechanism.
1. 2.1. Turn inner actuating mechanism -A- until the actuator in the mounting is
released.
2. 2.2. Remove actuator for inner actuating mechanism -1- from the mounting -B- .
Fig 2: Disengaging Inner Actuating Mechanism

INSTALLING INNER ACTUATING MECHANISM FOR DOOR LOCK
1. Installation of inner actuating mechanism for door lock is performed in reverse order to
removal.

SUBSEQUENT WORK

2. Remove sun blind on door window. → REMOVING SUN BLIND ON DOOR WINDOW
CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING DOOR OPENER
Information
1. Swivel insulating mat aside.
2. Turn holder with door opener light anti-clockwise as far as it will go -A- and remove it from the
door handle -B- .
Fig 1: Removing Door Opener Light
3. Unscrew five fastening screws -2- on cover for rear door opener.
Fig 2: Removing Cover On Door
4. Remove cover for rear door opener.
5. Unscrew five fastening screws -1- on the door opener.
6. Remove door opener -C- .

Fig 3: Removing Door Screws

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING DOOR OPENER
The door opener is installed in reverse order to removal.

1. Install sun blind on door window. → INSTALLING SUN BLIND ON DOOR WINDOW
WM 585115 ADJUSTING REAR DOOR (CAYENNE, CAYENNE GTS, CAYENNE TURBO


star gauges Special tool NR.127-1
for body gap
dimensions

B-pillar trim on Gap dimension 4.2 mm +/-1 mm

front door to
B-pillar trim on
rear door (T2)
B-pillar trim on Flush Gap dimension 0 mm +0.5 mm -1.5 mm

front door to
B-pillar trim on
rear door (T2b)
Front door to Gap dimension 4.2 mm +/-0.8 mm

rear door (T3)
Front door to Rear door Gap dimension 0 mm -1 mm

rear door (T3b) recessed
Front door Gap dimension 5.7 mm +1.2 mm -1 mm

panel to rear
door panel
(T6)
Front door Flush Gap dimension 0 mm +0.5 mm -1.5 mm

panel to rear
door panel
(T6b)
Door panel to Gap dimension 4.8 mm +/-1.5 mm

door entry
guard (T4)
Door panel to Gap dimension 0.3 mm +0.5 mm -1.5 mm

door entry
guard (T5)
Rear door to Gap dimension 3.7 mm +/-0.5 mm

side panel (T7)
Rear door to side panel
Rear door to Flush Gap dimension 0 mm -1 mm

side panel
(T7b)
Rear door to side panel
C-pillar trim on Gap dimension 3.8 mm +/-1 mm

rear door to
C-pillar trim on
side window
(T8)
C-pillar trim on rear door to C-pillar trim on side window
C-pillar trim on Flush Gap dimension 0 mm +0.5 mm -1.5 mm

rear door to
C-pillar trim on
side window
(T8b)
C-pillar trim on rear door to C-pillar trim on side window
Door molding Gap dimension 5.6 mm +/-2 mm

to side panel
(T9)
Door molding to side panel
Door molding Flush Gap dimension 0 mm +2 mm

to side panel
(T9b)
Door molding to side panel

screw for door torque ftlb.)
hinge at door,
M10 x 25
Fastening Item 1+2 Tightening 50 Nm (37

screws torque ftlb.)
securing door
hinge to body,
M8 x 24
(internal
serration
screw)

peg, M8 x 22
(internal
serration
screw)

CAYENNE (3.0)) > TECHNICAL VALUES > GAP DIMENSIONS OF REAR DOOR

Fig 1: Identifying Gap Dimension Of B-Pillar Trim On Front And Rear Door

Fig 2: Identifying Gap Dimension Of B-Pillar Trim On Rear And Front Door


→ Gap dimension: 5.7 mm+1.2 mm-1 mm





Fig 9: Identifying Gap Dimension Of Rear Door To Side Panel

Fig 10: Identifying Gap Dimension Of Rear Door To Side Panel

Fig 11: Identifying Gap Dimension Of C-Pillar Trim On Rear Door To Side Window

Fig 12: Identifying Gap Dimension Of C-Pillar Trim On Rear Door To Side Window

Fig 13: Identifying Gap Dimension Of Door Molding To Side Panel
→ Gap dimension: 0 mm+2 mm

Fig 14: Identifying Gap Dimension Of Door Molding To Side Panel

CAYENNE (3.0)) > ADJUSTING REAR DOOR

Danger of injury
Loss of torque
Information
Only tighten the fastening screws on the door hinges hand-tight from the inside until the doors are set
correctly.
Information
specifications.
accessories must be centered accordingly.
Information
The door hinge must be aligned after installing the door.
Loosen fastening screws for door hinge at the door and fastening screws for door hinge at the
B-pillar so that the threaded connections can be moved.
↓Information
1. Adjust rear door with door hinge at the door.

Fig 1: Identifying Rear Door Hinge On Door Side
1. Fastening screw -1- Adjustment of gap Loosen.

securing door hinge dimensions in Y and Z
-2- to rear door direction
2. Rear door Adjust gap dimensions

in X and Y direction by
moving the door.
3. Fastening screw -1- Adjustment of gap Tighten fastening

securing door hinge dimensions in Y and Z screw -1- for door
-2- to rear door direction hinge -2- at rear door
to → Tightening
torque: 50 Nm (37
ftlb.) .
2. Adjust rear door with door hinge at the body.

Fig 2: Loosening Rear Door Hinge On Body Side At Inside

Fig 3: Loosening Rear Door Hinge On Body Side At Outside
Fastening screws securing door

Adjustment of gap
hinge to body on outside -2-
1. dimensions in X Loosen.
and inside -1- → Removing
and Z direction
Rear Door Hinge
Adjust gap dimensions in Z

2. Rear door
direction by moving the rear door.
Fastening screws securing door Tighten fastening screws securing

Adjustment of gap
hinge to body on outside -2- door hinge to body on outside -2-
3. dimensions in X
and inside -1- → Installing Rear and inside -1- → Tightening
and Z direction
Door Hinge torque: 50 Nm (37 ftlb.) .
3. Adjust rear door with lock peg (striker pin).

Fastening screws -2-

Locking mechanism for rear
1. for lock peg -1- at the Loosen.
door
rear
Adjust gap dimensions in Y and Z

2. Rear door direction at the rear by moving the
rear door.
Tighten fastening screws -2- for

Fastening screws -2- Adjust gap dimensions in Z
lock peg -1- at rear to →
3. for lock peg -1- at the direction at the rear by
Tightening torque: 20 Nm (15
rear moving the rear door.
ftlb.)

CAYENNE (3.0)) > CHECKING REAR DOOR LOCK
1. Check the function of the rear door lock.

2. Check closing and opening forces and compare with the other doors.
If these forces differ, adjust the door again.
WM 585119 REMOVING AND INSTALLING REAR DOOR (CAYENNE, CAYENNE GTS,


screw for torque ftlb.)
B-pillar
Tightening fastening screw for A-pillar
Fastening Tightening 23 Nm (17 +/-3.5 Nm

screw for door torque ftlb.) (+/-2.5 ftlb.)
hinge
Loosening fastening screws for hinge connection

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR DOOR
2. Detach rubber cover.

2. 2.2. Swivel rubber cover -1- down -arrow B- .

Fig 1: Removing Rubber Cover

2. 3.2. Unplug electric plug connection -1- by pulling it outwards.
4. Unscrew and remove fastening screw on the door arrester -4- at the B-pillar.
Fig 3: Removing Screw On Door Arrester
5. Pull plastic caps -3- off the hinge screws at the top and bottom hinge joints -6- .
Fig 4: Pulling Off Caps On Hinge Screws
6. Loosen fastening screws -5- on the upper and lower hinge joint -6- .
Fig 5: Loosening Hinge Joint
7. Get another person to hold the vehicle door.
8. Lift the vehicle door up slightly until the hinge bolts come out of the hinge halves on the door
side.
Fig 6: Lifting Vehicle Door
9. Remove vehicle door.

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR DOOR
1. The front door is installed in reverse order to removal.
2. Tighten fastening screw on door hinge to Tightening torque 23 Nm (17 ftlb.) +/-3.5 Nm
(+/-2.5 ftlb.) .
3. Tighten fastening screw securing door arrester to B-pillar to Tightening torque 30 Nm (22
ftlb.) .
WM 585155 REPLACING REAR DOOR (CAYENNE, CAYENNE GTS, CAYENNE TURBO

CAYENNE (3.0)) > DISASSEMBLING REAR DOOR
Information
1. Remove rear door. → Removing Rear Door
3. Replace window guide. → REMOVING REAR WINDOW GUIDE
5. Remove cover for rear door. → REMOVING COVER FOR REAR DOOR
6. Remove rear door arrester. → Removing Door Arrester
7. Remove rear door hinge on door side. → Removing Rear Door Hinge
WM 585155 REPLACING REAR DOOR (CAYENNE, CAYENNE GTS, CAYENNE TURBO

CAYENNE (3.0)) > ASSEMBLING REAR DOOR
Information
1. Install rear door hinge on door side. → Installing Rear Door Hinge
2. Install rear door arrester. → Installing Door Arrester
3. Install cover for rear door. → INSTALLING COVER FOR REAR DOOR
5. Replace window guide. → INSTALLING REAR WINDOW GUIDE
7. Install rear door. → Installing Rear Door Sub-Frame
WM 585319 REMOVING AND INSTALLING REAR DOOR HINGE (CAYENNE, CAYENNE


door hinge to
outer B-pillar
Mounting for rear door hinge on body side at the outside

door hinge to
inner B-pillar
Mounting for rear door hinge on body side at the inside

door hinge to
rear door
Removing rear door hinge on door side

WORK FOR REAR DOOR HINGE ON DOOR SIDE

WORK FOR REAR DOOR HINGE ON BODY SIDE
2. Remove B-pillar trim panel. → REMOVING B-PILLAR TRIM
3. Remove rear inner door sill trim. → REMOVING INNER DOOR ENTRY GUARD

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR DOOR HINGE >
REMOVING REAR DOOR HINGE ON DOOR SIDE
Information
Fig 1: Identifying Rear Door Hinge Position

1. Place the door on a secure, padded surface and make sure that it cannot fall.
2. Unscrew and remove fastening screws -1- from both hinges -2- .

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR DOOR HINGE >
REMOVING REAR DOOR HINGE ON BODY SIDE
Information
Fig 1: Identifying Rear Door Hinge Installation Position
1. Unscrew and remove fastening screws -2- from both hinges -3- at the outside.
Fig 2: Loosening Rear Door Hinge On Body Side At Outside
2. Unscrew and remove fastening screws -1- from the B-pillar at the inside.
Fig 3: Loosening Rear Door Hinge On Body Side At Inside

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR DOOR HINGE >
INSTALLING REAR DOOR HINGE ON DOOR SIDE
Danger of injury
Loss of torque
Information
1. Tighten fastening screws -1- on both hinges -2- to Tightening torque 50 Nm (37 ftlb.) until
secure.

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR DOOR HINGE >
INSTALLING REAR DOOR HINGE ON BODY SIDE
Danger of injury
Loss of torque

Information
1. Tighten fastening screws -2- on both hinges -3- at the outside to Tightening torque 50 Nm
(37 ftlb.) until secure.
Fig 1: Identifying Mounting Screws Of Rear Door Hinge At Outside
2. Tighten fastening screws -1- on both hinges at the inside to Tightening torque 50 Nm (37
Fig 2: Identifying Mounting Screws Of Rear Door Hinge At Inside

WORK FOR REAR DOOR HINGE ON DOOR SIDE
1. Install rear door → Removing Rear Door

WORK FOR REAR DOOR HINGE ON BODY SIDE
1. Install B-pillar trim panel → INSTALLING B-PILLAR TRIM .
2. Install inner door sill trim. → INSTALLING INNER DOOR ENTRY GUARD
3. Install rear door → Installing Rear Door
WM 585919 REMOVING AND INSTALLING REAR DOOR ARRESTER (CAYENNE,


B-pillar
Tightening fastening screw for A-pillar
Fastening Tightening 9 Nm (6.5 ftlb.)

screw for door torque


TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING DOOR ARRESTER
Information
1. Unscrew and remove fastening screw for B-pillar -1- .

Fig 1: Loosening Door Arrester
2. Unscrew and remove fastening screws for door -2- .

Fig 2: Removing Door Arrester
3. Remove door arrester by moving it inwards.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING DOOR ARRESTER
Information
1. Position door arrester.
2. Tighten fastening screws for door -2- to Tightening torque 9 Nm (6.5 ftlb.) .
Fig 1: Installing Door Arrester
3. Tighten fastening screw for B-pillar -1- to Tightening torque 30 Nm (22 ftlb.) .
Fig 2: Securing Door Arrester

WM 586319 REMOVING AND INSTALLING RUBBER SEAL FOR REAR DOOR

1. Remove rear inner door sill trim. → REMOVING INNER DOOR ENTRY GUARD
2. Remove B-pillar trim but not the seat belt. → REMOVING B-PILLAR TRIM
3. Remove rear grab handle. → REMOVING REAR HANDLE
4. Remove C-pillar trim but not the seat belt. → REMOVING C-PILLAR TRIM
5. Remove rear side trim panel. → REMOVING REAR SIDE TRIM PANEL

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING RUBBER
SEAL FOR REAR DOOR
1. Detach headliner -1- close to the rubber seal for the rear door -2- .
Fig 1: Detaching Headliner
2. Pull off rubber seal all around the sheetmetal flange.

Fig 2: Removing Rubber Seal For Rear Door

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING RUBBER
SEAL FOR REAR DOOR
1. Fit vulcanization point of rubber seal -1- close to the door arrester on the sheetmetal flange.
Fig 1: Positioning Rubber Seal For Rear Door
The air vents in the seal must be facing the outside of the vehicle.
2. Press rubber seal onto the sheetmetal flange all the way around.
Fig 2: Installing Rubber Seal For Rear Door
3. Check that the rubber seal is fitted correctly.
1. 3.1. Pay particular attention to correct fitting in the areas near the tight radii; there
must be no deformation or stretching.
2. 3.2. Check the air vents; they must not be closed or covered.
4. Guide headliner into the rubber seal.

Fig 3: Removing Headliner Into Rubber Seal For Rear Door

1. Install rear inner door sill trim. → INSTALLING INNER DOOR ENTRY GUARD
2. Install B-pillar trim without the seat belt. → INSTALLING B-PILLAR TRIM
3. Install rear grab handle. → INSTALLING REAR HANDLE
4. Install C-pillar trim without the seat belt. → INSTALLING C-PILLAR TRIM
5. Install rear side trim panel. → INSTALLING REAR SIDE TRIM PANEL
WM 586455 REPLACING RUBBER SEAL FOR REAR DOOR SUB-FRAME (CAYENNE,


Rubber seal to Contact force 40 N
door
Installing rubber seal

1. Detach door arrester at the B-pillar. → Removing Door Arrester

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REPLACING OUTER RUBBER SEAL
FOR REAR DOOR
Information
It is not possible to remove the seal without damaging it.
The bonding surface will be damaged during removal.
The seal must be replaced with a new one.
Information
2. Mark the position of the rubber seal in the lower area with adhesive strips.
3. Pull rubber seal off the door.

↓ Information
removed.
facing outwards.
Fig 3: Fitting Rubber Seal
2. 4.2. Position the rubber seal on the sheetmetal flange and on the adhesive strips all
the way around.
4. 4.4. Press on rubber seal using press-on roller Contact force 40 N.
5. Remove strips of adhesive tape.

1. Secure door arrester at the B-pillar. → Installing Door Arrester
WM 586455 REPLACING OUTER RUBBER SEAL FOR REAR DOOR (EXCEPT

Rubber seal to Pressing force 40 N

door

1. Detach door arrester at the B-pillar. → Removing Door Arrester

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REPLACING OUTER
RUBBER SEAL FOR REAR DOOR
Information
Information

2. Mark the position of the rubber seal in the lower area with adhesive strips.
3. Pull rubber seal off the door.

Information
removed.
facing outwards.
Fig 3: Installing Rubber Seal
2. 4.2. Position the rubber seal on the sheetmetal flange and on the adhesive strips all
the way around.
4. 4.4. Press rubber seal onto the sheetmetal flange using a press-on roller and →
Pressing force: 40 N .
5. Remove adhesive strips.

1. Secure door arrester at the B-pillar. → Installing Door Arrester
WM 586619 REMOVING AND INSTALLING ADDITIONAL SEAL (EXCEPT CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING ADDITIONAL SEAL
Information
Information
To reduce the unclipping forces and thereby the risk of damage during removal, the removal steps must
be carried out at the accessible connection points using a suitable tool.
Fig 1: Identifying Additional Seal Position
1. Unclip additional seal -1- downwards from above using a plastic wedge.
Fig 2: Removing Additional Seal
WM 586619 REMOVING AND INSTALLING ADDITIONAL SEAL (EXCEPT CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING ADDITIONAL SEAL
Information
Information
Check that all fixing clips are positioned fully and correctly.
Check that the fixing clips are not bent or broken.
Replace damaged or missing clips with new ones.
1. Clip in additional seal -1- downwards from above.

Fig 1: Installing Additional Seal
WM 587319 REMOVING AND INSTALLING REAR DOOR CONTROL UNIT (EXCEPT


generation
PIWIS Tester

Information
If the control unit has to be replaced, the values/coding must be read out prior to removal using the 2nd
generation PIWIS Tester 9818 .
→ WM 577319 REMOVING AND INSTALLING CONTROL UNIT FOR FRONT DOOR .
Remove rear door trim panel. → REMOVING REAR SIDE TRIM PANEL

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR DOOR
CONTROL UNIT
NOTE: Voltage peaks
Information

Fig 1: Identifying Rear Door Control Unit Position
1. Release electrical plug connection -1- (-a- ) and pull it off -A- .
2. Unlock the electrical plug connection -2- by pulling -b- the tab and pressing -c- the locking
mechanism and pull off the connector -B- .
Fig 2: Disconnecting Plug Connections
Information
The door control unit is fitted into the door sub-frame -1- and engaged in the door sub-frame
with a locking lug -2- .
If you are unclipping the door control unit for the first time, greater force will be required in
order to release the locking lug -2- from the door sub-frame.
Fig 3: Releasing Lock Lug Of Door Control Unit
Press the control unit back against the door sub-frame while you are releasing it.
3. Release the catch -A- on the control unit and remove it in the direction of the arrow -B- .
Fig 4: Locking Hook On Control Unit For Front Door

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR DOOR
CONTROL UNIT
1. Engage control unit for front door in the door sub-frame and clip it in.
Fig 1: Installing Door Control Unit
2. Insert the electrical plug connection -1- (-A- ) until the connector engages securely.
3. Plug in electrical plug connection -2- (-B- ) and lock it -a- .


Install rear door panel. → INSTALLING REAR DOOR PANEL
1. If a new door control unit was installed, the values must be loaded into the new door control
unit and the coding must be checked. → WM 577319 REMOVING AND INSTALLING
Service Manual: 60 - SLIDING ROOF, TILTING ROOF -- 92A CAYENNE
WM 600519 REMOVING AND INSTALLING SLIDING ROOF > TECHNICAL VALUES
Sliding Roof To Item 2, 3 Diameter 12 mm

Body
Fitting Punches
Fastening Item 2 Tightening 8 Nm (6 ft. lb.)

Screw For Torque
Sliding Roof,
Front
Loosening Front Sliding Roof Mounting

Fastening Observe Tightening 8 Nm (6 ft. lb.)
Screw For Specified Torque
Sliding Roof, Tightening
Side Sequence
Loosening Side Sliding Roof Mounting
WM 600519 REMOVING AND INSTALLING SLIDING ROOF > PRELIMINARY WORK
1. Remove headliner. → 708419 REMOVING AND INSTALLING HEADLINER
WM 600519 REMOVING AND INSTALLING SLIDING ROOF > REMOVING SLIDING

ROOF
Fig 1: Identifying Sliding Roof Installation Position
NOTE: Sliding-roof frame removed/fitted incorrectly
Risk of damage to seats
→ Fold rear seat assembly over and tilt the front-seat backrests back.
1. Pull off water drain hoses.
1. 1.1. Pull front water drain hoses -2- off the connection piece -1- .
Fig 2: Pulling Off Front Water Drain Hoses
2. 1.2. Pull rear water drain hoses -2- off the connection piece -1- .
Fig 3: Pulling Off Rear Water Drain Hoses
2. Release plug connection for sunroof motor -2- (-a- ) and pull it off -B- .
Fig 4: Disconnecting Plug Connection From Motor
3. Loosen the sliding roof. (Get another person to hold the sliding roof to prevent it from falling
down)
1. 3.1. Unscrew front fastening screws -2- for the sliding roof -1- from the outside in.
Fig 5: Loosening Front Sliding Roof Mounting Screws
2. 3.2. Unscrew side fastening screws -2- for the sliding roof -1- .
Fig 6: Loosening Side Sliding Roof Mounting Screws
3. 3.3. Remove the sliding roof with the help of another person and pull it out of the
passenger compartment through the rear lid opening.
WM 600519 REMOVING AND INSTALLING SLIDING ROOF > INSTALLING SLIDING

ROOF
1. Place sliding roof in installation position.
1. 1.1. Guide the sliding roof through the rear lid opening into the passenger
compartment with the help of another person.
2. 1.2. Fit the sliding roof on the roof frame.

3. 1.3. Screw in fastening screws so that the frame for the sliding roof can still be
moved slightly.
4. 1.4. Move the sliding roof until the locating bores are free.
5. 1.5. Position the sliding roof -1- at the locating bores using the punches -2 and 3-
and tighten to Diameter 12 mm .
Fig 1: Fitting Punches
2. Secure the sliding roof.
1. 2.1. Screw in front fastening screws -2- from the inside out and tighten to
Tightening Torque 8 Nm (6 ft. lb.) .
Fig 2: Securing Sliding Roof At Front
2. 2.2. Screw in side fastening screws -2- from front to rear and tighten to Tightening
Torque 8 Nm (6 ft. lb.) .
Fig 3: Securing Sliding Roof At Sides
3. 2.3. Remove the punches -2 and 3- from the sliding roof -1- .
Fig 4: Removing Punches
3. Connect plug connection for sunroof motor -2- .

Fig 5: Connecting Plug Connection To Motor
4. Secure water drain hoses.
1. 4.1. Connect front water drain hoses -2- to the connection piece -1- .
Fig 6: Connecting Water Drain Hoses At Front
2. 4.2. Connect rear water drain hoses -2- to the connection piece -1- .
Fig 7: Connecting Water Drain Hoses At Rear
3. 4.3. Check that the water drain hoses are fitted securely.
WM 600519 REMOVING AND INSTALLING SLIDING ROOF > SUBSEQUENT WORK
1. Install headliner. → 708419 REMOVING AND INSTALLING HEADLINER
2. Program/teach sliding roof. → 600525 PROGRAMMING/TEACHING SLIDING ROOF
WM 600519 REMOVING AND INSTALLING SUNROOF > TECHNICAL VALUES
Location Description Type Basic Value Tolerance 1 Tolerance 2

Sunroof To Diameter 12 mm
Body

Screws Tightening Torque
Securing Sequence
Sunroof At The
Front

Screws Tightening Torque
Securing Sequence
Sunroof At The
Sides
WM 600519 REMOVING AND INSTALLING SUNROOF > PRELIMINARY WORK
1. Remove headliner. → REMOVING HEADLINER - section on "Removing"
WM 600519 REMOVING AND INSTALLING SUNROOF > REMOVING SUNROOF

Fig 1: Identifying Sunroof Installation Position
1. Pull off water drain hoses.
1. 1.1. Pull front water drain hoses -2- off the connection piece -1- .
Fig 2: Pulling Off Front Water Drain Hoses
2. 1.2. Pull rear water drain hoses -2- off the connection piece -1- .
Fig 3: Pulling Off Rear Water Drain Hoses
2. Release plug connection for sunroof motor -2- (-a- ) and pull it off -B- .
Fig 4: Disconnecting Plug Connection From Motor
3. Loosen the sunroof. (Get another person to hold the sunroof to prevent it from falling down)
1. 3.1. Unscrew front fastening screws -2- for the sunroof -1- from the outside in.
Fig 5: Loosening Front Sunroof Attachment Point
2. 3.2. Unscrew side fastening screws -2- for the sunroof -1- .
Fig 6: Loosening Side Sunroof Attachment Point
3. 3.3. Remove the sunroof with the help of another person and pull it out of the
WM 600519 REMOVING AND INSTALLING SUNROOF > INSTALLING SUNROOF
1. Place the sunroof in installation position.
1. 1.1. Guide the sunroof through the rear lid opening into the passenger compartment
with the help of another person.
2. 1.2. Fit the sunroof on the roof frame.

3. 1.3. Screw in fastening screws so that the frame for the sunroof can still be moved
slightly.
4. 1.4. Move the sunroof until the locating bores are free.
5. 1.5. Position the sunroof -1- using the punches -2 and 3- with a diameter of →
Diameter: 12 mm on the locating bores.
Fig 1: Fitting Punches
2. Secure the sunroof.
1. 2.1. Screw in front fastening screws -2- from the inside out → Tightening Torque: 8
Nm (6 ft. lb.) .
Fig 2: Securing Sunroof At Front
2. 2.2. Screw in side fastening screws -2- from front to rear → Tightening Torque: 8
Nm (6 ft. lb.) .
Fig 3: Securing Sunroof At Sides
3. 2.3. Remove the punches -2 and 3- from the sunroof -1- .

Fig 4: Removing Punches

4. Secure water drain hoses.
1. 4.1. Connect front water drain hoses -2- to the connection piece -1- .
Fig 6: Connecting Water Drain Hoses At Front
2. 4.2. Connect rear water drain hoses -2- to the connection piece -1- .
Fig 7: Connecting Water Drain Hoses At Rear
3. 4.3. Check that the water drain hoses are seated securely.
WM 600519 REMOVING AND INSTALLING SUNROOF > SUBSEQUENT WORK
1. Install headliner. → INSTALLING HEADLINER - section on "Installing"
2. Teach the end position. → PROGRAMMING/TEACHING SLIDING ROOF END POSITION -

section on "Teaching"
WM 600525 PROGRAMMING/TEACHING SLIDING ROOF >

PROGRAMMING/TEACHING SLIDING ROOF END POSITION
Information
The end positions are lost and must be re-taught in the following situations:
After disconnecting or connecting the vehicle battery
When the vehicle battery is completely flat or after jump-lead starting
After emergency operation
After changing the electric fuse
After replacing the glass panel, motor, powered sunroof mechanism or sun blind
NOTE: Electrically moved components
Risk of damage to components
→ Move objects out of the range of movement.
The force limiter is not available when storing the end position so that the roof will close with full force.
1. Start the engine.
2. Press the actuating button forward towards Close and keep it pressed until the roof stops
moving. The process for storing the end position will start after approx. 10 seconds.
The process takes up to 20 seconds for the sliding roof.
If you release the actuating button before the roof/sun blind has stopped moving, the process
for storing the end position must be repeated.
3. Check the roof fully to ensure that it operates correctly.
WM 600619 REMOVING AND INSTALLING ROOF ASSEMBLY (PANORAMIC ROOF) >

TECHNICAL VALUES

Screws For Specified Torque
Roof Assembly Tightening
Sequence
Positioning Roof Assembly

Screws For Torque
Console
Removing Console
Roof Assembly Item 4 Diameter 8 mm (6 ft. lb.)

To Body
Positioning Roof Assembly

PRELIMINARY WORK

REMOVING ROOF ASSEMBLY (PANORAMIC ROOF)
Fig 1: Identifying Panoramic Roof Installation Position
NOTE: Voltage peaks
Information
1. Pull front and rear water drain hoses off the connection pieces.
Fig 2: Pulling Off Water Drain Hoses
2. Release and disconnect plug connection for front wiring harness.

Fig 3: Disconnecting Wiring Harness
3. Bend tab on the head airbag holder down.

Fig 4: Bending Tab On Head Airbag Holder
4. Loosen the roof assembly. (Get another person to hold the roof assembly to prevent it from
falling down)
1. 4.1. Unscrew fastening screws -1- on the side brackets -2- .

Fig 5: Removing Bracket
2. 4.2. Unscrew and remove fastening nuts -1- on the grab handle brackets -2- .
Fig 6: Removing Grab Handle Bracket
3. 4.3. Unscrew fastening screws (22 ea.) -3- for the roof assembly, working from back
to front.
Fig 7: Removing Roof Assembly
4. 4.4. Lower the roof assembly with the help of another person and pull it out of the

INSTALLING ROOF ASSEMBLY (PANORAMIC ROOF)
Information
Information
Three people are needed in order to position the roof assembly when installing it on the vehicle.
1. Place roof assembly in installation position.
1. 1.1. Guide the roof assembly through the rear lid opening into the passenger
compartment with the help of another person.
2. 1.2. Press the roof assembly up and position it.
3. 1.3. Screw in fastening screws so that the roof assembly can still be moved slightly.
4. 1.4. Move the roof assembly until the locating bores are free.
5. 1.5. Position the roof assembly at the locating bores using the punches -4- and
tighten to Diameter 8 mm (6 ft. lb.) .
Fig 1: Positioning Roof Assembly
2. Check that the outer seal is positioned correctly.
3. Secure the roof assembly.
1. 3.1. Tighten fastening screws -3- from front to rear in alternating sequence at the left
and right to Tightening Torque 8 Nm (6 ft. lb.) .
Fig 2: Installing Roof Assembly
2. 3.2. Remove the punches -4- from the roof assembly.
3. 3.3. Screw in fastening screws -1- on the brackets -2- at the sides and tighten to
Tightening Torque 8 Nm (6 ft. lb.) .
Fig 3: Installing Bracket
4. 3.4. Screw on and tighten fastening nuts -1- on the grab handle brackets -2- .
Fig 4: Installing Grab Handle Bracket
4. Bend tab on the head airbag holder back up into its original shape again.
Fig 5: Bending Tab On Head Airbag Holder
5. Connect plug connection to the wiring harness.

Fig 6: Connecting Wiring Harness
6. Connect water drain hoses to the connection pieces and check that they are seated securely.
Fig 7: Connecting Water Drain Hoses
7. Check the gap dimensions of the glass panel. → 5X00IN DIAGRAM - BODY GAP
DIMENSIONS

SUBSEQUENT WORK

2. Program/teach roof assembly (panoramic roof). → 600625 PROGRAMMING/TEACHING
ROOF ASSEMBLY (PANORAMIC ROOF)
WM 600625 PROGRAMMING/TEACHING ROOF ASSEMBLY (PANORAMA ROOF) >

PROGRAMMING/TEACHING ROOF ASSEMBLY (PANORAMA ROOF) END POSITION
Information
The end positions are lost and must be re-taught in the following situations:
After disconnecting or connecting the vehicle battery
When the vehicle battery is completely flat or after jump-lead starting
After emergency operation
After changing the electric fuse
After replacing the glass panel, motor, powered sunroof mechanism or sun blind
NOTE: Electrically moved components
→ Move objects out of the range of movement.
The force limiter is not available when storing the end position so that the roof will close with full force.
1. Start the engine.
Information
When storing the end positions, always save the settings for the panorama roof and sun blind
fully one after the other. If one of the processes is interrupted, it is not possible to start the
process for the other drive mechanism.
2. Press the actuating button forward towards Close and keep it pressed until the roof/sun blind
stops moving. The process for storing the end position will start after approx. 10 seconds.
The process takes up to 45 seconds for the panorama roof/sun blind.
If you release the actuating button before the roof/sun blind has stopped moving, the process
for storing the end position must be repeated.
3. Check the roof fully to ensure that it operates correctly.
WM 601419 REMOVING AND INSTALLING MOTOR FOR SLIDING ROOF >

TECHNICAL VALUES
Mounting for Tightening 3 Nm (2 ft. lb.)

sunroof motor Torque
PRELIMINARY WORK
Remove roof console. → REMOVING ROOF CONSOLE - section on "Removing"
WM 601419 REMOVING AND INSTALLING MOTOR FOR SLIDING ROOF > REMOVING
MOTOR FOR SLIDING ROOF > REMOVING SUNROOF MOTOR
NOTE: Voltage peaks
Information

Fig 1: Identifying Sunroof Motor Installation Position
1. Pull lock for electric plug connection -2- off the sunroof motor -A- .
Fig 2: Pulling Lock For Electric Plug Connection
2. Release electric plug connection -2- for sunroof motor -a- and pull it off -B- .
3. Unscrew three fastening screws -3- on the sunroof motor -1- .

Fig 3: Identifying Sunroof Motor And Screws

INSTALLING MOTOR FOR SLIDING ROOF
1. Carefully position the motor in installation position so that the bores for screwing the motor to
the front part of the frame are aligned.
Information
Do not continue to turn the motor after inserting the pinion into the drive cables because if you
do, the control bolts will move closer together.
2. Press the motor into position.
3. Tighten three fastening screws -3- on the sunroof motor -1- to → Tightening Torque: 3 Nm
(2 ft. lb.) .


SUBSEQUENT WORK
1. Teach the roof system. → WM 600625 PROGRAMMING/TEACHING ROOF ASSEMBLY

(PANORAMA ROOF) Teaching roof systems
2. Install roof console. → INSTALLING ROOF CONSOLE - section on "Installing"
WM 601419 REMOVING AND INSTALLING MOTOR FOR ROOF ASSEMBLY

(PANORAMIC ROOF) > TECHNICAL VALUES

Screws For Torque
Sunroof Motor
Removing Sunroof Motor

(PANORAMIC ROOF) > PRELIMINARY WORK

(PANORAMIC ROOF) > REMOVING MOTOR FOR SLIDING ROOF > REMOVING
SUNROOF MOTOR
NOTE: Voltage peaks
Information



(PANORAMIC ROOF) > INSTALLING MOTOR FOR SLIDING ROOF > INSTALLING
SUNROOF MOTOR
Information
3. Screw in three fastening screws -3- on the sunroof motor -1- and tighten to Tightening
Torque 3 Nm (2 ft. lb.) .
Fig 1: Identifying Sunroof Motor Screw


(PANORAMIC ROOF) > SUBSEQUENT WORK
2. Program/teach roof assembly. → 600625 PROGRAMMING/TEACHING ROOF ASSEMBLY

(PANORAMIC ROOF)
WM 601419 REMOVING AND INSTALLING SUNROOF MOTOR > TECHNICAL VALUES

screws for Torque
sunroof motor
Removing Sunroof Motor
WM 601419 REMOVING AND INSTALLING SUNROOF MOTOR > PRELIMINARY WORK
Remove roof console. → 708319 REMOVING AND INSTALLING ROOF CONSOLE
WM 601419 REMOVING AND INSTALLING SUNROOF MOTOR > REMOVING

SUNROOF MOTOR
NOTE: Voltage peaks
Information


WM 601419 REMOVING AND INSTALLING SUNROOF MOTOR > INSTALLING

SUNROOF MOTOR
Information
3. Screw in three fastening screws -3- on the sunroof motor -1- and tighten to Tightening
Torque 3 Nm (2 ft. lb.) until secure.

WM 601419 REMOVING AND INSTALLING SUNROOF MOTOR > SUBSEQUENT

WORK
1. Program/teach sliding roof. → 600525 PROGRAMMING/TEACHING SLIDING ROOF
2. Install roof console. → 708319 REMOVING AND INSTALLING ROOF CONSOLE

(PANORAMA ROOF) > TECHNICAL VALUES
Mounting for Tightening 3 Nm (2 ft. lb.)

sunroof motor Torque

(PANORAMA ROOF) > PRELIMINARY WORK

(PANORAMA ROOF) > REMOVING MOTOR FOR SLIDING ROOF > REMOVING
SUNROOF MOTOR
NOTE: Voltage peaks
Information



(PANORAMA ROOF) > INSTALLING MOTOR FOR SLIDING ROOF
Information
3. Tighten three fastening screws -3- on the sunroof motor -1- to → Tightening Torque: 3 Nm
(2 ft. lb.) .
Fig 1: Identifying Sunroof Motor Screws


(PANORAMA ROOF) > SUBSEQUENT WORK

WM 602855 REPLACING FRAME FOR ROOF ASSEMBLY (PANORAMIC ROOF) >

DISASSEMBLING FRAME FOR ROOF ASSEMBLY (PANORAMIC ROOF)
The mechanism and air deflector remain in the frame while carrying out the repairs described here.
Spare part: → FRAME
1. Remove roof assembly. → 600619 REMOVING AND INSTALLING ROOF ASSEMBLY

(PANORAMIC ROOF)
2. Remove both roof assembly panels. → 60401900 REMOVING AND INSTALLING ROOF
ASSEMBLY PANELS (PANORAMIC ROOF)
3. Remove sun blind. → 607019 REMOVING AND INSTALLING SUN BLIND

4. Remove motor for roof assembly. → 60141900 REMOVING AND INSTALLING MOTOR FOR
5. Remove motor for sun blind. → 607219 REMOVING AND INSTALLING MOTOR FOR SUN
BLIND
6. Remove air deflector for panoramic roof. → 60331901 REMOVING AND INSTALLING AIR
DEFLECTOR FOR PANORAMIC ROOF
WM 602855 REPLACING FRAME FOR ROOF ASSEMBLY (PANORAMIC ROOF) >

ASSEMBLING FRAME FOR ROOF ASSEMBLY (PANORAMIC ROOF)
1. Install motor for roof assembly. → 60141900 REMOVING AND INSTALLING MOTOR FOR
2. Install motor for sun blind. → 607219 REMOVING AND INSTALLING MOTOR FOR SUN
BLIND
3. Install sun blind. → 607019 REMOVING AND INSTALLING SUN BLIND
4. Install air deflector for panoramic roof. → 60331901 REMOVING AND INSTALLING AIR
DEFLECTOR FOR PANORAMIC ROOF
5. Install both panels for roof assembly. → 60401900 REMOVING AND INSTALLING ROOF
ASSEMBLY PANELS (PANORAMIC ROOF)
6. Install roof assembly. → 600619 REMOVING AND INSTALLING ROOF ASSEMBLY

(PANORAMIC ROOF)

WM 602855 REPLACING FRAME FOR ROOF ASSEMBLY (PANORAMA ROOF) >

DISASSEMBLING FRAME FOR ROOF ASSEMBLY (PANORAMA ROOF)
The drive mechanism remains in the frame while carrying out the repairs described here. Spare part: →
FRAME
1. Remove roof assembly (panorama roof). → 600619 REMOVING AND INSTALLING ROOF
ASSEMBLY (PANORAMA ROOF) - section on "Removing"
2. Remove both roof assembly panels (panorama roof). → 60401901 REMOVING AND
INSTALLING ROOF ASSEMBLY PANELS (PANORAMA ROOF) - section on "Removing"
3. Remove sun blind. → 607019 REMOVING AND INSTALLING SUN BLIND - section on
"Removing"
4. Remove motor for roof assembly (panorama roof). → 60141901 REMOVING AND
INSTALLING MOTOR FOR ROOF ASSEMBLY (PANORAMA ROOF) - section on "Removing"
5. Remove motor for sun blind. → 607219 REMOVING AND INSTALLING MOTOR FOR SUN
BLIND - section on "Removing"
6. Remove air deflector for panorama roof. → 60331901 REMOVING AND INSTALLING AIR
DEFLECTOR FOR PANORAMA ROOF - section on "Removing"
WM 602855 REPLACING FRAME FOR ROOF ASSEMBLY (PANORAMA ROOF) >
ASSEMBLING FRAME FOR ROOF ASSEMBLY (PANORAMA ROOF)
1. Install motor for roof assembly (panorama roof). → 60141901 REMOVING AND INSTALLING
MOTOR FOR ROOF ASSEMBLY (PANORAMA ROOF) - section on "Installing"
2. Install motor for sun blind. → 607219 REMOVING AND INSTALLING MOTOR FOR SUN
BLIND - section on "Installing"
3. Install sun blind. → 607019 REMOVING AND INSTALLING SUN BLIND - section on
"Installing"
4. Install air deflector for panorama roof. → 60331901 REMOVING AND INSTALLING AIR
DEFLECTOR FOR PANORAMA ROOF - section on "Installing"
5. Install roof assembly panels (panorama roof). → 60401901 REMOVING AND INSTALLING
ROOF ASSEMBLY PANELS (PANORAMA ROOF) - section on "Installing"
6. Install roof assembly (panorama roof). → 600619 REMOVING AND INSTALLING ROOF
ASSEMBLY (PANORAMA ROOF) - section on "Installing"

WM 603319 REMOVING AND INSTALLING AIR DEFLECTOR FOR SLIDING ROOF >
REMOVING AIR DEFLECTOR FOR SLIDING ROOF
Information
1. Open sliding roof.
2. Press the air deflector down slightly and pull the bearing pin -1- inwards out of the bearing.
Fig 1: Removing Air Deflector
3. Remove air deflector.
4. Screw the air deflector spring -2- sideways out of the bearing and remove it.
Fig 2: Removing Spring
INSTALLING AIR DEFLECTOR FOR SLIDING ROOF
Information
On a new air deflector, the sliding channel for the spring -2- and the bearing pin -1- for the bearing must
be greased.
Fig 1: Identifying Spring And Bearing Pin Of Air Deflector
Grease: → GREASE 958.564.902.00
1. Guide the air deflector forward with the rubber stops under the roof.
2. Guide the air deflector springs into the sliding channel.
3. Press the air deflector arms down and insert the bearing pin -1- into the air deflector bearing.
Fig 2: Installing Air Deflector
4. Check the power function of the air deflector and make sure that the vibration damper (tab in
the middle) is facing upwards.
SUBSEQUENT WORK > GREASING
If you hear squeaking noises from the very front when closing the sliding roof, the upper side sliding
surface of the air deflector must also be greased.
Grease: → GREASE 958.564.902.00
WM 603319 REMOVING AND INSTALLING AIR DEFLECTOR FOR PANORAMIC ROOF

> REMOVING AIR DEFLECTOR FOR PANORAMIC ROOF
Information
1. Open the front glass panel fully.
2. Pull the power supply strip -4- completely out of the assembly frame -5- (-A- ).
Fig 1: Loosening Air Deflector
3. Pull support bar -3- with support lever -2- out of the mounting -B- .
4. Pull the air deflector frame -1- back slightly -C- and disengage the tension spring -2- (-D- ).
Fig 2: Removing Air Deflector
5. Remove air deflector frame with air deflector power supply.
WM 603319 REMOVING AND INSTALLING AIR DEFLECTOR FOR PANORAMIC ROOF

> INSTALLING AIR DEFLECTOR FOR PANORAMIC ROOF
Information
1. Engage tension spring -2- (-A- ).

Fig 1: Engaging Tension Spring
2. Fit support lever -2- into the guide.

Fig 2: Installing Air Deflector
3. Pull the air deflector frame -1- forward -B- and engage the support bar -3- .
4. Centre the power supply strip -4- and press it into the assembly frame -5- (-D- ).
WM 603519 REMOVING AND INSTALLING POWERED SUNROOF MECHANISM >

PRELIMINARY WORK
1. Remove sliding roof. → 600519 REMOVING AND INSTALLING SLIDING ROOF
2. Remove sliding-roof panel. → 60401901 REMOVING AND INSTALLING SLIDING-ROOF

PANEL
3. Remove sunroof motor. → 60141901 REMOVING AND INSTALLING SUNROOF MOTOR

REMOVING POWERED SUNROOF MECHANISM
Information
1. Unclip end pieces -1- and pull them off the frame.
Fig 1: Unclipping End Pieces Of Frame
2. Pull the sliding sun screen back out of the frame.

Fig 2: Removing Sliding Sun Screen From Frame
3. Pull the powered sunroof mechanism evenly to the rear on both sides -A- .
4. Unclip water drain strip -3- (-B- ).

Fig 3: Removing Water Drain Strip
5. Pull the powered sunroof mechanism and drive cables completely out of the frame.

INSTALLING POWERED SUNROOF MECHANISM
Information
1. Clean the frame if you intend to use it again.
1. 1.1. Remove sealing material and clean sealing surfaces.
2. 1.2. Clean the guides -1, 2, 3, 4- .

Fig 1: Identifying Guide Pin Of Sunroof Mechanism
2. Grease the frame and powered sunroof mechanism.
1. 2.1. Grease the guides -1, 2, 3, 4- with → GREASE.
2. 2.2. Grease sliding pieces on the powered sunroof mechanism with → GREASE.
3. 2.3. Grease sliding track on the front and rear powered sunroof mechanism -5- with
→ GREASE.
Fig 2: Identifying Front And Rear Powered Sunroof Mechanism Sliding Track
3. Carefully guide the drive cable into the frame without kinking it.
4. Guide the powered sunroof mechanism into the frame.
5. Clip in water drain strip -3- (-A- ) and slide in the guide -B- .
Fig 3: Installing Water Drain Strip
6. Position the powered sunroof mechanism.
1. 6.1. Slide the powered sunroof mechanism forward as far as it will go.
2. 6.2. Push the slide for the powered sunroof mechanism -6- forward until the guide
screw -7- is over the marking -8- .
The front edge of the slide -6- must also be between the two notches.
3. 6.3. Set the same position on both sides.
Fig 4: Positioning Powered Sunroof Mechanism
7. Install end pieces.
1. 7.1. Apply sealing compound -9- → SEALING COMPOUND to the new end pieces.
Fig 5: Applying Sealing Compound Pieces

2. 7.2. Fit the end pieces at the outside first and then clip them in -1- .
Fig 6: Clipping End Pieces
3. 7.3. Press the end pieces gently onto the frame and remove any excess sealing
compound.

SUBSEQUENT WORK
1. Install sunroof motor. → 60141901 REMOVING AND INSTALLING SUNROOF MOTOR
2. Check the position of the powered sunroof mechanism.

3. Install sliding-roof panel. → 60401901 REMOVING AND INSTALLING SLIDING-ROOF

PANEL
4. Install sliding roof. → 600519 REMOVING AND INSTALLING SLIDING ROOF
WM 603555 REPLACING DRIVE MECHANISM FOR ROOF ASSEMBLY (PANORAMA

ROOF) > TOOLS
Retaining Special Tool 9695

Frame
Holder Special Tool 9695/1
Telescopic Commercially Nr. 126 Pos.

Measuring Rod Available Tool 1
Film Eraser Commercially Nr. 174 Pos.

Available Tool 1

ROOF) > TECHNICAL VALUES
Fastening Item 2 Tightening 2 Nm (1.5 ft.

Screws For Torque lb.)
Rear Part Of
Roof Assembly
Fitting Rear Part

ROOF) > PRELIMINARY WORK
1. Remove roof assembly (panoramic roof). → 600619 REMOVING AND INSTALLING ROOF
ASSEMBLY (PANORAMIC ROOF)
2. Remove roof assembly panels (panoramic roof). → 60401900 REMOVING AND INSTALLING
ROOF ASSEMBLY PANELS (PANORAMIC ROOF)
3. Remove sun blind. → 607019 REMOVING AND INSTALLING SUN BLIND
4. Remove motor for roof assembly (panoramic roof). → 60141900 REMOVING AND
INSTALLING MOTOR FOR ROOF ASSEMBLY (PANORAMIC ROOF)

ROOF) > REMOVING DRIVE MECHANISM FOR ROOF ASSEMBLY (PANORAMA
ROOF)
Information
1. Measure the distance of the rails (dimension -X- ) using the Telescopic Measuring Rod Nr.
126 Pos. 1 between the two bores -1- in front of the rear end and write it down.
Alternatively, the roof assembly can be positioned and secured like the Targa roof on the
Retaining Frame 9695 using the Holder 9695/1 on the WE1082 Transmission Jack VAG
1383 A.
Fig 1: Measuring Distance Of Rails
2. Remove the rear end -1- from the frame -3- .
1. 2.1. Disconnect wiring harness from the rear end.
2. 2.2. Unscrew screws -2- .
3. 2.3. Cut the sealing cord -5- between the guide rails -3- and rear end -1- with a
knife.
4. 2.4. Pull the complete rear end -1- with the operating cables and sun blind sliders
-4- off the frame -3- towards the rear -arrow- .
Fig 2: Removing Rear End
3. Pull the drive mechanism for the front panel -1- together with the operating cables and drivers
-3- towards the rear and out of the guide rails.
Fig 3: Removing Powered Sunroof Mechanism

ROOF) > INSTALLING DRIVE MECHANISM FOR ROOF ASSEMBLY (PANORAMA
ROOF)
Information
1. Grease sliding areas again.
The guide rails -2- must only be cleaned if they are very dirty.
Fig 1: Identifying Roof Assembly Grease Sliding Areas
1. 1.1. Clean the guide rails.
2. 1.2. Then grease the sliding areas -3- of the guide rails with a light coating of →
GREASE using a paint brush.
1. The inner seal -1- and outer seal -4- have an anti-friction coating and must not
be greased.
2. The operating cables and motor plates must not be greased.
2. Slide the drive mechanism -1- together with the operating cables and drivers -3- into the
guide rails.
Make sure that the operating cables are not kinked.
The operating cables and powered sunroof mechanism may only be replaced in pairs. → SET
→ SET
Fig 2: Installing Powered Sunroof Mechanism
3. Fit the rear end -1- on the frame -3- .
1. 3.1. Remove any adhesive residue on the guide rails using the Film Eraser Nr. 174
Pos. 1 .
2. 3.2. Clean the bonding area -5- of the rear end -1- and guide rails -3- thoroughly.
Fig 3: Fitting Rear End
3. 3.3. Insert sealing cord → SEALING CORD -6- into the bonding channel -5- on the
rear end -1- .
Fig 4: Fitting Sealing Cord
4. 3.4. Guide the rear end -1- with the operating cables and sun blind sliders -4- into
the guide rails -3- and slide it into position.
Make sure that the operating cables are not kinked.
5. 3.5. Screw in fastening screws -2- shortly before final fitting.
6. 3.6. Adjust the distance of the rails (dimension -X- , which you wrote down earlier)
using the Telescopic Measuring Rod Nr. 126 Pos. 1 between the two bores -1- in
front of the rear end so that the guide rails are parallel.
Fig 5: Measuring Distance Of Rails
7. 3.7. Tighten fastening screws -2- to Tightening Torque 2 Nm (1.5 ft. lb.) until
secure.
4. Set the same position and parallel setting for the powered sunroof mechanism on both sides
based on the marking on the frame and the rib on the drive mechanism -Line- .
5. Check the frame for leaks before assembling other components.
1. 5.1. Seal the water drain connection piece with sealing cord.
2. 5.2. Fill the rear end and frame area with water.
3. 5.3. Wait at least 5 minutes and then check for leaks.
4. 5.4. Seal any leaks with sealing cord → SEALING CORD.

ROOF) > SUBSEQUENT WORK
1. Install motor for roof assembly (panoramic roof). → 60141900 REMOVING AND INSTALLING
MOTOR FOR ROOF ASSEMBLY (PANORAMIC ROOF)
2. Check the function and smooth operation of the drive mechanism manually.
3. Install sun blind. → 607019 REMOVING AND INSTALLING SUN BLIND
4. Install roof assembly panels (panoramic roof). → 60401900 REMOVING AND INSTALLING
ROOF ASSEMBLY PANELS (PANORAMIC ROOF)
5. Install roof assembly (panoramic roof). → 600619 REMOVING AND INSTALLING ROOF
ASSEMBLY (PANORAMIC ROOF)

WM 604019 REMOVING AND INSTALLING ROOF ASSEMBLY PANELS (PANORAMIC

Fastening Screw Item 2 Tightening 7 Nm (5 ft. lb.)

For Front Panel Torque
On Panoramic
Roof
Removing Front Panel

Screws For Torque
Rear Panel On
Panoramic Roof
Removing Rear Panel
Roof To Front Gap Dimension 10 mm +/-1.2 mm

Lid (D3)
Roof To Front Lid
Roof To Front Gap Dimension 1.4 mm +/-1 mm

Lid (D4)
Roof To Front Lid
Front Panel To Gap Dimension 2 mm +/-0.5 mm

Rear Panel (D5)
Front Panel To Rear Panel
Front Panel To Gap Dimension 1 mm +1.2 mm -0.6 mm

Rear Panel (D6)
Front Panel To Rear Panel
Rear Lid To Gap Dimension 10 mm +/-1.2 mm

Roof (D7)
Rear Lid To Roof
Rear Lid To Gap Dimension 0.8 mm +/-1 mm

Roof (D8)
Rear Lid To Roof

ROOF) > REMOVING ROOF ASSEMBLY PANELS > REMOVING FRONT PANEL FOR
ROOF ASSEMBLY
Information
1. Raise the glass panel -2- until the side covers -1- are accessible.
Fig 1: Removing Covers
2. Pull the panels -1- out to the rear from the passenger compartment -A- .
3. Pull the seal -3- off the assembly frame until the fastening screws -2- are accessible.
Fig 2: Removing Front Panel
4. Unscrew fastening screws -2- on the glass panel -1- .
5. Lift the glass panel up and remove it.

ROOF) > REMOVING ROOF ASSEMBLY PANELS > REMOVING REAR PANEL FOR
ROOF ASSEMBLY

Fig 1: Removing Rear Panel For Roof Assembly
3. Raise the front panel -4- .
4. Slide the rear glass panel -1- slightly under the front glass panel -4- (-A- ).
Fig 2: Removing Rear Panel
5. Only lift the rear part of the rear glass panel -1- out of the roof cut-out -B- .
6. Guide out the rear glass panel -1- by moving it up at an angle -C- over the roof and under the
front glass panel -4- .

ROOF) > INSTALLING ROOF ASSEMBLY PANELS > INSTALLING FRONT PANEL FOR
ROOF ASSEMBLY
Information
1. Move the powered sunroof mechanism -3- as far as required on both sides until the sliding
piece -6- is between the markings -5- .
Fig 1: Adjusting Powered Sunroof Mechanism
Information
Always use new screws when installing the glass panel.
2. Insert the glass panel into the powered sunroof mechanism -3- from above and screw in but
do not tighten the fastening screws -2- .
Fig 2: Installing Front Panel
3. Set gap dimensions for the front panel. Gap dimension 1.4 mm +/-1 mm Gap dimension 10
mm +/-1.2 mm Gap dimension 2 mm +/-0.5 mm Gap dimension 1 mm +1.2 mm -0.6 mm
When positioning the panel, check that there is an equal gap between the panel and roof
aperture. Align the panel in the longitudinal and transverse direction if necessary.
4. Tighten fastening screws -2- to Tightening Torque 7 Nm (5 ft. lb.) .
5. Press seal -3- onto the assembly frame.
6. Slide the covers -1- into the rails for the front glass panel -2- (-A- ).
Fig 3: Installing Covers
7. After completing all tasks, program/teach the roof assembly (panoramic roof). → 600625
PROGRAMMING/TEACHING ROOF ASSEMBLY (PANORAMIC ROOF)

ROOF) > INSTALLING ROOF ASSEMBLY PANELS > INSTALLING REAR PANEL FOR
ROOF ASSEMBLY
1. Slide the rear glass panel -1- from above at an angle under the front glass panel -1- (-A- ).
Fig 1: Fitting Rear Panel
2. Fit the rear part of the rear glass panel -1- down into the roof cut-out -B- and slide it towards
the rear -C- .
Information
3. Screw in fastening screws -2- , but do not tighten them.

Fig 2: Installing Rear Panel
4. Adjust gap dimensions. Gap dimension 0.8 mm +/-1 mm gap dimension 10 mm +/-1.2 mm
Gap dimension 1 mm +1.2 mm -0.6 mm Gap dimension 2 mm +/-0.5 mm
cut-out. Align the panel in the longitudinal and transverse direction if necessary.
5. Tighten fastening screws -2- to Tightening Torque 7 Nm (5 ft. lb.) .
6. Press seal -3- onto the assembly frame.
7. After completing all tasks, program/teach the roof assembly (panoramic roof). → 600625
PROGRAMMING/TEACHING ROOF ASSEMBLY (PANORAMIC ROOF)
WM 604019 REMOVING AND INSTALLING SLIDING-ROOF PANEL > TECHNICAL

VALUES
Roof To Panel Only Gap Dimension 1 mm -1 mm

Sliding-Roof Recessed
Panel (D1)
Roof To Sliding-Roof Panel
Sliding-Roof Panel Only Gap Dimension 0.8 mm +0.2 mm -0.8 mm

Panel To Roof Raised
(D2)
Sliding-Roof Panel To Roof
Panel To Drive Tightening 4.5 Nm (3 ft.

Mechanism Torque lb.)
WM 604019 REMOVING AND INSTALLING SLIDING-ROOF PANEL > TECHNICAL

VALUES > GAP DIMENSIONS OF SUNROOF
→ Gap dimension: 1 mm -1 mm
Fig 1: Identifying Gap Dimensions Of Roof To Sliding Panel
→ Gap dimension: 0.8 mm +0.2 mm -0.8 mm

Fig 2: Identifying Gap Dimensions Of Sliding Panel To Roof
WM 604019 REMOVING AND INSTALLING SLIDING-ROOF PANEL > REMOVING

SLIDING-ROOF PANEL
Information
1. Raise the sliding roof fully.
2. Remove the bellows.
1. 2.1. Unclip the bellows from the panel -A- .
2. 2.2. Slide the bellows forward slightly -B- and unclip it from the upper rear catch -1-
.
3. 2.3. Unclip the bellows from the lower edge -C- .

Fig 1: Unclipping Upper Rear Catch
3. Remove sliding-roof panel.
1. 3.1. Loosen the center fastening screw -2- .
2. 3.2. Unscrew front and rear fastening screws -3- .

Fig 2: Identifying Screw Of Sliding-Roof Panel
4. Lift the panel up and remove it.
WM 604019 REMOVING AND INSTALLING SLIDING-ROOF PANEL > INSTALLING

SLIDING-ROOF PANEL
Information
1. Position the panel and guide the clips into the drive mechanism.
2. Install sliding-roof panel.
Use new screws during installation: → SET

Fig 1: Identifying Screw Of Sliding-Roof Panel
1. 2.1. Screw in front and rear fastening screws -3- and adjust gap dimensions.
When positioning the panel, check that there is an equal gap between the panel and
roof cut-out. Align the panel in the longitudinal and transverse direction if necessary.
2. 2.2. Tighten all fastening screws -2, 3- to → Tightening Torque: 4.5 Nm (3 ft. lb.) .
3. Install the bellows.

Fig 2: Clipping Upper Rear Catch
1. 3.1. Clip the bellows into the upper rear catch -1- (-A- ).
2. 3.2. Clip in the bellows on the panel -B- .
3. 3.3. Clip the bellows onto the lower edge -C- .
4. Teach the end position. → WM 600525 PROGRAMMING/TEACHING SLIDING ROOF

Teaching roof systems
WM 604019 REMOVING AND INSTALLING ROOF ASSEMBLY PANELS (PANORAMA

Tolerance Tolerance
Location Description Type Basic value
1 2
Roof to front lid (D3) Gap dimension 10 mm +/-1.2 mm

Roof to front lid
Roof to front lid (D4) Gap dimension 1.4 mm +/-1 mm
Roof to front lid
Front lid to rear lid (D5) Gap dimension 2 mm +/-0.5 mm
Front lid to rear lid
Front lid to rear lid (D6) Gap dimension 1 mm +1.2 mm -0.6 mm

Front lid to rear lid
Rear lid to roof (D7) Gap dimension 10 mm +/-1.2 mm
Rear lid to roof
Rear lid to roof (D8) Gap dimension 0.8 mm +/-1 mm
Rear lid to roof
Fastening screws for front Tightening 7 Nm (5 ft.

panel Torque lb.)
Fastening screws for rear Tightening 7 Nm (5 ft.

panel Torque lb.)

ROOF) > TECHNICAL VALUES > GAP DIMENSIONS OF PANORAMA ROOF
→ Gap dimension: 10 mm +/-1.2 mm

Fig 1: Identifying Gap Dimensions Of Roof To Front Lid
→ Gap dimension: 1.4 mm +-1/mm

Fig 2: Identifying Gap Dimensions Of Front Lid To Roof

Fig 3: Identifying Gap Dimensions Of Front To Rear Lid
→ Gap dimension: 1 mm +1.2 mm -0.6 mm

Fig 4: Identifying Gap Dimensions Of Rear To Front Lid

Fig 5: Identifying Gap Dimensions Of Rear Lid To Roof
→ Gap dimension: 0.8 mm+-1/mm

Fig 6: Identifying Gap Dimensions Of Roof To Rear Lid

ROOF) > REMOVING ROOF ASSEMBLY PANELS > REMOVING FRONT PANEL FOR
ROOF ASSEMBLY
Information
1. Raise the glass panel -2- until the side covers -1- are accessible.
2. Pull the covers -1- out to the rear from the passenger compartment -A- .
Fig 1: Removing Side Covers

Fig 2: Removing Front Panel
5. Lift the glass panel up and remove it.

ROOF) > REMOVING ROOF ASSEMBLY PANELS > REMOVING REAR PANEL FOR
ROOF ASSEMBLY

Fig 1: Removing Rear Panel For Roof Assembly
3. Raise the front panel -4- .
4. Slide the rear glass panel -1- slightly under the front glass panel -4- (-A- ).
5. Only lift the rear part of the rear glass panel -1- out of the roof cut-out -B- .
6. Guide out the rear glass panel -1- by moving it up at an angle -C- over the roof and under the
front glass panel -4- .
Fig 2: Removing Rear Panel

ROOF) > INSTALLING ROOF ASSEMBLY PANELS > INSTALLING FRONT PANEL FOR
ROOF ASSEMBLY
Information
1. Move the powered sunroof mechanism -3- as far as required on both sides until the slider -6-
is between the markings -5- .
Fig 1: Adjusting Powered Sunroof Mechanism
Information
2. Insert the glass panel into the powered sunroof mechanism -3- from above and screw in but
do not tighten the fastening screws -2- .
Fig 2: Installing Front Panel
3. Set gap dimensions for the front panel. Gap dimension 10 mm +/-1.2 mm Gap dimension
1.4 mm +/-1 mm Gap dimension 2 mm +/-0.5 mm Gap dimension 1 mm +1.2 mm -0.6 mm
4. Tighten fastening screws -2- to → Tightening Torque: 7 Nm (5 ft. lb. . )
5. Press the seal -3- onto the assembly frame.
6. Slide the covers -1- into the rails for the front glass panel -2- (-A- ).
Fig 3: Installing Covers
7. Once you have completed all required work, teach the roof system. → WM 600625
PROGRAMMING/TEACHING ROOF ASSEMBLY (PANORAMA ROOF) Teaching roof
systems

ROOF) > INSTALLING ROOF ASSEMBLY PANELS > INSTALLING REAR PANEL FOR
ROOF ASSEMBLY
1. Slide the rear glass panel -1- from above at an angle under the front glass panel -1- (-A- ).
Fig 1: Fitting Rear Panel
2. Fit the rear part of the rear glass panel -1- down into the roof cut-out -B- and slide it towards
the rear -C- .
Information
3. Screw in fastening screws -2- , but do not tighten them.

Fig 2: Installing Glass Panel Screws
4. Adjust gap dimensions. Gap dimension 2 mm +/-0.5 mm Gap dimension 1 mm +1.2 mm

-0.6 mm Gap dimension 10 mm +/-1.2 mm Gap dimension 0.8 mm +/-1 mm
5. Tighten fastening screws -2- to → Tightening Torque: 7 Nm (5 ft. lb. . )
6. Press the seal -3- onto the assembly frame.
7. Once you have completed all required work, teach the roof system. → WM 600625
PROGRAMMING/TEACHING ROOF ASSEMBLY (PANORAMA ROOF) Teaching roof
systems
WM 604619 REMOVING AND INSTALLING SEAL FOR SLIDING ROOF >

PRELIMINARY WORK
Remove sliding-roof panel. → 604019 REMOVING AND INSTALLING SLIDING-ROOF PANEL - section
on "Removing"
WM 604619 REMOVING AND INSTALLING SEAL FOR SLIDING ROOF > REMOVING
SEAL FOR SLIDING ROOF
1. Pull the seal -1- out of the glass panel at any position.
2. Pull off the seal all the way around the glass panel.
Fig 1: Removing Seal
WM 604619 REMOVING AND INSTALLING SEAL FOR SLIDING ROOF > INSTALLING
SEAL FOR SLIDING ROOF
1. Position the seal.
1. 1.1. Align the gap in the seal -1- with the rear edge of the glass panel.
2. 1.2. Place the seal loosely around the glass panel.

Fig 1: Fitting Seal
2. Fit the seal.
1. 2.1. On the front of the panel, press the seal into the panel, starting from the center.
2. 2.2. Insert the seal all the way around.
3. 2.3. Insert the seal without tension at the gap -1- .
WM 604619 REMOVING AND INSTALLING SEAL FOR SLIDING ROOF >

SUBSEQUENT WORK
Install sliding-roof panel. → 604019 REMOVING AND INSTALLING SLIDING-ROOF PANEL - section
on "Installing"
WM 605455 REPLACING SEALS FOR ROOF ASSEMBLY > TOOLS

Commercially Nr. 174
Film Eraser
Available Tool Pos. 1
WM 605455 REPLACING SEALS FOR ROOF ASSEMBLY > PRELIMINARY WORK >
PRELIMINARY WORK FOR REPLACING OUTER SEAL
1. Move front roof panel to the open position.
2. Remove rear panel. → 60401900 REMOVING AND INSTALLING ROOF ASSEMBLY PANELS
(PANORAMIC ROOF)
WM 605455 REPLACING SEALS FOR ROOF ASSEMBLY > PRELIMINARY WORK >
PRELIMINARY WORK FOR REPLACING SEAL FOR REAR PANEL
(PANORAMIC ROOF)
WM 605455 REPLACING SEALS FOR ROOF ASSEMBLY > REPLACING SEALS FOR
ROOF ASSEMBLY > REPLACING OUTER SEAL
Information
1. Pull outer seal -1- off the bonding surface -3- on the roof -2- .
Fig 1: Pulling Outer Seal
2. Remove any adhesive residue from the roof using an erasing disc Film Eraser Nr. 174 Pos. 1
.
Information
using isopropyl to ensure that all traces of silicone, grease and oil are completely
removed.
3. Clean bonding surface with isopropyl.
4. Centre the new outer seal -1- with the gap -arrow- facing the middle of the rear roof cut-out.
5. Pull off protective film on the adhesive tape -3- and press the seal evenly onto the roof -2- .
6. Press the outer seal firmly onto the roof by pressing it on evenly twice all the way around using
a press-on roller.
WM 605455 REPLACING SEALS FOR ROOF ASSEMBLY > REPLACING SEALS FOR
ROOF ASSEMBLY > REPLACING SEAL FOR REAR PANEL
1. Remove seal for rear panel.
1. 1.1. Pull off seal at the side -4- of the rear glass panel -2- sideways.
2. 1.2. Pull off seal at the front -3- of the rear glass panel -2- in an upward direction.
Fig 1: Removing Seal For Rear Panel
2. Install seal for rear panel.
Information
To make installation easier, the area should be moistened with a soapy solution.
1. 2.1. Press seal at the front -3- into the front mounting from above and center it.
2. 2.2. Press seal at the side -4- into the mounting on the glass panel.
WM 605455 REPLACING SEALS FOR ROOF ASSEMBLY > SUBSEQUENT WORK >
SUBSEQUENT WORK FOR REPLACING OUTER SEAL
1. Install rear panel. → 60401900 REMOVING AND INSTALLING ROOF ASSEMBLY PANELS
(PANORAMIC ROOF)
2. Close the front panel.
WM 605455 REPLACING SEALS FOR ROOF ASSEMBLY > SUBSEQUENT WORK >
SUBSEQUENT WORK FOR REPLACING SEAL FOR REAR PANEL
1. Install rear panel. → 60401900 REMOVING AND INSTALLING ROOF ASSEMBLY PANELS
(PANORAMIC ROOF)
WM 606119 REMOVING AND INSTALLING FABRIC LINING > PRELIMINARY WORK
1. Remove sliding-roof panel. → 60401901 REMOVING AND INSTALLING SLIDING-ROOF

PANEL
WM 606119 REMOVING AND INSTALLING FABRIC LINING > REMOVING FABRIC

LINING
NOTE: Components stored or set down incorrectly
Risk of damage to component surfaces
→ Set the component down on a clean surface, workbench or assembly fixture.
1. Move fabric lining until all fastening screws on the guide elements are freely accessible.
2. Loosen front guide elements.
1. 2.1. Unscrew fastening screws -3- at the front on both sides.
2. 2.2. Lift up the guide elements -2- (-A- ) and push them over the fabric lining -1- to
the middle -B- .
Fig 1: Loosening Front Guide Elements
3. Loosen rear guide elements.
1. 3.1. Unscrew fastening screws -3- at the rear on both sides.
2. 3.2. Lift up the guide elements -2- (-A- ) and push them over the fabric lining -1- to
the middle -B- .
Fig 2: Loosening Rear Guide Elements
4. Swivel guide elements -2- up and out.

Fig 3: Lifting Up Guide Elements
5. Push fabric lining -1- forward and lift it up and off.

Fig 4: Removing Fabric Lining
WM 606119 REMOVING AND INSTALLING FABRIC LINING > INSTALLING FABRIC

LINING
1. Fit fabric lining -1- from above.

Fig 1: Fitting Fabric Lining
2. Insert guide elements -2- so that they are centered in the sliding-roof frame.
Fig 2: Inserting Guide Elements
3. Secure fabric lining at the front.
1. 3.1. Lift up guide elements -2- (-A- ) and push them into the cut-outs in the fabric
lining -1- (-B- ).
Information
1. Never make alterations to the micro-self-locking screws, which have a negative

effect on the bonding (e.g. using lubricant, loosening bolts and screwing them
down again).
2. Replace micro-self-locking screws.
2. 3.2. Screw in front fastening screws -3- .

Fig 3: Securing Fabric Lining At Front
4. Secure fabric lining at the rear.
1. 4.1. Lift up guide elements -2- (-A- ) and push them into the cut-outs in the fabric
lining -1- (-B- ).
Information
1. Never make alterations to the micro-self-locking screws, which have a negative
effect on the bonding (e.g. using lubricant, loosening bolts and screwing them
down again).
2. Replace micro-self-locking screws.
2. 4.2. Screw in rear fastening screws -3- .

Fig 4: Securing Fabric Lining At Rear
WM 606119 REMOVING AND INSTALLING FABRIC LINING > SUBSEQUENT WORK
1. Install sliding-roof panel. → 60401901 REMOVING AND INSTALLING SLIDING-ROOF

PANEL
WM 607019 REMOVING AND INSTALLING SUN BLIND > TECHNICAL VALUES
Tolerance Tolerance
1 2
Fastening screws for sun Tightening 3 Nm (2 ft.

Item 2, 5
blind Torque lb.)
Removing guide
WM 607019 REMOVING AND INSTALLING SUN BLIND > PRELIMINARY WORK
1. Open the sun blind fully.
(PANORAMIC ROOF)
3. Remove rear headliner. → 708419 REMOVING AND INSTALLING HEADLINER
WM 607019 REMOVING AND INSTALLING SUN BLIND > REMOVING SUN BLIND
Information
1. Detach strut from sun blind.
1. 1.1. Press down the locking mechanism -3- on the left side -A- .
Fig 1: Releasing Strut From Sun Blind
2. 1.2. Slide the strut -4- fully to the left side -B- .
3. 1.3. On the opposite side, slide the strut -4- towards the rear and off the sun blind
slider -2- (-C- ).
Fig 2: Loosening Strut
4. 1.4. Pull the strut -4- completely off the sun blind -1- at the side.
2. Carefully lift up the locking hook on the sun blind slider -2- using a flat screwdriver -3- (-A- )
and remove the sun blind -1- together with the driver -4- from the sun blind slider -2- by
pulling it towards the rear -B- .
Fig 3: Removing Sun Blind
3. Unscrew fastening screws from the guide -3- at the top -2- and bottom -5- .
Fig 4: Removing Guide
4. Pull the sun blind -1- complete with the sun blind holders -2- and drivers -4- out of the sun
blind module -3- (-arrow- ).
Fig 5: Pulling Out Sun Blind
WM 607019 REMOVING AND INSTALLING SUN BLIND > INSTALLING SUN BLIND
Information
Information
The sun blind sliders and operating cables must not be greased.
1. Slide the sun blind -1- complete with the sun blind holders -2- and drivers -4- into the sun
blind module -3- and position it.
Fig 1: Positioning Sun Blind
2. Screw in fastening screws used to secure the guide -3- at the top -2- and bottom -5- to the
frame -4- and tighten to Tightening Torque 3 Nm (2 ft. lb.) until secure.
Fig 2: Installing Guide
3. Guide the sun blind -1- together with the driver -4- into the rail -A- until the driver locks on the
sun blind slider -2- .
Fig 3: Installing Sun Blind
Check that the fabric is fitted correctly. → Positioning fabric

Fig 4: Positioning Fabric
4. Install sun blind strut.
1. 4.1. Slide the strut onto the sun blind at the side.
2. 4.2. Press down the locking mechanism -3- on the left side -A- .
Fig 5: Installing Sun Blind Strut
3. 4.3. Slide the strut -4- fully to the left side -B- .
4. 4.4. On the opposite side, slide the strut -4- onto the sun blind slider -2- from the
rear -C- .
Fig 6: Positioning Strut Of Sun Blind
5. 4.5. Slide the sun blind strut to the right -D- until the locking mechanism -3-
engages.
WM 607019 REMOVING AND INSTALLING SUN BLIND > SUBSEQUENT WORK
Information
After installing the sun blind, check that it moves perfectly and smoothly. To do this, move the sun blind
drive mechanism forwards and backwards at the motor by hand by actuating it manually using a
commercially available hexagon wrench and check that the sun blind fabric folds and moves correctly.
1. Install rear panel. → 60401901 REMOVING AND INSTALLING SLIDING-ROOF PANEL

2. Program/teach roof assembly (panoramic roof) → 600625 PROGRAMMING/TEACHING
WM 607219 REMOVING AND INSTALLING MOTOR FOR SUN BLIND > TECHNICAL
VALUES
Tolerance Tolerance
1 2
Fastening screw for sun blind Tightening 3 Nm (2 ft.

Item 3
motor Torque lb.)
Removing motor
WM 607219 REMOVING AND INSTALLING MOTOR FOR SUN BLIND > PRELIMINARY
WORK
WM 607219 REMOVING AND INSTALLING MOTOR FOR SUN BLIND > REMOVING
MOTOR FOR SUN BLIND
NOTE: Voltage peaks
Information

Fig 1: Identifying Motor For Sun Blind Installation Position
2. Release electric plug connection -2- for sunroof motor -a- and disconnect it -B- .
3. Unscrew fastening screws -3- on motor for sun blind -1- .

4. Remove the motor.

Fig 3: Removing Motor
WM 607219 REMOVING AND INSTALLING MOTOR FOR SUN BLIND > INSTALLING
MOTOR FOR SUN BLIND
1. Align the sun blind so that it is parallel.
1. 1.1. The sun blind must be parallel before installing the motor.
2. 1.2. Set the same distance -a- from the front edge -4- and sun blind module -5- on
both sides.
Fig 1: Aligning Sun Blind
the frame are aligned.
Information
4. Screw in fastening screws -3- on sun blind motor -1- and tighten to Tightening Torque 3 Nm
(2 ft. lb.) .
Fig 2: Installing Motor
5. Connect plug connection for sun blind motor -2- .

WM 607219 REMOVING AND INSTALLING MOTOR FOR SUN BLIND > SUBSEQUENT
WORK
1. Install headliner. → INSTALLING HEADLINER - section on "Installing"
2. Program/teach roof assembly (panoramic roof) → 600625 PROGRAMMING/TEACHING

Service Manual: 63 - BUMPERS -- 92A CAYENNE
WM 631019 REMOVING AND INSTALLING FRONT BUMPER (CAYENNE, CAYENNE
Fastening screw Item 5 Tightening 60 Nm (44 +/-5 Nm (+/- 3.5

for body torque ftlb.) ftlb.)
Detaching bumper
Fastening Item 2 Tightening 12 Nm (9 ftlb.) +/-1 Nm (+/- 0.5

carrier
Detaching lock carrier and radiator
Fastening Item 3. The Tightening 25 Nm (19 +/-2.5 Nm (+/- 2

screws securing thread must be torque ftlb.) ftlb.)
bumper to re-cut on a new
radiator radiator mounting
mounting
Detaching lock carrier and radiator
Fastening screw Item 1 Tightening 9 Nm (6.5 ftlb.) +/-9 Nm (+/- 6.5

securing lock torque ftlb.)
support to
bumper
Loosening lock support

2. Only with charge-air cooler
Detach the charge air cooler at the side of the bumper. → 214319 REMOVING AND
INSTALLING CHARGE-AIR COOLER

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT BUMPER
Information
Information
1. Unscrew fastening screw -1- from the lock support.

Fig 1: Loosening Lock Support
2. Unscrew fastening screws -2- for lock carrier.

Fig 2: Detaching Lock Carrier And Radiator
3. Unscrew fastening screws -3- for the radiator mounting.
4. Turn the radiator mounting -4- 90° -A- and support the radiator on the longitudinal members.
Fig 3: Supporting Radiator
5. Unscrew fastening screws -5- for the longitudinal member.

Fig 4: Detaching Bumper
6. Pull the bumper forward and remove it in a downward direction.

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT BUMPER
Information
1. Fit the bumper between the lock carrier and longitudinal member from underneath and position
it.
3. Tighten fastening screws for the body to Tightening torque 60 Nm (44 ftlb.) +/-5 Nm (+/-3.5
ftlb.) .
4. Tighten fastening screws on body mounts to Tightening torque 25 Nm (19 ftlb.) +/-2.5 Nm
(+/-2 ftlb.) .
5. Tighten fastening screws on the lock carrier to Tightening torque 12 Nm (9 ftlb.) +/-1 Nm
(+/-0.5 ftlb.) .
6. Tighten fastening screw on the lock support to Tightening torque 9 Nm (6.5 ftlb.) +/-9 Nm
(+/-6.5 ftlb.) .

1. Only with charge-air cooler
Secure the charge air cooler at the side of the bumper. → Installing Charge-Air Cooler
2. Install front apron. → Installing Front Apron
WM 631519 REMOVING AND INSTALLING FRONT APRON (EXCEPT CAYENNE,

storage system Workshop WE 1473

VAS 6760 equipment

Screws, top Tightening 8 Nm (6 ftlb.) +/-1 Nm (+/-0.5

front torque ftlb.)
Screws, bottom Tightening 8 Nm (6 ftlb.) +/-1 Nm (+/-0.5
torque ftlb.)

1. Remove main headlight. → 941519 REMOVING AND INSTALLING MAIN HEADLIGHTS
2. Remove cover for lock support. → 703919 REMOVING AND INSTALLING COVER FOR
FRONT LOCK SUPPORT
3. Remove side direction indicator light. → 945319 REMOVING AND INSTALLING SIDE
DIRECTION INDICATOR LIGHT
4. Remove front wheel cover. → 661919 REMOVING AND INSTALLING FRONT WHEEL
COVER
5. Loosen front engine guard. → 108019 REMOVING AND INSTALLING ENGINE GUARD

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT APRON
Information
1. Unscrew fastening screws -1- at the bottom of the front apron.

Fig 1: Loosening Front Apron
2. Unscrew fastening screws -2- for the wing and attachment strip.
Fig 2: Loosening Front Apron At Sides
3. Pull safety clips -3- at the left and right off the guide pins.
Fig 3: Pulling Off Safety Clips
4. Unscrew front fastening screws -1- at the top.

Fig 4: Loosening Front Apron At Top
5. Disconnect wire harness on the right side.
1. 5.1. Press locking lugs -a- and pull off the connectors.
Fig 5: Disconnecting Wire Harness
6. Take off front apron with the help of an assistant.
1. 6.1. Loosen the front apron and pull it forward slightly.

Fig 6: Pulling Front Apron
2. 6.2. Disconnect line for headlight washer system.
1. 6.2.1. Press off line with a hose clamp.

Fig 7: Disconnecting Line
2. 6.2.2. Unclip line from the front apron.
3. 6.2.3. Pull line off the spray nozzle.

Fig 8: Disconnecting Line From Spray Nozzle
3. 6.3. Remove trim panel fully.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT APRON
1. Fit the trim panel with the help of another person.
1. 1.1. Attach line for headlight washer system until it engages securely.
Fig 1: Connecting Line To Spray Nozzle
2. 1.2. Clip line into the front apron.
3. 1.3. Loosen hose clamp on the hose.
4. 1.4. Attach and position the front apron.

Fig 2: Fitting Front Apron
5. 1.5. Plug in connectors for wire harness at the right until they engage securely.
Fig 3: Connecting Wire Harness
2. Screw in front fastening screws -1- at the top and tighten to → Tightening torque: 8 Nm (6
ftlb.)+/-1 Nm (+/-0.5 ftlb.) .
Fig 4: Securing Front Apron At Top
3. Push on fixing device.
1. 3.1. Fit safety clips -3- at the left and right fully on the guide pins.
Fig 5: Securing Front Apron
4. Screw in and tighten fastening screws -2- on the wing.

Fig 6: Securing Front Apron At Sides
5. Screw in fastening screws -1- at the bottom of the front apron and tighten to → Tightening
torque: 8 Nm (6 ftlb.)+/-1 Nm (+/-0.5 ftlb.) .
Fig 7: Securing Front Apron At Bottom

1. Place front apron in storage system VAS 6760 WE 1473 .
2. Secure front engine guard. → 108019 REMOVING AND INSTALLING ENGINE GUARD
3. Secure front wheel cover. → 661919 REMOVING AND INSTALLING FRONT WHEEL COVER
4. Install side direction indicator light. → 945319 REMOVING AND INSTALLING SIDE
DIRECTION INDICATOR LIGHT
5. Install cover for lock support. → 703919 REMOVING AND INSTALLING COVER FOR FRONT
LOCK SUPPORT
6. Install main headlights. → Installing Headlights
WM 631537 DISASSEMBLING AND ASSEMBLING FRONT APRON (CAYENNE,

2. Remove number plate cover. → 668319 REMOVING AND INSTALLING NUMBER PLATE
COVER
3. Remove front wire harness. → 971519 REMOVING AND INSTALLING FRONT WIRE
HARNESS
4. Remove outside temperature sensor. → 916819 REMOVING AND INSTALLING OUTSIDE

TEMPERATURE SENSOR
5. Remove auxiliary headlights. → 947119 REMOVING AND INSTALLING AUXILIARY

HEADLIGHTS
6. Remove fog lights. → 946419 REMOVING AND INSTALLING FOG LIGHTS
7. Remove front air grille. → 660419 REMOVING AND INSTALLING FRONT AIR GRILLE
8. Remove radiator grille. → 660519 REMOVING AND INSTALLING RADIATOR GRILLE
9. Remove front ParkAssist sensors. → 917519 REMOVING AND INSTALLING PARKASSIST

SENSOR
10. Remove front spoiler. → 660319 REMOVING AND INSTALLING FRONT SPOILER

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > DISASSEMBLING FRONT APRON
1. Remove covers for towing lugs -1- .
1. 1.1. Press covers for towing lugs -1- at the top forward out of the front apron.
2. 1.2. Unhook covers for towing lugs -1- at the bottom out of the front apron.
3. 1.3. Unhook safety strap -2- and remove covers for towing lugs -1- .
Fig 1: Removing Covers For Towing Lugs
2. Remove fastening clamps -1- for hose for headlight cleaning system from the front apron.
Fig 2: Removing Fastening Clamps

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > ASSEMBLING FRONT APRON
1. Assembly is performed in reverse order to disassembly.

1. Install front spoiler. → 660319 REMOVING AND INSTALLING FRONT SPOILER
2. Install front ParkAssist sensors. → 917519 REMOVING AND INSTALLING PARKASSIST

SENSOR
3. Install radiator grille. → 660519 REMOVING AND INSTALLING RADIATOR GRILLE
4. Install front air grille. → 660419 REMOVING AND INSTALLING FRONT AIR GRILLE
5. Install fog lights. → 946419 REMOVING AND INSTALLING FOG LIGHTS

6. Install auxiliary headlights. → 947119 REMOVING AND INSTALLING AUXILIARY
HEADLIGHTS
7. Install outside temperature sensor. → 916819 REMOVING AND INSTALLING OUTSIDE

TEMPERATURE SENSOR
8. Install front wire harness. → Installing Front Wire Harness
9. Install number plate cover. → 668319 REMOVING AND INSTALLING NUMBER PLATE
COVER
WM 631719 REMOVING AND INSTALLING FRONT RETAINING STRIP (EXCEPT

VALUES
Centre retaining Tightening 8 Nm (6 ftlb.) +/-1 Nm (+/-0.5

strip to lock torque ftlb.)
carrier

WORK

FRONT RETAINING STRIP
Information
1. Unscrew front fastening screws -1- .

Fig 1: Loosening Front Retaining Strip
2. Unscrew fastening screws at the side -1- .

Fig 2: Loosening Side Retaining Strip
3. Unclip retaining strip at the sides -A- , then towards the front -B- .
Fig 3: Unclipping Retaining Strip
4. Remove retaining strip.

FRONT RETAINING STRIP > REMOVING CENTRE RETAINING STRIP

Fig 1: Removing Centre Retaining Strip
2. Unclip retaining strip at the sides and remove by pulling it towards the front.

FRONT RETAINING STRIP > INSTALLING SIDE RETAINING STRIP
The side retaining strip is installed in reverse order to removal.

FRONT RETAINING STRIP > INSTALLING CENTRE RETAINING STRIP
The center retaining strip is installed in reverse order to removal.
Screw in fastening screws and tighten to → Tightening torque: 8 Nm (6 ftlb.)+/-1 Nm (+/-0.5 ftlb.) .

WORK
WM 635019 REMOVING AND INSTALLING REAR BUMPER (CAYENNE, CAYENNE

Fastening screw Tightening 80 Nm (59 +/-2 Nm (+/-1.5

for rear bumper torque ftlb.) ftlb.)


CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR BUMPER
2. Remove bumper.
Fig 1: Removing Bumper

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR BUMPER
1. Fit the bumper and screw in fastening screws.
2. Tighten fastening screws to Tightening torque 80 Nm (59 ftlb.) +/-2 Nm (+/-1.5 ftlb.) .

1. Install rear apron. → Installing Rear Apron
WM 635519 REMOVING AND INSTALLING REAR APRON (CAYENNE, CAYENNE GTS,


storage system Workshop WE 1473
VAS 6760 equipment

Fastening screw Tightening 3.5 Nm (2.5

for rear apron, torque ftlb.)
bottom
Loosening rear apron at the bottom
Fastening screw Tightening 3 Nm (2 ftlb.)

for rear apron, torque
side
Loosening rear apron at the sides

for guide pin torque ftlb.)
Removing guide pin

for rear apron, torque
top
Loosening rear apron at the top

1. Remove tail lights. → 943119 REMOVING AND INSTALLING TAIL LIGHT
2. Detach rear wheel cover as far as the middle. → 664519 REMOVING AND INSTALLING
REAR WHEEL COVER
Information
Only for vehicles with I-no. 6GB "Wider wheel covers, offroad"
3. Remove wheel covers on the rear apron. → 664519 REMOVING AND INSTALLING REAR
WHEEL COVER (OFFROAD)

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR APRON
Information
1. Unscrew fastening screw -1- in frame for light.

Fig 1: Detaching Rear Apron At Top
2. Unscrew fastening screw -2- and remove guide pin -3- .

Fig 2: Removing Guide Pin
3. Unscrew fastening screws -1- from wheel housing liner.

Fig 3: Loosening Wheel Housing Liner
4. Pull wheel cover aside -A- and unscrew fastening screws -1- at the sides of the rear apron
-B- .
Fig 4: Loosening Rear Apron At Sides
5. Unscrew fastening screws -4- at the bottom of the rear apron.

Fig 5: Loosening Rear Apron At Bottom
6. Unhook the rear apron at both sides.

Fig 6: Removing Rear Apron
7. Press left wheel housing liner aside and release and disconnect the wire harness on the left
side -a- .
8. Unclip top of rear apron from the attachment strip.

Fig 8: Unclipping Rear Apron At Top
9. Remove rear apron with the help of another person.

Fig 9: Removing Rear Apron

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR APRON
Information
1. Fit rear apron with the help of another person.

Fig 1: Fitting Rear Apron
2. Clip top of rear apron into the attachment strip.
3. Connect wire harness on the left side.

Fig 2: Connecting Wire Harness
4. Clip sides of rear apron into the attachment strip.

Fig 3: Clipping In Rear Apron At Sides
5. Screw in fastening screws -4- underneath the rear apron and tighten to Tightening torque 3.5
Nm (2.5 ftlb.) .
Fig 4: Securing Rear Apron At Bottom
6. Screw in fastening screws -1- at the sides of the rear apron and tighten to Tightening torque
3 Nm (2 ftlb.) .
Fig 5: Securing Rear Apron At Sides
7. Screw in fastening screws -1- on the wheel housing liner.

Fig 6: Securing Wheel Housing Liner
8. Position guide pins -3- , screw in fastening screw -2- and tighten to Tightening torque 10
Nm (7.5 ftlb.) .
Fig 7: Fitting Guide Pin
9. Tighten fastening screws -1- in frame for light to Tightening torque 3 Nm (2 ftlb.) .
Fig 8: Detaching Rear Apron At Top

1. Place rear apron in storage system VAS 6760 WE 1473 .
Information
Only for vehicles with I-no. 6GB "Wider wheel covers, offroad"
2. Install wheel covers on the rear apron. → Installing Rear Wheel Cover
3. Secure rear wheel cover. → 664519 REMOVING AND INSTALLING REAR WHEEL COVER
4. Install tail lights. → 943119 REMOVING AND INSTALLING TAIL LIGHT
5. The control unit must be calibrated on vehicles with Lane Change Assist.
→ 917025 PROGRAMMING CONTROL UNIT FOR LANE CHANGE ASSIST
WM 635537 DISASSEMBLING AND ASSEMBLING REAR APRON (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > DISASSEMBLING REAR APRON
2. Remove rear skirt. → 636819 REMOVING AND INSTALLING REAR SKIRT
3. Remove sensors for ParkAssist. → 917519 REMOVING AND INSTALLING PARKASSIST

SENSOR
4. Remove reversing light.
WM 635537 DISASSEMBLING AND ASSEMBLING REAR APRON (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > ASSEMBLING REAR APRON
1. Install reversing light.
2. Install ParkAssist sensors. → 917519 REMOVING AND INSTALLING PARKASSIST SENSOR
3. Install rear skirt. → 636819 REMOVING AND INSTALLING REAR SKIRT
WM 635619 REMOVING AND INSTALLING REAR PANEL (CAYENNE, CAYENNE GTS,

2. Remove trim frame for tailpipe cover. → 637019 REMOVING AND INSTALLING TRIM FRAME
FOR TAILPIPE COVER

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR PANEL
Information

Fig 1: Identifying Rear Panel Screws
2. Remove expansion rivets -1- .
3. Unclip plastic bracket -2- on rear panel.

Fig 2: Removing Expansion Rivet
4. Unclip reinforcement -1- by pulling it up out of the rear panel.
5. Unclip locking lugs -2- on the rear panel on the rear skirt.
Fig 3: Unclipping Lock Lugs On Rear Panel
6. Remove rear panel.

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR PANEL

1. Install trim frame for tailpipe cover. → 637019 REMOVING AND INSTALLING TRIM FRAME
FOR TAILPIPE COVER
WM 635719 REMOVING AND INSTALLING REAR RETAINING STRIP (CAYENNE,


for side torque
retaining strip
Removing side retaining strip

for upper torque
retaining strip
Removing upper retaining strip
Fastening nut Item 3 Tightening 6 Nm (4.5 ftlb.)

for lower torque
retaining strip
Removing lower retaining strip


TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR RETAINING STRIP
> REMOVING SIDE RETAINING STRIP

Fig 1: Removing Side Retaining Strip
2. Remove side retaining strips.

> REMOVING UPPER RETAINING STRIP
1. Disconnect wire harness from the retaining strip.
2. Screw off fastening nuts -2- .

Fig 1: Identifying Upper Retaining Strip
3. Remove upper retaining strip.

> REMOVING LOWER RETAINING STRIP

Fig 1: Identifying Lower Retaining Strip
2. Remove lower retaining strip.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR RETAINING
STRIP > INSTALLING SIDE RETAINING STRIP
1. Fit side retaining strips.
2. Screw in fastening screws -1- and tighten to Tightening torque 3 Nm (2 ftlb.) .

Fig 1: Installing Side Retaining Strip

STRIP > INSTALLING UPPER RETAINING STRIP
1. Fit upper retaining strip.
2. Screw in fastening nuts -2- and tighten to Tightening torque 3 Nm (2 ftlb.) .

Fig 1: Identifying Upper Retaining Strip
3. Secure wire harness at the retaining strip.

STRIP > INSTALLING LOWER RETAINING STRIP
1. Fit lower retaining strip.
2. Screw in fastening nuts -3- and tighten to Tightening torque 6 Nm (4.5 ftlb.) .
Fig 1: Identifying Lower Retaining Strip

WM 636819 REMOVING AND INSTALLING REAR SKIRT (CAYENNE, CAYENNE GTS,

2. Remove wire harness for ParkAssist. → 975919 REMOVING AND INSTALLING WIRE
HARNESS FOR PARKASSIST .

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR SKIRT
Information

Fig 1: Identifying Rear Panel Screws
2. Unclip reinforcement -1- by pulling it up out of the rear skirt -3- .
3. Release locking lugs -2- on the rear skirt -3- .

Fig 2: Identifying Reinforcement And Lock Lugs
4. Remove rear skirt -3- .

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR SKIRT
The rear skirt is installed in reverse order to removal.

1. Install wire harness for ParkAssist. → 975919 REMOVING AND INSTALLING WIRE
HARNESS FOR PARKASSIST .
WM 636855 REPLACING REAR SKIRT (CAYENNE, CAYENNE GTS, CAYENNE TURBO

1. Remove rear skirt. → 636819 REMOVING AND INSTALLING REAR SKIRT

CAYENNE (3.0)) > REPLACING REAR SKIRT
1. Remove rear panel. → 635619 REMOVING AND INSTALLING REAR PANEL
2. Remove trim frame for tailpipe cover. → 637019 REMOVING AND INSTALLING TRIM FRAME
FOR TAILPIPE COVER
3. Replace rear panel.
4. Fit trim frame for tailpipe cover. → 637019 REMOVING AND INSTALLING TRIM FRAME FOR
TAILPIPE COVER
5. Fit rear panel. → 635619 REMOVING AND INSTALLING REAR PANEL

1. Install rear skirt. → 636819 REMOVING AND INSTALLING REAR SKIRT
WM 637019 REMOVING AND INSTALLING TRIM FRAME FOR TAILPIPE COVER

WORK
1. Remove rear apron. → 635519 REMOVING AND INSTALLING REAR APRON .

TRIM FRAME FOR TAILPIPE COVER
Information
1. Remove fixing clips -1- .
2. Unclip locking lugs -2- from the trim frame -3- .

Fig 1: Identifying Fixing Clips
3. Remove trim frame -3- .

TRIM FRAME FOR TAILPIPE COVER
The trim frame for the tailpipe cover is installed in reverse order to removal.

WORK

Service Manual: 64 - GLAZING, WINDOW CONTROL -- 92A CAYENNE
WM 641219 REMOVING AND INSTALLING WINDSCREEN (ALL MODELS) >
PRELIMINARY WORK
1. Remove interior rear-view mirror. → REMOVING INTERIOR REAR-VIEW MIRROR
2. On vehicles with a rain sensor - Remove rain sensor. → REMOVING RAIN SENSOR
3. On vehicles with a telephone - Remove antenna for telephone. → REMOVING MOBILE

4. Remove cowl panel cover. → REMOVING COWL PANEL COVER
5. Remove A-pillar trim panel at the left and right. → REMOVING A-PILLAR TRIM
6. Remove sun visors. → REMOVING SUN VISOR
7. Detach headliner at the front. → REMOVING HEADLINERREMOVING HEADLINER
8. Remove molding for windscreen. → REMOVING MOLDING FOR WINDSCREEN

TECHNICAL VALUES
Windscreen to Gap dimension 2.6 mm +/-0.5 mm

roof (W1)
Windscreen to roof
Windscreen to Gap dimension 2.4 mm +1 mm

roof (W2)
Windscreen to roof

TECHNICAL VALUES > GAP DIMENSIONS OF WINDSCREEN

Fig 1: Identifying Gap Dimension Of Windscreen To Roof
→ Gap dimension: 2.4 mm+1 mm

Fig 2: Identifying Gap Dimension Of Roof To Windscreen
WM 641219 REMOVING AND INSTALLING WINDSCREEN (ALL MODELS) > TOOLS

AND MATERIALS
The following tools and materials are required for removing and installing the rear window with
2-component adhesive:
A - Double cartridge gun VAS 5237

B - Suction cups VAG 1344
C - Special electric cutter (fine) VAG 1561 A
D - Flashing knife, U-type 639.031.130.22
H - 2-component window bonding agent 000.043.300.94, contains set components H1-H8
H1 - Cleaning solution
H2 - Primer
H3 - Activator
H4 - Swab
H5 - Cartridge, component A
H6 - Cartridge, component B
H7 - Mixing nozzle
H8 - Processing nozzle
Fig 1: Identifying Tools And Materials
A - Removal kit for flush bonded windows VAG 1474 B, contains set components A1-A9
B - Cutting thread
A1 - Guide rail
A4 - Awl
A5 - Guide rail
A6 - Filler
A7 - Steering roller with arm bracket
A8 - Handle

Fig 2: Identifying Guide Rail, Handle And Steering Roller

REMOVING WINDSCREEN
Danger of cuts
1. Cut out the windscreen.
1. 1.1. Remove the windscreen using wire for cutting tool.

Information
1. The procedure for removing car windows is described in → 6X00IN GENERAL

INFORMATION ON REMOVING CAR WINDOWS .
Fig 1: Identifying Windscreen

PREPARING WINDOW APERTURE FOR INSTALLATION
1. Remove adhesive from the body.
1. 1.1. When removing adhesive residue -1- from the body using the cutting tool -C-
and flashing knife -D- , ensure that only a surface coating of adhesive remains -2- .
Information
1. The surface coating of adhesive residue helps new adhesive to stick. Keep cut
surfaces clean and free of grease and do not clean with cleaning solution.
Fig 1: Identifying Adhesive
2. Clean and prime paint damage and newly built-up paint surfaces in the window aperture of the
body.
1. 2.1. Clean new paint surfaces and damage to the top coat paint in the non-visible
area of the window aperture in the body with cleaning solution -H1- and touch up
with primer -H2- .
Information
1. A drying time of at least 10 minutes must be observed between cleaning the

bonding surface and applying primer! Always ensure that no cleaning solution
residues remain on the body.
Fig 2: Cleaning Window Aperture And Adhesive

PREPARING WINDSCREEN FOR INSTALLATION > PREPARING WINDSCREEN FOR
INSTALLATION (RE-INSTALLATION ONLY)
Information
The removed windscreen can be reinstalled if there was no prior damage to the windscreen and
the windscreen was removed without damage.
1. Remove adhesive from the windscreen.

Fig 1: Removing Adhesive From Windscreen
1. 1.1. Fit cutter -C- with the flashing knife -D- and remove adhesive residue from the
windscreen, ensuring that a surface coating of adhesive remains.
Information
1. The remaining adhesive helps new adhesive to stick. Keep cut surfaces clean
and free of grease and do not clean with cleaning solution.
2. Check the foam element around the chassis number for damage and replace it if necessary.
3. Activate the bonding section of the windscreen.
1. 3.1. During long idle periods, apply activator to the adhesive residue that was cut
back.
Fig 2: Applying Activator To Adhesive Residue

PREPARING WINDSCREEN FOR INSTALLATION > PREPARING WINDSCREEN FOR
INSTALLATION (NEW WINDSCREEN)
1. Clean and prime the window.

Fig 1: Cleaning Prime Window
1. 1.1. Clean glass with cleaning solution.
2. 1.2. Apply primer to the marked area of the window flange.
Information
1. A ventilation period of at least 10 minutes must be observed between the

cleaning of the glass and the application of primer! No cleaning solution
residues may remain on the windscreen.

INSTALLING WINDSCREEN
Information
Only with new windscreens
Information
The removed windscreen can be reinstalled if there was no prior damage to the windscreen and
the windscreen was removed without damage.
Information
Two persons are needed to insert and adjust the windscreen.
CAUTION: Danger of material damage if specified curing time of adhesive is not

observed! In order to ensure that the bonded joint is sufficiently strong, the following
conditions must be adhered to:
The vehicle must not be used until the curing time has elapsed.
Curing time: 2 hours
Temperature: at least 10 °C
Fixing time: approx. 1 hour
1. Prepare 2-component adhesive for processing. → 6X00IN WORKING WITH PORSCHE

2-COMPONENT WINDOW ADHESIVE
Information
1. The adhesive has an open time of -15 min- , which means that the bonding material
must be applied and the component must be affixed within this period of time.
2. To ensure that the substance is completely mixed, apply a 30-mm long bead of fresh
adhesive to a piece of cardboard before processing.
Fig 1: Identifying Bonding Material Applying Time
Information
1. When applying the adhesive, it is essential to ensure that the adhesive bead overlaps by
approx. 30 mm at the beginning and at the end.
2. Apply adhesive to the windscreen.

Fig 2: Applying Adhesive
1. 2.1. Using a bonding gun -A- , apply 2-component adhesive to the rear window
along the preliminary coat and on the primer in the form of a triangular bead
measuring -X = approx. 15 mm- .
3. Insert the windscreen into the body.
1. 3.1. Affix suction cups to the windscreen.
2. 3.2. Guide the windscreen into the window aperture.
3. 3.3. Push the windscreen up against the seal.
4. 3.4. Insert the windscreen at the sides of the window aperture and lower it (do not
press at the sides ).
5. 3.5. Press the bottom of the windscreen onto the body as far as the guide stop.
6. 3.6. Adjust gap dimension of windscreen with respect to the roof. → Technical
Values
Information
1. Only if the windscreen is re-installed

7. 3.7. Secure the windscreen with adhesive tape -1- to prevent it from slipping.
Fig 3: Securing Windscreen
4. Adhesive that has oozed out must be removed immediately and the affected fields of vision
must be cleaned using cleaning solution -H1- .
Fig 4: Removing Emerging Adhesive Residue

SUBSEQUENT WORK
1. Secure headliner at the front. → INSTALLING HEADLINER
2. Install sun visor. → 682319 REMOVING AND INSTALLING SUN VISOR
3. Install cowl panel cover. → INSTALLING SUN VISOR
4. On vehicles with a rain sensor - Install rain sensor. → 921219 REMOVING AND INSTALLING
RAIN SENSOR
5. On vehicles with a telephone - Install antenna for telephone. → INSTALLING MOBILE

6. On vehicles with front camera - Calibrate front camera. → 963825 PROGRAMMING FRONT
CAMERA
7. Install interior rear-view mirror. → INSTALLING INTERIOR REAR-VIEW MIRROR
8. Install A-pillar trim panel at the left and right. → INSTALLING A-PILLAR TRIM PANEL
9. Install molding for windscreen. → INSTALLING MOLDING FOR WINDSCREEN
WM 6412IN PROCESSING OF PORSCHE 2-COMPONENT WINDOW BONDING

AGENTS (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S,
PRE-TREATMENT OF BONDING SURFACES > PRE-TREATING ADHESIVE FLANGES
ON VEHICLE WINDOWS
Information
The table below shows how to use cleaners, primers and activators when preparing the adhesive
surface.
Preparing the body glass for installation
Old glass New glass
(window removed) with preliminary coat (durable primer)
Cleaner ?
Clean rim (ceramic layer and durable primer)?
Activate adhesive bead (only necessary after Apply primer from the adhesive kit over the durable
idle periods > 24 h)? primer on the spare part?
Apply adhesive
Install glass

PRE-TREATMENT OF BONDING SURFACES > PRE-TREATING ADHESIVE FLANGES
ON VEHICLE BODY
Information
The table below shows how to use cleaners, primers and activators when preparing the adhesive
surface.
Preparing the window flange for installation
Old flange (old paint job) New flange (new paint job)
Cleaner ?
Clean flange surface?
Activate adhesive bead (only necessary after idle periods > 24 h)? Prime flange surface?
Apply adhesive
Install glass

HANDLING PROCESSING DEVICE > DOUBLE CARTRIDGE PRESS
WARNING: Toxic substances
Danger of poisoning or suffocation
→ Ventilate the work area well.
→ Never ingest or inhale.
→ Read specific information on the Hazard Sheet.
Information
In addition to this information, observe the relevant job descriptions for installing car windows!
1. Preparing cartridge components A and B
1. 1.1. Pierce the membrane in the nozzle connection of components A and B

(aluminum cartridge) -H5, H6- with a screwdriver and extend the opening.
2. 1.2. Remove flanged cover on end of cartridge.

Fig 1: Removing Flanged Cover
2. Screw on mixing nozzle.
1. 2.1. Screw both cartridges -H5, H6- onto the mixing nozzle.
Fig 2: Turning Cartridges Onto Mixing Nozzle
3. Placing cartridges in the double cartridge gun
1. 3.1. Move pressure piston back fully.
2. 3.2. Insert the double cartridges -H5, H6- into the bonding gun -A- .
Fig 3: Inserting Double Cartridges
4. Press out the adhesive
1. 4.1. By activating the valve -arrow- allow the pressure piston to move out slowly
until both components of the bonding material emerge at the mixing pipe.
2. 4.2. Wipe off the emerging adhesive.

Fig 4: Pressing Adhesive
5. Screwing on processing nozzle
1. 5.1. Screw processing nozzle -H8- onto the mixing nozzle -H7- .
Fig 5: Turning Screw Of Processing Nozzle
6. Align processing nozzle
1. 6.1. Turn the processing nozzle on the mixing nozzle until the illustrated position is
reached.
Fig 6: Aligning Processing Nozzle
7. Mixing adhesive components
1. 7.1. By activating the valve -arrow- allow the pressure piston to move out slowly
until the adhesive is visible in the processing pipe.
Information
In this position, when the mixing nozzle is horizontal, the closed surfaces must be
visible on the processing nozzle from above and below and the mixer insert's mixing
plates must be visible from the sides.
Fig 7: Pressing Adhesive
8. Affixing car window
Information
1. The bonding material has an open time of 15 min , which means that the bonding
material must be applied and the car window must be assembled within this period of
time.
2. In order to ensure that the substance is completely mixed, apply a 30 mm long adhesive
bead of fresh adhesive to a piece of cardboard before processing.
WM 642919 REMOVING AND INSTALLING FRONT CORNER WINDOW PANE

CAYENNE TURBO) > TECHNICAL VALUES
Fastening Item 1 Tightening 4.5 Nm (3.5

corner window
pane, outer
Unscrewing fastening screw for corner window pane, outer
Fastening Item 2 Tightening 4.5 Nm (3.5

corner window
pane, inner
Unscrewing fastening screws for corner window pane, inner

CAYENNE TURBO) > PRELIMINARY WORK
1. Remove front door sub-frame. → REMOVING FRONT DOOR SUB-FRAME
2. Remove front door window. → Removing Front Door Window 644019 REMOVING AND
INSTALLING FRONT DOOR WINDOW

CAYENNE TURBO) > REMOVING FRONT CORNER WINDOW PANE
Information
1. Pull front window guide off the rear door frame.
If you intend to re-use the window guide, make sure it is not kinked or bent.
Fig 1: Pulling Off Rear Window Guide
2. Pull the front window guide off the front corner window pane.
Fig 2: Pulling Window Guide Off Corner Window Pane
3. Remove front window guide completely.
4. Unscrew fastening screw -1- on the front corner window pane at the top outer side.
Fig 3: Loosening Corner Window Pane At Top
5. Unscrew fastening screws -2- on the inside.

Fig 4: Loosening Corner Window Pane On Inside
6. Pull corner window pane to the rear -A- and turn it 90° -B- .
7. Lift the corner window pane up -C- through the window channel and remove it.
Fig 5: Pulling Corner Window Pane Out To Rear

CAYENNE TURBO) > INSTALLING FRONT CORNER WINDOW PANE
Information
1. Guide the corner window pane into the window channel -D- and turn it 90° -E- .
Fig 1: Removing Corner Window Pane
2. Slide the corner window pane forward into position.

Fig 2: Positioning Corner Window Pane
3. Tighten fastening screw -1- at the top outer side to Tightening torque 4.5 Nm (3.5 ftlb.) .
Check that there is an equal gap with respect to the door frame so that the window
guide can be fitted.
Fig 3: Securing Corner Window Pane On Outside
4. Fit front window guide at the triangular window -3- .
Do not kink or bend the window guide out of shape during installation.
Fig 4: Identifying Front Window Guide
5. Fit window guide into the front corner window pane.

Fig 5: Fitting Front Window Guide
6. Fit window guide on the door window frame at the top and rear.
Fig 6: Fitting Rear Window Guide
7. Tighten inner fastening screw -2- to Tightening torque 4.5 Nm (3.5 ftlb.) .
Fig 7: Securing Corner Window Pane On Inside

CAYENNE TURBO) > SUBSEQUENT WORK
1. Install front door window. → Installing Front Door Window 644019 REMOVING AND
INSTALLING FRONT DOOR WINDOW
2. Install front door sub-frame. → INSTALLING FRONT DOOR SUB-FRAME
WM 642949 REWORKING (COATING) FRONT CORNER WINDOW PANE (CAYENNE,

TURBO) > GENERAL WARNING NOTES > WARNING NOTE FOR HYDROPHOBIC
WINDOW
NOTE: Smears
Impaired vision and dazzling

→ A coating may only be applied to the side windows.
→ Never apply a coating on the windscreen in particular.

TURBO) > PRELIMINARY WORK > CHECKING WINDOW GLASS
Information
The hydrophobic coating is extremely durable. If the hydrophobic characteristics are reduced, a
new coating can be applied to the windows without any special measures.
Check whether new coating needs to be applied by examining drops of water on the windows.
Spray on water using a water spray bottle with an atomiser and check the hydrophobic coating by
examining the drops.
Drop size - hydrophobic coating OK

Fig 1: Identifying Drop Size - Hydrophobic Coating (OK)
Drop size - coating worn.

Fig 2: Identifying Drop Size - Hydrophobic Coating (Worn)

TURBO) > PRELIMINARY WORK > PREPARING COMPONENTS FOR PROCESSING
Information
Mixed hydrophobic coating agent must be used within 24 hours!
1. Pour the entire contents of the Component 2 bottle into the Component 1 bottle.
2. Close the bottle tightly again and shake well immediately for at least three minutes.

TURBO) > PRELIMINARY WORK > CLEANING WINDOW SURFACES
Information
The window must be coated immediately after being polished.

1. Clean the window using commercially available glass cleaner.
2. Shake the polish well before use.
3. Dampen polishing cloths with water, apply polish and buff for several minutes.
4. Allow the film of polish to dry and then wipe it off completely.

TURBO) > APPLYING COATING
Information
The hydrophobic coating must not come into contact with water or other fluids for at least 30
minutes after applying the coating.
1. Apply hydrophobic coating agent as a flat liquid film and rub immediately and uniformly with a
paper towel.
2. A grey fog forms on the treated surface following application. Polish off this grey fog completely
using a new, dry and clean paper towel.
3. The coating must not come into contact with water or other fluids for at least 30 minutes.
1. Dried-on coating agent can be softened by rubbing with the moist cloth and can then be
rubbed off with a clean paper towel.
WM 644019 REMOVING AND INSTALLING FRONT DOOR WINDOW (CAYENNE,

TURBO) > TECHNICAL VALUES

screw for torque
mounting
pieces for door
window

Front door Adjustment 160 mm +/-2 mm
window value
opening
Guiding down door window

TURBO) > PRELIMINARY WORK
Information
Front door window
1. Guide front door window Adjustment value 160 mm +/-2 mm down from the upper edge of
the door.
Fig 1: Identifying Down Door Window Dimension
3. Remove cover for front door (B-pillar). → REMOVING B-PILLAR TRIM

TURBO) > REMOVING FRONT DOOR WINDOW
Information
1. Pull off front window guide close to the B-pillar. → Removing Front Window Guide -
2. Remove two stoppers -3- from the door sub-frame.
Fig 1: Removing Stoppers
3. Move the door window down until the screws on the mounting pieces for the window lifter are
visible through the openings.
Information
4. Loosen fastening screws -4- on the mounting pieces.

Fig 2: Loosening Mounting Pieces
5. Remove door window glass by pulling it upwards.

Fig 3: Removing Door Window

TURBO) > INSTALLING FRONT DOOR WINDOW
Information
1. Fit door window glass into the guide.

Fig 1: Fitting Door Window
2. Fit door window glass as far as it will go into the mounting pieces for the window lifter without
forcing it.
3. Check that the window glass is parallel to the window guide close to the B-pillar.
4. Tighten fastening screws on the mounting pieces to Tightening torque 6 Nm (4.5 ftlb.) .
Fig 2: Tightening Mounting Pieces
5. Fit two stoppers -3- in the door sub-frame.

Fig 3: Fitting Stoppers
6. Fit front window guide on the B-pillar. → Installing Front Window Guide

TURBO) > SUBSEQUENT WORK
1. Install cover for front door (B-pillar). → INSTALLING B-PILLAR TRIM
WM 644049 REWORKING (COATING) FRONT DOOR WINDOW (CAYENNE, CAYENNE

GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S HYBRID, CAYENNE TURBO) >
GENERAL WARNING NOTES > WARNING NOTE FOR HYDROPHOBIC WINDOW
NOTE: Smears
Impaired vision and dazzling

→ A coating may only be applied to the side windows.
→ Never apply a coating on the windscreen in particular.

PRELIMINARY WORK > CHECKING WINDOW GLASS
Information
The hydrophobic coating is extremely durable. If the hydrophobic characteristics are reduced, a
new coating can be applied to the windows without any special measures.
Check whether new coating needs to be applied by examining drops of water on the windows.
Spray on water using a water spray bottle with an atomiser and check the hydrophobic coating by
examining the drops.
Drop size - hydrophobic coating OK

Fig 1: Identifying Drop Size - Hydrophobic Coating (OK)
Drop size - coating worn.

Fig 2: Identifying Drop Size - Hydrophobic Coating (Worn)

PRELIMINARY WORK > PREPARING COMPONENTS FOR PROCESSING
Information
Mixed hydrophobic coating agent must be used within 24 hours!
1. Pour the entire contents of the Component 2 bottle into the Component 1 bottle.
2. Close the bottle tightly again and shake well immediately for at least three minutes.

PRELIMINARY WORK > CLEANING WINDOW SURFACES
Information
The window must be coated immediately after being polished.

1. Clean the window using commercially available glass cleaner.
2. Shake the polish well before use.
3. Dampen polishing cloths with water, apply polish and buff for several minutes.
4. Allow the film of polish to dry and then wipe it off completely.

APPLYING COATING
Information
The hydrophobic coating must not come into contact with water or other fluids for at least 30
minutes after applying the coating.
1. Apply hydrophobic coating agent as a flat liquid film and rub immediately and uniformly with a
paper towel.
2. A grey fog forms on the treated surface following application. Polish off this grey fog completely
using a new, dry and clean paper towel.
3. The coating must not come into contact with water or other fluids for at least 30 minutes.
1. Dried-on coating agent can be softened by rubbing with the moist cloth and can then be
rubbed off with a clean paper towel.
WM 644519 REMOVING AND INSTALLING FRONT WINDOW GUIDE (CAYENNE,

1. Remove trim strip for front door. → REMOVING TRIM STRIP FOR FRONT DOOR
2. Remove front B-pillar cover. → REMOVING B-PILLAR TRIM

TURBO) > REMOVING FRONT WINDOW GUIDE
Information
1. Pull the front window guide off the door frame.
If you intend to re-use the window guide, make sure it is not kinked or bent.
Fig 1: Pulling Off Window Guide At B-Pillar
2. Pull front window guide off the front corner window pane.
Fig 2: Pulling Window Guide Off Corner Window Pane
3. Remove front window guide completely.

TURBO) > INSTALLING FRONT WINDOW GUIDE
Information
To make it easier to install the window guide in the door channel area, this section of the window guide
must be moistened with a soapy solution.
Information
1. Fit front window guide at the triangular window -3- .
Fig 1: Identifying Front Window Guide
2. Fit window guide into the front corner window pane.

Fig 2: Fitting Front Window Guide
3. Fit window guide on the door window frame at the top and rear.
Check that the window guide is seated securely.

Fig 3: Pulling Window Guide At B-Pillar

1. Install front B-pillar cover. → INSTALLING B-PILLAR TRIM
2. Install trim strip for front door. → INSTALLING TRIM STRIP FOR FRONT DOOR
WM 644655 REPLACING REAR WINDOW GUIDE (EXCEPT CAYENNE, CAYENNE GTS,

1. Remove molding for rear door. → REMOVING REAR DOOR MOLDING

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR WINDOW GUIDE
Information
1. Unclip rear window guide.

Fig 1: Unclipping Rear Window Guide
2. Remove cover for rear door. → REMOVING COVER FOR REAR DOOR
3. Pull the window guide completely off the door frame.

Fig 2: Pulling Off Window Guide

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR WINDOW GUIDE
Information
To make it easier to install the window guide in the door channel area, this section of the window guide
must be moistened with a soapy solution.
Information
1. Position and fit the window guide on the rear door window frame at the top.
Fig 1: Fitting Window Guide
2. Install cover for rear door. → INSTALLING COVER FOR REAR DOOR
3. Fit window guide on door window frame.
Check that the window guide is seated securely.

Fig 2: Fitting Window Guide On Door Window Frame
4. Clip in rear window guide. Check that it is seated correctly.
Replace damaged clips.

Fig 3: Clipping In Rear Window Guide

1. Install molding for rear door. → INSTALLING REAR DOOR MOLDING
WM 644819 REMOVING AND INSTALLING FRONT WINDOW CHANNEL SEAL

CAYENNE TURBO) > REMOVING FRONT WINDOW CHANNEL SEAL > REMOVING
AND INSTALLING FRONT WINDOW CHANNEL SEAL
Information
1. Open the front door window fully.
2. Lift up the front window channel seal using a plastic wedge.

Fig 1: Lifting Up Window Channel Seal
3. Pull front window channel seal up at the rear end, starting at the sheetmetal flange.
4. Remove window channel seal -1- at the front.

Fig 2: Removing Window Channel Seal
WM 644819 REMOVING AND INSTALLING FRONT WINDOW CHANNEL SEAL

CAYENNE TURBO) > INSTALLING FRONT WINDOW CHANNEL SEAL
The front window channel seal is installed in reverse order to removal.
WM 644919 REMOVING AND INSTALLING FRONT INNER WINDOW BAY SEAL

WORK

FRONT INNER WINDOW BAY SEAL
Information
1. Pull front inner window bay seal off the front door panel.
Fig 1: Pulling Off Window Bay Seal

FRONT INNER WINDOW BAY SEAL
1. Fit front inner window bay seal on the door panel.

WORK
WM 645419 REMOVING AND INSTALLING FRONT WINDOW REGULATOR MOTOR

WORK

FRONT WINDOW REGULATOR MOTOR
NOTE: Voltage peaks
Information
Information
The end positions of the power windows are deleted from the control unit when the electric connectors
are disconnected and connected.
Fig 1: Identifying Front Window Regulator Motor Installation Position
1. Unscrew three fastening screws -1- for the front window regulator motor -2- .
Fig 2: Removing Screws Of Front Window Regulator Motor
2. Pull the front window regulator motor -2- out of the splines.
3. Release and pull off electric plug connection -3- (-a- ).


FRONT WINDOW REGULATOR MOTOR
1. The window regulator motor is installed in reverse order to removal.

WORK
2. Teach end positions of power window motor.
1. 2.1. Pull rocker switch and close window fully.
2. 2.2. Pull rocker switch again. (Upper end position is stored)

3. 2.3. Press rocker switch again. (The lower end position is stored) Power window
motor
3. Perform a function test.
WM 645819 REMOVING AND INSTALLING SWITCH FOR FRONT POWER WINDOWS

WORK
1. Remove armrest for front door panel. → REMOVING ARMREST FOR FRONT DOOR PANEL

SWITCH FOR FRONT POWER WINDOWS
NOTE: Voltage peaks
Information
Fig 1: Identifying Switch For Front Power Windows Installation Position
1. Unclip the complete switch -1- using a plastic wedge.

Fig 2: Pulling Out Switch
2. Release electric plug connection -a- and pull it off the switch -A- .

SWITCH FOR FRONT POWER WINDOWS
The switch for front power windows is installed in reverse order to removal.

WORK
1. Install armrest for front door panel. → INSTALLING ARMREST FOR FRONT DOOR PANEL
WM 646019 REMOVING AND INSTALLING REAR DOOR WINDOW (CAYENNE,

TURBO) > TECHNICAL VALUES

screw for torque
mounting
pieces for door
window
Rear door Adjustment 205 mm +/-2 mm

window value
opening
Guiding down rear door window

Information
Guide rear door window Adjustment value 205 mm +/-2 mm down from the upper edge of the door.
Fig 1: Identifying Rear Door Window Dimension

TURBO) > REMOVING REAR DOOR WINDOW
Information
Information
Cover add-on parts and adjacent areas.
Protect components against scratching and damage.
1. Pull off the rear window guide in the C-pillar area.

2. Remove inner channel strip by pulling it upwards.
3. Remove stoppers -3- from the door sub-frame.

4. Move the door window down until the clamping screws on the mounting pieces for the window
lifter are visible through the opening.
Information
5. Loosen fastening screws on the mounting pieces -4- .

Fig 2: Loosening Mounting Pieces For Door Window
6. Lift the door window up out of the guide and remove it.
Fig 3: Removing Door Window

TURBO) > INSTALLING REAR DOOR WINDOW
Information
1. Fit door window glass into the guide.

Fig 1: Fitting Door Window
2. Fit door window glass as far as it will go into the mounting pieces for the window lifter without
forcing it.
3. Check that the window glass is parallel to the window guide close to the B-pillar.
4. Tighten fastening screws on the mounting pieces -4- to Tightening torque 6 Nm (4.5 ftlb.) ,
working from the left.
Fig 2: Tightening Mounting Pieces For Door Window
5. Fit two stoppers -3- in the door sub-frame.

Fig 3: Fitting Stoppers
6. Insert rear window guide.
7. Insert inner channel strip

1. Install covers for rear door. → INSTALLING COVER FOR REAR DOOR
WM 646119 REMOVING AND INSTALLING REAR POWER WINDOW MOTOR (EXCEPT


CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR
POWER WINDOW MOTOR
Information
Information
The end positions of the power windows are deleted from the control unit when the electric connectors
are disconnected and connected.
Fig 1: Identifying Rear Power Window Motor Installation Position
NOTE: Voltage peaks

1. Unscrew three fastening screws -1- for the rear power window motor -2- .
Fig 2: Removing Power Window Motor
2. Pull rear power window motor -2- out of the toothing.
3. Release and pull off electric plug connection -3- (-a- ).


CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR
POWER WINDOW MOTOR
1. The rear power window motor is installed in reverse order to removal.

WM 646819 REMOVING AND INSTALLING REAR WINDOW CHANNEL SEAL

CAYENNE TURBO) > REMOVING REAR WINDOW CHANNEL SEAL
Information
1. Open the rear door window fully.
2. Carefully lift up the rear window channel seal using a plastic wedge.
Fig 1: Lifting Up Channel Seal
3. Pull rear window channel seal up off the sheetmetal flange, starting at the rear end.
4. Remove window channel seal -1- .

Fig 2: Removing Window Channel Seal
WM 646819 REMOVING AND INSTALLING REAR WINDOW CHANNEL SEAL

CAYENNE TURBO) > INSTALLING REAR WINDOW CHANNEL SEAL
The rear window channel seal is installed in reverse order to removal.
WM 646919 REMOVING AND INSTALLING INNER REAR WINDOW CHANNEL SEAL

CAYENNE TURBO) > PRELIMINARY WORK

CAYENNE TURBO) > REMOVING INNER REAR WINDOW CHANNEL SEAL
Information
1. Pull inner rear window channel seal off the door frame.
Fig 1: Pulling Off Window Channel Seal

CAYENNE TURBO) > INSTALLING INNER REAR WINDOW CHANNEL SEAL
1. Press inner rear window channel seal onto the door frame.

CAYENNE TURBO) > SUBSEQUENT WORK
WM 647519 REMOVING AND INSTALLING REAR SIDE WINDOW (EXCEPT CAYENNE,

Bracket for Tightening 9 Nm (6.5

luggage torque ftlb.)
compartment net
cover

1. Remove trim frame for side window. → REMOVING TRIM FRAME FOR SIDE WINDOW
2. Remove side trim panel for luggage compartment. → REMOVING LUGGAGE

COMPARTMENT TRIM (LUGGAGE COMPARTMENT COVER)

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TOOLS AND MATERIALS
D - Flashing knife, U-shaped 639.031.130.22
H - 2-component window bonding agent 000.043.300.94, contains set components H1-H8
H2 - Primer
H3 - Activator
H4 - Swab
H7 - Mixing nozzle
A - Removal kit for flush bonded windows VAG 1474 B, contains set components A1-A9
B - Cutting thread
A1 - Guide rail
A4 - Awl
A5 - Guide rail
A6 - Filler
A8 - Handle

Fig 2: Identifying Guide Rail, Handle And Spooling Device

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR SIDE WINDOW
1. Unscrew fastening screw -2- on the bracket for the luggage compartment net cover at the
D-pillar.
Fig 1: Loosening Bracket For Rear Luggage Net Cover
2. Loosen headliner in the area of the rear side window.
3. Lift trim at the side window -A- up slightly and pull it forward to remove it -B- .
Fig 2: Removing Trim On Side Window
1. Danger of cuts
2. Risk of eye injuries
4. Apply a bead of adhesive from the inside out to the lower C-pillar using the scratch awl.
Information

Information
1. When cutting out the side window, three fixing clips will also be cut through. Greater force
will need to be applied at these points.
5. Cut out the side window.
1. 5.1. Cut out the side window with the cutting-wire separating device.
Fig 3: Cutting Out Side Window
2. 5.2. Cut through three fixing clips -1- when removing.

Fig 4: Identifying Fixing Clips At Side Window

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > PREPARING WINDOW APERTURE
FOR INSTALLATION
1. Remove adhesive on the body.
Information
1. The surface coating of adhesive residue helps new adhesive to stick. Keep cut surfaces
clean and free of grease and do not clean with cleaning solution.
1. 1.1. When removing the adhesive residue with a cutter -C- and flashing knife -D- on
the body, ensure that a surface coating of adhesive remains.
Fig 1: Removing Adhesive Residue At Rear Side Window Aperture
2. Clean new paint areas or damage to the top coat paint in the non-visible area of the window
aperture in the body with cleaning solution -H1- and coat with primer -H2- .
Information
1. A drying time of at least 10 minutes must be observed between cleaning the bonding
surface and applying primer! Always ensure that no cleaning solution residues remain on
the body.
Fig 2: Identifying Paint Damage

Fig 3: Cleaning Paint Areas

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > PREPARING REAR SIDE WINDOW
FOR INSTALLATION > PREPARING REAR SIDE WINDOW FOR INSTALLATION
(RE-INSTALLATION ONLY)
Information
The removed side window can be reinstalled if there was no prior damage to the side window and
the side window was removed without damage.
1. Remove adhesive from the side window.
1. 1.1. Equip cutter -C- with flashing knife -D- and remove adhesive residue from the
side window, ensuring that a surface coating of adhesive remains.
Fig 1: Removing Adhesive From Side Window
Information
2. Apply activator to the bonding section of the side window.
1. 2.1. Following a long idle period, apply activator -H3- to the adhesive residue.
Fig 2: Applying Activator To Bonding Section Of Side Window

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > PREPARING REAR SIDE WINDOW
FOR INSTALLATION > PREPARING SIDE WINDOW FOR INSTALLATION (ONLY FOR
NEW REAR SIDE WINDOW)
1. 1.1. Clean the window with cleaning solution -H1- .
2. 1.2. Apply primer -H2- to the glass flange in the area of the marking.
Information


TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR SIDE WINDOW


Information
Information
Check stop bits.
Replace damaged or missing stop bits.
1. Prepare 2-component adhesive for processing. → 6X00IN PROCESSING OF PORSCHE

Information
2. Apply adhesive to the side window.
1. 2.1. Using a bonding gun -A- , apply 2-component adhesive to the side window
along the precoating or on the primer in the form of a triangular bead measuring -X =
approx. 15 mm- .
Fig 2: Applying Adhesive To Side Window
Information
1. When applying the adhesive, it is essential to ensure that the adhesive bead
overlaps by approx. 30 mm at the beginning and at the end.
3. Insert side window into the body.
1. 3.1. Affix suction cups to the side window.
2. 3.2. Guide the side window into the window aperture. At the same time, insert the
three fixing clips -1- into the holes in the bodyshell.
Fig 3: Identifying Fixing Clips For Side Window
3. 3.3. Press the side window uniformly onto the body.
4. 3.4. Only when reinstalling the old window (the three fixing clips -1- are not
available):
1. 3.4.1. Set a uniform gap dimension by moving the side window.
2. 3.4.2. Secure the side window to the top of the body with adhesive tape to
prevent it from slipping.
Fig 4: Securing Side Window
4. Clean the fields of vision.

Fig 5: Identifying Paint Damage Area
1. 4.1. Adhesive that has oozed out must be removed immediately and the affected
fields of vision must be cleaned using cleaning agent -H1- .
Fig 6: Cleaning Paint Areas
5. Tighten screws on the bracket for the luggage compartment net cover -2- to → Tightening
torque: 9 Nm (6.5 ftlb.) .
Fig 7: Securing Bracket For Rear Luggage Net Cover
6. Push on trim from front to back -arrow- .

Fig 8: Installing Trim On Side Window

1. Install trim frame for side window. → INSTALLING TRIM FRAME FOR SIDE WINDOW
2. Install luggage compartment trim. → INSTALLING SIDE TRIM PANEL FOR REAR LUGGAGE
COMPARTMENT
WM 647555 REPLACING REAR SIDE WINDOW (CAYENNE, CAYENNE GTS, CAYENNE

TURBO S, CAYENNE S, CAYENNE S HYBRID, CAYENNE TURBO) > TECHNICAL
VALUES
Bracket for Item 2 Tightening 9 Nm (6.5 ftlb.)

rear luggage torque
net cover
Screws securing holder for rear luggage net cover

TURBO S, CAYENNE S, CAYENNE S HYBRID, CAYENNE TURBO) > PRELIMINARY
WORK
1. Remove side trim panel for luggage compartment. → REMOVING SIDE TRIM PANEL FOR
2. Remove trim frame for side window. → REMOVING TRIM FRAME FOR SIDE WINDOW

TURBO S, CAYENNE S, CAYENNE S HYBRID, CAYENNE TURBO) > TOOLS AND
MATERIALS
D - Flashing knife, U-shaped 639.031.130.22
H - 2-component window bonding agent 000.043.300.94, contains set components H1 - H8
H2 - Primer
H3 - Activator
H4 - Swab
H7 - Mixing nozzle
A - Removal kit for flush bonded windows VAG 1474 B, contains set components A1 - A9
B - Cutting thread
A1 - Guide rail
A4 - Awl
A5 - Guide rail
A6 - Spatula
A8 - Handle


TURBO S, CAYENNE S, CAYENNE S HYBRID, CAYENNE TURBO) > REMOVING REAR
SIDE WINDOW
Information
The new side window is supplied complete with trim frame and trim.
1. Unscrew and remove fastening screw -2- on the bracket for the luggage compartment net
cover at the D-pillar.
2. Loosen headliner in the rear side window area.
3. On vehicles with antenna , disconnect electric plug connection.
4. Lift trim on the side window -A- up slightly and pull it forward to remove it -B- .
Fig 2: Removing Trim On Side Window
1. Danger of cuts
5. Pierce bead of adhesive on the lower C-pillar from the inside out using the scratch awl.
Information

Information
1. When cutting out the side window, fixing clips will also be cut through. Greater force will
be needed at these points.
6. Cut out the side window.
1. 6.1. Cut out the side window using a cutting wire.
2. 6.2. Cut through fixing clips -1- when removing the window.
Fig 3: Identifying Fixing Clips Installation Position

TURBO S, CAYENNE S, CAYENNE S HYBRID, CAYENNE TURBO) > PREPARING
WINDOW APERTURE FOR INSTALLATION
Information
1. 1.1. When removing adhesive residue with a cutter -C- and flashing knife -D- on the
body, ensure that a surface coating of adhesive remains.
Fig 1: Removing Adhesive Residue At Rear Side Window Aperture
2. Clean new paint surfaces and damage to the top coat paint in the non-visible area of the
window aperture in the body with cleaning solution -H1- and touch up with primer -H2- .
Information
the body.
Fig 2: Cleaning Window Aperture And Adhesive (Shown On Windscreen)

TURBO S, CAYENNE S, CAYENNE S HYBRID, CAYENNE TURBO) > PREPARING
WINDOW APERTURE FOR INSTALLATION > PREPARING SIDE WINDOW FOR
INSTALLATION
Information
A ventilation period of at least 10 minutes must be observed between the cleaning of the glass and
the application of primer! No cleaning solution residues may remain on the windscreen.
1. 1.1. Clean glass with cleaning solution.
2. 1.2. Apply primer to the marked area of the window flange.

Fig 1: Cleaning Side Window (Shown On Windscreen)

TURBO S, CAYENNE S, CAYENNE S HYBRID, CAYENNE TURBO) > INSTALLING
REAR SIDE WINDOW

Information
Check stop bits.


Information
2. Apply adhesive to the side window.
1. 2.1. Using a bonding gun -A- , apply 2-component adhesive to the side window
Fig 2: Applying Adhesive
Information
3. Insert side window into the body.
1. 3.1. Affix suction cups to the side window.
2. 3.2. Position side window in the cut-out. At the same time, insert the three fixing clips
-1- into the holes in the bodyshell.
Fig 3: Identifying Fixing Clips Installation Position
3. 3.3. Press the side window uniformly onto the body.
4. Clean visible areas.
Fig 4: Removing Emerging Adhesive Residues (Shown On Windscreen)
5. On vehicles with antenna , clip in electric plug connection.
6. Tighten screws on the bracket for the luggage compartment net cover -2- to Tightening
Fig 5: Securing Holder Screws For Rear Luggage Net Cover

TURBO S, CAYENNE S, CAYENNE S HYBRID, CAYENNE TURBO) > SUBSEQUENT
WORK
1. Remove side trim panel for luggage compartment. → REMOVING SIDE TRIM PANEL FOR
WM 648619 REMOVING AND INSTALLING REAR WINDOW (CAYENNE, CAYENNE

GTS, CAYENNE TURBO S, CAYENNE TURBO, CAYENNE S DIESEL) > PRELIMINARY
WORK
1. Remove tailgate trim panel. → REMOVING TRIM PANEL FOR TAILGATE
2. Remove wiper motor for rear window wiper system. → REMOVING WIPER MOTOR FOR
REAR WIPER SYSTEM
3. Remove rear spoiler. → REMOVING REAR SPOILER

GTS, CAYENNE TURBO S, CAYENNE TURBO, CAYENNE S DIESEL) > TECHNICAL
VALUES
Rear window Gap dimension 4.5 mm +/-0.8 mm

to side panel
(H1)
Rear window to side panel
Rear window Heat-insulating glass Gap dimension 2 mm +/-0.8 mm

to side panel (single-glazed safety
(H2) glass)
Rear window Insulating glass Gap dimension 1 mm +/-0.8 mm

to side panel (laminated safety
(H2) glass)
Rear window Gap dimension 4.5 mm +/-0.8 mm

to rear lid (H3)
Rear window to rear lid
Rear window Heat-insulating glass Gap dimension 3 mm +/-0.5 mm

to rear lid (H4) (single-glazed safety
glass)
Rear window Insulating glass Gap dimension 2 mm +/-0.5 mm

to rear lid (H4) (laminated safety
glass)

GTS, CAYENNE TURBO S, CAYENNE TURBO, CAYENNE S DIESEL) > TECHNICAL
VALUES > GAP DIMENSIONS OF REAR WINDOW

Fig 1: Identifying Gap Dimension Of Rear Window To Side Panel

Fig 2: Identifying Gap Dimension Of Side Panel To Rear Window

Fig 3: Identifying Gap Dimension Of Rear Window To Side Panel

Fig 4: Identifying Gap Dimension Of Rear Window To Lid

Fig 5: Identifying Gap Dimension Of Rear Lid To Window

Fig 6: Identifying Gap Dimension Of Rear Window To Lid

GTS, CAYENNE TURBO S, CAYENNE TURBO, CAYENNE S DIESEL) > REMOVING
REAR WINDOW
Information
Make sure not to damage the heated rear window connections when removing the glass with the
cutting wire.
Cut up to just before the connection.
Slacken the cutting wire.
Guide the cutting wire past the connection on the inside.

Fig 1: Cutting Wire Past Electric Connection

Counter with an awl.
Fig 2: Cutting Wire Past Electric Connection Using Awl
Make sure that the cutting wire does not press against the electric connection when separating the
glass.
Continue separating the window glass.
1. Remove rubber sleeve from the wiper arm.

2. Release and disconnect electric plug connections for antenna amplifier control unit. →
REMOVING CONTROL UNIT FOR ANTENNA AMPLIFIER
3. Release and disconnect electric plug connections on antenna amplifier. → REMOVING

4. Disconnect electric plug connections for rear window heating. → REMOVING WIRE
HARNESSES FOR TAILGATE
5. Release and disconnect electric plug connections on actuating cylinders for the rear lid. →
REMOVING ACTUATING CYLINDER FOR REAR LID
6. Fix plug connections for the antenna amplifier control unit and antenna amplifier in place on
the rear window using adhesive tape.
7. Affix adhesive tape -1- to the top right corner of the rear window at the rear lid.
Fig 3: Positioning Adhesive Tape
1. Danger of cuts

8. Apply a bead of adhesive from inside out in the area protected by the adhesive tape using the
scratch awl.
Information

9. Remove rear window using the cutting-wire separating device.

Fig 4: Removing Rear Window

GTS, CAYENNE TURBO S, CAYENNE TURBO, CAYENNE S DIESEL) > PREPARING
WINDOW APERTURE FOR INSTALLATION > PREPARING WINDOW APERTURE FOR
RE-INSTALLATION
Information
1. 1.1. When removing adhesive residue from the body using a cutter -C- and flashing
knife -D- , ensure that only a surface coating of adhesive remains.
Fig 1: Removing Adhesive Residue On Rear Lid
2. Clean new paint areas and damage to the top coat paint in the non-visible area of the window
aperture in the body with cleaning solution -H1- and touch up with primer -H2- .
Information
the body. ↓
Fig 2: Identifying Paint Damage Area

REAR WINDOW FOR INSTALLATION > PREPARING REAR WINDOW FOR
Information
The removed rear window can be reinstalled if there was no prior damage to the rear window and
the rear window was removed without damage.
Information
Replace the seal at the bottom of the rear window.
1. Remove adhesive from the rear window.
1. 1.1. Fit cutter -C- with the flashing knife -D- and remove adhesive residue from the
rear window, ensuring that a surface coating of adhesive remains.
Fig 1: Removing Adhesive From Rear Window
Information
2. Apply activator to the bonding section of the rear window.
1. 2.1. During long idle periods, apply activator -H3- to the remaining adhesive.
Fig 2: Applying Activator To Bonding Section Of Rear Window

REAR WINDOW FOR INSTALLATION > PREPARING REAR WINDOW FOR
INSTALLATION (NEW REAR WINDOW)
1. 1.1. Clean the window with cleaning solution -H1- .
2. 1.2. Apply primer -H2- to the marked area on the window flange.
Information


GTS, CAYENNE TURBO S, CAYENNE TURBO, CAYENNE S DIESEL) > INSTALLING
REAR WINDOW


Information
The removed rear window can be reinstalled if there was no prior damage to the rear window and
the rear window was removed without damage.
Information
Check stop bits.

Information
2. Apply adhesive to the rear window.
1. 2.1. Using a bonding gun -A- , apply 2-component adhesive to the rear window
Fig 2: Applying Adhesive To Rear Window
Information
Information
1. Two persons are needed to insert, position and secure the rear window.
3. Close the rear lid and insert the rear window into the body.
Fig 3: Inserting Rear Window
1. 3.1. Affix suction cups to the rear window.
2. 3.2. Guide the rear window into the window aperture at the top.
3. 3.3. Insert the rear window at the sides of the window aperture and lower it.
4. 3.4. Press the rear window uniformly into the body.
5. 3.5. Adjust the size of the gap by moving the rear window. → Technical Values
6. 3.6. Secure the rear window to the top of the rear lid with adhesive tape -1- to
prevent it from slipping.
Fig 4: Identifying Rear Window
4. Clean visible areas.

Fig 5: Identifying Adhesive Visible Areas
Fig 6: Removing Emerging Adhesive Residue
5. Fit rubber sleeve on the wiper arm.
6. Plug in and lock electric plug connections on actuating cylinders for the rear lid. →
INSTALLING ACTUATING CYLINDER FOR REAR LID
7. Plug in electric plug connections for rear window heating. → INSTALLING
8. Plug in and lock electric plug connections on the antenna amplifier. → INSTALLING ANTENNA
AMPLIFIER
9. Plug in and lock electric plug connections for the antenna amplifier control unit. →
INSTALLING CONTROL UNIT FOR ANTENNA AMPLIFIER

GTS, CAYENNE TURBO S, CAYENNE TURBO, CAYENNE S DIESEL) > SUBSEQUENT
WORK
1. Install rear spoiler. → INSTALLING REAR SPOILER
2. Install wiper motor for rear window wiper system. → INSTALLING WIPER MOTOR
3. Install tailgate trim panel. → INSTALLING TRIM PANEL FOR TAILGATE

Service Manual: 66 - EXTERIOR EQUIPMENT -- 92A CAYENNE
WM 660319 REMOVING AND INSTALLING FRONT SPOILER (CAYENNE, CAYENNE
Front spoiler to Tapping screw, Ø 5 Tightening 2 Nm (1.5 ftlb.)

front apron x 11 torque
Front spoiler Tapping screw, Ø 5 Tightening 2 Nm (1.5 ftlb.)

section to front x 11 torque
spoiler

2. Remove number plate cover. → Removing Number Plate Cover 668319 REMOVING AND
INSTALLING NUMBER PLATE COVER
3. Pull outside temperature sensor out of the front spoiler. → REMOVING OUTSIDE
TEMPERATURE SENSOR
4. Disconnect front right wire harness at the front spoiler. → REMOVING FRONT WIRE
HARNESS

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT SPOILER
1. Unscrew fastening screws -1- securing front spoiler to front apron at the left and right sides.
Fig 1: Loosening Front Spoiler On Front Apron
2. Remove front apron -1- from front spoiler -2- .
1. 2.1. Keep the front apron -1- tensioned towards the rear.
2. 2.2. Disengage locking mechanisms -3- in the area marked in yellow.
3. 2.3. Remove front apron -1- from the front spoiler -2- .
Fig 2: Removing Front Apron From Front Spoiler
3. Remove front spoiler sections -1- on the front spoiler -2- .
1. 3.1. Unscrew fastening screws -3- .
2. 3.2. Keep front spoiler section -1- tensioned towards the rear.
3. 3.3. Disengage locking mechanisms -arrows a- and pull front spoiler section -1- off
the front spoiler -2- (-arrow b- ).
Fig 3: Removing Front Spoiler Section At Left And Right Of Front Spoiler

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT SPOILER
1. Tighten fastening screws securing front spoiler section to front spoiler. Tightening torque 2
Nm (1.5 ftlb.)
2. Tighten fastening screws securing front spoiler to front apron at the left and right sides.
1. Insert outside temperature sensor into front spoiler until the outside temperature sensor
engages securely. INSTALLING OUTSIDE TEMPERATURE SENSOR
2. Secure front right wire harness on the front spoiler. → INSTALLING FRONT WIRE HARNESS
3. Install number plate cover. → Installing Number Plate Cover 668319 REMOVING AND
INSTALLING NUMBER PLATE COVER
WM 660419 REMOVING AND INSTALLING FRONT AIR GRILLE (CAYENNE, CAYENNE

2. Remove ventilation guide. → Removing Vent Guide 661319 REMOVING AND INSTALLING
VENTILATION GUIDE
3. Remove fog light. → REMOVING FOG LIGHTS
4. Remove auxiliary headlight. → REMOVING AUXILIARY HEADLIGHT
5. Disconnect front wire harness at the air grille. → REMOVING FRONT WIRE HARNESS

Fig 1: Identifying Air Grille Position

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT AIR GRILLE
Information
1. Remove trim panels -1- .
1. 1.1. Disengage locking mechanisms -arrows- .
2. 1.2. Pull trim panels -1- forward off the front air grille -2- .
Fig 1: Removing Trim Panels
2. Keep the front air grille -12- tensioned towards the rear, release locking lugs in the sequence
-1 to 11- and remove front air grille -12- .
Fig 2: Removing Front Air Grille

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT AIR GRILLE

1. Secure front wire harness at the air grille. → INSTALLING FRONT WIRE HARNESS
2. Install auxiliary headlight. → INSTALLING AUXILIARY HEADLIGHT
3. Install fog light. → INSTALLING FOG LIGHTS
4. Install ventilation guides. → Installing Vent Guide 661319 REMOVING AND INSTALLING
VENTILATION GUIDE

WM 660519 REMOVING AND INSTALLING RADIATOR GRILLE (CAYENNE, CAYENNE
2. Disconnect front wire harness at the radiator grille. → REMOVING FRONT WIRE HARNESS
3. Remove control unit for garage door opener. → REMOVING CONTROL UNIT FOR GARAGE
DOOR OPENER

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING RADIATOR GRILLE
1. Keep radiator grille tensioned towards the rear and release locking lugs.
Fig 1: Unclipping Radiator Grille
2. Remove radiator grille from the front apron.

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING RADIATOR GRILLE

1. Install control unit for garage door opener. → INSTALLING CONTROL UNIT FOR GARAGE
DOOR OPENER
2. Secure front wire harness at the radiator grille. → INSTALLING FRONT WIRE HARNESS
WM 660719 REMOVING AND INSTALLING FRONT LOGO (CAYENNE, CAYENNE GTS,

Logo Tightening 1 Nm (0.5 ftlb.) 0.3 Nm (0.2 ftlb.)

torque

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT LOGO

Fig 1: Loosening Logo Nuts

2. Take fastening nuts out of the opening in the front lid.
3. Remove logo -1- and base -2- in an upward direction.

Fig 2: Removing Logo And Base

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT LOGO
Information
The fastening nuts for the logo must always be replaced.
1. Position logo -1- and base -2- .

Fig 1: Fitting Front Logo Of Base
2. Replace fastening nuts -3- .
3. Screw in fastening nuts -3- and tighten to the specified tightening torque → Tightening
torque: 1 Nm (0.5 ftlb.) 0.3 Nm (0.2 ftlb.) .
WM 661319 REMOVING AND INSTALLING VENT GUIDE (CAYENNE, CAYENNE GTS,

1. Remove cover on spray nozzle for headlight cleaning system. → REMOVING COVER FOR
SPRAY NOZZLE
3. Remove spray nozzle for headlight cleaning system. → REMOVING SPRAY NOZZLE FOR
HEADLIGHT CLEANING SYSTEM

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING VENT GUIDE > REMOVING
VENTILATION GUIDE
Information
Fig 1: Identifying Ventilation Guide Position
1. Keep the ventilation guide -7- tensioned towards the rear and release locking lugs in the
sequence -1 to 6- .
Fig 2: Loosening Ventilation Guide From Front Air Grille
2. Press locking lugs up using a plastic wedge -a- and pull ventilation guide -1- to the rear and
out of the air grille -2- .
Fig 3: Removing Ventilation Guide

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING VENT GUIDE > INSTALLING
VENTILATION GUIDE

1. Install spray nozzle for headlight cleaning system. → INSTALLING SPRAY NOZZLE FOR
HEADLIGHT CLEANING SYSTEM
3. Install cover on spray nozzle for headlight cleaning system. → INSTALLING COVER FOR
SPRAY NOZZLE
WM 661819 REMOVING AND INSTALLING WING TRIM PANEL (CAYENNE, CAYENNE

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING WING TRIM PANEL
Information
1. Carefully unclip the wing trim panel -1- using a plastic wedge.
2. Remove wing trim panel -1- with fixing clips -3- .
3. Pull grommets -2- out of the body or from the fixing clips -3- .
Fig 1: Removing Wing Trim Panel
WM 661819 REMOVING AND INSTALLING WING TRIM PANEL (CAYENNE, CAYENNE

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING WING TRIM PANEL
Information
Information
Always fit new grommets before installing the wing trim panel.
Check fixing clips and replace if necessary.
1. If you intend to re-use the wing trim panel -2- , replace double-sided adhesive tape -1- at the
top of the wing trim panel -2- .
1. 1.1. Remove old adhesive tape -1- completely from the wing trim panel -2- .
2. 1.2. Carefully clean and de-grease the bonding area.
3. 1.3. Stick new double-sided adhesive tape -1- on the top of the wing trim panel -2-
and press it on firmly.
Fig 1: Identifying Double-Sided Adhesive Tape And Wing Trim Panel
2. Clip new grommets -1- into the body.
3. Check fixing clips -2- for damage and check that they are fitted securely in the wing trim panel
-3- .
4. Carefully clean and de-grease bonding area -arrow- of the double-sided adhesive tape -4- on
the wing.
5. Pull protective strip off the double-sided adhesive tape -4- .

6. Position wing trim panel -3- , clip it in and press firmly on the double-sided adhesive tape -4-
to secure it to the wing.
Fig 2: Installing Wing Trim Panel
WM 661919 REMOVING AND INSTALLING FRONT WHEEL COVER (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT WHEEL COVER
1. Detach front wheel housing liner at the wheel arch.
1. 1.1. Unscrew fastening screws along the wheel arch -1- .

2. Press wheel housing liner aside.
3. Unscrew fastening screws -1- at the front for the front apron.
Fig 2: Removing Front Wheel Cover
4. Unscrew fastening screws -2- on the wing.

Fig 3: Removing Rear Wheel Cover
5. Pull off retaining clip -3- .

Fig 4: Pulling Off Retaining Clip
6. Remove wheel cover.
1. 6.1. Unclip the wheel cover from the body evenly all the way around using an
assembly wedge -Arrows A, B and C- .
2. 6.2. Pull the wheel cover up and off -arrow D- .

Fig 5: Removing Wheel Cover
WM 661919 REMOVING AND INSTALLING FRONT WHEEL COVER (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT WHEEL COVER
The front wheel cover is installed in reverse order to removal.
WM 661919 REMOVING AND INSTALLING FRONT WHEEL COVER (OFFROAD)

hot-air blower Service WE Leister-

equipment Electron
erasing disc Commercially Nr.174 Pos.1
available tool

FRONT WHEEL COVER
1. Detach front wheel housing liner at the wheel arch.
1. 1.1. Unscrew fastening screws on the wheel arch -1- .

Fig 1: Detaching Wheel Housing Liner
2. Press the wheel housing liner aside.

3. Unscrew front fastening screws -1- on the front apron -2- .
Fig 2: Securing Screws Of Wheel Cover To Front Apron
4. Pull off safety clip -3- .

Fig 3: Pulling Off Safety Clip
5. Unscrew fastening screws -4- on the wing -5- .

Fig 4: Removing Screws Of Wheel Cover To Wing
6. Remove wheel cover on wing.
1. 6.1. Heat up wheel cover -6- on the wing -5- using a hot-air blower (hot-air blower
WE Leister-Electron ).
2. 6.2. Prise wheel cover -6- off the wing -5- evenly all the way around using an
assembly wedge -arrow- .
Fig 5: Removing Wheel Cover On Wing
7. Remove wheel cover on front apron.
1. 7.1. Heat up wheel cover -7- on the front apron -2- with a hot-air blower.
2. 7.2. Prise wheel cover -7- off the front apron -2- evenly all the way around using an
assembly wedge -arrow- .
Fig 6: Removing Wheel Cover On Front Apron
8. Clean bonding areas.
1. 8.1. Remove adhesive residue in the assembly area -A- with an erasing disc
(erasing disc Nr.174 Pos.1 ).
2. 8.2. Wipe off fitting area -A- with a cloth soaked in isopropanol.
Fig 7: Cleaning Bonding Areas

FRONT WHEEL COVER
Information
The object and room temperature must be at least 18° C for bonding the components.
The components must be bonded for at least 24 hours before washing the vehicle.
1. Fit wheel cover on front apron.
1. 1.1. Position wheel cover -7- on the front apron -2- and clip it in.
Fig 1: Fitting Wheel Cover On Front Apron
2. 1.2. Pull protective paper -9- off the adhesive tape.
3. 1.3. Press evenly and firmly on wheel cover in area of adhesive -7- with the ball of
your hand.
Fig 2: Pulling Off Protective Paper
2. Fit wheel cover on wing.
1. 2.1. Position wheel cover -6- on the wing -5- and clip it in.
Fig 3: Fitting Wheel Cover On Wing

your hand.
3. Screw in fastening screws -1- at the front of the front apron -2- .
Fig 5: Securing Screws Of Wheel Cover To Front Apron
4. Screw in fastening screws -4- on the wing -5- .

Fig 6: Removing Screws Of Wheel Cover To Wing
5. Fit safety clip -3- .

Fig 7: Fitting Safety Clip
6. Secure front wheel housing liner at the wheel arch.
1. 6.1. Screw in fastening screws along the wheel arch -1- .

WM 662219 REMOVING AND INSTALLING COVER FOR FRONT DOOR (CAYENNE,


screw for cover torque
Loosening cover

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING COVER FOR FRONT
DOOR
Information
2. Remove the stopper -1- at the inside of the door using a plastic wedge.
Fig 1: Removing Stopper
3. Unscrew and remove fastening screw -2- behind the stopper -1- .
Fig 2: Loosening Cover
4. Slide the cover -3- back as far as it will go.

Fig 3: Sliding Cover
5. Guide a plastic wedge in between the cover and door from above and unclip the cover.
Fig 4: Unclipping Cover
6. Swivel out cover in a downward direction and remove it.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING COVER FOR FRONT
DOOR
Information
Information
Check fastening clips and grommets for damage and replace them if necessary.
1. Slide fastening clips -5- into position.

Fig 1: Identifying Clips
2. Insert grommets -5- and position the cover -4- .

Fig 2: Positioning Cover
3. Engage cover at the bottom of the door.
4. Swivel the cover upwards and clip into place with the fastening clips.
5. Slide the cover -3- forward as far as it will go.

6. Tighten fastening screw on the cover to Tightening torque 2 Nm (1.5 ftlb.) .
7. Insert stopper -1- at the door.

Fig 4: Installing Stopper
WM 662619 REMOVING AND INSTALLING SIDE STEP (SKIDPAD) (EXCEPT


on step torque

1. Remove wing trim panel. → Removing Wing Trim Panel
2. Remove front wheel cover. → Removing Front Wheel Cover

Fig 1: Identifying Front Wheel Cover Area
3. Remove rear wheel cover. → Removing Rear Wheel Cover

Fig 2: Identifying Rear Wheel Cover Area
4. Remove cover for center underbody. → REMOVING COVER FOR CENTRE UNDERBODY
5. Open vehicle doors.

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING STEP
1. Remove cover strip on front step -1- .
1. 1.1. Unclip cover strip on front step -1- using an assembly wedge.↓
2. 1.2. First guide cover strip on front step -1- out to the rear -A- and then remove it by
pulling it outwards -B- .
Fig 1: Unclipping Front Cover Strip
2. Remove cover strip on rear step.
1. 2.1. Unclip cover strip on rear step -2- using an assembly wedge.
2. 2.2. Take off cover strip on rear step -2- , -C-

Fig 2: Unclipping Rear Cover Strip
3. Remove the step.
1. 3.1. Unscrew fastening nuts -3- on the step -4- .
2. 3.2. Remove the step -4- .

Fig 3: Removing Step

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING STEP
1. The step is installed in reverse order to removal.
2. Tighten fastening nuts on the step to → Tightening torque: 6 Nm (4.5 ftlb.) .

1. Install cover for center underbody. → INSTALLING COVER FOR CENTRE UNDERBODY
2. Secure rear wheel cover. → Installing Rear Wheel Cover
3. Secure front wheel cover. → Installing Front Wheel Cover
4. Close vehicle doors
5. Install wing trim panel. → Installing Wing Trim Panel

WM 663119 REMOVING AND INSTALLING DOOR ENTRY GUARD (CAYENNE,
Sill cover on Nut, M6 Tightening 6 Nm

body torque
Sill cover on One M6 nut on the Tightening 4 Nm

body wing strut torque
Removing sill cover

1. Remove wing trim panel. → Removing Wing Trim Panel 661819 REMOVING AND
INSTALLING WING TRIM PANEL
2. Remove front wheel cover. → Removing Front Wheel Cover 661919 REMOVING AND
INSTALLING FRONT WHEEL COVER
3. Remove rear wheel cover. → Removing Rear Wheel Cover 664519 REMOVING AND
INSTALLING REAR WHEEL COVER
4. Remove cover for center underbody. → REMOVING COVER FOR CENTRE UNDERBODY
5. Open vehicle doors.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING DOOR ENTRY GUARD
Information
1. Remove cover strip for door entry guard at the front -1- .
1. 1.1. Unclip cover strip for door entry guard at the front -1- using an assembly wedge
-B- .
2. 1.2. Guide cover strip for door entry guard at the front -1- to the rear -A- and
remove it.
Fig 1: Unclipping Cover Strip For Door Entry Guard At Front
2. Remove cover strip for door entry guard at the rear -2- .
1. 2.1. Unclip cover strip for door entry guard at the rear -2- using an assembly wedge.
2. 2.2. Remove cover strip for door entry guard at the rear -2- (-C- ).
Fig 2: Unclipping Cover Strip For Door Entry Guard At Rear
3. Remove door entry guard.
1. 3.1. Unscrew and remove fastening nuts -3- for the door entry guard -4- .
2. 3.2. Remove door entry guard -4- .

Fig 3: Removing Door Entry Guard

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING DOOR ENTRY GUARD
2. Tighten fastening nuts securing door entry guard to body.
1. 2.1. Tightening a fastening nut in the area of the front wing strut with Tightening
torque 4 Nm
2. 2.2. Tighten nine fastening nuts, front, middle and rear with Tightening torque 6
Nm
Fig 1: Removing Nuts For Sill Cover

1. Close vehicle doors.
2. Install cover for center underbody. → INSTALLING COVER FOR CENTRE UNDERBODY
3. Install rear wheel cover. → Installing Rear Wheel Cover 664519 REMOVING AND
INSTALLING REAR WHEEL COVER
4. Install front wheel cover. → Installing Front Wheel Cover 661919 REMOVING AND
INSTALLING FRONT WHEEL COVER
5. Install wing trim panel. → Installing Wing Trim Panel 661819 REMOVING AND INSTALLING
WING TRIM PANEL
WM 663319 REMOVING AND INSTALLING TRIM STRIP FOR FRONT DOOR

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING TRIM STRIP
FOR FRONT DOOR
Information
2. Carefully unclip trim strip -1- from the seal.

Fig 1: Unclipping Trim Strip
WM 663319 REMOVING AND INSTALLING TRIM STRIP FOR FRONT DOOR

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING TRIM STRIP
FOR FRONT DOOR
1. During installation, fit the trim strip at the top and press it down into the guide.
2. With the vehicle door closed, check that the trim strip and seal are seated correctly.
WM 663319 REMOVING AND INSTALLING TRIM STRIP FOR REAR DOOR (EXCEPT
CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING TRIM STRIP
FOR REAR DOOR
Information
2. Carefully unclip the trim strip -1- .

Fig 1: Unclipping Trim Strip
WM 663319 REMOVING AND INSTALLING TRIM STRIP FOR REAR DOOR (EXCEPT
CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING TRIM STRIP
FOR REAR DOOR
1. Position the trim strip and press it carefully into the guide.
2. With the vehicle door closed, check that the trim strip and seal are seated correctly.
WM 663319 REMOVING AND INSTALLING REAR DOOR MOLDING (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR DOOR MOLDING
Information
2. Carefully unclip molding -1- .

Fig 1: Unclipping Molding
WM 663319 REMOVING AND INSTALLING REAR DOOR MOLDING (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR DOOR MOLDING
1. Position molding and press it carefully into the guide.
2. With the vehicle door closed, check that the molding and seal are seated correctly.
WM 664219 REMOVING AND INSTALLING COVER FOR REAR DOOR (CAYENNE,


screw for cover torque
Loosening cover

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING COVER FOR REAR
DOOR
Information
2. Remove the stopper -1- at the inside of the door using a plastic wedge.
Fig 1: Removing Stopper
3. Unscrew and remove fastening screw -2- behind the stopper -1- .
Fig 2: Loosening Cover
4. Slide the cover -3- back as far as it will go.

Fig 3: Sliding Back Cover
5. Insert a plastic wedge under the door cover from above and unclip the cover.
Fig 4: Unclipping Cover
6. Swivel out cover in a downward direction and remove it.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING COVER FOR REAR
DOOR
Information
Check fastening clips and grommets for damage and replace them if necessary.
1. Insert grommets -4- .

Fig 1: Inserting Grommets
2. Slide fastening clips -5- into position.

Fig 2: Identifying Clips
3. Engage cover at the bottom of the door.
4. Swivel cover upwards and clip it in.
5. Slide the cover -3- forward as far as it will go.

6. Tighten fastening screw on the cover to Tightening torque 2 Nm (1.5 ftlb.) .
7. Insert stopper.
WM 664419 REMOVING AND INSTALLING COWL PANEL COVER (CAYENNE,

1. Remove rear profile seal for front lid. → REMOVING FRONT LID SEAL
2. Remove both wiper arms. → REMOVING WIPER ARMS

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING COWL PANEL COVER
1. Lift left cover flap -A- and unclip it by pulling it forward ↓-B- .
Fig 1: Unclipping Left Cover Flap
2. Lift right cover flap -A- and unclip it by pulling it forward -B- .
Fig 2: Unclipping Right Cover Flap
3. Lift cowl panel cover -1- at the sides using a plastic wedge -arrow- and unclip it from the
attachment strip -2- .
Fig 3: Unclipping Cowl Panel Cover

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING COWL PANEL COVER
The cowl panel cover is installed in reverse order to removal.

1. Install both wiper arms. → INSTALLING WIPER ARMS
2. Install rear profile seal for front lid. → INSTALLING FRONT LID SEAL
WM 664519 REMOVING AND INSTALLING REAR WHEEL COVER (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR WHEEL COVER
1. Unscrew lower fastening screw -1- .

Fig 1: Loosening Rear Wheel Cover
2. Unscrew fastening screws -1- from the wheel housing liner -2- .
3. Press the wheel housing liner -2- aside -A- and unscrew the fastening screw -3- and
fastening nut -4- from the inside.
Fig 3: Loosening Front Wheel Cover
4. Pull off retaining clip -5- .

Fig 4: Pulling Off Retaining Clip
5. Remove wheel cover.
1. 5.1. Unclip wheel cover from the body evenly all the way around using an assembly
wedge -arrows A, B and C- .
2. 5.2. Pull the wheel cover up and off -arrow D- .

Fig 5: Removing Wheel Cover
WM 664519 REMOVING AND INSTALLING REAR WHEEL COVER (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR WHEEL COVER
The wheel cover is installed in reverse order to removal.
WM 664519 REMOVING AND INSTALLING REAR WHEEL COVER (OFFROAD)

hot-air blower Service WE Leister-

equipment Electron
erasing disc Commercially Nr.174 Pos.1
available tool

REAR WHEEL COVER
1. Unscrew bottom fastening screw -1- .

Fig 1: Removing Rear Wheel Cover
2. Unscrew fastening screws -1- on the wheel housing liner -2- .

Fig 2: Releasing Wheel Housing Liner
3. Press the wheel housing liner -2- aside -A- and unscrew the fastening screw -3- and
Fig 3: Removing Front Wheel Cover
4. Pull off safety clip -5- .

Fig 4: Pulling Off Safety Clip
5. Remove wheel cover at the door.
1. 5.1. Heat up wheel cover -8- at the door -9- using a hot-air blower.
2. 5.2. Prise wheel cover -8- off evenly all the way around at the door -9- using an
assembly wedge.
Fig 5: Removing Wheel Cover At Door
6. Remove wheel cover on rear apron.
1. 6.1. Heat up wheel cover -10- on the rear apron -11- using a hot-air blower.
2. 6.2. Prise wheel cover -10- off the rear apron -11- evenly all the way around using
an assembly wedge -arrow- .
Fig 6: Removing Wheel Cover On Rear Apron
7. Remove wheel cover on the side panel.
1. 7.1. Heat up wheel cover -6- on the side panel -7- using a hot-air blower (hot-air
blower WE Leister-Electron ).
2. 7.2. Prise wheel cover -6- off the side panel -7- evenly all the way around, starting
from the rear, using an assembly wedge -arrow- .
Fig 7: Removing Wheel Cover On Side Panel
8. Clean bonding areas.
1. 8.1. Remove adhesive residue in the assembly area -A- with an erasing disc
(erasing disc Nr.174 Pos.1 ).
2. 8.2. Wipe off fitting area -A- with a cloth soaked in isopropanol.
Fig 8: Cleaning Bonding Area

REAR WHEEL COVER
Information
The object and room temperature must be at least 18° C for bonding the components.
The components must be bonded for at least 24 hours before washing the vehicle.
1. Fit the wheel cover to the side panel.
1. 1.1. Position wheel cover -6- on the side panel -7- and clip it in.
Fig 1: Fitting Wheel Cover To Side Panel

your hand.
2. Fit wheel cover at the door.
Information
1. Start positioning the wheel cover at the top.
2. Align the cover flush with the edge of the door.

Fig 3: Identifying Protective Paper And Wheel Cover
2. 2.2. Position wheel cover -8- at the door -9- .
your hand.
Fig 4: Fitting Wheel Cover At Door
3. Fit wheel cover on rear apron.
1. 3.1. Position wheel cover -10- on the rear apron -11- and clip it in.
Fig 5: Fitting Wheel Cover On Rear Apron

your hand.
4. Screw in bottom fastening screw -1- .

Fig 7: Securing Rear Wheel Cover
5. Fit safety clip -5- .

Fig 8: Fitting Safety Clip
6. Press the wheel housing liner -2- aside -A- and screw in the fastening screw -3- and
Fig 9: Securing Front Wheel Cover
7. Screw in fastening screws -1- for the wheel housing liner -2- .
WM 664755 REPLACING REAR LID MOLDING (EXCEPT CAYENNE, CAYENNE GTS,


hot-air blower, Service WE 1119
Leister- equipment
Electron/V.A.G.
1416
WM 664755 REPLACING REAR LID MOLDING (EXCEPT CAYENNE, CAYENNE GTS,

CAYENNE S DIESEL, CAYENNE (3.0)) > REPLACING REAR LID MOLDING
1. Remove molding for rear lid.
1. 1.1. Heat molding using hot-air blower, Leister-Electron/V.A.G. 1416 WE 1119 .
2. 1.2. Carefully detach molding -1- using a plastic wedge -2- and remove it from the
rear lid -3- .
Fig 1: Removing Molding
2. Install rear lid molding.
1. 2.1. Clean bonding surface with isopropanol.
2. 2.2. Pull protective film off the bonding area on the molding.
3. 2.3. Position the molding -1- using centering pins -2- and press it on the lid -3- .
Fig 2: Installing Molding For Rear Lid
4. 2.4. Press the molding firmly onto the rear lid, starting from the middle and moving
outwards.
WM 664819 REMOVING AND INSTALLING TRIM PANEL FOR REAR LID (HANDLE
STRIP) (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S,
TECHNICAL VALUES
Fastening nuts Tightening 6 Nm (4.5 ftlb)

for handle strip torque
PRELIMINARY WORK
1. Remove lower part of rear trim panel. → REMOVING TRIM PANEL FOR TAILGATE
2. Remove number plate light. → REMOVING NUMBER PLATE LIGHT

3. Remove release for rear lid. → REMOVING RELEASE FOR REAR LID
REMOVING TRIM PANEL FOR REAR LID (HANDLE STRIP)
1. Loosen fastening nuts for handle strip -1- .

Fig 1: Identifying Fastening Nuts For Handle Strip
2. Loosen bonding on handle strip by pressing with the socket wrench -arrow against the
fastening nuts.
Fig 2: Detaching Handle Strip
3. Screw off fastening nuts for handle strip.
4. Carefully remove the handle strip from the rear lid.
INSTALLING TRIM PANEL FOR REAR LID (HANDLE STRIP)
1. Replace bonding on handle strip if necessary.
2. The handle strip is installed in reverse order to removal.
3. Tighten the fastening nuts for the handle strip to → Tightening torque: 6 Nm (4.5 ftlb) .
SUBSEQUENT WORK
1. Install release for rear lid. → INSTALLING RELEASE FOR REAR LID
2. Install number plate lights. → INSTALLING NUMBER PLATE LIGHT
3. Install lower part of rear trim panel. → INSTALLING TRIM PANEL FOR TAILGATE
WM 665055 REPLACING REAR LOGO (EXCEPT CAYENNE, CAYENNE GTS,

Logo template - Special tool 9864

E2
Interchangeable Special tool 9864/1

insert - E2

insert - E2 S
insert - E2turbo

insert - E2turbo
S

insert - E2 S
hybrid

insert - E2 GTS
hot-air blower Commercially v.a.g 1416
available tool

Temperature Nominal value +15°C
Humidity Nominal value 50 % +/-10 %
Standing time Nominal value 72 h

CAYENNE S DIESEL, CAYENNE (3.0)) > REPLACING REAR LOGO
1. Heat the rear lid.
1. 1.1. Heat the rear lid close to the logo -1- using the hot-air blower v.a.g 1416 -2- .
Fig 1: Heating Rear Lid
2. Remove logo.
1. 2.1. Insert a plastic spatula -2- under the logo -1- and prise off the logo -2- .
Fig 2: Removing Logo
3. Clean the rear lid.
1. 3.1. Loosen adhesive residue on the rear lid using silicone remover and remove it.

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR LOGO WITHOUT MODEL
DESIGNATION
Information
Carefully clean any dirt, grease, wax and other impurities off the installation area of the body using
isopropanol.
Always use a clean cloth.
The room and object temperature must be at least → Nominal value: +15°C .
Humidity should be → Nominal value: 50 %+/-10 % .
Do not touch the bonding surface again after removing the protective paper.
Wear clean gloves during the bonding process in order to guarantee adequate adhesion.
The parts must have been bonded for at least → Nominal value: 72 h before washing the vehicle
in a car wash.
1. Logo template - E2 9864 -1- must be positioned on the vehicle.
1. 1.1. Position the edges -2, 3- of the logo template -1- flush with the rear lid.
2. 1.2. Press logo template -1- firmly onto the rear lid.
Fig 1: Positioning Logo Template
2. Remove protective paper from the logo -1- .
3. Align the logo -1- at the lower edge -arrow- in the logo template -2- and press it on firmly.
Fig 2: Aligning Logo At Lower Edge
4. Remove logo template from the vehicle.

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR LOGO WITH MODEL
DESIGNATION
1. Insert the correct interchangeable insert -1- into logo template - E2 9864 -2- .
The following interchangeable inserts can be selected: Interchangeable insert - E2 9864/1 ,

Interchangeable insert - E2 S 9864/2 , Interchangeable insert - E2turbo 9864/3 ,
Interchangeable insert - E2turbo S 9864/4 , Interchangeable insert - E2 S hybrid 9864/5 ,
Interchangeable insert - E2 GTS 9864/6
Fig 1: Preparing Logo Template
2. Position the logo template -1- on the vehicle.
1. 2.1. Position the edges -2, 3- of the logo template -1- flush with the rear lid.
2. 2.2. Press logo template -1- firmly onto the rear lid.
Fig 2: Positioning Logo Template
3. Remove protective paper from the logo -1- .
4. Align the logo -1- using the logo template -2- and press it on firmly.
Fig 3: Aligning Logo
WM 665419 REMOVING AND INSTALLING SWITCH FOR REAR-VIEW MIRROR

WORK

SWITCH FOR REAR-VIEW MIRROR
NOTE: Voltage peaks
Information
Fig 1: Identifying Switch For Rear-View Mirror Position
1. Unclip the complete switch -1- using a plastic wedge.

Fig 2: Pulling Out Switch
2. Release electric plug connection -a- and pull it off the switch for power windows -A- .

SWITCH FOR REAR-VIEW MIRROR
The switch for rear-view mirror is installed in reverse order to removal.

WORK
WM 665819 REMOVING AND INSTALLING REAR SPOILER (CAYENNE, CAYENNE

Fastening nut Item 2 Tightening 6 Nm (4.5 ftlb.)

for rear spoiler torque
Positioning rear spoiler

1. Remove trim panel for rear lid at the center. → REMOVING TRIM PANEL FOR REAR LID

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR SPOILER
1. Release electric plug connection for the antenna cable -a- and disconnect it -B- .
Fig 1: Disconnecting Plug Connection For Antenna
2. Remove caps -1- .
3. Screw off fastening nuts from the inside -2- .
4. Unscrew fastening screws from the inside -3- .
5. Use a plastic wedge to unclip the rear spoiler in direction of arrow -4- .
Fig 2: Loosening Rear Spoiler
6. Remove rubber sleeves -2, 3- from the antenna and additional brake light from the rear lid -1-
and pull out antenna cable.
7. Release electric plug connection -1- for the additional brake light -a- and disconnect it
-arrow- .
8. Remove rear spoiler.

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR SPOILER
1. Position rear spoiler.
2. Plug in electric plug connection -1- for additional brake light -arrow- .
Fig 1: Plugging Electric Plug Connection
3. Guide in antenna cable and fit rubber sleeves -2, 3- from the antenna and additional brake
light into the rear lid -1- .
4. Clip in rear spoiler -4- in direction of arrow.
6. Tighten fastening nuts on rear spoiler to Tightening torque 6 Nm (4.5 ftlb.) .
7. Fit caps -1- .

Fig 3: Positioning Rear Spoiler
8. Connect electric plug connection for the antenna cable -arrow- until it engages securely.

1. Install trim panel for rear lid at the center. → INSTALLING TRIM PANEL FOR REAR LID
WM 666119 REMOVING AND INSTALLING MOLDING FOR WINDSCREEN (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING MOLDING FOR
WINDSCREEN
Information
1. Unclip molding -1- from top to bottom -arrow- .

Fig 1: Removing Molding For Windscreen
WM 666119 REMOVING AND INSTALLING MOLDING FOR WINDSCREEN (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING MOLDING FOR
WINDSCREEN
1. Fit molding -1- at the top and clip it into the attachment strip from top to bottom -arrow- .
Fig 1: Installing Molding For Windscreen
WM 666719 REMOVING AND INSTALLING TRIM FRAME FOR SIDE WINDOW

Information
The trim frame can only be replaced if the side window is removed without damage.
There is more work involved in installing the old window.
Check gap and joint dimensions when installing the old side window.
1. Remove rear side window. → REMOVING REAR SIDE WINDOW

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING TRIM FRAME
FOR SIDE WINDOW
Information
Fig 1: Identifying Trim Frame For Side Window Position
1. Carefully unclip clips -2- on the trim frame -1- using a plastic wedge.
Fig 2: Removing Trim Frame For Side Window

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING TRIM FRAME
FOR SIDE WINDOW
Information
1. Clip in clips -2- for the trim frame -1- into the side window.
1. 1.1. Check that the trim frame is seated correctly.

Fig 1: Installing Trim Frame For Side Window

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > PREPARING REAR SIDE
WINDOW FOR INSTALLATION > PREPARING REAR SIDE WINDOW FOR
Information
1. Remove adhesive from the side window.
1. 1.1. Make sure not to damage the window
2. 1.2. Equip cutter -C- with flashing knife -D- and remove adhesive residue from the
side window, ensuring that a surface coating of adhesive remains.
Fig 1: Removing Adhesive From Side Window
Information
1. The remaining adhesive helps new adhesive to stick. Keep cut surfaces clean and free of
grease and do not clean with cleaning solution.
2. Apply activator to the bonding section of the side window.
1. 2.1. During long idle periods, apply activator -H3- to the remaining adhesive.
Fig 2: Applying Activator To Bonding Section Of Side Window

1. Install rear side window. → INSTALLING REAR SIDE WINDOW
2. Push on trim from front to rear -arrow- .

Fig 1: Installing Trim On Side Window
WM 667819 REMOVING AND INSTALLING MIRROR GLASS (CAYENNE, CAYENNE

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING MIRROR GLASS
Information
1. Press the outside of the mirror glass inwards -A- and carefully pull it out on the inside -B- .
Fig 1: Removing Mirror Glass
2. Unclip electric plug connection -2- from the bracket -3- .
4. Disconnect electric plug connections -4- from the mirror glass.

WM 667819 REMOVING AND INSTALLING MIRROR GLASS (CAYENNE, CAYENNE

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING MIRROR GLASS

WM 667919 REMOVING AND INSTALLING HOUSING FOR REARVIEW MIRROR
PRELIMINARY WORK FOR REMOVING AND INSTALLING UPPER PART OF HOUSING
1. Remove mirror glass. → Removing Mirror Glass

PRELIMINARY WORK FOR REMOVING AND INSTALLING LOWER PART OF
HOUSING
1. Remove rearview mirror. → Removing Rearview Mirror
2. Remove mirror adjusting motor. → Removing Mirror Adjusting Motor

PRELIMINARY WORK FOR REMOVING AND INSTALLING BASE HOUSING
1. Remove rearview mirror. → Removing Rearview Mirror
2. Remove mirror adjusting motor. → Removing Mirror Adjusting Motor

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING HOUSING
FOR REARVIEW MIRROR > REMOVING UPPER PART OF HOUSING FOR REARVIEW
MIRROR
Information
-1- - Upper part of housing
-2- - Lower part of housing
-3- - Front part of base housing
-4- - Rear part of base housing

Fig 1: Identifying Upper Part Of Housing
2. Release locks -5- using a screwdriver.

Fig 2: Identifying Mounting Screw For Upper Part Of Housing
3. Insert a plastic wedge -7- from outside -A- between the upper part of the housing -1- and the
lower part of the housing -2- and carefully unclip it by pressing it towards the front -B- .
4. Take off upper part of housing -1- by pulling it upwards -C- .

Fig 3: Removing Upper Part Of Housing

FOR REARVIEW MIRROR > REMOVING BASE HOUSING FOR REARVIEW MIRROR
1. Remove seal -6- at the bottom at the base housing.

Fig 1: Removing Seal For Base Housing
2. Unscrew fastening screw -7- in the base section.

Fig 2: Identifying Fastening Screw In Base Section
3. Release the locks -8- between the front part -3- and the rear part of the base housing -4-
using a screwdriver and take off front part of base housing.
Fig 3: Identifying Front Part, Locks And Base Housing
4. Move mirror into folding position and take off rear part of base housing.

FOR REARVIEW MIRROR > REMOVING LOWER PART OF HOUSING FOR REARVIEW
MIRROR
1. Unclip lock -9- and pull the lower part of the housing downwards.
Fig 1: Identifying Lower Part Of Housing
2. Guide lower part of housing downwards and release locks -10- .


CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING HOUSING
FOR REARVIEW MIRROR > INSTALLING UPPER PART OF HOUSING FOR REARVIEW
MIRROR
1. Insert the locks -5- for the upper part of the housing -1- into the lower part of the housing -2-
and carefully clip them in by pressing in the direction of the arrow.
Fig 1: Installing Upper Part Of Housing
2. Screw in fastening screw -6- .

Fig 2: Securing Upper Part Of Housing

FOR REARVIEW MIRROR > INSTALLING BASE HOUSING FOR REARVIEW MIRROR
1. Move mirror into folding position and insert rear part of base housing.
2. Assemble front part -3- and rear part of base housing -4- and clip them in.
Fig 1: Assembling Base Housing
3. Screw fastening screw -7- into the base section.

Fig 2: Identifying Fastening Screw In Base Section
4. Insert seal -6- at the bottom at the base housing.

Fig 3: Installing Seal For Base Housing

FOR REARVIEW MIRROR > INSTALLING LOWER PART OF HOUSING
1. Engage lock -9- and press the lower part of the housing upwards.
Fig 1: Removing Lower Part Of Housing
2. Guide lower part of housing upwards and engage locks -10- .


SUBSEQUENT WORK FOR REMOVING AND INSTALLING UPPER PART OF HOUSING
1. Install mirror glass. → Installing Mirror Glass

SUBSEQUENT WORK FOR REMOVING AND INSTALLING LOWER PART OF
HOUSING
2. Install rear-view mirror. → Installing Rearview Mirror
3. Install mirror adjusting motor. → Installing Mirror Adjusting Motor

SUBSEQUENT WORK FOR REMOVING AND INSTALLING BASE HOUSING
2. Install rear-view mirror. → Installing Rearview Mirror
3. Install mirror adjusting motor. → Installing Mirror Adjusting Motor
WM 667919 REMOVING AND INSTALLING REAR-VIEW MIRROR HOUSING (UPPER

PART) (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S
WORK
1. Remove mirror glass. → Removing Mirror Glass 667819 REMOVING AND INSTALLING
MIRROR GLASS

REAR-VIEW MIRROR HOUSING (UPPER PART)
Information
2. Move upper part of housing -2- in the lower, front area -arrows- forward and up at the same
time and unclip at lower part of housing -3- .
3. Unclip upper part of housing -2- all the way around and lift it up as far as required until the
electric plug connections are accessible.
Fig 1: Removing Upper Part Of Housing
4. Disconnect electric plug connections -1- .
5. Remove upper part of housing -2- .

Fig 2: Identifying Electric Plug Connections

REAR-VIEW MIRROR HOUSING (UPPER PART)

WORK
1. Install mirror glass. → Installing Mirror Glass 667819 REMOVING AND INSTALLING MIRROR
GLASS
WM 667919 REMOVING AND INSTALLING REAR-VIEW MIRROR HOUSING (LOWER

WORK
1. Remove rear-view mirror housing (upper part). → Removing Rear-View Mirror Housing (Upper
Part) 66791901 REMOVING AND INSTALLING REAR-VIEW MIRROR HOUSING (UPPER
PART)
2. Remove rear-view mirror. → Removing Rearview Mirror 668919 REMOVING AND

INSTALLING REAR-VIEW MIRROR
3. Remove rear-view mirror housing (trim panel for mirror base). → Removing Rear-View Mirror
Housing (Trim Panel For Mirror Base) 66791905 REMOVING AND INSTALLING REAR-VIEW
MIRROR HOUSING (TRIM PANEL FOR MIRROR BASE)

REAR-VIEW MIRROR HOUSING (LOWER PART)
Information
2. Unclip area lighting -2- from lower part of housing -3- .
3. Guide out lower part of housing -3- at the wire harness -4- and remove lower part of housing
-3- .

REAR-VIEW MIRROR HOUSING (LOWER PART)

WORK
1. Install rear-view mirror housing (upper part). → Installing Rear-View Mirror Housing (Upper
PART)
2. Install rear-view mirror. → Installing Rearview Mirror 668919 REMOVING AND INSTALLING
REAR-VIEW MIRROR
3. Install rear-view mirror housing (trim panel for mirror base). → Installing Rear-View Mirror
Housing (Trim Panel For Mirror Base) 66791905 REMOVING AND INSTALLING REAR-VIEW
MIRROR HOUSING (TRIM PANEL FOR MIRROR BASE)
WM 667919 REMOVING AND INSTALLING REAR-VIEW MIRROR HOUSING (TRIM

PANEL FOR MIRROR BASE) (CAYENNE, CAYENNE GTS, CAYENNE TURBO S,
1. Remove rear-view mirror housing (upper part). → Removing Rear-View Mirror Housing (Upper
PART)
2. Remove rear-view mirror. → Removing Rearview Mirror 668919 REMOVING AND

INSTALLING REAR-VIEW MIRROR

CAYENNE (3.0)) > REMOVING REAR-VIEW MIRROR HOUSING (TRIM PANEL FOR
MIRROR BASE)
2. Remove seal -2- .
3. Remove trim panel -3- in a downward direction and guide it out at the mirror support and wire
harness.
4. Remove seal -4- .

Fig 1: Identifying Trim Panel For Mirror Base

CAYENNE (3.0)) > INSTALLING REAR-VIEW MIRROR HOUSING (TRIM PANEL FOR
MIRROR BASE)

1. Install rear-view mirror. → Installing Rearview Mirror 668919 REMOVING AND INSTALLING
REAR-VIEW MIRROR
2. Install rear-view mirror housing (upper part). → Installing Rear-View Mirror Housing (Upper
PART)
WM 668219 REMOVING AND INSTALLING MIRROR ADJUSTING MOTOR (EXCEPT

1. Remove mirror glass. → Removing Mirror Glass

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING MIRROR
ADJUSTING MOTOR
NOTE: Voltage peaks
Information
Fig 1: Identifying Mirror Adjusting Motor Position
1. Unscrew three fastening screws -1- for the mirror adjusting motor.
Fig 2: Removing Mirror Adjusting Motor
2. Pull off electric plug connection.

Fig 3: Pulling Off Plug Connection

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING MIRROR
ADJUSTING MOTOR

2. Place mirror adjusting motor in installation position.
3. Secure mirror adjusting motor with three fastening screws -1- .

Fig 2: Installing Mirror Adjusting Motor

WM 668319 REMOVING AND INSTALLING NUMBER PLATE COVER (EXCEPT

Drill bit for Diameter 8 mm

number plate
cover

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING NUMBER
PLATE COVER
1. Remove number plate.
2. Press in expansion rivet pins and pull out the expansion rivets -1- .
Fig 1: Removing Number Plate Cover
3. Remove number plate cover.

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING NUMBER
PLATE COVER
Information
Additional assembly operations must be performed when replacing the front apron since the
replacement part is supplied without bore holes.
1. Drill holes for number plate cover in the front apron.
1. 1.1. Cut off the centering mandrel -3- on the inside of the number plate cover.
Fig 1: Cutting Off Centering Mandrel
2. 1.2. Stick a strip of adhesive tape that can be written on -1- approximately in the
center of the front apron.
Fig 2: Pressing Adhesive Tape Of Front Apron
3. 1.3. Find the center between the vertical shafts on the air grille and mark this spot on
the adhesive tape -1- affixed to the front apron -arrow- .
4. 1.4. Approximately in the center of the front number plate cover -1- , affix a strip of
adhesive tape that can be written on -2- .
Fig 3: Pressing Adhesive Tape Of Front Number Plate Cover
5. 1.5. Find the center between the outer edges of the front number plate cover and
mark this spot on the strip of adhesive tape -2- affixed to the front number plate
cover -arrow- .
6. 1.6. Position front number plate cover -2- on the contour of the front apron and align
it according to the markings on the adhesive tape.
Fig 4: Drilling Holes
7. 1.7. Drill holes for expansion rivets using → Diameter: 8 mm .
8. 1.8. Pull off strips of adhesive tape -1 and 2- (-arrows- ).

Fig 5: Removing Adhesive Strips
2. Insert expanding rivets and push the pins in flush.

Fig 6: Installing Number Plate Cover
WM 668919 REMOVING AND INSTALLING REARVIEW MIRROR (CAYENNE,

Fastening Item 1 Tightening 9 Nm (6.5 ftlb.)

screws for torque
rear-view
mirror
Removing rear-view mirror

Remove front door panel. → INSTALLING FRONT DOOR PANEL

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REARVIEW MIRROR
NOTE: Voltage peaks
1. Release and disconnect electric plug connections -1, 2- .
2. Expose wire harness and guide the rubber sleeve -3- out of the door sub-frame.
Fig 1: Identifying Plug Connection For Rear-View Mirror
3. Pull off covers over fastening holes.

Fig 2: Removing Rear-View Mirror
5. Guide rubber sleeve out of the door -arrow- .

Fig 3: Pulling Out Rubber Sleeve Of Rear-View Mirror
6. Remove rear-view mirror -3- and wire harness -2- from the door.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REARVIEW MIRROR
The rear-view mirror is installed in reverse order to removal.
1. Tighten fastening screws for the rear-view mirror to Tightening torque 9 Nm (6.5 ftlb.) .

WM 669019 REMOVING AND INSTALLING TRAILER HITCH (CAYENNE, CAYENNE

Trailer hitch to Tightening 120 Nm (89

body torque ftlb.)
Removing trailer hitch

1. Remove rear apron. → REMOVING REAR APRON .
2. Disconnect wire harness for removable trailer hitch in the outer area. → REMOVING WIRE
HARNESS FOR REMOVABLE TRAILER HITCH

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING TRAILER HITCH
Information
Another person is needed for removing and installing the trailer hitch because of its weight.
1. Unscrew fastening screws -1- for trailer hitch.

Fig 1: Removing Trailer Hitch
2. Remove trailer hitch.

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING TRAILER HITCH
Information
Another person is needed for removing and installing the trailer hitch because of its weight.
1. Position trailer hitch and fix in place using the fastening screws.
2. Tighten fastening screws to Tightening torque 120 Nm (89 ftlb.) .

1. Install wire harness for removable trailer hitch. → INSTALLING WIRE HARNESS FOR
REMOVABLE TRAILER HITCH
WM 669419 REMOVING AND INSTALLING COVERS FOR REAR DOOR (EXCEPT

1. Remove molding for rear door. → Removing Rear Door Molding
2. Remove rear window channel seal. → REMOVING REAR WINDOW CHANNEL SEAL

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING COVERS FOR
REAR DOOR > REMOVING COVER FOR REAR DOOR AT THE B-PILLAR
Information
1. Roll the door window down fully.
2. Pull off the window guide in the B-pillar area. → 644655 REPLACING REAR WINDOW GUIDE
3. Unscrew three fastening screws -2- on the cover for the rear door at the B-pillar.
Fig 1: Identifying B-Pillar Cover
Information
The window guide is bonded close to the B-pillar at the front. The entire rear window guide
must be replaced whenever the cover for the rear door at the B-pillar is removed. → 644655
REPLACING REAR WINDOW GUIDE
4. Pull bonded window guide at the front -3- off the B-pillar cover.
5. Carefully lift the cover up and remove it -A- .

Fig 2: Pulling Off Bonded Window Guide

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING COVERS FOR
REAR DOOR > REMOVING COVER FOR REAR DOOR AT THE C-PILLAR
Information
2. Pull off the window guide in the C-pillar area. → 644655 REPLACING REAR WINDOW GUIDE
3. Unscrew three fastening screws -4- on the cover for the rear door at the C-pillar.
Fig 1: Removing C-Pillar Cover
4. Carefully lift the cover up and remove it.

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING COVERS
FOR REAR DOOR > INSTALLING COVERS FOR REAR DOOR
The rear covers are installed in reverse order to removal.

1. Install rear window channel seal. → INSTALLING REAR WINDOW CHANNEL SEAL
2. Install molding for rear door. → Installing Rear Door Molding
WM 669419 REMOVING AND INSTALLING COVERS FOR REAR DOOR (B AND

C-PILLAR) (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE
S HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > PRELIMINARY
WORK
1. Remove molding for rear door. → 66331903 MOLDING FOR REAR DOOR
2. Remove rear window channel seal. → REMOVING REAR WINDOW CHANNEL SEAL

COVERS FOR REAR DOOR > REMOVING COVER FOR REAR DOOR AT THE
B-PILLAR
Information
2. Pull off the window guide in the B-pillar area. → 644655 REPLACING REAR WINDOW GUIDE
3. Unscrew three fastening screws -2- on the cover for the rear door at the B-pillar.
Fig 1: Identifying B-Pillar Cover
Information
The window guide is bonded close to the B-pillar at the front. The entire rear window guide
must be replaced whenever the cover for the rear door at the B-pillar is removed. → 644655
REPLACING REAR WINDOW GUIDE
4. Pull bonded window guide at the front -3- off the B-pillar cover.↓
5. Carefully lift the cover up and remove it -A- .

Fig 2: Pulling Off Bonded Window Guide

COVERS FOR REAR DOOR > REMOVING COVER FOR REAR DOOR AT THE
C-PILLAR
Information
2. Pull off the window guide in the C-pillar area. → 644655 REPLACING REAR WINDOW GUIDE
3. Unscrew three fastening screws -4- on the cover for the rear door at the C-pillar.
Fig 1: Removing C-Pillar Cover
4. Carefully lift the cover up and remove it.

S HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING
COVERS FOR REAR DOOR
The rear covers are installed in reverse order to removal.

S HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > SUBSEQUENT
WORK
1. Install rear window channel seal. → INSTALLING REAR WINDOW CHANNEL SEAL
2. Install molding for rear door. → Installing Rear Door Molding
WM 669419 REMOVING AND INSTALLING COVER FOR FRONT DOOR (B-PILLAR)

1. Remove trim strip for front door. → Removing Trim Strip For Front Door 66331901 REMOVING
AND INSTALLING TRIM STRIP FOR FRONT DOOR
2. Remove front window channel seal. → REMOVING REAR WINDOW CHANNEL SEAL

B-PILLAR COVER
Information
2. Detach front window guide at the trim. → REMOVING FRONT WINDOW GUIDE
3. Unscrew fastening screws -1- on B-pillar cover.
Fig 2: Removing B-Pillar Cover
4. Pull the cover up and off.

B-PILLAR COVER
The front B-pillar cover is installed in reverse order to removal.

1. Install front window channel seal. → INSTALLING REAR WINDOW CHANNEL SEAL
2. Install trim strip for front door. → Installing Trim Strip For Front Door 66331901 REMOVING
AND INSTALLING TRIM STRIP FOR FRONT DOOR
WM 669419 REMOVING AND INSTALLING FRONT B-PILLAR COVER (EXCEPT

1. Remove trim strip for front door. → Removing Trim Strip For Front Door
2. Remove front window shaft seal. → REMOVING REAR WINDOW CHANNEL SEAL

B-PILLAR COVER
Information

2. Detach front window guide at the trim. → REMOVING FRONT WINDOW GUIDE
3. Unscrew fastening screws -1- on B-pillar cover.

Fig 2: Detaching B-Pillar Cover

B-PILLAR COVER
1. The front B-pillar cover is installed in reverse order to removal.

1. Install front window channel seal. → INSTALLING REAR WINDOW CHANNEL SEAL
2. Install trim strip for front door. → Installing Trim Strip For Front Door
WM 669619 REMOVING AND INSTALLING TRAILER HITCH CONTROL UNIT

II

1. Read out values and coding using PIWIS Tester II 9818 when installing a new control unit. →
669655 REPLACING TRAILER HITCH CONTROL UNIT .
2. Remove loudspeaker amplifier. → 914419 REMOVING AND INSTALLING LOUDSPEAKER

AMPLIFIER

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING TRAILER
HITCH CONTROL UNIT
Fig 1: Identifying Trailer Hitch Control Unit Position
NOTE: Voltage peaks
Information
2. Unscrew fastening screws -1- on the bracket -2- and remove control unit.
Fig 2: Removing Bracket
3. Release electric plug connection for trailer hitch power socket using a screwdriver -2- (-arrow
a- ) and disconnect it -arrow B- .
Fig 3: Releasing Electric Plug Connection For Trailer Hitch Power Socket
4. Release electric plug connection using a screwdriver -1- (-arrow a- ) and disconnect it -arrow
B- .

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING TRAILER
HITCH CONTROL UNIT
Information
1. Plug in electric plug connection -arrow A- until it engages securely.

2. Plug in electric plug connection for trailer hitch power socket -arrow B- until it engages
securely.
3. Position control unit with bracket -2- and tighten fastening screws -1- .
Fig 2: Installing Bracket

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REPLACING TRAILER
HITCH CONTROL UNIT
1. Unscrew fastening screws -1- from the trailer hitch control unit.
Fig 1: Identifying Control Unit From Bracket
2. Remove old trailer hitch control unit from the bracket.
3. Position new trailer hitch control unit on the bracket.
4. Tighten fastening screws -1- on the trailer hitch control unit.

1. Install loudspeaker amplifier. → 914419 REMOVING AND INSTALLING LOUDSPEAKER

AMPLIFIER
2. If a new control unit is installed, teach the stored values and coding using PIWIS Tester II
9818 . → 669655 REPLACING TRAILER HITCH CONTROL UNIT .
WM 669655 REPLACING TRAILER HITCH CONTROL UNIT (CAYENNE, CAYENNE


II


CAYENNE S DIESEL, CAYENNE (3.0)) > READING AND WRITING VALUES
NOTE: Voltage drop
battery.
Information
Tester releases.
2. Switch on ignition and press [F12] to continue.
4. Select the required control unit, e.g. Trailer hitch in the overview .
TRAILER HITCH CONTROL UNIT .
11. Switch on ignition, select the Write data menu (procedure described above), then press [F12]
to continue.
12. Press [F8] to start installing the data that was read out.
14. Fault memory must be selected and erased if necessary.

Service Manual: 68 - INTERIOR EQUIPMENT -- 92A CAYENNE
WM 680519 REMOVING AND INSTALLING INNER DOOR ENTRY GUARD (CAYENNE,
PRELIMINARY WORK FOR FRONT INNER DOOR SILL TRIM
1. Remove front side-section trim panel. → 702419 REMOVING AND INSTALLING FRONT
SIDE-SECTION TRIM PANEL

PRELIMINARY WORK FOR REAR INNER DOOR SILL TRIM
1. Detach B-pillar trim panel without loosening the seat belt from the seat. → 706719 REMOVING
AND INSTALLING UPPER PART OF B-PILLAR TRIM PANEL
2. Detach rear side trim panel at the rear inner door sill trim. → 707519 REMOVING AND
INSTALLING REAR SIDE TRIM PANEL

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING INNER DOOR ENTRY
GUARD > REMOVING FRONT INNER DOOR SILL TRIM
Information
Information
1. Remove actuating lever for front lid -1- .

Fig 1: Removing Lever For Front Lid
1. 1.1. Release lock -2- using a small screwdriver -A- .
2. 1.2. Remove actuating lever for front lid release -1- (-B- ).

Fig 2: Removing Fastening Screw
3. Swivel front inner door sill trim -1- inwards close to the actuating lever for the front lid -A- and
unclip it -B- .
Fig 3: Removing Front Inner Door Sill Trim
4. Loosen clips in the door sill area -C- .
5. Unclip rear inner door sill trim -2- in the front door aperture -A- .
Fig 4: Removing Rear Inner Door Sill Trim In Front Door Aperture

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING INNER DOOR ENTRY
GUARD > REMOVING REAR INNER DOOR SILL TRIM
Information
1. Unclip each rear inner door sill trim -2- in direction of arrow -a to e- .
Fig 1: Removing Rear Inner Door Sill Trim

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING INNER DOOR ENTRY
GUARD > INSTALLING FRONT INNER DOOR SILL TRIM
Information
The front inner door sill trim is installed in reverse order to removal.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING INNER DOOR ENTRY
GUARD > INSTALLING REAR INNER DOOR SILL TRIM
Information
The rear inner door sill trim is installed in reverse order to removal.

SUBSEQUENT WORK FOR FRONT INNER DOOR SILL TRIM
1. Install front side-section trim panel. → 702419 REMOVING AND INSTALLING FRONT
SIDE-SECTION TRIM PANEL

SUBSEQUENT WORK FOR REAR INNER DOOR SILL TRIM
1. Install B-pillar trim panel. → 706719 REMOVING AND INSTALLING UPPER PART OF
B-PILLAR TRIM PANEL
2. Detach rear side trim panel at the rear inner door sill trim. → 707519 REMOVING AND
INSTALLING REAR SIDE TRIM PANEL
WM 681119 REMOVING AND INSTALLING GLOVE COMPARTMENT LOCK (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING GLOVE COMPARTMENT
LOCK
1. Unscrew and remove fastening screws -1- from the handle -3- in the glove compartment
cover -2- .
Fig 1: Identifying Screws For Glove Compartment Cover
2. Remove handle -3- from glove compartment cover -2- .
NOTE: Lock cylinder removed and installed incorrectly
1. Risk of damage to lock cylinder
→ Do not take the ignition key out of the lock cylinder during removal and installation.
Otherwise, the spring-loaded locking elements will spring out of the lock cylinder.
3. Insert ignition key -5- fully into the lock cylinder. This locks the locking elements in the lock
cylinder.
4. Press three catches -6- on the lock cylinder -4- outwards -A- .
5. Pull lock cylinder -4- with ignition key -5- out of the handle -3- .
WM 681119 REMOVING AND INSTALLING GLOVE COMPARTMENT LOCK (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING GLOVE
COMPARTMENT LOCK
The glove compartment lock is installed in reverse order to removal.
WM 681219 REMOVING AND INSTALLING GLOVE COMPARTMENT LID (EXCEPT

WORK
Remove glove compartment. → 681519 REMOVING AND INSTALLING GLOVE COMPARTMENT

GLOVE COMPARTMENT LID
1. Pull out cotter pin -1- at insulation for lid -2- on both sides -arrow- .
Fig 1: Removing Cotter Pin At Insulation For Lid
2. Drive hinge bolts out towards the center -arrow- .

Fig 2: Pulling Out Hinge Bolts On Glove Compartment Lid
3. Remove glove compartment lid.

GLOVE COMPARTMENT LID
The glove compartment lid is installed in reverse order to removal.

WORK
Install glove compartment. → 681519 REMOVING AND INSTALLING GLOVE COMPARTMENT
WM 681519 REMOVING AND INSTALLING GLOVE COMPARTMENT (CAYENNE,

Fastening screw Item 1 Tightening 1.5 Nm (1

for glove torque ftlb.)
compartment
Loosening glove compartment mounting

1. Remove molding for dashboard on passenger's side. → 705819 REMOVING AND

INSTALLING DASHBOARD MOLDING ON PASSENGER'S SIDE
2. Remove dashboard trim panel on passenger's side. → 701619 REMOVING AND INSTALLING
DASHBOARD TRIM PANEL
3. Remove cover under dashboard on passenger's side. → 702219 REMOVING AND

INSTALLING COVER UNDER DASHBOARD

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING GLOVE COMPARTMENT
NOTE: Voltage peaks

1. Unscrew six fastening screws -1- at the sides, bottom and top.
Fig 1: Loosening Glove Compartment
2. Remove glove compartment -arrow- .
3. Pull off hose -2- for glove compartment cooling -A- .
4. Release electric plug connection -3- for the glove compartment light -a- and disconnect it -B-
.
Fig 2: Disconnecting Hose And Connector
5. Disconnect electric plug connection for glove compartment light switch -A- .
Fig 3: Disconnecting Connector On Light Switch
6. Release electric plug connection for airbag switch -a- and disconnect it -A- .
Fig 4: Disconnecting Connector On Airbag Switch

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING GLOVE
COMPARTMENT
The glove compartment is installed in reverse order to removal. Pay particular attention to the
following:
1. Tighten six fastening screws for the glove compartment to Tightening torque 1.5 Nm (1 ftlb.)
.

1. Install molding for dashboard on passenger's side. → 705819 REMOVING AND INSTALLING
DASHBOARD MOLDING ON PASSENGER'S SIDE
2. Install cover under dashboard on passenger's side. → 702219 REMOVING AND INSTALLING
3. Install trim panel for dashboard on passenger's side. → 701619 REMOVING AND
INSTALLING DASHBOARD TRIM PANEL
WM 681619 REMOVING AND INSTALLING ODDMENTS TRAY (CAYENNE, CAYENNE

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING ODDMENTS TRAY
Fig 1: Identifying Oddments Tray Installation Position
1. Open cover for oddments tray.
2. Remove rubber mat -2- from oddments tray -1- .

Fig 2: Identifying Rubber Mat And Oddments Tray
3. Unscrew screws -2- from oddments tray -1- .

Fig 3: Removing Screws On Oddments Tray
4. Carefully pull oddments tray out of the center console.
5. Unclip fixing clip for wire harness -1- from the oddments tray.
6. Remove tie-wrap -2- .
7. Release electric plug connection for plug socket -3- and disconnect it.
8. Unscrew screw -4- and guide out the bracket with electric plug connections for multimedia
interface.
Fig 4: Identifying Plug Connections For Oddments Tray
9. Remove oddments tray.

CAYENNE S DIESEL, CAYENNE (3.0)) > REPLACING ODDMENTS TRAY
1. Remove plug socket from oddments tray. → 905819 REMOVING AND INSTALLING PLUG
SOCKET

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING ODDMENTS TRAY
The center console oddments tray is installed in reverse order to removal.
WM 681719 REMOVING AND INSTALLING CENTRE CONSOLE (EXCEPT CAYENNE,


on selector torque ftlb.)
support
Fastening Tightening 8 Nm (6 ftlb.)

screws on torque
center console

PRELIMINARY WORK FOR REMOVING AND INSTALLING CENTRE CONSOLE
1. Remove switch console. → 962719 REMOVING AND INSTALLING SWITCH CONSOLE
2. Remove oddments tray. → 681619 REMOVING AND INSTALLING ODDMENTS TRAY
3. Remove cupholder. → 683019 REMOVING AND INSTALLING CUPHOLDER
4. Remove rear air-conditioning system regulator. → 881119 REMOVING AND INSTALLING

REAR AIR-CONDITIONING SYSTEM REGULATOR

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING CENTRE CONSOLE
Fig 1: Identifying Centre Console Installation Position
1. Unclip trim -2- for plug sockets using a suitable tool -wedge- at the sides of the center
console -1- .
Fig 2: Removing Centre Console Trim
2. Release electric plug connection -3- (-a- ) and pull it off -arrow- .
3. Unscrew fastening screws -2- from the center console -1- .

Fig 3: Identifying Centre Console Screws
4. Unclip fixing clip -2- on wire harness for selector support from the center console -1- (-arrow-
).
Fig 4: Removing Clip On Wire Harness For Switch Console
5. Release electric plug connection -1- from the selector support -a- and pull it off -arrow- .
Fig 5: Removing Plug Connection On Selector Support
6. Unscrew fastening screws -2- for the selector support -3- from the center console -1- .
Fig 6: Identifying Screws On Selector Support
7. Unclip fixing clip -2- on wire harness for cigarette lighter from the center console -1- (-arrow-
).
Fig 7: Removing Clip On Wire Harness For Cigarette Lighter
8. Lift up center console -1- at the rear as far as possible -A- and pull it out to the rear -B- .
Fig 8: Removing Centre Console
9. Remove center console.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING CENTRE CONSOLE
1. Insert center console -1- under the dashboard -arrow- .
Make sure that the locking lugs on the dashboard trim panel fit into the guides -2- on the
center console.
Fig 1: Installing Centre Console
2. Clip fixing clip -2- for wire harness for cigarette lighter into the center console -1- (-arrow- ).
Fig 2: Clipping Wire Harness For Cigarette Lighter
3. Tighten fastening screws -2- for selector support -3- in center console -1- to → Tightening
torque: 10 Nm (7.5 ftlb.) .
Fig 3: Identifying Screws On Selector Support
4. Plug in electric plug connection in selector support -1- (-arrow- ) and lock it -a- .
Fig 4: Removing Plug Connection On Selector Support
5. Secure fixing clip -2- on wire harness for selector support to the center console -1- .
Fig 5: Securing Clip On Wire Harness For Selector Support
6. Tighten fastening screws -2- on center console -1- to → Tightening torque: 8 Nm (6 ftlb.) .
Fig 6: Identifying Centre Console Screws
7. Plug in electric plug connection -3- (-arrow- ) and lock it -a- .

Fig 7: Installing Rear Plug Socket Cover
8. Clip cover -2- for plug sockets into the center console -1- at the side.

SUBSEQUENT WORK FOR REMOVING AND INSTALLING CENTRE CONSOLE
1. Install rear air-conditioning system regulator. → 881119 REMOVING AND INSTALLING REAR
AIR-CONDITIONING SYSTEM REGULATOR
2. Install switch console. → 962719 REMOVING AND INSTALLING SWITCH CONSOLE
3. Install cupholder. → 683019 REMOVING AND INSTALLING CUPHOLDER
4. Install oddments tray. → 681619 REMOVING AND INSTALLING ODDMENTS TRAY
WM 681919 REMOVING AND INSTALLING COVER FOR CENTRE CONSOLE (EXCEPT

E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TOOLS
assembly tool VW tool T10118

WORK
1. Remove selector knob. → 370419 REMOVING AND INSTALLING SELECTOR KNOB
2. Only when removing lower part:
1. 2.1. Remove PCM display and operator control unit. → 911019 REMOVING AND
2. 2.2. Remove upper part of center console cover. → 681919 REMOVING AND
INSTALLING CENTRE CONSOLE COVER

COVER FOR CENTRE CONSOLE > REMOVING UPPER PART OF CENTRE CONSOLE
COVER
Information
The selector knob must be in the "N" position when removing the center console cover.
Move selector lever to "N" position.
1. Hold lower center console cover -1- securely.
2. Insert tool assembly tool T10118 into the cut-out next to the selector lever -A- and lever off
the cover -B- .
Fig 1: Removing Upper Part Of Centre Console Cover

COVER FOR CENTRE CONSOLE > REMOVING LOWER PART OF CENTRE CONSOLE
COVER
1. Remove ashtray by pulling it up.
2. Press lens -1- for ashtray light to the rear and push it down -arrow- to remove it.
Fig 1: Removing Lens For Ashtray
3. Hold the cover -1- securely at the front.

Fig 2: Removing Lower Part Of Centre Console Cover
4. Insert tool assembly tool T10118 at the corners of the cover -1- and unclip the cover
-arrows- .

COVER FOR CENTRE CONSOLE
1. Guide cable with LED -1- for the ashtray light into the lens -2- and insert the lens.
Check that the cable is routed correctly.

Fig 1: Installing Lens For Ashtray
2. Clip in lower part of cover.
3. Position upper part of cover and clip it in.
4. Check that the covers are seated correctly.

WORK
Install PCM display and operator control unit. → 911019 REMOVING AND INSTALLING PCM
3.1 DISPLAY AND OPERATOR CONTROL UNIT
2. Install selector knob. → Installing Selector Knob
WM 681919 REMOVING AND INSTALLING CENTRE CONSOLE COVER (CAYENNE,


1. Remove selector knob. → 370419 REMOVING AND INSTALLING SELECTOR KNOB
1. 2.1. Remove PCM display and operator control unit. → 911019 REMOVING AND
INSTALLING PCM DISPLAY AND OPERATOR CONTROL UNIT
2. 2.2. Remove upper part of center console cover. → 681919 REMOVING AND
INSTALLING CENTRE CONSOLE COVER

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING COVER FOR CENTRE
CONSOLE > REMOVING UPPER PART OF CENTRE CONSOLE COVER
Information
The selector knob must be in the "N" position when removing the center console cover.
Move selector lever to "N" position.
1. Hold lower center console cover -1- securely.
2. Insert tool assembly tool T10118 into the cut-out next to the selector lever -A- and lever off
the cover -B- .
Fig 1: Removing Upper Part Of Centre Console Cover

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING COVER FOR CENTRE
CONSOLE > REMOVING LOWER PART OF CENTRE CONSOLE COVER
1. Remove ashtray insert by pulling it up.
2. Press lens -1- for ashtray light to the rear and push it down -arrow- to remove it.
Fig 1: Removing Lens For Ashtray
3. Hold the cover -1- securely at the front.

Fig 2: Removing Lower Part Of Centre Console Cover
4. Insert tool assembly tool T10118 at the corners of the cover -1- and unclip the cover
-arrows- .

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING COVER FOR CENTRE
CONSOLE
1. Guide cable with LED -1- for the ashtray light into the lens -2- and insert the lens.
Check that the cable is routed correctly.

Fig 1: Installing Lens For Ashtray
2. Clip in lower part of cover.
3. Position upper part of cover and clip it in.
4. Check that the covers are seated correctly.

1. Install selector knob. → Installing Selector Knob
Install PCM display and operator control unit. → 911019 REMOVING AND INSTALLING PCM
DISPLAY AND OPERATOR CONTROL UNIT
WM 682019 REMOVING AND INSTALLING FRONT ASHTRAY (CAYENNE, CAYENNE

WORK FOR REMOVING AND INSTALLING FRONT ASHTRAY
1. Remove center console cover. → 681919 REMOVING AND INSTALLING CENTRE

CONSOLE COVER

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT ASHTRAY
1. Unscrew fastening screws -2- on the ashtray -1- .

Fig 1: Removing Ashtray
2. Unclip ashtray from the center console cover -arrow- .

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT ASHTRAY
The front ashtray is installed in reverse order to removal.

WORK FOR REMOVING AND INSTALLING FRONT ASHTRAY
1. Install center console cover. → Installing Cover For Centre Console
WM 682119 REMOVING AND INSTALLING REAR ASHTRAY (CAYENNE, CAYENNE

1. Remove rear door panel. → 707319 REMOVING AND INSTALLING REAR DOOR PANEL
2. Remove rear door handle cover. → 584519 REMOVING AND INSTALLING DOOR OPENER

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR ASHTRAY
Information
1. Disconnect electric plug connection from the ashtray.


Fig 2: Identifying Screws Of Ashtray
3. Press the ashtray out from behind and remove it by pulling it forward.
Fig 3: Removing Ashtray

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR ASHTRAY
The rear ashtray is installed in reverse order to removal.

1. Install rear door handle cover. → 584519 REMOVING AND INSTALLING DOOR OPENER
2. Install rear door panel. → Installing Rear Door Panel
WM 682319 REMOVING AND INSTALLING SUN VISOR (CAYENNE, CAYENNE GTS,

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING SUN VISOR
Information
1. Disengage adjustable part of the sun visor from the mounting saddle and swivel towards the
roof frame.
2. Loosen mounting saddle.
1. 2.1. Unclip cap -2- on the mounting saddle -3- using a screwdriver and open it -B- .
2. 2.2. Unscrew fastening screw -4- .

Fig 1: Loosening Mounting Saddle
3. Remove mounting saddle.

1. 3.1. Fold rear sun visor -5- down.
Fig 2: Removing Mounting Saddle
2. 3.2. Pull mounting saddle -3- back -D- and unclip it -E- .
3. 3.3. Remove latch -6- from the mounting saddle -3- (-F- ).
Fig 3: Removing Latch From Mounting Saddle
4. 3.4. Swivel locking hook out of the headliner -7- (-G- ).

Fig 4: Removing Lock Hook
4. Remove pivot bearing.
1. 4.1. Carefully unclip cover on pivot bearing -1- at the rear with a screwdriver -A- .
Fig 5: Removing Cover For Pivot Bearing
2. 4.2. Loosen expanding clip -2- for securing the pivot bearing -3- using a screwdriver
-B- .
Fig 6: Removing Pivot Bearing
4. 4.4. Remove pivot bearing -3- with sun visor in a downward direction -C- .
5. 4.5. Release electric plug connection -5- using a screwdriver -a- and disconnect it
-D- .
Fig 7: Disconnecting Plug Connection For Sun Visor
WM 682319 REMOVING AND INSTALLING SUN VISOR (CAYENNE, CAYENNE GTS,

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING SUN VISOR
The sun visor is installed in reverse order to removal.
WM 682337 DISASSEMBLING AND ASSEMBLING SUN VISOR (EXCEPT CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > DISASSEMBLING SUN VISOR
Information
1. Fold sun visor down.
2. Open cover on mirror -1- fully -A- .

Fig 1: Opening Cover On Mirror
3. Press into the small indent on the mounting frame -B- and open the cover -1- approx. 5 mm
further -C- .
Fig 2: Opening Cover
4. Insert a screwdriver between the mirror frame -2- and cover on mirror -1- and unclip mirror
frame and mirror.
Fig 3: Removing Mirror Frame
5. Remove light bulb -3- .

Fig 4: Identifying Light Bulb
WM 682337 DISASSEMBLING AND ASSEMBLING SUN VISOR (EXCEPT CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > ASSEMBLING SUN VISOR
The sun visor is assembled in reverse order to disassembly.
WM 682719 REMOVING AND INSTALLING INTERIOR REAR-VIEW MIRROR

WORK
1. Remove roof console. → 708319 REMOVING AND INSTALLING ROOF CONSOLE
2. Vehicles with GPS antenna: Remove GPS antenna. → 911319 REMOVING AND INSTALLING
GPS ANTENNA

INTERIOR REAR-VIEW MIRROR
1. Remove left and right caps.
1. 1.1. Insert a narrow screwdriver between the cover caps -2- and carefully press
them apart -arrow- .
Fig 1: Removing Caps
2. 1.2. Remove caps.
2. Remove rearview mirror.
1. 2.1. Turn the rearview mirror anti-clockwise until it comes to a stop -A- .
Fig 2: Removing Rearview Mirror
2. 2.2. Remove the rearview mirror by pulling it downwards -B- .
3. Spread the upper cover -A- and pull it forwards -B- .

Fig 3: Removing Cover On Top Of Rearview Mirror
4. Unplug two electrical plug connections -A- .

Fig 4: Pulling Off Plug Connections

INTERIOR REAR-VIEW MIRROR
The interior rearview mirror is installed in reverse order to removal.

WORK
1. Install roof console. → Installing Roof Console
2. Vehicles with GPS antenna: Install GPS antenna. → 911319 REMOVING AND INSTALLING
GPS ANTENNA
WM 683019 REMOVING AND INSTALLING CUPHOLDER (CAYENNE, CAYENNE GTS,

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING CUPHOLDER
Information
1. Remove rubber mat -2- from cupholder -1- (-A- ).
Lever out using a suitable tool if necessary.
Fig 1: Removing Rubber Mat
2. Unscrew and remove screws -3- for the cupholder -1- .

Fig 2: Removing Cupholder
3. Unclip side trim panels -4- on the center console -2- from the rear as far as the cupholder -1-
using a suitable tool -A- .
4. Pull cupholder -1- out of the center console -2- .

Fig 3: Disconnecting Plug Connection For Cigarette Lighter
5. Release electric plug connection -3- for the cigarette lighter -a- and disconnect it -arrow- .
6. Remove cupholder.

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING CUPHOLDER > REPLACING
CUPHOLDER
1. Remove cigarette lighter from the cupholder. → 906219 REMOVING AND INSTALLING
CIGARETTE LIGHTER

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING CUPHOLDER
1. Press inner part of cigarette lighter into the cupholder.
2. Connect electric plug connection for cigarette lighter.

3. Fit cupholder into the center console.
4. Press out inner part of cigarette lighter.
Further installation of the cupholder is performed in reverse order to removal.
WM 683519 REMOVING AND INSTALLING FRONT HANDLE (CAYENNE, CAYENNE

Fastening screw Tightening 5.5 Nm (4 ftlb.)

for grab handle torque
Securing grab handle

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT HANDLE > REMOVING
FRONT GRAB HANDLES
Information
1. Fold out grab handle.

Fig 1: Pulling Out Grab Handle
2. Open covers -2- on the grab handle -1- .

Fig 2: Identifying Covers And Grab Handle

Fig 3: Detaching Grab Handle
4. Remove grab handle -1- .

Fig 4: Removing Grab Handle

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT GRAB HANDLES
Information
1. Fit grab handle -1- .

Fig 1: Fitting Grab Handle
2. Screw in fastening screws -3- and tighten to Tightening torque 5.5 Nm (4 ftlb.) .
Fig 2: Securing Grab Handle
3. Close covers -2- .

Fig 3: Identifying Covers
Information
The handle must return itself to a normal position after it is released!
4. Check fold-in function.

Fig 4: Folding In Grab Handle
WM 683719 REMOVING AND INSTALLING REAR HANDLE (CAYENNE, CAYENNE

Fastening screw Tightening 5.5 Nm (4 ftlb.)

for grab handle torque
Securing grab handle

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR HANDLE > REMOVING
REAR GRAB HANDLES
Information
1. Fold out grab handle.

Fig 1: Folding Out Grab Handle
2. Unclip cover -2- on the grab handle -1- using a screwdriver.

Fig 2: Identifying Cover On Grab Handle

Fig 3: Detaching Grab Handle
4. Remove grab handle -1- .

Fig 4: Removing Grab Handle

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR HANDLE > INSTALLING
REAR GRAB HANDLES
Information
1. Fit grab handle -1- .

Fig 1: Fitting Grab Handle
2. Screw in fastening screws -3- and tighten to Tightening torque 5.5 Nm (4 ftlb.) .
Fig 2: Securing Grab Handle
3. Clip in cover -2- .

Fig 3: Identifying Cover On Grab Handle
Information
The handle must return itself to a normal position after it is released!
4. Check fold-in function.

Fig 4: Folding In Grab Handle
WM 684819 REMOVING AND INSTALLING COVER FOR PACKAGE BOX (CAYENNE,

PRELIMINARY WORK FOR REMOVING AND INSTALLING COVER FOR REAR TRAY

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING COVER FOR REAR
TRAY
1. Unscrew and remove fastening screws -2- from cover -1- for rear tray.
Fig 1: Identifying Screws On Rear Cover
2. Tilt cover -1- backwards -A- .
Make sure that the bore in the base of the cover is above the front locating peg -2- .
3. Pull cover -1- forward and remove it -B- .

Fig 2: Removing Cover

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING COVER FOR REAR
TRAY
1. The cover of the rear tray is installed in reverse order to removal.
When installing the cover -1- , make sure that the outer guides -2- of the rear cover fit into the
cut-outs -3- on the center console and the inner guides -4- are around the rear locating peg
-5- .
Fig 1: Installing Cover

SUBSEQUENT WORK FOR REMOVING AND INSTALLING COVER FOR REAR TRAY
WM 684819 REMOVING AND INSTALLING COVER FOR REAR TRAY (EXCEPT

WORK > PRELIMINARY WORK FOR REMOVING AND INSTALLING COVER FOR
REAR TRAY

COVER FOR REAR TRAY
1. Unscrew fastening screws -2- from cover -1- for rear tray.
Fig 1: Identifying Screws On Rear Cover
2. Tilt cover -1- backwards -A- .
Make sure that the bore in the base of the cover is above the front locating peg -2- .
3. Pull cover -1- forward and remove it -B- .


COVER FOR REAR TRAY
1. The cover of the rear tray is installed in reverse order to removal.
When installing the cover -1- , make sure that the outer guides -2- of the rear cover fit into the
cut-outs -3- on the center console and the inner guides -4- are around the rear locating peg
-5- .

WORK > SUBSEQUENT WORK FOR REMOVING AND INSTALLING COVER FOR
REAR TRAY
WM 689619 REMOVING AND INSTALLING SUN BLIND ON DOOR WINDOW

WORK

SUN BLIND ON DOOR WINDOW
1. Unscrew and remove fastening screws for the sun blind -2- .
Fig 1: Identifying Screws For Sun Blind
2. Remove sun blind -1- .


SUN BLIND ON DOOR WINDOW
1. Position the sun blind -1- on the door panel -3- and engage it securely.
2. Screw in fastening screws on the sun blind -2- .

Fig 2: Identifying Screws On Sun Blind

WORK
1. Install rear door panel. → Installing Rear Door Panel
WM 689619 REMOVING AND INSTALLING DRIVE MECHANISM FOR SUN BLIND ON

DOOR WINDOW (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S,
2. Pull the bar -2- up out of the drive.

Fig 1: Removing Bar And Sleeve
3. Pull sleeve -3- up out of the grommet -4- .
4. Remove rear door sub-frame. → 583019 REMOVING AND INSTALLING REAR DOOR
SUB-FRAME

CAYENNE (3.0)) > REMOVING DRIVE MECHANISM FOR SUN BLIND ON DOOR
WINDOW

Fig 1: Identifying Fastening Screws For Sun Blind On Door Window
2. Disengage connector on the control unit.

Fig 2: Unplugging Connector
3. Unscrew fastening screws on the holder -7- and remove the holder -8- .
Fig 3: Removing Holder
4. Press the sleeve -6- out at the feed-through point.

Fig 4: Pressing Sleeve
5. Guide the drive mechanism out in a downward direction and remove it.

CAYENNE (3.0)) > INSTALLING DRIVE MECHANISM FOR SUN BLIND ON DOOR
WINDOW
1. Guide in drive mechanism.
2. Press the sleeve -6- in at the feed-through point.

Fig 1: Positioning Sleeve
3. Position damping rubber -9- close to the bracket.

Fig 2: Positioning Damping Rubber
4. Fit holder -8- and screw in fastening screws -7- .

Fig 3: Fitting Holder

Fig 4: Identifying Fastening Screws
6. Engage connector on the control unit.

Fig 5: Plugging Connector On Control Unit

2. Check that the grommet -4- is seated correctly.
3. Guide the sleeve -3- into the grommet -4- and engage it securely in the drive.
4. Guide the bar -2- down into the drive and engage it securely.
Fig 1: Installing Bar And Sleeve
5. Install rear door sub-frame. → Installing Rear Door Panel
WM 689619 REMOVING AND INSTALLING SUN BLIND ON DOOR WINDOW)

(CAYENNE TIP, CAYENNE MAN, CAYENNE S, CAYENNE TURBO, CAYENNE GTS,
CAYENNE S HYBRID, CAYENNE TURBO S, CAYENNE DIESEL, CAYENNE S DIESEL,
CAYENNE TIP (3.0)) > PRELIMINARY WORK

CAYENNE TIP (3.0)) > REMOVING SUN BLIND ON DOOR WINDOW

Fig 1: Identifying Screws Of Sun Blind On Door Window
2. Take off the sun blind -1- .


CAYENNE TIP (3.0)) > INSTALLING SUN BLIND ON DOOR WINDOW
1. Position the sun blind -1- on the door panel -3- and engage it securely.


CAYENNE TIP (3.0)) > SUBSEQUENT WORK
1. Install door panel. → Installing Rear Door Panel

Service Manual: 70 - LININGS, INSULATION -- 92A CAYENNE
WM 700219 REMOVING AND INSTALLING FRONT TRIM PANEL (ENGINE
COMPARTMENT) (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S,
PRELIMINARY WORK
FRONT LOCK SUPPORT

REMOVING FRONT TRIM PANEL (ENGINE COMPARTMENT)
1. Release expansion rivets -1- and pull them out of the front trim panel (engine compartment)
-2- .
Installation: Align expansion rivets -1- with the longitudinal axis of the vehicle before locking
them.
2. Lift up front trim panel (engine compartment) -2- , guide it out at the pneumatic spring -3- and
remove it.
Fig 1: Identifying Front Trim Panel (Engine Compartment)

INSTALLING FRONT TRIM PANEL (ENGINE COMPARTMENT)

SUBSEQUENT WORK
FRONT LOCK SUPPORT
WM 700319 REMOVING AND INSTALLING SIDE TRIM PANEL FOR REAR LUGGAGE
COMPARTMENT (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S,
1. Remove C-pillar trim. → 706819 REMOVING AND INSTALLING C-PILLAR TRIM
2. Remove the rear side trim panel. → 707519 REMOVING AND INSTALLING REAR SIDE TRIM
PANEL
3. Remove D-pillar trim. → 706919 REMOVING AND INSTALLING D-PILLAR TRIM
4. Remove cover for rear lock support. → 703919 REMOVING AND INSTALLING COVER FOR
REAR LOCK SUPPORT
CAYENNE (3.0)) > REMOVING SIDE TRIM PANEL FOR REAR LUGGAGE
COMPARTMENT > REMOVING REAR LUGGAGE COMPARTMENT SIDE TRIM PANEL
Information
These must be carried out as a mirror image of the steps shown for the front and rear .
Information
1. Unscrew the expansion rivets -1- .

Fig 1: Removing Rear Luggage Compartment Side-Trim Panel
2. Detach rear side trim panel in area -A- .
3. Release electrical plug connection for loudspeaker -a- and pull it off -B- .
Fig 2: Disconnecting Loudspeaker Plug Connection
4. On left side only: Disconnect electrical plug connection from socket. → 905819 REMOVING
AND INSTALLING SOCKET
5. Unclip side trim panel at the marked areas -circles- .
CAYENNE (3.0)) > INSTALLING SIDE TRIM PANEL FOR REAR LUGGAGE
COMPARTMENT
Information
Information
1. Position side trim panel at bottom.

Fig 1: Installing Side Trim Panel
2. Plug in electrical plug connection for loudspeaker until it engages securely.

Fig 2: Inserting Loudspeaker Plug Connection
3. On left side only: Plug in electrical plug connection of socket. → Installing Plug Socket
4. Clip in side trim panel at the marked areas -circles- .
5. Screw in the expansion rivets -1- .
1. Install the rear side trim panel. → 707519 REMOVING AND INSTALLING REAR SIDE TRIM
PANEL
2. Install C-pillar trim. → 706819 REMOVING AND INSTALLING C-PILLAR TRIM
3. Install D-pillar trim. → 706919 REMOVING AND INSTALLING D-PILLAR TRIM
4. Install cover for rear lock support. → 703919 REMOVING AND INSTALLING COVER FOR
REAR LOCK SUPPORT
WM 700419 REMOVING AND INSTALLING INSULATION FOR FRONT LID (CAYENNE,
TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING INSULATION FOR
FRONT LID
1. Press fixing clips -2- together -A- and remove them -B- .
2. Remove insulation -1- .

Fig 1: Removing Insulation For Front Lid
WM 700419 REMOVING AND INSTALLING INSULATION FOR FRONT LID (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING INSULATION FOR
FRONT LID
Information

1. Position insulation for lid and press in fixing clips.
WM 700619 REMOVING AND INSTALLING TRIM PANEL FOR LUGGAGE

COMPARTMENT (LUGGAGE COMPARTMENT COVER) AT THE LOCK SUPPORT
VALUES

securing lashing torque
point to body
Removing lashing points

TRIM PANEL FOR LUGGAGE COMPARTMENT (LUGGAGE COMPARTMENT COVER)
AT THE LOCK SUPPORT > REMOVING LUGGAGE COMPARTMENT TRIM PANEL
(LUGGAGE COMPARTMENT COVER)
Information
1. Remove center part of luggage compartment cover.
1. 1.1. Lift up center part of luggage compartment cover -1- (-A- ) and pull it to the rear
-B- .
Fig 1: Removing Luggage Compartment Cover
2. Remove side parts of luggage compartment cover.
1. 2.1. At four lashing points -3- , fold up the tab -4- and unscrew fastening screws -5-
.
Fig 2: Identifying Screws Of Lashing Points
2. 2.2. Slide side part of luggage compartment cover -2- forward -C- and remove it.
Fig 3: Removing Side Part Of Luggage Compartment Cover

TRIM PANEL FOR LUGGAGE COMPARTMENT (LUGGAGE COMPARTMENT COVER)
AT THE LOCK SUPPORT > INSTALLING LUGGAGE COMPARTMENT TRIM
(LUGGAGE COMPARTMENT COVER)
1. The luggage compartment cover is installed in reverse order to removal.
2. Tighten fastening screws for the lashing points to Tightening torque 8 Nm (6 ftlb.) until
secure.
WM 700619 REMOVING AND INSTALLING LUGGAGE COMPARTMENT TRIM

(LUGGAGE COMPARTMENT COVER) (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE
Lashing points for Tightening 8 Nm (6 ftlb.)

luggage torque
compartment
cover

DIESEL, CAYENNE (3.0)) > REMOVING > REMOVING LUGGAGE COMPARTMENT
TRIM (LUGGAGE COMPARTMENT COVER)
Information
1. Remove center part of luggage compartment cover.
1. 1.1. Lift up center part of luggage compartment cover -1- (-A- ) and pull it to the rear
-B- .
2. Remove side parts of luggage compartment cover.
1. 2.1. At four lashing points -3- , fold up the tab -4- and unscrew fastening screws -5-
.
Fig 2: Identifying Screws Of Lashing Points
2. 2.2. Slide side part of luggage compartment cover -2- forward -C- and remove it.
Fig 3: Removing Side Part Of Luggage Compartment Cover

DIESEL, CAYENNE (3.0)) > INSTALLING > INSTALLING LUGGAGE COMPARTMENT
TRIM (LUGGAGE COMPARTMENT COVER)
1. The luggage compartment cover is installed in reverse order to removal.
2. Tighten fastening screws for lashing points to → Tightening torque: 8 Nm (6 ftlb.) .
WM 701619 REMOVING AND INSTALLING DASHBOARD TRIM PANEL (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING DASHBOARD TRIM
PANEL
1. Unclip dashboard trim panel -1- by pushing it upwards from below.

Fig 1: Identifying Dashboard Trim Panel
WM 701619 REMOVING AND INSTALLING DASHBOARD TRIM PANEL (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING DASHBOARD TRIM
PANEL
1. Clip in dashboard trim panel -1- by pushing it downwards from above.

Fig 1: Identifying Dashboard Trim Panel
WM 701619 REMOVING AND INSTALLING DASHBOARD COVER (EXCEPT CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING DASHBOARD COVER
1. Unclip dashboard cover -1- upwards from below.

Fig 1: Identifying Dashboard Cover
WM 701619 REMOVING AND INSTALLING DASHBOARD COVER (EXCEPT CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING DASHBOARD COVER
1. Clip in dashboard cover -1- downwards from above.

Fig 1: Identifying Dashboard Cover
WM 701815 ADJUSTING THE DASHBOARD (CAYENNE, CAYENNE GTS, CAYENNE

DIESEL, CAYENNE (3.0)) > ADJUSTING THE DASHBOARD
Fig 1: Identifying Dashboard Installation Position
Information
There must be an even transition between the dashboard and the door panels. The dashboard
should be centered in the vehicle so that the gaps with respect to the door panels are the same
width on both sides .
1. Check the installation position of the dashboard. To do this, check the gap dimension and
height difference between the dashboard -1- and door panels -2- visually and adjust the
dashboard if necessary.
Fig 2: Identifying Gap Dimension Between Dashboard And Door Panel
2. If the gap dimension and height difference are not correct, the difference by which the
dashboard is set incorrectly must be noted. The dashboard bracket will be adjusted
horizontally and vertically by this difference later.
3. Remove dashboard. → 701819 REMOVING AND INSTALLING DASHBOARD
4. Loosen all fastening screws and fastening nuts used to secure the dashboard bracket to the
body. → 516819 REMOVING AND INSTALLING DASHBOARD BRACKET
5. Adjust the dashboard bracket horizontally and vertically according to the noted values so that it
is positioned correctly.
6. Check gap dimensions and height differences again.
7. Tighten all fastening screws and fastening nuts used to secure the dashboard bracket to the
body. → 516819 REMOVING AND INSTALLING DASHBOARD BRACKET
8. Check the gap dimension and height difference -arrows- between the dashboard -1- and
door panels -2- again.
Fig 3: Identifying Gap Dimension Between Dashboard And Door Panel

WM 701819 REMOVING AND INSTALLING DASHBOARD (CAYENNE, CAYENNE GTS,

at front of torque ftlb.)
dashboard
Removing dashboard

at side of torque ftlb.)
dashboard
Removing dashboard

at top of torque ftlb.)
dashboard
Removing dashboard
Fastening screw -Item 2- Tightening 8 Nm (6 ftlb.)

securing torque
passenger's
airbag unit to
dashboard

Information
Before disconnecting the battery, move the driver and passenger seat all the way back.
1. Remove glove compartment. → 681519 REMOVING AND INSTALLING GLOVE

COMPARTMENT
2. Remove center console. → 681719 REMOVING AND INSTALLING CENTRE CONSOLE
3. Remove trim panel under dashboard. → 701919 REMOVING AND INSTALLING TRIM PANEL
UNDER DASHBOARD
4. Remove dashboard trim panel. → 701619 REMOVING AND INSTALLING DASHBOARD

TRIM PANEL
5. Remove A-pillar trim panel. → 705719 REMOVING AND INSTALLING A-PILLAR TRIM
PANEL
6. Remove air vent for door window. → 855919 REMOVING AND INSTALLING AIR VENT FOR
DOOR WINDOW
7. Remove instrument cluster. → 902519 REMOVING AND INSTALLING INSTRUMENT

CLUSTER
8. Remove steering-column switch. → 945019 REMOVING AND INSTALLING STEERING-

COLUMN SWITCH
9. Remove PCM display and operator control unit. → 911019 REMOVING AND INSTALLING
PCM DISPLAY AND OPERATOR CONTROL UNIT
10. Remove front loudspeakers (dashboard). → 914019 REMOVING AND INSTALLING FRONT
LOUDSPEAKERS (DASHBOARD)
11. Remove cover for dashboard (defroster trim). → 702019 REMOVING AND INSTALLING
COVER FOR DASHBOARD (DEFROSTER TRIM)

CAYENNE S DIESEL, CAYENNE (3.0)) > PRELIMINARY WORK > SAFETY
INSTRUCTIONS FOR PASSENGER AIRBAG
starting terminals.
avoided.
airbag.
person.
Danger of injury
Loss of torque

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING DASHBOARD
1. Loosen two fastening screws -1- on the passenger airbag unit from the mounting bracket.
Fig 2: Identifying Passenger Airbag Unit
2. Release and unplug the two electric plug connections for the passenger airbag unit.
Fig 3: Unplugging Connectors On Passenger Airbag Unit
3. Unclip line bracket -2- from the dashboard at the left and right.
Fig 4: Unclipping Wiring
4. Unplug electric plug connections for the servo motors for the center air vents at the top.
Fig 5: Unplugging Connectors For Servo Motors For Air Vents
5. Unplug electric plug connection for the temperature sensor for the outer air vents at the left
and right.
Fig 6: Disconnecting Connector For Temperature Sensor For Air Vents
6. Disconnect electric plug connection for the ignition starter switch. → 280419 REMOVING AND
INSTALLING IGNITION STARTER SWITCH
Fig 7: Identifying Dashboard Screw
1. 7.1. Unscrew and remove fastening screw -3- from the top.
2. 7.2. Unscrew and remove fastening screws -4- at the sides of the dashboard.
3. 7.3. Unscrew and remove fastening screws -5- at the front of the dashboard.
8. Pull the dashboard -6- inwards out of the three retaining clips -7- .
Fig 8: Identifying Dashboard And Retaining Clips

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING DASHBOARD
1. Carefully guide the dashboard into place and position it.
2. Push the dashboard -6- into the three retaining clips -7- .
Make sure that no lines are trapped when guiding in the dashboard.
Fig 1: Identifying Retaining Clips And Dashboard
3. Secure the dashboard.

Fig 2: Identifying Dashboard Screw
1. 3.1. Tighten fastening screws -5- at the front to Tightening torque 1.5 Nm (1 ftlb.) .
2. 3.2. Tighten fastening screws -4- at the sides to Tightening torque 1.5 Nm (1 ftlb.)
.
3. 3.3. Tighten fastening screw -3- at the top to Tightening torque 1.5 Nm (1 ftlb.) .
4. Plug in electric plug connection for the ignition starter switch. → 280419 REMOVING AND
INSTALLING IGNITION STARTER SWITCH
5. Plug in electric plug connection for the temperature sensor for the outer air vents at the left and
right.
Fig 3: Plugging Connector For Temperature Sensor For Air Vents
6. Plug in electric plug connections for the servo motors for the center air vents at the top.
Fig 4: Plugging Connectors For Servo Motors For Air Vents
7. Clip wiring into the dashboard at the left and right.

Fig 5: Fastening Wiring
8. Plug in and lock the two electric plug connections for the passenger airbag unit.
Fig 6: Plugging Connectors On Passenger Airbag Unit
9. Tighten two fastening screws -1- on the passenger airbag unit to Tightening torque 8 Nm (6
ftlb.) .
Fig 7: Securing Passenger Airbag Unit

1. Install cover for dashboard (defroster trim). → 702019 REMOVING AND INSTALLING COVER
FOR DASHBOARD (DEFROSTER TRIM)
2. Install front loudspeakers (dashboard). → Installing Front Loudspeakers (Dashboard)
3. Install display and operator control unit. → 911019 REMOVING AND INSTALLING PCM
DISPLAY AND OPERATOR CONTROL UNIT
4. Install steering-column switch. → 945019 REMOVING AND INSTALLING STEERING-

COLUMN SWITCH
5. Install instrument cluster. → 902519 REMOVING AND INSTALLING INSTRUMENT CLUSTER
6. Install air vent for door window. → 855919 REMOVING AND INSTALLING AIR VENT FOR
DOOR WINDOW
7. Install A-pillar trim panel. → Installing A-Pillar Trim Panel

8. Install dashboard trim panel. → 701619 REMOVING AND INSTALLING DASHBOARD TRIM
PANEL
9. Install trim panel under dashboard. → 701919 REMOVING AND INSTALLING TRIM PANEL
UNDER DASHBOARD
10. Install center console. → Installing Centre Console
11. Install glove compartment. → 681519 REMOVING AND INSTALLING GLOVE

COMPARTMENT
12. Teach servo motor for left center vent. → 872019 REMOVING AND INSTALLING SERVO
MOTOR FOR TOP LEFT CENTRE VENT
13. Teach servo motor for right center vent. → 872019 REMOVING AND INSTALLING SERVO
MOTOR FOR TOP RIGHT CENTRE VENT
WM 701919 REMOVING AND INSTALLING TRIM PANEL UNDER DASHBOARD

WORK
1. Remove dashboard inset at the bottom. → 900319 REMOVING AND INSTALLING

DASHBOARD INSET
2. Remove cover under dashboard on driver's side. → 702219 REMOVING AND INSTALLING

TRIM PANEL UNDER DASHBOARD
Information
1. Unscrew seven fastening screws -1- .

Fig 1: Identifying Trim Panel Under Dashboard Screws
2. Unclip trim panel at the top -2- .

Fig 2: Unclipping Clips
3. Remove trim panel -3- from the guide -4- (-A- ).

Fig 3: Removing Trim Panel
4. Disconnect electric plug connection from the main headlight switch -A- .
Fig 4: Disconnecting Connector From Main Headlight Switch
5. Release electric plug connection from parking brake switch -a- and disconnect it -A- .
Fig 5: Disconnecting Connector From Parking Brake Switch
6. Release electric plug connection from diagnostic connector -a- and disconnect it -A- .
Fig 6: Disconnecting Diagnostic Connector

The trim panel under the dashboard is installed in reverse order to removal .

WORK
1. Install dashboard inset at the bottom. → Installing Dashboard Inset
2. Install cover under dashboard on driver's side. → 702219 REMOVING AND INSTALLING
WM 702019 REMOVING AND INSTALLING COVER FOR DASHBOARD (DEFROSTER

TRIM) (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S
WORK
Remove cover for loudspeaker at the left and right. → 709019 REMOVING AND INSTALLING
LOUDSPEAKER TRIM PANEL

Information
Fig 1: Identifying Cover For Dashboard Installation Position (Defroster Trim)
1. Insert a plastic wedge between the dashboard -2- and defroster trim -1- and unclip defroster
trim from left to right.
Fig 2: Removing Defroster Trim
2. Press catches on defroster trim -1- apart -A- and press sun sensor -2- out -B- .
Fig 3: Removing Sun Sensor

The defroster trim is installed in reverse order to removal .

WORK
Install cover for loudspeaker at the left and right. → 709019 REMOVING AND INSTALLING
WM 702219 REMOVING AND INSTALLING COVER UNDER DASHBOARD (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING COVER UNDER
DASHBOARD
Information
Information
Fig 1: Identifying Cover Under Dashboard Installation Position
1. Unscrew and remove fastening screw -2- .
2. Pull cover under dashboard -1- out of the locks and swivel it down -A- .
3. Pull cover under dashboard -1- out of the guides -3- (-B- ).
Fig 2: Removing Mounting Screw Of Trim Panel Under Dashboard
4. Release electric plug connection for light -a- and disconnect it -A- .
Fig 3: Disconnecting Connector For Light
5. Passenger's side only: Release electric plug connection for plug socket -a- and disconnect
it -A- .
Fig 4: Disconnecting Connector At Socket
WM 702219 REMOVING AND INSTALLING COVER UNDER DASHBOARD (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING COVER UNDER
DASHBOARD
The cover under the dashboard is installed in reverse order to removal .
WM 702419 REMOVING AND INSTALLING FRONT SIDE SECTION TRIM (EXCEPT

WORK
Remove dashboard cover. → 701619 REMOVING AND INSTALLING DASHBOARD COVER

FRONT SIDE SECTION TRIM
Information
Information
1. Unclip front side section trim -1- at the bottom from the locks -A- .
Fig 1: Removing Front Side Section Trim
2. Pull front side section trim -1- downwards -B- out of the A-pillar trim.

E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING >
INSTALLING FRONT SIDE SECTION TRIM PANEL
Information
Information
1. Push front side section trim -1- upwards -A- over the A-pillar trim.
Fig 1: Installing Front Side Section Trim
2. Engage lock for front side section trim -1- at the bottom -B- .

WORK
Install dashboard cover. → 701619 REMOVING AND INSTALLING DASHBOARD COVER
WM 703919 REMOVING AND INSTALLING COVER FOR FRONT LOCK SUPPORT

(CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL,
CAYENNE (3.0)) > REMOVING COVER FOR FRONT LOCK SUPPORT
2. Release expansion rivets -1- and pull them out of the cover for the front lock support -2- .
Installation: Align expansion rivets -1- with the longitudinal axis of the vehicle before locking
them.
Fig 1: Identifying Expansion Rivets And Front Lock Support
3. Pull out cover for front lock support -1- under the headlights and remove it by pulling it
upwards.
Fig 2: Removing Cover For Front Lock Support
WM 703919 REMOVING AND INSTALLING COVER FOR FRONT LOCK SUPPORT

CAYENNE (3.0)) > INSTALLING COVER FOR FRONT LOCK SUPPORT
WM 703919 REMOVING AND INSTALLING COVER FOR REAR LOCK SUPPORT

(CAYENNE, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S
DIESEL, CAYENNE (3.0)) > REMOVING COVER FOR REAR LOCK SUPPORT
2. Lift up loadspace floor.
3. Remove cover for rear lock support -7- .
1. 3.1. Fold over seal -8- in the retaining clip area and carefully unclip cover for rear
lock support -7- by prising it upwards using a plastic wedge -9- in the sequence -1
to 6- .
Fig 1: Loosening Cover For Rear Lock Support
2. 3.2. Fold up cover for rear lock support -1- and pull it out between the luggage
compartment trim panels.
Fig 2: Removing Cover For Rear Lock Support
WM 703919 REMOVING AND INSTALLING COVER FOR REAR LOCK SUPPORT

(CAYENNE, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S
DIESEL, CAYENNE (3.0)) > INSTALLING COVER FOR REAR LOCK SUPPORT
1. Check retaining clips -1- and sound absorbers -2- for damage and check that they are seated
correctly in the cover for the rear lock support -3- .
Fig 1: Identifying Retaining Clips And Sound Absorbers
2. Install cover for rear lock support -1- .
1. 2.1. Position cover for rear lock support -1- between the luggage compartment trim
panels and carefully fold it downwards.
Fig 2: Installing Cover For Rear Lock Support
2. 2.2. Check sound absorbers -1- again to make sure they are seated correctly in the
cover for the rear lock support -2- .
3. 2.3. Position all retaining clips -3- and guide pins -4- in the appropriate openings on
the body, but do not engage them!
Fig 3: Positioning Retaining Clips
4. 2.4. Fold out sealing lip -1- over the entire length under the cover for the rear lock
support -2- .
Fig 4: Folding Out Sealing Lip
5. 2.5. Press cover for rear lock support -1- downwards -arrows- until the retaining
clips engage securely.
Fig 5: Clipping Cover For Rear Lock Support
3. Fold down loadspace floor.
4. Close the rear lid.
WM 703919 REMOVING AND INSTALLING COVER FOR LOCK SUPPORT (EXCEPT

COVER FOR FRONT LOCK SUPPORT
2. Pull expansion rivets -1- out of the cover -2- .

Fig 1: Identifying Expansion Rivets And Cover
3. Unclip cover -2- in the middle in an upward direction -A- and swivel it out at one side -B- .

COVER FOR REAR LOCK SUPPORT
1. Press seal for rear lid -2- away from the lock support cover -1- .
Fig 1: Removing Lock Support Cover
2. Unclip lock support cover -1- in an upward direction using a plastic wedge -3- .
3. Pull the lock support cover out to the rear -arrow- .

COVER FOR FRONT LOCK SUPPORT
The cover for the front lock support is installed in reverse order to removal.

COVER FOR REAR LOCK SUPPORT
The lock support cover is installed in reverse order to removal.
WM 704119 REMOVING AND INSTALLING CARPET (EXCEPT CAYENNE, CAYENNE

WORK FOR CARPET ON DRIVER'S SIDE
1. Remove driver's seat. → 720119 REMOVING AND INSTALLING FRONT SEAT
3. Remove front inner door sill trim on driver's side. → 680519 REMOVING AND INSTALLING
INNER DOOR SILL TRIM
4. Remove cover under dashboard on the driver's side. → 702219 REMOVING AND

WORK FOR CARPET ON PASSENGER'S SIDE
1. Remove passenger seat. → Installing Front Seat
3. Remove front inner door sill trim on passenger's side. → 680519 REMOVING AND
INSTALLING INNER DOOR SILL TRIM
4. Remove cover under dashboard on the passenger's side. → 702219 REMOVING AND

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING CARPET > REMOVING CARPET
ON DRIVER'S SIDE
1. Unclip one mounting plug -1- on the center console and one push button -2- in the footwell.
Fig 1: Removing Carpet On Driver Side
2. Lift up the carpet -3- at the rear and remove it by pulling it back -arrow- .

ON PASSENGER'S SIDE
1. Unclip one mounting plug -1- on the center console and one push button -2- in the footwell.
Fig 1: Removing Carpet On Passenger Side

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING CARPET > INSTALLING
CARPET ON DRIVER'S SIDE
The carpet on the driver's side is installed in reverse order to removal.

CARPET ON PASSENGER'S SIDE
The carpet on the passenger's side is installed in reverse order to removal.

1. Install driver's seat. → Installing Front Seat
3. Install front inner door sill trim on driver's side. → 680519 REMOVING AND INSTALLING
4. Install cover under dashboard on the driver's side. → 702219 REMOVING AND INSTALLING

1. Install passenger seat. → Installing Front Seat
3. Install front inner door sill trim on passenger's side. → Installing Inner Door Entry Guard
4. Install cover under dashboard on the passenger's side. → 702219 REMOVING AND
WM 704119 REMOVING AND INSTALLING FRONT CARPET (CAYENNE, CAYENNE

1. Remove driver's seat. → 720119 REMOVING AND INSTALLING FRONT SEAT
3. Remove front inner door sill trim on driver's side. → 680519 REMOVING AND INSTALLING
4. Remove cover under dashboard on driver's side. → 702219 REMOVING AND INSTALLING

1. Remove passenger seat. → 720119 REMOVING AND INSTALLING FRONT SEAT
3. Remove front inner door sill trim on passenger's side. → 680519 REMOVING AND
INSTALLING INNER DOOR SILL TRIM
4. Remove cover under the dashboard on the passenger's side. → 702219 REMOVING AND

ON DRIVER'S SIDE
1. Unclip one fastening plug -1- on the center console and one press-stud -2- in the footwell.
Fig 1: Removing Carpet On Driver Side

ON PASSENGER'S SIDE
1. Unclip one fastening plug -1- on the center console and one press-stud -2- in the footwell.
Fig 1: Removing Carpet On Passenger Side

CARPET ON DRIVER'S SIDE
The carpet on the driver's side is installed in reverse order to removal .

CARPET ON PASSENGER'S SIDE
The carpet on the passenger's side is installed in reverse order to removal .

1. Install driver's seat. → Installing Front Seat
3. Install front inner door sill trim on driver's side. → 680519 REMOVING AND INSTALLING
4. Install cover under dashboard on driver's side. → 702219 REMOVING AND INSTALLING

1. Install passenger seat. → 720119 REMOVING AND INSTALLING FRONT SEAT
3. Install front inner door sill trim on passenger's side. → 680519 REMOVING AND INSTALLING
4. Install cover under the dashboard on the passenger's side. → 702219 REMOVING AND
WM 704619 REMOVING AND INSTALLING CENTRE FLOOR COVERING (CAYENNE S,

PRELIMINARY WORK
1. Remove both front seats. → 720119 REMOVING AND INSTALLING FRONT SEAT
2. Remove rear scuff plate. → 680519 REMOVING AND INSTALLING INNER DOOR SILL TRIM
3. Remove 1/3-split folding rear seat. → 724819 REMOVING AND INSTALLING 1/3-SPLIT
FOLDING REAR SEAT
FOLDING REAR SEAT
5. Remove rear side trim panel. → 707519 REMOVING AND INSTALLING REAR SIDE TRIM
PANEL
6. Remove trim panel for luggage compartment (luggage compartment cover) at the lock carrier.
→ 700619 REMOVING AND INSTALLING TRIM PANEL FOR LUGGAGE COMPARTMENT
(LUGGAGE COMPARTMENT COVER) AT THE LOCK CARRIER

REMOVING CENTRE FLOOR COVERING
1. Guide out and lift up the carpet in the rear area -arrow A- .
2. Guide out all electric lines -1- at the carpet.
3. Remove air guides -2- .
4. Pull carpet at the side forward under the center console -arrow B- .
5. Pull carpet forward and remove it -arrow C- .

Fig 1: Removing Centre Floor Cover

INSTALLING REAR FLOOR COVERING
The carpet is installed in reverse order to removal .

SUBSEQUENT WORK
1. Install trim panel for luggage compartment (luggage compartment cover) at the lock carrier. →
700619 REMOVING AND INSTALLING TRIM PANEL FOR LUGGAGE COMPARTMENT
(LUGGAGE COMPARTMENT COVER) AT THE LOCK CARRIER
2. Install rear side trim panel. → 707519 REMOVING AND INSTALLING REAR SIDE TRIM
PANEL
3. Install 2/3-split folding rear seat. → 724819 REMOVING AND INSTALLING 2/3-SPLIT
FOLDING REAR SEAT
FOLDING REAR SEAT
5. Install rear scuff plate. → 680519 REMOVING AND INSTALLING INNER DOOR SILL TRIM
6. Install both front seats. → Installing Front Seat
WM 705719 REMOVING AND INSTALLING A-PILLAR TRIM PANEL (CAYENNE,

Remove side-section trim panel. → 702419 REMOVING AND INSTALLING FRONT SIDE-SECTION
TRIM PANEL

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING A-PILLAR TRIM PANEL
Information
CAUTION:
Risk of damage to electric wires and head airbag.
→ When unclipping the trim panel using a tool, make sure not to damage the electric wires lying behind
it and the head airbag.
1. Carefully pull out A-pillar trim panel at the top of the door aperture -arrow- .
Fig 1: Loosening A-Pillar Trim Panel
2. Turn the locking mechanism -1- at the front by 90° using pointed-nose pliers and guide it out
at the trim panel -2- .
Fig 2: Identifying Lock Mechanism And Trim Panel
3. Detach A-pillar trim panel from the locking mechanisms -arrow- .

Fig 3: Loosening Pillar Trim Panel
4. Pull off A-pillar trim panel in an upward direction -arrow- .

Fig 4: Removing Pillar Trim Panel
5. Release upper locking mechanism -1- using a screwdriver -A- and pull it out -B- .
Fig 5: Removing Upper Lock Mechanism For A-Pillar Trim Panel

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING A-PILLAR TRIM PANEL
Information
The upper clip -1- of the A-pillar trim must not be reused.
It must always be replaced, even if there is no visible damage.

Fig 1: Identifying Upper Clip For Pillar Trim
Information
The A-pillar trim panel is installed in reverse order to removal .

Install side-section trim panel. → 702419 REMOVING AND INSTALLING FRONT SIDE-SECTION TRIM
PANEL
WM 705719 REMOVING AND INSTALLING A-PILLAR TRIM (EXCEPT CAYENNE,

Remove side section trim. → 702419 REMOVING AND INSTALLING FRONT SIDE SECTION TRIM

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING A-PILLAR TRIM
Information
CAUTION:
1. Carefully pull out trim for upper A-pillar at the door aperture -arrow- .
Fig 1: Loosening Pillar Trim
2. Turn lock -1- through 90° using pointed-nose pliers and pull off trim -2- .
Fig 2: Releasing Lock For Pillar Trim
3. Detach A-pillar trim out of locks -arrow- .

Fig 3: Loosening Pillar Trim
4. Pull off A-pillar trim in an upward direction -arrow- .

Fig 4: Removing Pillar Trim
Information

5. Release upper lock -1- using a screwdriver -A- and pull it off -B- .
Fig 6: Removing Upper Lock For Pillar Trim

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING A-PILLAR TRIM
Information

Information
The A-pillar trim is installed in reverse order to installation.

Install side section trim. → 702419 REMOVING AND INSTALLING FRONT SIDE SECTION TRIM
WM 705819 REMOVING AND INSTALLING DASHBOARD MOLDING ON DRIVER'S

SIDE (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S,
INFORMATION
Fig 1: Identifying Dashboard Molding On Driver Side Installation Position
1. Dashboard molding on driver's side (left).
2. Dashboard molding on driver's side (right).

PRELIMINARY WORK > PRELIMINARY WORK FOR DASHBOARD MOLDING ON
DRIVER'S SIDE (LEFT)
Remove air vent for door window. → 855919 REMOVING AND INSTALLING AIR VENT FOR DOOR
WINDOW

PRELIMINARY WORK > PRELIMINARY WORK FOR DASHBOARD MOLDING ON
DRIVER'S SIDE (RIGHT)
Remove center air vent. → 855319 REMOVING AND INSTALLING CENTRE AIR VENT

REMOVING DASHBOARD MOLDING ON DRIVER'S SIDE > REMOVING DASHBOARD
MOLDING ON DRIVER'S SIDE (LEFT)
Information
1. Carefully unclip dashboard molding on driver's side (left) -1- .

Fig 1: Removing Dashboard Molding On Driver Side (Left)

REMOVING DASHBOARD MOLDING ON DRIVER'S SIDE > REMOVING DASHBOARD
MOLDING ON DRIVER'S SIDE (RIGHT)
Information
1. Carefully unclip dashboard molding on driver's side (right) -2- .

Fig 1: Removing Dashboard Molding On Driver Side (Right)

INSTALLING DASHBOARD MOLDING ON DRIVER'S SIDE > INSTALLING
DASHBOARD MOLDING ON DRIVER'S SIDE (LEFT)
The dashboard molding on the driver's side (left) is installed in reverse order to removal.

INSTALLING DASHBOARD MOLDING ON DRIVER'S SIDE > INSTALLING
DASHBOARD MOLDING ON DRIVER'S SIDE (RIGHT)
The dashboard molding on the driver's side (right) is installed in reverse order to removal.
SUBSEQUENT WORK > SUBSEQUENT WORK FOR DASHBOARD MOLDING ON
DRIVER'S SIDE (LEFT)
Install air vent for door window. → 855919 REMOVING AND INSTALLING AIR VENT FOR DOOR
WINDOW

SUBSEQUENT WORK > SUBSEQUENT WORK FOR DASHBOARD MOLDING ON
DRIVER'S SIDE (RIGHT)
Install center air vent. → 855319 REMOVING AND INSTALLING CENTRE AIR VENT
WM 705819 REMOVING AND INSTALLING DASHBOARD MOLDING ON

PASSENGER'S SIDE (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S,
PRELIMINARY WORK
1. Remove center air vent. → 855319 REMOVING AND INSTALLING CENTRE AIR VENT
2. Remove air vent for door window. → 855919 REMOVING AND INSTALLING AIR VENT FOR
DOOR WINDOW

REMOVING DASHBOARD MOLDING ON PASSENGER'S SIDE
Information
Fig 1: Identifying Dashboard Molding On Passenger Side Installation Position
1. Carefully unclip dashboard molding on passenger's side -1- (-arrows- ).

Fig 2: Removing Dashboard Molding

INSTALLING DASHBOARD MOLDING ON PASSENGER'S SIDE
1. Clip in dashboard molding on passenger's side -1- (-arrows- ).

Fig 1: Installing Dashboard Molding

SUBSEQUENT WORK
1. Install center air vent. → 855319 REMOVING AND INSTALLING CENTRE AIR VENT
2. Install air vent for door window. → 855919 REMOVING AND INSTALLING AIR VENT FOR
DOOR WINDOW
WM 705919 REMOVING AND INSTALLING ARMREST FOR FRONT DOOR TRIM

PANEL (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S,
REMOVING ARMREST FOR FRONT DOOR TRIM PANEL > REMOVING FRONT DOOR
PANEL ARMREST
Information
1. Unclip armrest in an upward direction using an assembly wedge.

Fig 1: Removing Armrest
2. Remove armrest.
WM 705919 REMOVING AND INSTALLING ARMREST FOR FRONT DOOR TRIM

PANEL (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S,
INSTALLING ARMREST FOR FRONT DOOR TRIM PANEL > INSTALLING FRONT
DOOR PANEL ARMREST
The front door panel armrest is installed in reverse order to removal.
WM 705919 REMOVING AND INSTALLING ARMREST FOR FRONT DOOR PANEL

ARMREST FOR FRONT DOOR PANEL
Information
1. Unclip armrest in an upward direction using an assembly wedge.

2. Remove armrest.
WM 705919 REMOVING AND INSTALLING ARMREST FOR FRONT DOOR PANEL

ARMREST FOR FRONT DOOR PANEL > INSTALLING FRONT DOOR PANEL
ARMREST
The front door panel armrest is installed in reverse order to removal.
WM 705919 REMOVING AND INSTALLING FRONT DOOR PANEL (CAYENNE,


for door panel torque ftlb.)
Door panel mounting

for door panel torque
Door panel mounting

1. Remove strip for door panel. → 706019 REMOVING AND INSTALLING STRIP FOR DOOR
PANEL
2. Remove handle. → 706319 REMOVING AND INSTALLING HANDLE

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT DOOR PANEL
Information
1. Pull door opener and unclip the cover on the door opener -1- using a plastic wedge.
Fig 1: Unclipping Cover For Door Opener
2. Unscrew and remove fastening screws -2 and 3 - from the door panel.
Fig 2: Releasing Door Panel
3. Unclip door panel at the bottom and swivel it out of the sealing channel at the top.
Fig 3: Unclipping Door Panel
4. Release and disconnect electric plug connection on wiring harness for door.
Fig 4: Disconnecting Electric Plug Connection For Wiring Harness
5. Disconnect electric plug connection from door control unit.

Fig 5: Disconnecting Electric Plug Connection For Door Control Unit
1. 5.1. Release electric plug connection from the door control unit -a- .
2. 5.2. Swivel securing clip -4- forward by 90° -A- and disconnect electric plug
connection from the door control unit -B- .
6. Disconnect electric plug connection from the mid-range loudspeaker.

Fig 6: Disconnecting Electric Plug Connection For Mid-Range Loudspeaker
7. Disengage cable for door opener.

Fig 7: Removing Cable For Door Opener
1. 7.1. Spread locking lugs outwards -A- .
2. 7.2. Remove cable from the guide by pulling it to the rear -B- .
3. 7.3. Swivel cable forward -C- until the driver at the front is free.
4. 7.4. Remove driver from door opener.
8. Remove door panel.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT DOOR PANEL
1. The front door panel is installed in reverse order to removal.
2. Tighten fastening screw for door panel to Tightening torque 4.5 Nm (3.5 ftlb.) .
3. Tighten fastening screw for bottom of door panel to Tightening torque 2 Nm (1.5 ftlb.) .

1. Install handle. → 706319 REMOVING AND INSTALLING HANDLE
2. Install strip for door panel. → 706019 REMOVING AND INSTALLING STRIP FOR DOOR
PANEL
WM 706019 REMOVING AND INSTALLING STRIP FOR DOOR TRIM PANEL (EXCEPT
STRIP FOR DOOR TRIM PANEL
Information
1. Unclip strip for door trim panel using a plastic wedge.

Fig 1: Unclipping Strip

2. Remove strip for door trim panel.
WM 706019 REMOVING AND INSTALLING STRIP FOR DOOR TRIM PANEL (EXCEPT
STRIP FOR DOOR TRIM PANEL
The strip for the door trim panel is installed in reverse order to removal.
WM 706019 REMOVING AND INSTALLING STRIP FOR REAR DOOR PANEL (EXCEPT
STRIP FOR REAR DOOR PANEL
Information
1. Carefully unclip strip for door panel using a plastic wedge.

Fig 1: Unclipping Strip
2. Remove strip for door panel.
WM 706019 REMOVING AND INSTALLING STRIP FOR REAR DOOR PANEL (EXCEPT
STRIP FOR REAR DOOR PANEL
The strip for the rear door panel is installed in reverse order to removal.
WM 706319 REMOVING AND INSTALLING REAR INNER DOOR HANDLE (EXCEPT

VALUES
Fastening Tightening 4.5 Nm (3.5

screws for inner torque ftlb.)
door handle
WORK
1. Remove armrest for rear door. → 707319 REMOVING AND INSTALLING ARMREST FOR
REAR DOOR PANEL

REAR INNER DOOR HANDLE
1. Unclip the large cover -1- using a plastic wedge and remove it by pulling it inwards.
Fig 1: Unclipping Large Cover
2. Unclip the small cover -2- using a plastic wedge and remove it by pulling it inwards.
Fig 2: Unclipping Small Cover
3. Unscrew fastening screws -3- for inner door handle -4- .

Fig 3: Removing Handle
4. Remove inner door handle -4- by pulling it inwards.

1. The rear inner door handle is installed in reverse order to removal.
2. Tighten fastening screws for rear inner door handle to → Tightening torque: 4.5 Nm (3.5
ftlb.) .

WORK
1. Install armrest for rear door panel. → 707319 REMOVING AND INSTALLING ARMREST FOR
REAR DOOR PANEL
WM 706319 REMOVING AND INSTALLING HANDLE (CAYENNE, CAYENNE GTS,

for handle torque ftlb.)

1. Remove armrest for front door panel. → 705919 REMOVING AND INSTALLING ARMREST
FOR FRONT DOOR PANEL

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING HANDLE
1. Unclip cover -1- using a plastic wedge and remove it by pulling it inwards.
2. Unclip cover -2- using a plastic wedge and remove it by pulling it inwards.
3. Unscrew and remove fastening screws -3- for handle -4- .

4. Remove handle -4- by pulling it inwards.

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING HANDLE
1. The handle is installed in reverse order to removal.
2. Tighten fastening screws for handle to Tightening torque 4.5 Nm (3.5 ftlb.) .

1. Install armrest for front door panel. → 705919 REMOVING AND INSTALLING ARMREST FOR
FRONT DOOR PANEL

VALUES
Fastening Tightening 4.5 Nm (3.5

screws for inner torque ftlb.)
door handle

WORK
1. Remove armrest for rear door. → 707319 REMOVING AND INSTALLING ARMREST FOR
REAR DOOR PANEL

1. Unclip the large cover -1- using a plastic wedge and remove it by pulling it inwards.
2. Unclip the small cover -2- using a plastic wedge and remove it by pulling it inwards.
3. Unscrew fastening screws -3- for inner door handle -4- .

4. Remove inner door handle -4- by pulling it inwards.

1. The rear inner door handle is installed in reverse order to removal.
2. Tighten fastening screws for rear inner door handle to → Tightening torque: 4.5 Nm (3.5
ftlb.) .

WORK
1. Install armrest for rear door panel. → 707319 REMOVING AND INSTALLING ARMREST FOR
REAR DOOR PANEL
WM 706719 REMOVING AND INSTALLING UPPER PART OF B-PILLAR TRIM PANEL
WORK
Detach belt fitting at the seat. → 691119 REMOVING AND INSTALLING FRONT THREE-POINT BELT

B-PILLAR TRIM PANEL
Information
1. Unclip lower B-pillar trim panel -1- at the sides from the door seal -A- .
Fig 1: Removing B-Pillar Trim Panel
2. Unclip clips -circles- from the bottom upwards and swivel out trim panel -B- .
Only complete the following steps for vehicles with air conditioning in the rear of the
vehicle .
3. Release and disconnect electric plug connection for light for air vents.
4. Remove B-pillar trim panel -1- in a downward direction.
5. Guide seat belt through the belt adjustment guide -2- .

B-PILLAR TRIM PANEL
Information
The B-pillar trim is installed in reverse order to removal .
1. Check that seat belt adjustment is working properly.

WORK
Secure belt fitting to the seat. → Installing Front Three-Point Belt
WM 706719 REMOVING AND INSTALLING B-PILLAR TRIM (EXCEPT CAYENNE,

Detach belt fitting at the seat. → 691119 REMOVING AND INSTALLING FRONT THREE-POINT BELT

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING B-PILLAR TRIM
Information
1. Unclip B-pillar trim -1- out of the door seal underneath at the sides -A- .
Fig 1: Removing B-Pillar Trim
2. Unclip clips -circles- from the bottom upwards and swivel out trim -B- .
3. Take out B-pillar trim -1- in downward direction.
4. Guide seat belt through the belt adjustment guide -2- .

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING B-PILLAR TRIM
Information
The B-pillar trim is installed in reverse order to removal.

Secure belt fitting to the seat. → Installing Front Three-Point Belt
WM 706819 REMOVING AND INSTALLING C-PILLAR TRIM (EXCEPT CAYENNE,

special inserts Commercially Nr.170

available tool
Open-end/ring Commercially Nr.98-1

wrench insert available tool Pos.1


for seat belt torque ftlb.)

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING C-PILLAR TRIM
1. Slide rear seat bench forward.
2. Unscrew fastening screw for the seat belt -1-.

Tools: Open-end/ring wrench insert Nr.98-1 Pos.1 and special inserts Nr.170
Fig 1: Loosening Seat Belt
3. Unclip C-pillar trim panel from the C-pillar at the marked areas -circles- . To do this, raise the
bottom of the trim panel -A- slightly and lever out the fastening clips.
Fig 2: Unclipping C-Pillar Trim Panel

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING C-PILLAR TRIM
1. The C-pillar trim is installed in reverse order to removal.
Information
Always replace the fastening screws on the three-point seat belt. The micro-self-locking
screws must not be treated (e.g. greased) or loosened and then screwed on again.
2. Tighten fastening screw for seat belt to → Tightening torque: 50 Nm (37 ftlb.) .
Tools: Open-end/ring wrench insert Nr.98-1 Pos.1 and special inserts Nr.170
WM 706919 REMOVING AND INSTALLING D-PILLAR TRIM (EXCEPT CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING D-PILLAR TRIM
CAUTION:
1. Unclip D-pillar trim from the D-pillar at the marked areas -circles- . To do this, raise the trim
slightly at position -A- and lever out the fastening clips using a plastic wedge.
Fig 1: Removing D-Pillar Trim

WM 706919 REMOVING AND INSTALLING D-PILLAR TRIM (EXCEPT CAYENNE,
TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING D-PILLAR TRIM
The D-pillar trim is installed in reverse order to removal.
WM 706819 REMOVING AND INSTALLING C-PILLAR TRIM PANEL (CAYENNE,

Socket-wrench set, Workshop WE 1640

39-piece equipment


for rear seat belt torque ftlb.)
Fastening screw for seat belt

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING C-PILLAR TRIM
1. Slide rear seat bench forward.
2. Unscrew fastening screw for the seat belt -1- .

Tools: Socket-wrench set, 39-piece WE 1640
Fig 1: Loosening Seat Belt
3. Unclip C-pillar trim panel from the C-pillar at the marked areas -circles- . To do this, raise the
bottom of the trim panel -A- slightly and lever out the fastening clips.
Fig 2: Unclipping C-Pillar Trim Panel

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING C-PILLAR TRIM
1. The C-pillar trim panel is installed in reverse order to removal.
Information
Always replace the fastening screws on the three-point seat belt. The micro-self-locking
screws must not be treated (e.g. greased) or loosened and then screwed on again.
2. Tighten fastening screw for the seat belt to Tightening torque 50 Nm (37 ftlb.) .
Tools: Socket-wrench set, 39-piece WE 1640
WM 706919 REMOVING AND INSTALLING D-PILLAR TRIM PANEL (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING D-PILLAR TRIM PANEL
CAUTION:
1. Unclip D-pillar trim panel -circles- from the D-pillar at the marked areas.
1. 1.1. Lift trim panel slightly at position -A- .
2. 1.2. Lever out fastening clips using a plastic wedge.

Fig 1: Identifying D-Pillar Trim Panel

2. Loosen expansion rivet and remove rebound strap on the body.
WM 706919 REMOVING AND INSTALLING D-PILLAR TRIM PANEL (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING D-PILLAR TRIM PANEL
The D-pillar trim panel is installed in reverse order to removal .
WM 707319 REMOVING AND INSTALLING ARMREST FOR REAR DOOR TRIM PANEL
ARMREST FOR REAR DOOR TRIM PANEL
Information
1. Unclip armrest in an upward direction using an assembly wedge and push it slightly to the rear.

2. Remove armrest.
WM 707319 REMOVING AND INSTALLING ARMREST FOR REAR DOOR TRIM PANEL
ARMREST FOR REAR DOOR TRIM PANEL > INSTALLING ARMREST FOR REAR
DOOR PANEL
The armrest for the rear door panel is installed in reverse order to removal.
WM 707319 REMOVING AND INSTALLING REAR DOOR PANEL (CAYENNE,


Loosening door panel

for door panel, torque
bottom

Information
Only for vehicles with "Electric sun blind for rear side windows"
The push rod cannot be disassembled .
Make sure that the push rod is not kinked during removal and installation .
During installation, make sure that the push rod engages correctly in the drive mechanism for the
sun blind .
1. Remove strip for rear door panel. → 706019 REMOVING AND INSTALLING STRIP FOR
REAR DOOR PANEL
2. Remove rear handle. → 706319 REMOVING AND INSTALLING REAR HANDLE

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR DOOR PANEL
Information
1. Pull door opener and unclip the cover on the door opener -1- using a plastic wedge.
Fig 1: Unclipping Cover For Door Opener
2. Unscrew and remove fastening screws -2 and 3- from the door panel.
Fig 2: Releasing Door Panel
3. Unclip the door panel all the way around and swivel the bottom outwards.
4. On vehicles with sun blind .
The push rod for the sun blind cannot be disassembled .
1. 4.1. Open the sun blind flap and pull sun blind with push rod up fully.
2. 4.2. Pull door panel with the sun blind open up out of the sealing channel and guide.
5. Swivel trim panel inwards, release electric plug connection -a- and disconnect it from the door
control unit.
Fig 3: Disconnecting Electric Plug Connection For Door Control Unit
6. Disconnect electric plug connection for tweeter in the rear door.

Fig 4: Disconnecting Electric Plug Connection For Tweeter
7. Disengage cable for door opener.

Fig 5: Removing Cable For Door Opener
1. 7.1. Spread locking lugs outwards -A- .
2. 7.2. Remove cable by pulling it to the rear out of the guide -2- (-B- ).
3. 7.3. Swivel cable in direction of arrow -C- until the driver at the front is free.
4. 7.4. Remove the driver from the door opener -D- .
8. Remove door panel.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR DOOR PANEL
Information
Only for vehicles with "Electric sun blind for rear side windows"
The push rod cannot be disassembled .
Make sure that the push rod is not kinked during removal and installation .
During installation, make sure that the push rod engages correctly in the drive mechanism for the
sun blind .
1. The rear door panel is installed in reverse order to removal.
2. On vehicles with sun blind
1. 2.1. To install the door panel, pull the sun blind up completely and guide the push rod
into the guide tube on the bare door shell.
3. Tighten fastening screws for top of door panel to Tightening torque 4.5 Nm (3.5 ftlb.) .
4. Tighten fastening screw for bottom of door panel to Tightening torque 2 Nm (1.5 ftlb.) .

1. Install rear handle. → 706319 REMOVING AND INSTALLING REAR HANDLE
2. Install strip for rear door panel. → 706019 REMOVING AND INSTALLING STRIP FOR REAR
DOOR PANEL
WM 707519 REMOVING AND INSTALLING REAR SIDE TRIM PANEL (CAYENNE,

Remove C-pillar trim panel. → 706819 REMOVING AND INSTALLING C-PILLAR TRIM PANEL

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR SIDE TRIM PANEL
Information
1. Loosen clips -circles- for the side trim panel through the door opening.
Fig 1: Detaching Rear Side Trim Panel
2. Swivel trim panel inwards at the door opening -A- and pull it forward -B- .
Fig 2: Removing Rear Side Trim Panel

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR SIDE TRIM
PANEL
Information
1. Guide rear side trim panel into the locking mechanism -A- and clip it in at the door opening
-B- .
Fig 1: Fitting Side Trim Panel
2. Clip in clips -circles- for side trim panel, starting at the bottom.
Fig 2: Installing Rear Side Trim Panel

Install C-pillar trim panel. → 706819 REMOVING AND INSTALLING C-PILLAR TRIM PANEL
WM 708319 REMOVING AND INSTALLING ROOF CONSOLE (CAYENNE, CAYENNE

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING ROOF CONSOLE
NOTE: Voltage peaks
Information
2. Unclip trim for headliner.

Fig 1: Unclipping Trim
3. Unclip headliner at the two side cut-outs -A- and swivel it downwards -B- .
Fig 2: Unclipping Headliner
4. Lift headliner off towards the rear.

Fig 3: Lifting Off Headliner
5. Disconnect wire harness.

1. 5.1. Release plug connections -a- and disconnect them -B- .
2. 5.2. Unclip fastening clip for wire harness -C- .
WM 708319 REMOVING AND INSTALLING ROOF CONSOLE (CAYENNE, CAYENNE

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING ROOF CONSOLE
1. Secure wire harness.

Fig 1: Securing Wire Harness
1. 1.1. Connect plug connections -A- until they engage securely.
2. 1.2. Clip in wire harness -B- .
2. Engage headliner at the two retaining pins.

Fig 2: Engaging Headliner
3. Swivel in headliner and clip it into place.

Fig 3: Clipping Headliner
4. Clip in trim for headliner.

Fig 4: Clipping Trim For Headliner
WM 708355 REPLACING ROOF CONSOLE (EXCEPT CAYENNE, CAYENNE GTS,

Battery charger Workshop WE 1393

45A equipment

1. Remove and install roof console. → 708319 REMOVING AND INSTALLING ROOF
CONSOLE

CAYENNE S DIESEL, CAYENNE (3.0)) > TEACHING ROOF CONSOLE
Tools:
PIWIS Tester II 9818 with PIWIS Tester test software version 14.300 (or higher) installed.
Suitable battery charger (charging current of at least 40 A), e.g. Battery charger 45A WE 1393
Procedure:
Information
The procedure described here is based on the PIWIS Tester II test software version 14.300 .
The PIWIS Tester instructions take precedence and in the event of a discrepancy, these are the
instructions that must be followed.
A discrepancy may arise with later software versions for example.
1. Connect a battery charger with a current rating of at least 40 A to the jump-start terminals in
the engine compartment.
2. Switch on the ignition using the original driver's key .
To do this, replace the control panel in the ignition lock with the original driver's key if
necessary.
3. PIWIS Tester II 9818 with software version 14.300 (or higher) installed must be connected to
the vehicle communication module (VCI) via the USB cable . Then, connect the
communication module to the vehicle and switch on the PIWIS Tester.
4. On the PIWIS Tester start screen, call up the ==> 'Diagnostics' menu and select the relevant
vehicle type.
The diagnostic application is then started and the control unit selection screen is populated.
5. Re-code rear-end electronics control unit automatically.
1. 5.1. In the control unit selection screen (==> 'Overview' menu), select the ==
'Rear-end electronics' control unit and press [>>] to confirm your selection → see
Fig 1.
Fig 1: Display - Rear-End Electronics Screen
2. 5.2. Once the 'rear-end electronics' control unit has been found and is displayed in
the overview, select the ==> 'Codings/adaptations' menu.
3. 5.3. Select the ==> 'Automatic coding' function and press [>>] to start coding →
see Fig 2.
Fig 2: Display - Automatic Coding Screen
4. 5.4. When coding is complete, the message "Coding has been completed
successfully" is displayed and a tick appears in the 'Status' box → see Fig 3.
If coding is not completed successfully (error message "Coding was not completed
successfully"), coding must be repeated .
Fig 3: Display - Coding Successful Screen
5. 5.5. Once coding has been completed successfully, press [>>] to return to the start
page of the ==> 'Codings/adaptations' menu.
6. Teach the roof console to suit the vehicle.
1. 6.1. Select the ==> 'Drive links/checks' menu on the PIWIS Tester.
2. 6.2. Select the ==> 'Teach' function and press [>>] to confirm your selection → see
Fig 4.
Fig 4: Display - Teach Function Screen
3. 6.3. Select the ==> 'Teach roof console' function and confirm your selection by
pressing [>>] (→ see Fig 5).
Fig 5: Display - Teaching Roof Console Screen

4. 6.4. Start the ==> 'Teach roof console' function by pressing [F8].
Once the roof console has been taught, the message "Successful execution
without return value" appears in the PIWIS Tester display → see Fig 6.
If the roof console cannot be taught successfully, the process must be repeated .
Fig 6: Display - Successful Execution Without Return Value Screen
5. 6.5. Once the roof console has been taught successfully, press [<<] to return to the
start page of the ==> "Drive links/checks" menu.
6. 6.6. Select the ==> 'Overview' menu and press [<<] to return to the control unit
selection screen.
7. Read out and erase fault memories.
1. 7.1. In the control unit selection screen (==> 'Overview' menu), press [F7] to call up
the ==> 'Additional menu' (→ see Fig 7).
Fig 7: Display - Control Unit Selection Screen
2. 7.2. Select the function ==> 'Read all fault memories and erase if required' and
press [>>] to confirm → see Fig 8.
The fault memories of the control units are read out.

Fig 8: Display - Erasing Fault Memories Screen
3. 7.3. Once you have read out the fault memories, delete the fault memory entries by
pressing [F8].
4. 7.4. Confirm the query as to whether you really want to delete all fault memory
entries and press [>>] ("Yes") to confirm.
The faults stored in the fault memories of the various control units are deleted.
Information
The fault memories of individual control units (e.g. fault memories of the control units
for front-end electronics, rear-end electronics, etc.) cannot be erased, proceed as
follows:
1. Switch off ignition .
2. Disconnect the PIWIS Tester diagnostic connector from the diagnostic socket .
3. Lock the vehicle using the driver's key .
4. Wait approx. 1 minute before unlocking the vehicle again .
5. Plug the PIWIS Tester diagnostic connector into the diagnostic socket again
and restore communication with the vehicle .
6. Read out the fault memories of these control units again and erase the fault
memories separately .
If control units are found to have faults, which cannot be erased and are not caused
by replacing the roof console, these faults must be found and corrected.
5. 7.5. Once you have erased the fault memories, select the ==> 'Overview' menu and
press [<<] to return to the control unit selection screen → see Fig 9.
Fig 9: Display - Control Unit Selection Screen
9. Disconnect the PIWIS Tester from the vehicle.
10. Switch off and disconnect the battery charger.
11. On vehicles with Porsche Entry & Drive, replace the original vehicle key in the ignition lock with
the control panel again.
WM 708419 REMOVING AND INSTALLING HEADLINER (CAYENNE, CAYENNE GTS,

Bracket for rear Item 2 Tightening 9 Nm (6.5 ftlb.)

luggage net torque
cover

luggage net torque
cover at the
sides
Loosening holder at luggage net cover at the sides

WORK FOR REMOVING AND INSTALLING HEADLINER
1. Remove A-pillar trim panel. → 705719 REMOVING AND INSTALLING A-PILLAR TRIM
PANEL
2. Remove B-pillar trim panel. → 706719 REMOVING AND INSTALLING UPPER PART OF
B-PILLAR TRIM PANEL
3. Loosen C-pillar trim panel. → 706819 REMOVING AND INSTALLING C-PILLAR TRIM PANEL
4. Remove D-pillar trim panel. → 706919 REMOVING AND INSTALLING D-PILLAR TRIM
PANEL
5. Remove roof console. → 708319 REMOVING AND INSTALLING ROOF CONSOLE
6. Remove sun visors. → 682319 REMOVING AND INSTALLING SUN VISOR
7. Remove front grab handles. → 683519 REMOVING AND INSTALLING FRONT GRAB
HANDLE
8. Remove rear grab handles. → 683719 REMOVING AND INSTALLING REAR GRAB HANDLE
9. Remove luggage compartment lamp. → 964019 REMOVING AND INSTALLING LUGGAGE

COMPARTMENT LAMP
10. Remove front camera. → 963819 REMOVING AND INSTALLING FRONT CAMERA
11. Remove rain sensor. → 921219 REMOVING AND INSTALLING RAIN SENSOR

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING HEADLINER
Information
Additional assembly operations must be performed on vehicles with sunroof or roof assembly.
Information
Make sure that the roof cover does not buckle.
Information
1. Unscrew and remove screws -1- for headliner under the roof console.
Fig 1: Identifying Headliner Screws At Front
2. Unclip headliner at the fixing clips close to the sliding-roof cut-out (only on vehicles with sliding
roof).
Fig 2: Unclipping Headliner At Sliding Roof
1. 2.1. Check the fixing clips on the headliner close to the sliding-roof cut-out for
deformation and replace them if necessary.
3. Unscrew and remove screws -2- on bracket for luggage compartment net cover at the D-pillar.
4. Unscrew and remove screws -1- on bracket for luggage net cover at the sides.
Fig 4: Loosening Holder At Luggage Net Cover
5. Loosen headliner at the fixing clips -3- at the rear of the body.
Fig 5: Identifying Clips Of Rear Roof Trim Panel
6. Carefully press roof lining down and unclip electric line -1- at the bracket -2- .
Fig 6: Unclipping Electric Line
7. Fold over the rear seat backrest.
8. Move the driver and passenger seat all the way forward and down.
9. Move the driver and passenger seat backrest back as far as possible.
10. Three people are needed in order to remove the headliner.
1. 10.1. Position of first person: Driver's side
2. 10.2. Position of second person: Passenger's side
3. 10.3. Position of third person: Luggage compartment
1. 11.1. Lower the headliner -1- on the passenger's side down as far as possible -A- .
2. 11.2. Pull the headliner -1- out towards the rear through the cut-out in the tailgate
-B- .
Fig 7: Removing Headliner

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING HEADLINER
Information
Make sure that the roof cover does not buckle.
1. Guide in the headliner -1- .
1. 1.1. Slide the headliner into the vehicle through the cut-out in the rear lid -B- .
2. 1.2. Lower the headliner -1- on the passenger's side down as far as possible -A- .
Fig 1: Installing Headliner
2. Carefully press roof lining down and clip electric line -1- into the bracket -2- .
Fig 2: Clipping Electric Line
3. Position the headliner on the roof of the vehicle and clip in the fixing clips -3- at the rear by
pressing them.
Fig 3: Identifying Clips Of Rear Roof Trim Panel
4. Check the fixing clips on the headliner close to the sliding-roof cut-out for deformation and
replace them if necessary.
5. Clip in the headliner close to the sliding-roof cut-out using the fixing clips (only on vehicles with
a sliding roof).
Fig 4: Clipping Headliner At Sunroof
6. Screw in screws -1- on bracket for luggage net cover at the sides and tighten to Tightening
Fig 5: Identifying Screws Of Holder
7. Screw in screws -2- on bracket for luggage net cover for rear luggage compartment and
tighten to Tightening torque 9 Nm (6.5 ftlb.) .
Fig 6: Identifying Screws On Bracket For Rear Luggage Net Cover
8. Screw in screws for the headliner under the roof console -1- .
Fig 7: Identifying Roof Console

WORK FOR REMOVING AND INSTALLING HEADLINER
1. Install rain sensor. → 921219 REMOVING AND INSTALLING RAIN SENSOR
2. Install front camera. → Installing Front Camera
3. Install A-pillar trim panel. → Installing A-Pillar Trim Panel
4. Install B-pillar trim panel. → 706719 REMOVING AND INSTALLING UPPER PART OF
B-PILLAR TRIM PANEL
5. Secure C-pillar trim panel. → 706819 REMOVING AND INSTALLING C-PILLAR TRIM PANEL
6. Install D-pillar trim panel. → 706919 REMOVING AND INSTALLING D-PILLAR TRIM PANEL
7. Install roof console. → Installing Roof Console
8. Install sun visors. → 682319 REMOVING AND INSTALLING SUN VISOR

9. Install front grab handles. → 683519 REMOVING AND INSTALLING FRONT GRAB HANDLE
10. Install rear grab handles. → 683719 REMOVING AND INSTALLING REAR GRAB HANDLE
11. Install luggage compartment lamp. → 964019 REMOVING AND INSTALLING LUGGAGE
COMPARTMENT LAMP
WM 708719 REMOVING AND INSTALLING TRIM PANEL FOR REAR LID (CAYENNE,
TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING TRIM PANEL FOR REAR
LID
1. Open the tailgate (rear lid).
2. Remove lower part of rear trim panel.
1. 2.1. Open lid of warning triangle storage compartment -A- .

Fig 1: Opening Warning Triangle Lid
2. 2.2. Remove warning triangle.
3. 2.3. Unscrew fastening screws -1- under the loop for securing the warning triangle.
Fig 2: Identifying Mounting Screws Of Warning Triangle
4. 2.4. Unclip two luggage compartment lamps -1- using a screwdriver.

Fig 3: Removing Luggage Compartment Lamps
5. 2.5. Release electric plug connection for luggage compartment lamps -2- at the side
of the connector -a- and disconnect it -B- .
Fig 4: Releasing Electric Plug Connection For Luggage Compartment Lamp
6. 2.6. Unscrew fastening screws -3- in the two finger plates.

Fig 5: Identifying Screws In Finger Plates
7. 2.7. Only with power tailgate closing facility:
Unclip switch for power tailgate closing. To do this, grasp the luggage compartment
lamp through the opening and press the switch out from the rear.
8. 2.8. Only with power tailgate closing facility:
Disconnect electric plug connection -a- .

9. 2.9. Unclip the clips -4- for the lock cover -5- using a plastic wedge and pull them off
in direction of arrow.
Fig 7: Removing Lock Cover
10. 2.10. Carefully unclip the clips for the lower part of the trim panel -6- at the marked
areas using a suitable tool.
Fig 8: Removing Retaining Clips From Lower Part Of Tailgate Trim Panel
11. 2.11. Remove lower part of trim panel by pulling it downwards.
WM 708719 REMOVING AND INSTALLING TRIM PANEL FOR REAR LID (CAYENNE,
TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING TRIM PANEL FOR
REAR LID
Information
WM 709019 REMOVING AND INSTALLING LOUDSPEAKER TRIM PANEL (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION > COMPONENT
OVERVIEW
Fig 1: Identifying Loudspeaker Trim Panel Installation Position
1. Loudspeaker trim panel at the left and right
2. Loudspeaker trim panel at the center

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING LOUDSPEAKER TRIM
PANEL > REMOVING LOUDSPEAKER TRIM PANEL AT THE LEFT AND RIGHT
Information
Information
1. Unclip loudspeaker trim panel from the dashboard using a plastic wedge -arrow- .
Fig 1: Unclipping Loudspeaker Trim Panel From Dashboard

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING LOUDSPEAKER TRIM
PANEL > REMOVING LOUDSPEAKER TRIM PANEL AT THE CENTRE
Information
1. Unclip rear part of loudspeaker trim panel -1- from the dashboard -2- (-A- ), then unclip the
other locking lugs.
Fig 1: Removing Loudspeaker Trim Panel
2. Lift loudspeaker trim panel -1- up slightly.
3. Release and disconnect electric plug connection on the compass -arrow- .

Fig 2: Disconnecting Electric Plug Connection On Compass

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING LOUDSPEAKER TRIM
PANEL > INSTALLING LOUDSPEAKER TRIM PANEL AT THE LEFT AND RIGHT
The loudspeaker trim panel at the left and right is installed in reverse order to removal .

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING LOUDSPEAKER TRIM
PANEL > INSTALLING LOUDSPEAKER TRIM PANEL AT THE CENTRE
The loudspeaker trim panel at the center is installed in reverse order to removal .
WM 709119 REMOVING AND INSTALLING LID HINGE TRIM (CAYENNE, CAYENNE

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING > REMOVING LID-HINGE COVER
Information
1. Unclip lid-hinge cover -1- using a plastic wedge -2- and remove it.
Fig 1: Removing Lid-Hinge Cover
WM 709119 REMOVING AND INSTALLING LID HINGE TRIM (CAYENNE, CAYENNE

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING > INSTALLING LID-HINGE
COVER
Information
1. Insert lid-hinge cover -1- with the guides -2- into the cut-outs and press it in until they engage
securely.
Fig 1: Installing Lid-Hinge Cover
WM 709219 REMOVING AND INSTALLING TRIM PANEL FOR TAILGATE (CAYENNE,

REAR LID

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING TRIM PANEL FOR
TAILGATE > REMOVING TAILGATE TRIM PANEL
Information
1. Remove trim panel for center window frame.

Fig 1: Removing Centre Window Frame
1. 1.1. Carefully unclip center clip -A- using a suitable tool.
2. 1.2. Carefully unclip outer clips -B- using a suitable tool.
3. 1.3. Remove center window trim panel in direction of arrow -C- .
2. Remove trim panels for window frame at the side.
1. 2.1. Carefully unclip the clips -1 to 4- one after the other in direction of arrow using a
suitable tool.
Fig 2: Removing Side Trim Panel
2. 2.2. Remove trim panels for window frame at the side.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING TRIM PANEL FOR
TAILGATE > INSTALLING TAILGATE TRIM PANEL
Information

1. Install trim panel for rear lid. → 708719 REMOVING AND INSTALLING TRIM PANEL FOR
REAR LID
Service Manual: 72 - SEAT FRAMES -- 92A CAYENNE
WM 720119 REMOVING AND INSTALLING FRONT SEAT (CAYENNE, CAYENNE GTS,
Fastening Tightening 50 Nm (37 +/-7.5 Nm (+/-

screws for front torque ftlb.) 5.5 ftlb.)
seat rail
Tightening fastening screws on front seat rail
Fastening Tightening 50 Nm (37 +/-7.5 Nm (+/-

screws for rear torque ftlb.) 5.5 ftlb.)
seat rail
Securing front seat to seat frame at the rear

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT SEAT
starting terminals.
avoided.
airbag.
person.
Information
Fig 1: Identifying Front Seat
1. Move backrest all the way forward. Move front seat all the way up and all the way forward.
2. Release rear caps -1- and pull them off the seat rails.
Fig 2: Identifying Caps On Rear Seat Rail
3. Unscrew fastening screws on the rear seat rails -2- .

Fig 3: Removing Screws On Rear Seat Rail
4. Remove seat belt mount.
1. 4.1. Disengage cap -1- and slide it over the seat belt mount -2- .
Fig 4: Identifying Seat Belt Mount On Front Seat
2. 4.2. Release retaining clip -3- on the seat belt mount using a suitable screwdriver
-arrow A- .
Fig 5: Releasing Seat Belt Mount
3. 4.3. Push seat belt mount over the retaining pin -arrow B- until the locking lug under
the retaining pin loosens the clip.
4. 4.4. Remove seat belt mount from the retaining pin.
5. Move the front seat back fully and lower the rear seat surface.
6. Remove remote control. Disconnect the battery. Route or isolate the ground strap so that all
contact with a ground carrier (e.g. body, seat frame) is avoided. → 2X00IN WORK
INSTRUCTIONS AFTER DISCONNECTING THE BATTERY .
7. Release front caps -3- and remove them from the seat rails.
Fig 6: Identifying Caps On Front Seat Rail
8. Unscrew and remove fastening screws on the front seat rail -4- .
Fig 7: Removing Screws On Front Seat Rail
9. Fold the front seat back.
10. Release and disconnect electric plug connections for the driver seat -1, 2 and 3- .
11. Release and disconnect electric plug connections for the passenger seat -1, 2 and 3- .
Fig 9: Removing Electric Plug Connections For Passenger Seat
12. Carefully remove the front seat.

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT SEAT
Information
1. Place front seat in the vehicle and tilt it backwards.
2. Plug in electric plug connections for the driver seat -1, 2 and 3- .
3. Plug in electric plug connections for the passenger seat -1, 2 and 3- .
Fig 2: Removing Electric Plug Connections For Passenger Seat
4. Fold the front seat forward -arrow A- and align it on the seat frame with the centering pins
-arrow B- .
Fig 3: Positioning Front Seat On Seat Frame
5. Connect the battery → 2X00IN WORK INSTRUCTIONS AFTER DISCONNECTING THE

BATTERY .
1. Danger of injury
2. Loss of torque
6. Move front seat all the way back. Screw in front fastening screws -4- only until the seat rails
are touching the seat console.
Fig 4: Tightening Screws On Front Seat Rail
7. Move the front seat all the way forward and secure it to the seat console at the rear with the
fastening screws -2- by tightening them to Tightening torque 50 Nm (37 ftlb.) +/-7.5 Nm (+/-5.5
Fig 5: Securing Front Seat To Rear Seat Console
8. Carefully fit the rear caps -1- .

Fig 6: Identifying Caps On Rear Seat Rail
9. Move the front seat all the way back and secure it to the seat console at the front with
fastening screws -4- by tightening them to Tightening torque 50 Nm (37 ftlb.) +/-7.5 Nm (+/-5.5
Fig 7: Tightening Screws On Front Seat Rail
10. Fit the caps at the front -3- on the seat rail.
Fig 8: Identifying Caps On Front Seat Rail
11. Install seat belt mount.
1. 11.1. Position seat belt mount -2- on the retaining pin -4- and pull upward until the
retaining clip -3- locks with an audible click.
Fig 9: Identifying Seat Belt Mount On Front Seat
2. 11.2. Pull on the belt strap. The retaining clip -3- must engage fully on the holder.
3. 11.3. Push the cap -1- over the seat belt mount -2- and lock it. The label on the seat
belt must be pushed into the cap when you slide the cover down.
WM 720919 REMOVING AND INSTALLING FRONT SEAT CONSOLE (CAYENNE,


screws for seat torque ftlb.)
console
Installing seat console

1. Remove front floor covering. → 704119 REMOVING AND INSTALLING FRONT FLOOR
COVERING

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT SEAT CONSOLE
Fig 1: Identifying Front Seat Console Installation Position
1. Lift up rear floor covering in the front area.
2. Unscrew and remove four fastening screws -1- on the seat console at the driver's side and
three fastening screws on the seat console at the passenger's side.
Fig 2: Removing Seat Console
3. Remove front seat console by pulling it upwards.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT SEAT
CONSOLE
1. Position seat console on the vehicle floor.
2. Tighten four fastening screws -1- on the seat console at the driver's side and three fastening
screws on the seat console at the passenger's side to Tightening torque 50 Nm (37 ftlb.).
Fig 1: Installing Seat Console

1. Install front floor covering. → 704119 REMOVING AND INSTALLING FRONT FLOOR
COVERING
WM 720919 REMOVING AND INSTALLING FRONT SEAT FRAME (CAYENNE,

INSTALLATION POSITION
Fig 1: Identifying Seat Frame Installation Position

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT SEAT FRAME
1. Remove backrest frame. → 721919 REMOVING AND INSTALLING FRONT BACKREST

FRAME
2. Remove seat frame.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT SEAT FRAME
1. Position the seat frame.
2. Install backrest frame. → 721919 REMOVING AND INSTALLING FRONT BACKREST

FRAME
WM 720955 REPLACING FRONT SEAT FRAME (CAYENNE, CAYENNE GTS, CAYENNE

DIESEL, CAYENNE (3.0)) > COMPONENT INFORMATION > INSTALLATION POSITION
Fig 1: Identifying Seat Frame Installation Position

1. Remove backrest frame. → 721919 REMOVING AND INSTALLING FRONT BACKREST

FRAME

DIESEL, CAYENNE (3.0)) > REPLACING FRONT SEAT FRAME
1. Remove padding for front seat. → 741019 REMOVING AND INSTALLING PADDING FOR
FRONT SEAT
2. Remove air cushion for seat. → 721419 REMOVING AND INSTALLING AIR CUSHION FOR
SEAT
3. On passenger's side only: Remove front seat occupancy detection system. → 695619
REMOVING AND INSTALLING SEAT OCCUPANCY DETECTION
4. Remove front belt lock. → 692419 REMOVING AND INSTALLING FRONT BELT LOCK
5. Remove control unit for memory seat adjustment. → 729319 REMOVING AND INSTALLING
CONTROL UNIT FOR MEMORY SEAT ADJUSTMENT
6. Remove wire harness for power seats. → 975719 REMOVING AND INSTALLING WIRE
HARNESS FOR POWER SEATS
7. Remove footwell lighting. → 961519 REMOVING AND INSTALLING FOOTWELL LIGHT
8. Replace front power seat frame.
9. Install footwell lighting. → 961519 REMOVING AND INSTALLING FOOTWELL LIGHT
10. Install wire harness for power seats. → Installing Wire Harness For Power Seats
11. Install control unit for memory seat adjustment. → 729319 REMOVING AND INSTALLING
12. Install front belt lock. → 692419 REMOVING AND INSTALLING FRONT BELT LOCK
13. On passenger's side only: Install front seat occupancy detection system. → 695619
REMOVING AND INSTALLING SEAT OCCUPANCY DETECTION
14. Install air cushion for seat. → 721419 REMOVING AND INSTALLING AIR CUSHION FOR
SEAT
FRONT SEAT

DIESEL, CAYENNE (3.0)) > SUBSEQUENT WORK
1. Install backrest frame. → 721919 REMOVING AND INSTALLING FRONT BACKREST

FRAME
WM 721419 REMOVING AND INSTALLING AIR CUSHION FOR SEAT (CAYENNE,

FRONT SEAT

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING AIR CUSHION FOR SEAT
1. Release and pull off the pressure line (red) -1- under the seat.
2. Remove tie-wrap.
Fig 1: Identifying Pressure Line
Information
1. Some of the repair illustrations show only one side of the vehicle .
2. Naturally, some steps also have to be performed on the opposite side of the vehicle as
well .
3. Unclip fixing clips -1- on both air cushions -2- from the brackets.
Fig 2: Loosening Air Cushions For Seat
4. Pull both air cushions -2- through the cut-out in the seat frame -A- .
5. Guide out pressure lines and remove air cushion.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING AIR CUSHION FOR
SEAT
Information
1. Pull both air cushions -1- up through the cut-outs in the seat frame from below -A- .
Fig 1: Fitting Air Cushion For Seat
2. Clip fixing clips -2- for both air cushions -1- into the brackets.
3. Fit the pressure line (red) -1- under the seat.

4. Secure the pressure line with a new tie-wrap.

1. Install padding for front seat. → 741019 REMOVING AND INSTALLING PADDING FOR
FRONT SEAT
WM 721619 REMOVING AND INSTALLING FRONT SEAT TRIM (EXCEPT CAYENNE,

PRELIMINARY WORK FOR STORAGE TRAY
1. Remove the front seat. → 720119 REMOVING AND INSTALLING FRONT SEAT

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT SEAT TRIM
Information
Information
1. Move front seat to the rearmost position.
2. Press in expansion rivet pin -1- and pull out the expansion rivet.
Fig 1: Detaching Seat Trim On Outside
3. Pull the outside of the seat trim -2- at the rear outwards -A- and press it up at the same time
-B- .
4. Pull the outside of the seat trim -2- forward out of the bracket -C- .
Fig 2: Removing Seat Trim On Outside
5. Release electric plug connection for seat adjustment -a- and pull it off -A- .
Fig 3: Unplugging Connector For Seat

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT SEAT TRIM >
REMOVING STORAGE TRAY UNDER SEAT
1. Open up storage tray.

Fig 1: Identifying Storage Tray Screws
3. Release the lock -1- on both sides using a screwdriver -A- .

Fig 2: Removing Storage Tray
4. Slide the storage tray back -B- and remove it from the guides -2- .

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT SEAT TRIM
Information
Replace expansion rivets and fixing clips during installation and do not re-use them.
1. The front seat trim is installed in reverse order to removal.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT SEAT TRIM >
INSTALLING STORAGE TRAY UNDER SEAT
1. The storage tray under the seat is installed in reverse order to removal.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > SUBSEQUENT WORK FOR
STORAGE TRAY UNDER SEAT
1. Install the front seat. → Installing Front Seat
WM 721619 REMOVING AND INSTALLING FRONT SEAT TRIM PANEL (CAYENNE,

PRELIMINARY WORK FOR STORAGE TRAY
1. Remove front seat. → 720119 REMOVING AND INSTALLING FRONT SEAT

PANEL > REMOVING TRIM PANEL FOR FRONT SEAT
Information
Information
2. Press in expansion rivet pin -1- and pull out the expansion rivet.
Fig 1: Loosening Trim Panel For Seat At Outside
3. Pull the outside of the seat trim panel -2- at the rear outwards -A- and press it up at the same
time -B- .
4. Press locking mechanism and pull the outside of the seat trim panel -2- forward out of the
bracket -C- .
Fig 2: Removing Trim Panel For Seat At Outside
5. Release electric plug connection for seat adjustment -a- and disconnect it -A- .
Fig 3: Disconnecting Connector For Seat

PANEL > REMOVING STORAGE TRAY UNDER SEAT
1. Open up storage tray.

Fig 1: Identifying Storage Tray Screws
3. On vehicles with memory seat adjustment, unscrew front screw -1- for control unit bracket.
Fig 2: Identifying Control Unit Bracket Screw
4. Release locking mechanism -1- on both sides using a screwdriver -A- .

Fig 3: Removing Storage Tray
5. Slide the storage tray back -B- and remove it from the guides -2- .

PANEL > INSTALLING TRIM PANEL FOR FRONT SEAT
Information
The trim panel for the front seat is installed in reverse order to removal .

PANEL > INSTALLING STORAGE TRAY UNDER SEAT
The storage tray under the seat is installed in reverse order to removal .
TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > SUBSEQUENT WORK FOR
STORAGE TRAY UNDER SEAT
1. Install front seat. → Installing Front Seat
WM 721719 REMOVING AND INSTALLING AIR CUSHION FOR FRONT BACKREST

VALUES
Fastening screw Item 1 Tightening 2.5 Nm (2 ftlb.) +/-0.3 Nm (+/-

securing holder torque 0.2 ftlb.)
for air cushion
to backrest
Loosening air cushion for backrest

WORK
1. Remove padding for front backrest. → 741719 REMOVING AND INSTALLING PADDING FOR
FRONT BACKREST
2. Unclip control valve for air cushion from the bracket. → 723819 REMOVING AND
INSTALLING CONTROL VALVE FOR AIR CUSHION

AIR CUSHION FOR BACKREST
1. Remove tie-wrap -1- from the air cushion pressure line (green) -2- .
Fig 1: Identifying Pressure Line And Tie-Wrap
2. Release control valve pressure line (green) -3- from the air cushion pressure line (green) -2-
and pull it off.
Electric plug connection on servo motor
3. Unscrew fastening screws -1- on the air cushion and remove air cushion -2- .
Fig 2: Identifying Screws Of Air Cushion For Backrest

AIR CUSHION FOR BACKREST
1. Fit air cushion -2- and tighten fastening screws -1- to Tightening torque 2.5 Nm (2 ftlb.)
+/-0.3 Nm (+/-0.2 ftlb.) .
Fig 1: Identifying Air Cushion And Screws
2. Connect control valve pressure line (green) -3- to the air cushion pressure line (green) -2- .
3. Fit tie-wrap -1- on the air cushion pressure line (green) -2- .

WORK
1. Clip control valve for air cushion into the bracket. → 723819 REMOVING AND INSTALLING
CONTROL VALVE FOR AIR CUSHION
2. Install padding for front backrest. → 741719 REMOVING AND INSTALLING PADDING FOR
FRONT BACKREST
WM 721919 REMOVING AND INSTALLING FRONT BACKREST FRAME (CAYENNE,


Fastening screw Item 5 Tightening 7.5 Nm (5.5 +/-0.5 Nm (+/-
securing side torque ftlb.) 0.5 ftlb.)
bracket to seat
Securing bracket at the sides
Fastening Item 1 Tightening 33 Nm (24 +/-3 Nm (+/- 2

screws securing torque ftlb.) ftlb.)
backrest frame
to seat frame
Removing backrest frame

Fig 1: Identifying Backrest Frame Installation Position

Information
The required preliminary work and subsequent work can vary depending on equipment.
The instructions provided in the document are for vehicles with the maximum possible equipment.
1. Remove side cover for backrest and disengage rear cover for backrest at the underside of the
seat. → 722619 REMOVING AND INSTALLING COVER FOR BACKREST
2. Remove front seat trim panel, without storage tray. → 721619 REMOVING AND INSTALLING
FRONT SEAT TRIM PANEL
3. Disconnect pressure line (red) under the seat. → 723819 REMOVING AND INSTALLING
4. Disconnect wire harness for side airbag at the underside of the seat. → 696319 REMOVING
AND INSTALLING FRONT SIDE AIRBAG
5. On vehicles with heated seats: Unplug electric plug connection for seat heating for backrest
and disconnect wire harness. → 741719 REMOVING AND INSTALLING PADDING FOR
FRONT BACKREST

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING BACKREST FRAME
1. Release two electric plug connections under the seat -arrows a- and disconnect them
-arrows A- .
Fig 1: Disconnecting Wire Harness For Backrest
2. Pull out fixing clip -1- and detach cover for rear seat surface -2- (-arrow A- ).
Fig 2: Loosening Cover For Rear Seat
3. Unscrew fastening screws -3- , pull bracket -4- down -arrow B out of the catches and detach
cover on seat frame.
Fig 3: Loosening Bracket At Sides
A second mechanic is required:
4. First mechanic: Unscrew two fastening screws -1- from the backrest frame on both sides.
Fig 4: Identifying Backrest Frame Screws
5. Second mechanic: Pull electric lines through between the seat frame and seat padding.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING BACKREST FRAME
A second mechanic is required:
1. First mechanic: Fit backrest frame.
1. 1.1. Fit backrest frame on seat frame.
2. 1.2. Pull electric line through between the seat frame and seat padding.
2. Second mechanic: Tighten two fastening screws -1- for the backrest frame on both sides to
Tightening torque 33 Nm (24 ftlb.) +/-3 Nm (+/-2 ftlb.) .
Fig 1: Identifying Screws Of Backrest Frame
3. Engage the bracket -6- from below -arrow J- .

Fig 2: Securing Bracket At Sides
4. Tighten fastening screws -5- to Tightening torque 7.5 Nm (5.5 ftlb.) +/-0.5 Nm (+/-0.5 ftlb.) .
5. Fit fixing clip -7- .

Fig 3: Securing Cover At Rear
6. Engage rear side cover -8- on the seat frame -arrow K- .
7. Fit two electric plug connections at the underside of the seat.

Fig 4: Plugging Connector For Backrest Wire Harness

Information
The required preliminary work and subsequent work can vary depending on equipment.
The instructions provided in the document are for vehicles with the maximum possible equipment.
1. On vehicles with heated seats: Connect electric plug connection for seat heating for
backrest and secure wire harness. → 741719 REMOVING AND INSTALLING PADDING FOR
FRONT BACKREST
2. Secure wire harness for side airbag at the underside of the seat. → Installing Side Airbag
3. Secure pressure line (red) under the seat. → 723819 REMOVING AND INSTALLING
4. Install side trim panel for front seat, without storage tray. → 721619 REMOVING AND
INSTALLING FRONT SEAT TRIM PANEL
5. Install side cover for backrest and engage rear cover for backrest at the underside of the seat.
→ 722619 REMOVING AND INSTALLING COVER FOR BACKREST
WM 721955 REPLACING FRONT BACKREST FRAME (CAYENNE, CAYENNE GTS,

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING BACKREST FRAME
Fig 1: Identifying Backrest Frame Installation Position
1. Remove lumbar support. → 723419 REMOVING AND INSTALLING LUMBAR SUPPORT
2. Remove guide elements for headrest.
1. 2.1. Release guide element at the right -1- and left -2- using a screwdriver -a- and
pull them up and out.
Fig 2: Removing Guide Elements
3. Remove air cushion for backrest. → 721719 REMOVING AND INSTALLING AIR CUSHION
FOR FRONT BACKREST
4. Remove motor for air cushion. → 723919 REMOVING AND INSTALLING MOTOR FOR AIR
CUSHION
5. Remove side airbag. → 696319 REMOVING AND INSTALLING FRONT SIDE AIRBAG
6. Unclip fixing clips on the wire harness and remove wire harness. → 975619 REMOVING AND
INSTALLING WIRING FOR BACKREST
WM 721955 REPLACING FRONT BACKREST FRAME (CAYENNE, CAYENNE GTS,

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING BACKREST FRAME
1. Position wire harness and clip the clips into the backrest frame. → 975619 REMOVING AND
INSTALLING WIRING FOR BACKREST
2. Install side airbag. → Installing Side Airbag
3. Install motor for air cushion. → 723919 REMOVING AND INSTALLING MOTOR FOR AIR
CUSHION
4. Install air cushion for backrest. → 721719 REMOVING AND INSTALLING AIR CUSHION FOR
FRONT BACKREST
5. Install guide element at the right -1- and left -2- for the headrests.
Fig 1: Installing Guide Elements
6. Install lumbar support. → 723419 REMOVING AND INSTALLING LUMBAR SUPPORT
WM 722619 REMOVING AND INSTALLING COVER FOR BACKREST (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING COVER FOR BACKREST
> REMOVING COVER FOR BACKREST AT THE SIDES
Information
2. Press in expansion rivet pins -1- and pull out expansion rivets.
Fig 1: Removing Cover For Backrest At Sides
3. Guide out and remove cover for backrest at the sides -2- on the seat.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING COVER FOR BACKREST
> REMOVING COVER FOR REAR BACKREST
Information
Information
1. Loosen the top fixing clips -2- on the backrest cover -1- (-A- ).
Fig 1: Loosening Cover For Backrest
2. Pull cover for backrest -1- up out of the bracket -3- (-B- ).
Fig 2: Removing Cover For Backrest
3. Guide tension straps -1- out of the retaining lugs -2- .

Fig 3: Loosening Tension Straps
4. Remove cover for backrest.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING COVER FOR
BACKREST > INSTALLING COVER FOR BACKREST AT THE SIDES
Information
1. The cover for the backrest at the sides is installed in reverse order to removal.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING COVER FOR
BACKREST > INSTALLING COVER FOR REAR BACKREST
1. The cover for the rear backrest is installed in reverse order to removal.
WM 723419 REMOVING AND INSTALLING LUMBAR SUPPORT (CAYENNE, CAYENNE

FRONT BACKREST

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING LUMBAR SUPPORT
Fig 1: Identifying Lumbar Support Installation Position
1. Release and disconnect electric plug connections for lumbar support adjustment motor -1-
and lumbar curvature motor -2- (-a- ).
Fig 2: Disconnecting Connectors For Motors
2. Drill out blind rivets -3- using a suitable drill bit.

Fig 3: Drilling Out Blind Rivets
3. Fold the lumbar support up -arrow A- and press the retaining bars -4- at the left and right
together.
Disengage retaining bars -4- from the backrest frame -arrow B- .

Fig 4: Removing Lumbar Support
4. Remove the complete lumbar support from the backrest frame.

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING LUMBAR SUPPORT
1. Press the retaining bars -4- together and engage them in the backrest frame -arrow A- .
2. Fold down lumbar support -arrow B- .

Fig 1: Positioning Lumbar Support
3. Join the lumbar support and backrest frame using a new blind rivet -3- .
Fig 2: Securing Lumbar Support And Backrest Frame
4. Plug in electric plug connections for lumbar support adjustment motor -1- and lumbar
curvature motor -2- until they engage securely.
Fig 3: Plugging Connectors For Motors

FRONT BACKREST
WM 723619 REMOVING AND INSTALLING MOTOR FOR LUMBAR SUPPORT

ADJUSTMENT AND LUMBAR CURVATURE (EXCEPT CAYENNE, CAYENNE GTS,
CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION > COMPONENT
INFORMATION
Fig 1: Identifying Installation Position Of Motor For Lumbar Support Adjustment And Lumbar Curvature

FRONT BACKREST
2. Remove side airbag. → 696319 REMOVING AND INSTALLING SIDE AIRBAG

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING MOTOR FOR LUMBAR SUPPORT
ADJUSTMENT AND LUMBAR CURVATURE > REMOVING MOTOR FOR LUMBAR
SUPPORT ADJUSTMENT
Information
Before removing the motor, move the lumbar support to the middle in order to take the strain off the
cable. If it is not possible to disengage the cable when the lumbar support is in the top position or if it is
blocked, the cable may have to be cut.
1. Release electric plug connection -arrow a- and unplug it -arrow A- .

Fig 1: Unplugging Connector
2. Remove the cable from the bracket -arrow- .

Fig 2: Removing Cable
3. Remove the cable sleeves from the brackets -arrows- .

Fig 3: Removing Cable Sleeve
4. Disengage the cable at the lumbar support -arrow A- and then disengage the cable from the
brackets -arrow B- .
Fig 4: Disengaging Lumbar Support Cable
5. Bore out blind rivets -arrows- and remove motor for lumbar support adjustment together with
the holder.
Fig 5: Locating Blind Rivets

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING MOTOR FOR LUMBAR SUPPORT
ADJUSTMENT AND LUMBAR CURVATURE > REMOVING MOTOR FOR LUMBAR
CURVATURE
1. Release electric plug connection -arrow a- and unplug it -arrow A- .

Fig 1: Unplugging Connector For Motor For Lumbar Curvature
2. Disengage cable sleeve for lumbar curvature by pulling it up out of the guide -arrow A- and
then disengage the cable at the side -arrow B- .
Fig 2: Disengaging Cable Sleeve
3. Disengage cable. To do this, slide the cable nipple up and out -arrow A- and pull the cable at
the side out of the bracket -arrow B- .
Fig 3: Disengaging Cable
4. Remove the deflection roller -1- together with the cable completely in a downward direction.
Remove the operating cable.

Fig 4: Removing Deflection Roller
5. Bore out blind rivets -arrows- and remove motor for lumbar curvature together with the holder.
Fig 5: Locating Blind Rivets On Motor For Lumbar Curvature

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING MOTOR FOR LUMBAR
SUPPORT ADJUSTMENT AND LUMBAR CURVATURE > INSTALLING MOTOR FOR
LUMBAR SUPPORT ADJUSTMENT
1. Install motor for lumbar support adjustment with holder and secure to the backrest frame with
blind rivets -arrows- .
Fig 1: Locating Blind Rivets On Motor For Lumbar Support Adjustment
2. Engage the cable sleeve at the bracket -arrows- for the lumbar support.
Fig 2: Engaging Cable Sleeve On Lumbar Support
3. Engage operating cable with spring in the lumbar support -arrow- .

Fig 3: Engaging Cable With Spring
4. Engage the cable sleeve in the brackets.

Fig 4: Engaging Cable Sleeve In Bracket
5. Engage the operating cable in the bracket -arrows- .

Fig 5: Engaging Operating Cable In Bracket
6. Plug in electric plug connection on the motor for lumbar support adjustment -arrow - until the
lock engages securely.
Fig 6: Plugging In Connector For Motor For Lumbar Support Adjustment

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING MOTOR FOR LUMBAR
SUPPORT ADJUSTMENT AND LUMBAR CURVATURE > INSTALLING MOTOR FOR
LUMBAR CURVATURE
1. Install motor for lumbar curvature with holder and secure to the backrest frame with blind rivets
-arrows- .
Fig 1: Locating Blind Rivets On Motor For Lumbar Curvature
2. Completely engage operating cable with deflection roller -1- .

Fig 2: Engaging Deflection Roller
3. Engage the operating cable at the side -arrow A- and then the cable nipple from above
-arrow B- into the bracket.
Fig 3: Engaging Cable Nipple
4. First engage the operating cable at the side -arrow A- and then the cable sleeve from above
-arrow B- into the guide.
Fig 4: Engaging Cable Sleeve
5. Plug in electric plug connection on the motor for lumbar curvature -arrow- until the lock
engages securely.
Fig 5: Plugging In Connector For Motor For Lumbar Curvature

1. Install side airbag. → 696319 REMOVING AND INSTALLING SIDE AIRBAG
FRONT BACKREST
WM 723819 REMOVING AND INSTALLING CONTROL VALVE FOR AIR CUSHION

FRONT BACKREST

CAYENNE (3.0)) > REMOVING CONTROL VALVE FOR AIR CUSHION
1. Release and disconnect pressure line (red) -1- under the seat.
Fig 1: Disconnecting Pressure Line Under Seat
2. Pull pressure line (red) -1- through between the backrest frame and seat.
3. Release control valve pressure line (green) -3- from the air cushion pressure line (green) -2-
and disconnect it.
Fig 2: Identifying Pressure Line For Air Cushion
4. Unscrew fastening screws from the backrest air cushion. → 721719 REMOVING AND
INSTALLING AIR CUSHION FOR BACKREST
5. Release locking mechanisms -2- on the control valve -1- (-A- ) and remove control valve -B-
.
Fig 3: Disconnecting Control Valve
6. Release pressure line (blue) -3- from the control valve and disconnect it.
Fig 4: Disconnecting Pressure Line And Connector

CAYENNE (3.0)) > INSTALLING CONTROL VALVE FOR AIR CUSHION
1. Connect pressure line (blue) -3- to the control valve.

Fig 1: Connecting Pressure Line And Connector
2. Plug in electric plug connection -4- (-A- ) until the plug connection engages securely.
3. Fit control valve -1- (-A- ) and engage it in the locking mechanisms -2- .
Fig 2: Securing Control Valve
4. Tighten fastening screws for the backrest air cushion. → 721719 REMOVING AND
INSTALLING AIR CUSHION FOR BACKREST
5. Connect control valve pressure line (green) -3- to the air cushion pressure line (green) -2- .
6. Pull pressure line (red) -1- through between the backrest frame and seat.
7. Fit pressure line (red) -1- under the seat.

Fig 4: Identifying Pressure Line Under Seat

FRONT BACKREST
WM 723919 REMOVING AND INSTALLING MOTOR FOR AIR CUSHION (CAYENNE,

FRONT BACKREST

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING MOTOR FOR AIR
CUSHION
Fig 1: Installation Position Of Motor For Air Cushion
1. Unscrew two fastening screws from the backrest air cushion. → 721719 REMOVING AND
INSTALLING AIR CUSHION FOR FRONT BACKREST
2. Release fixing clip -2- for the motor -1- .

Fig 2: Identifying Motor For Air Cushion And Clip
4. Release pressure line (blue) -3- from the control valve and pull it off.
Fig 3: Disconnecting Pressure Line And Connector

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING MOTOR FOR AIR
CUSHION
1. Clip in fixing clip -2- for the motor -1- .

Fig 1: Identifying Motor For Air Cushion
2. Plug in electric plug connection -3- .
3. Connect pressure line (blue) -3- to the control valve.

Fig 2: Connecting Pressure Line And Connector
4. Screw in two fastening screws for the backrest air cushion. → 721719 REMOVING AND
INSTALLING AIR CUSHION FOR FRONT BACKREST

FRONT BACKREST
WM 724719 REMOVING AND INSTALLING 1/3-SPLIT FOLDING REAR BACKREST

WORK > PRELIMINARY WORK FOR REMOVING AND INSTALLING 1/3-SPLIT
FOLDING BACKREST
FOLDING REAR SEAT
1/3-SPLIT FOLDING REAR BACKREST
1. Remove seat trim on the right.
1. 1.1. Unscrew fastening screw -1- on seat trim -2- at the right.
Press the control lever up to do this.
Fig 1: Identifying Right Trim On 1/3-Split Folding Rear Seat And Screw
2. 1.2. Carefully unclip the trim panel at the retaining lugs -3- on the seat.
3. 1.3. Carefully pull the trim panel up and remove it.
2. Remove seat trim on the left.

Fig 2: Identifying Left Trim Panel On 1/3-Split Folding Rear Seat And Screw
1. 2.1. Unscrew the fastening screw -1- on the seat trim -2- at the left.
3. Remove the shaft for 1/3-split folding backrest adjustment.
1. 3.1. Loosen the retaining lugs -1- on the adjustment device using a suitable tool -2-
and press the shaft -3- out from the other side.
Fig 3: Removing Backrest Adjustment Shaft - Step 1
2. 3.2. Pull the shaft -1- out of the seat frame -arrow- .
4. Remove the rear right belt lock. → 692519 REMOVING AND INSTALLING REAR BELT LOCK
5. Unscrew the fastening screws -1-3- on the 1/3-split folding backrest at the right.
Fig 5: Identifying Right Fastening Screws On 1/3-Split Folding Backrest And Screw
6. Unscrew the fastening screws -1-3- on the 1/3-split folding backrest at the left.
Fig 6: Identifying Left Fastening Screws On 1/3-Split Folding Backrest And Screw
7. Take the 1/3-split folding backrest down off the seat.

1. The 1/3-split folding rear backrest is installed in reverse order to removal.
2. Observe the correct tightening torques.

WORK > SUBSEQUENT WORK FOR REMOVING AND INSTALLING 1/3-SPLIT
FOLDING REAR BACKREST
FOLDING REAR SEAT
WORK > PRELIMINARY WORK FOR REMOVING AND INSTALLING 2/3-SPLIT
FOLDING REAR SEAT

1. Remove the left trim panel on the 2/3-split folding rear seat.
Fig 1: Identifying Left Trim Panel On 2/3-Split Folding Rear Seat And Screw
2. 1.2. Carefully unclip the trim panel -2- at the retaining lugs -3- on the seat.
2. Unscrew fastening screw -1- on the seat trim -2- at the right.
Fig 2: Identifying Right Trim Panel On 2/3-Split Folding Rear Seat And Screw
3. Carefully unclip the trim panel -2- at the brackets -3- and lift it up and off.
4. Remove the shaft for 2/3-split folding backrest adjustment.
1. 4.1. Loosen the retaining lugs -1- on the adjustment device using a suitable tool -2-
and press the shaft -3- out from the other side.
2. 4.2. Pull the shaft -1- out of the seat frame -arrow- .
5. Removing the rear belt lock at the center. → 692519 REMOVING AND INSTALLING REAR
BELT LOCK
6. Unscrew the fastening screws -1-3- on the 2/3-split folding backrest at the right.
Fig 5: Identifying Right Fastening Screws On 2/3-Split Folding Backrest And Screw
7. Unscrew the fastening screws -1-3- on the 2/3-split folding backrest at the left.
Fig 6: Identifying Left Fastening Screws On 2/3-Split Folding Backrest And Screw

1. The 2/3-split folding backrest is installed in reverse order to removal.
2. Observe the correct tightening torques.

WORK > SUBSEQUENT WORK FOR REMOVING AND INSTALLING 2/3-SPLIT
FOLDING BACKREST
FOLDING REAR SEAT
WM 724755 REPLACING 1/3-SPLIT FOLDING REAR BACKREST (EXCEPT CAYENNE,

PRELIMINARY WORK FOR REPLACING 1/3-SPLIT FOLDING REAR BACKREST
1. Remove 1/3-split folding backrest. → 724719 REMOVING AND INSTALLING 1/3-SPLIT


TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REPLACING 1/3-SPLIT FOLDING
REAR BACKREST
1. Remove lock for 1/3-split folding rear backrest. → 726319 REMOVING AND INSTALLING
LOCK FOR 1/3-SPLIT FOLDING REAR BACKREST
2. Remove padding for 1/3-split folding backrest. → 745219 REMOVING AND INSTALLING
PADDING FOR 1/3-SPLIT FOLDING REAR BACKREST
3. Remove side airbag for 1/3-split folding rear seat. → 696419 REMOVING AND INSTALLING
REAR SIDE AIRBAG
4. Using a suitable tool, carefully unclip fixing clips -1- for the trim panel on the lashing points -2-
from the backrest -3- from the front.
Fig 1: Identifying Trim Panel On Lashing Point
5. Pull the trim panel out to the rear -2- .
6. Carefully unclip the trim panel -1- on the top lashing point from behind using a suitable tool
-2- and pull it out of the backrest -3- .
Fig 2: Identifying Trim Panel On Top Lashing Point
7. Remove headrest guide.

Fig 3: Removing Headrest Guide
1. 7.1. Carefully press in the retaining lugs -1- on the headrest guide -2- using a
suitable tool -3- .
2. 7.2. Pull the headrest guide -2- up out of the brackets -4- (-arrows- ).
8. Replace backrest frame.
9. Install headrest guide -1- .

Fig 4: Installing Headrest Guide
1. 9.1. Slide the guide -1- for the headrest into the holder -2- on the backrest -3- from
above -arrows- .
10. Clip the trim panel for the top lashing point at the side into the rear cover on the backrest. →
Trim panel on top lashing point
11. Clip the trim panel for the center lashing point into the rear cover on the backrest. → Trim
panel on lashing point
12. Install the side airbag. → Installing Rear Side Airbag
13. Install padding for 1/3-split folding backrest. → Installing Padding For 1/3-Split Folding Rear
Backrest
14. Install lock for 1/3-split folding rear backrest. → 726319 REMOVING AND INSTALLING LOCK
FOR 1/3-SPLIT FOLDING REAR BACKREST

SUBSEQUENT WORK FOR REPLACING 1/3-SPLIT FOLDING REAR BACKREST
1. Install 1/3-split folding rear backrest. → 724719 REMOVING AND INSTALLING 1/3-SPLIT

PRELIMINARY WORK FOR REPLACING 2/3-SPLIT FOLDING REAR BACKREST
1. Remove 2/3-split folding backrest. → 724719 REMOVING AND INSTALLING 2/3-SPLIT


TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REPLACING 2/3-SPLIT FOLDING
REAR BACKREST
1. Remove load-through provision. → 745619 REMOVING AND INSTALLING LOAD-THROUGH

PROVISION
2. Remove lock for 2/3-split folding rear backrest. → 726319 REMOVING AND INSTALLING
3. Remove padding for 2/3-split folding backrest. → 745219 REMOVING AND INSTALLING
PADDING FOR 2/3-SPLIT FOLDING BACKREST
4. Remove rear seat belt at the center. → 691219 REMOVING AND INSTALLING REAR
THREE-POINT SEAT BELT
5. Remove side airbag for 2/3-split folding rear seat. → 696419 REMOVING AND INSTALLING
REAR SIDE AIRBAG
6. Using a suitable tool, carefully unclip fixing clips -1- for the trim panel on the lashing points -2-
from the backrest -3- from the front.
Fig 1: Identifying Trim Panel On Lashing Point
7. Pull the trim panel out to the rear -2- .
8. Carefully unclip the trim panel -1- on the top lashing point from behind using a suitable tool
-2- and pull it out of the backrest -3- .
Fig 2: Identifying Trim Panel On Top Lashing Point
9. Remove headrest guide.

Fig 3: Removing Headrest Guide
1. 9.1. Carefully press in the retaining lugs -1- on the headrest guide -2- using a
suitable tool -3- .
2. 9.2. Pull the headrest guide -2- up out of the brackets -4- (-arrows- ).
10. Replace backrest frame.
11. Install headrest guide -1- .

Fig 4: Installing Headrest Guide
1. 11.1. Slide the guide -1- for the headrest into the holder -2- on the backrest -3- from
above -arrows- .
12. Clip the trim panel for the top lashing point at the side into the rear cover on the backrest. →
Trim panel on top lashing point
13. Clip the trim panel for the center lashing point into the rear cover on the backrest. → Trim
panel on lashing point
14. Install the side airbag. → Installing Rear Side Airbag
15. Install rear seat belt at the center. → Installing Rear Three-Point Belt
16. Install padding for 2/3-split folding backrest. → Installing Padding For 2/3-Split Folding
Backrest
17. Install lock for 2/3-split folding rear backrest. → 726319 REMOVING AND INSTALLING LOCK
18. Install load-through provision. → 745619 REMOVING AND INSTALLING LOAD-THROUGH

PROVISION

SUBSEQUENT WORK FOR REPLACING 2/3-SPLIT FOLDING REAR BACKREST
1. Install 2/3-split folding backrest. → 724719 REMOVING AND INSTALLING 2/3-SPLIT

WM 724819 REMOVING AND INSTALLING 1/3-SPLIT FOLDING REAR SEAT (EXCEPT

VALUES
Fastening Items 1 and 2 Tightening 50 Nm (37 +/-7.5 Nm (+/-

screw, rear, torque ftlb.) 5.5 ftlb.)
M12

screw, front, torque ftlb.) 5.5 ftlb.)
M10

WORK
1. Remove padding for 1/3-split folding rear seat. → 744919 REMOVING AND INSTALLING
PADDING FOR 1/3-SPLIT FOLDING REAR SEAT

1/3-SPLIT FOLDING REAR SEAT
Fig 1: Identifying Installation Position Of 1/3-Split Folding Rear Seat
1. Unscrew fastening screws -1- on 1/3-split folding rear seat.

Fig 2: Identifying Fastening Screws On Rear Seat
2. Unclip electric plug connection -2- from the bracket.

Fig 3: Removing Electric Plug Connections For 1/3-Split Folding Rear Seat
3. Remove 1/3-split folding rear seat from the vehicle.

1. Position 1/3-split folding rear seat in the vehicle.
2. Tighten all fastening screws -1 - 4- hand-tight.
1. Danger of injury
2. Loss of torque

3. Observe tightening sequence 1...4 .

Fig 1: Identifying Tightening Sequence
4. Tighten M12 fastening screws at the rear -1 and 2- to → Tightening torque: 50 Nm (37
ftlb.)+/-7.5 Nm (+/-5.5 ftlb.) .
5. Tighten M10 fastening screws at the front -3 and 4- to → Tightening torque: 50 Nm (37
ftlb.)+/-7.5 Nm (+/-5.5 ftlb.) .
6. Clip electric plug connection -2- into the bracket.


WORK
1. Install padding for 1/3-split folding rear seat. → Installing Padding For 1/3-Split Folding Rear
Seat

VALUES

screw, rear, torque ftlb.) 5.5 ftlb.)
M12
screw, front, torque ftlb.) 5.5 ftlb.)
M10

WORK

Fig 1: Identifying Installation Position Of 2/3-Split Folding Rear Seat
1. Unscrew fastening screws -1- on 2/3-split folding rear seat.

Fig 2: Identifying Fastening Screws On Rear Seat
2. Unclip electric plug connection -2- from the bracket.

3. Remove 2/3-split folding rear seat from the vehicle.

1. Position 2/3-split folding rear seat in the vehicle.
2. Tighten all fastening screws -1 - 4- hand-tight.
1. Danger of injury
2. Loss of torque

3. Observe tightening sequence 1...4 .

Fig 1: Seat Bolts Tightening Sequence
4. Tighten M12 fastening screws at the rear -1 and 2- to → Tightening torque: 50 Nm (37
ftlb.)+/-7.5 Nm (+/-5.5 ftlb.) .
5. Tighten M10 fastening screws at the front -3 and 4- to → Tightening torque: 50 Nm (37
ftlb.)+/-7.5 Nm (+/-5.5 ftlb.) .
6. Clip electric plug connection -2- into the bracket.

Fig 2: Connecting Electric Plug Connections For 2/3-Split Folding Rear Seat

WORK
Install padding for 2/3-split folding rear seat. → Installing Padding For 2/3-Split Folding Rear Seat
WM 726319 REMOVING AND INSTALLING LOCK FOR 1/3-SPLIT FOLDING REAR

BACKREST (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S,
TECHNICAL VALUES
Fastening screw Tightening 20 Nm (15 +/-2 Nm (+/- 1.5

securing lock for torque ftlb.) ftlb)
1/3-split folding
rear backrest
on right trim torque
panel for
1/3-split folding
seat

FOLDING REAR SEAT

REMOVING LOCK FOR 1/3-SPLIT FOLDING REAR BACKREST
1. Remove seat trim panel on the right.
1. 1.1. Unscrew fastening screw -1- on seat trim panel -2- at the right.

Fig 1: Identifying Right Trim Panel On 1/3-Split Folding Rear Seat
2. Remove locking mechanism for 1/3-split folding rear seat.

Fig 2: Removing Lock For 1/3-Split Folding Rear Seat
1. 2.1. Unscrew fastening screw -1- from the locking mechanism -2- .
2. 2.2. Carefully lever off the lock -2- using a suitable tool -3- and remove it from the
joint -4- on the backrest frame.
3. Carefully lever off the joint -1- using a suitable tool -2- and remove it from the backrest frame
-3- .
Fig 3: Removing Joint On Locking Mechanism For 1/3-Split Folding Rear Backrest
4. Carefully unclip the locking lug -1- on the handle -2- of the locking mechanism using a
suitable tool -3- and remove it from the lever -4- . Then pull off the handle.
Fig 4: Removing Handle For Locking Mechanism

INSTALLING LOCK FOR 1/3-SPLIT FOLDING REAR BACKREST
1. Fit the joint -1- of the locking mechanism onto the pin -2- and check that it engages securely.
Fig 1: Identifying Locking Mechanism Joint
2. Install the lever for the locking mechanism.

Fig 2: Identifying Lever For Locking Mechanism
1. 2.1. Carefully clip the lever -1- for the locking mechanism onto the locking lug -2- on
the locking mechanism joint.
2. 2.2. Screw in fastening screw -3- for the locking mechanism and tighten to →
Tightening torque: 20 Nm (15 ftlb.)+/-2 Nm (+/-1.5 ftlb) .
3. Install right trim panel on 1/3-split folding seat.

Fig 3: Right Trim Panel On 1/3-Split Folding Rear Seat
1. 3.1. Guide the trim panel -2- into position on the seat from above and engage it
securely at the clips -3- .
2. 3.2. Screw in fastening screw -1- and tighten to → Tightening torque: 2 Nm (1.5
ftlb.).
4. Slide the handle -1- of the locking mechanism onto the lever -2- until the locking lug engages
securely -3- .
Fig 4: Installing Handle Of Locking Mechanism For 1/3-Split Folding Rear Backrest

FOLDING REAR SEAT

TECHNICAL VALUES
Fastening screw Tightening 20 Nm (15 +/-2 Nm (+/-1.5

securing lock for torque ftlb.) ftlb)
2/3-split folding
rear backrest

on left trim torque
panel for
2/3-split folding
seat

FOLDING REAR SEAT

REMOVING LOCK FOR 2/3-SPLIT FOLDING REAR BACKREST
1. Remove the left trim panel on the 2/3-split folding rear seat.

Fig 1: Identifying Left Trim Panel On 2/3-Split Folding Rear Seat
2. 1.2. Carefully unclip the trim panel -2- at the retaining lugs -3- on the seat.
2. Remove the lever for the locking mechanism.

Fig 2: Identifying Lever For Locking Mechanism And Screws
1. 2.1. Unscrew fastening screw -1- from the locking mechanism -2- .
2. 2.2. Carefully unclip and remove the lever -2- together with the joint at the locking
lug -3- .
3. Carefully unclip the locking lug -1- on the handle -2- of the locking mechanism using a
suitable tool -3- and remove it from the lever -4- . Then pull off the handle.
Fig 3: Removing Handle For Locking Mechanism

INSTALLING LOCK FOR 2/3-SPLIT FOLDING REAR BACKREST
1. Install the lever -2- for the locking mechanism.

Fig 1: Identifying Lever For Locking Mechanism
1. 1.1. Fit the joint on the retaining pin -3- and check that it engages securely.
2. 1.2. Screw in fastening screw -1- for the locking mechanism and tighten to →
Tightening torque: 20 Nm (15 ftlb.)+/-2 Nm (+/-1.5 ftlb) .
2. Install left trim panel on 2/3-split folding rear seat.

Fig 2: Identifying Left Trim Panel On 2/3-Split Folding Rear Seat
1. 2.1. Guide the trim panel into position on the seat from above and engage it securely
at the clips.
2. 2.2. Screw in fastening screw and tighten to → Tightening torque: 2 Nm (1.5 ftlb.).
3. Slide the handle -1- of the locking mechanism onto the lever -2- until the locking lug engages
securely -3- .
Fig 3: Installing Handle Of Locking Mechanism For 2/3-Split Folding Rear Backrest

FOLDING REAR SEAT
WM 728019 REMOVING AND INSTALLING HEADREST (CAYENNE, CAYENNE GTS,

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING HEADREST
Fig 1: Removing Headrest
1. Press adjusting knob -A- and pull headrest up as far as it will go.
2. Press down cushion beside the right headrest guide -B- .
Information
The locking mechanism is on the left-hand side of the vehicle on all outer headrests and must
always be pressed towards the right-hand side of the vehicle.
3. Press locking mechanism inwards with your finger -C- and pull the headrest up -D- and out at
the same time.
WM 728019 REMOVING AND INSTALLING HEADREST (CAYENNE, CAYENNE GTS,

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING HEADREST
1. Push headrest into the headrest guides.
2. Press adjusting knob -A- and push headrest down -B- until the locking lug engages at the
limit stop.
Fig 1: Installing Headrest
WM 728619 REMOVING AND INSTALLING SWITCH FOR SEAT ADJUSTMENT

WORK
1. Remove outside of front seat trim. → 721619 REMOVING AND INSTALLING FRONT SEAT
TRIM

SWITCH FOR SEAT ADJUSTMENT
Fig 1: Identifying Installation Position Of Seat Adjustment Switch

Fig 2: Identifying Seat Adjustment Fastening Screws

SWITCH FOR SEAT ADJUSTMENT
1. Screw in three fastening screws -1- .

Fig 1: Identifying Seat Adjustment Fastening Screws

WORK
1. Install outside of front seat trim. → Installing Front Seat Trim
WM 728719 REMOVING AND INSTALLING MOTOR FOR SEAT ADJUSTMENT

WORK

MOTOR FOR SEAT ADJUSTMENT
Fig 1: Identifying Installation Position Of Motor For Seat Adjustment
1. Push out locking mechanism for cover -2- from the rear and unclip cover -2- (-A- ).
Fig 2: Removing Cover For Motor
2. Pull electric plug connection -3- off the motor -B- .
3. Unscrew two fastening screws -4- .

Fig 3: Identifying Motor And Fastening Screws
4. Unclip fixing clip -5- for the long drive shaft -6- (-C- ).
Fig 4: Locating Long Drive Shaft Clips
5. Carefully bend the long drive shaft -6- (-D- ) and pull it off the motor -1- (-E- ).
6. Unclip the motor -1- from the seat frame -7- (-F- ) and pull it off the short drive shaft -8- (-G-
).
Fig 5: Disconnecting Motor From Short Drive Shaft

MOTOR FOR SEAT ADJUSTMENT
1. Fit the motor -1- on the short drive shaft -8- (-A- ) and engage it in the seat frame -7- (-B- ).
Fig 1: Fitting Motor On Short Drive Shaft
2. Carefully bend the long drive shaft -6- (-C- ) and connect it to the motor -1- (-D- ).
Fig 2: Connecting Long Drive Shaft To Motor
3. Clip in fixing clip -5- for the long drive shaft -6- (-E- ).
4. Screw in two fastening screws -4- .

Fig 3: Identifying Motor And Fastening Screws
5. Plug in electric plug connection -3- on the motor -F- .

Fig 4: Installing Cover For Motor
6. Clip in cover -2- for motor -1- (-G- ) and lock it.

WORK
WM 728819 REMOVING AND INSTALLING MOTOR FOR FRONT VERTICAL

ADJUSTMENT (SEAT ANGLE) (CAYENNE, CAYENNE GTS, CAYENNE TURBO S,
CAYENNE (3.0)) > INFORMATION
The motor for front vertical adjustment (seat angle) cannot be replaced separately. It can only be
replaced together with the front seat frame. → 720955 REPLACING FRONT SEAT FRAME
WM 728919 REMOVING AND INSTALLING MOTOR FOR BACKREST ADJUSTMENT

E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION
The backrest adjustment motor cannot be replaced separately. It can only be replaced together with the
front seat frame. → 720955 REPLACING FRONT SEAT FRAME
WM 729219 REMOVING AND INSTALLING MOTOR FOR REAR VERTICAL

ADJUSTMENT (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE
S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) >
PRELIMINARY WORK
FRONT SEAT

REMOVING MOTOR FOR REAR VERTICAL ADJUSTMENT
Fig 1: Identifying Installation Position Of Motor For Rear Vertical Adjustment
1. Release electric plug connection on motor for rear vertical adjustment -1- and pull it off -A- .
Fig 2: Unplugging Connector From Motor
2. Unscrew fastening screw -2- on the threaded spindle.

Fig 3: Identifying Screw On Threaded Spindle
3. Unscrew two fastening screws -3- on the seat shell at the rear.
Fig 4: Identifying Seat Shell And Screw
4. Unscrew two fastening screws -4- on the seat shell.
5. Lift up the seat shell -5- (-B- ).

Fig 5: Removing Motor For Rear Vertical Adjustment
6. Unscrew two fastening screws -6- on the bracket for the motor.

INSTALLING MOTOR FOR REAR VERTICAL ADJUSTMENT
1. Lift up the seat shell -5- (-B- ).

Fig 1: Installing Motor For Rear Vertical Adjustment
2. Screw in two fastening screws -6- on the bracket for the motor.
3. Screw in two fastening screws -3- on the seat shell at the rear.
Fig 2: Identifying Seat Shell And Screws
4. Screw in two fastening screws -4- on the seat shell.
5. Screw in fastening screw -2- on the threaded spindle.

Fig 3: Identifying Screw On Threaded Spindle
6. Plug in electric plug connection -1- (-A- ) until the connector engages securely.
Fig 4: Plugging In Connector On Motor For Vertical Adjustment

SUBSEQUENT WORK
FRONT SEAT
WM 729319 REMOVING AND INSTALLING CONTROL UNIT FOR MEMORY SEAT

ADJUSTMENT (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S,
TOOLS


PRELIMINARY WORK

REMOVING CONTROL UNIT FOR MEMORY SEAT ADJUSTMENT
NOTE: Voltage peaks
Information
1. Release clip -1- (-a- ), swivel it aside -b- and remove electric plug connection from the
control unit for memory seat adjustment -2- .
2. Release electric plug connection -3- (-c- ) and disconnect it from the control unit for memory
seat adjustment.
3. Release electric plug connection -1- (-a- ) and disconnect it from the control unit for memory
seat adjustment -2- .
4. Disengage control unit for memory seat adjustment -1- by moving it forward out of the holder
-2- and remove it.
Fig 3: Identifying Control Unit For Memory Seat Adjustment

INSTALLING CONTROL UNIT FOR MEMORY SEAT ADJUSTMENT
Installation is performed in reverse order to removal .

SUBSEQUENT WORK
1. Install left front seat. → Installing Front Seat
2. If the control unit for memory seat adjustment was replaced, teach the new control unit for
memory seat adjustment to suit the vehicle using PIWIS Tester II 9818 . → 729355
REPLACING CONTROL UNIT FOR MEMORY SEAT ADJUSTMENT
WM 729355 REPLACING CONTROL UNIT FOR MEMORY SEAT ADJUSTMENT


VALUES

E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > CODING AND
STANDARDIZING CONTROL UNIT
NOTE: Voltage drop
battery.
Information
Tester releases.
2. Connect the PIWIS Tester to the vehicle and start the Tester. Switch on ignition.
4. Select the Driver/Passenger seat memory control unit in the Overview .
5. Extended identifications must now be selected.
6. Check the VIN and correct it if necessary.
8. Automatic coding must then be selected. Press [F12] to start coding.
continue.
10. Control unit replacement must now be selected.
11. Select the Standardize seat motors function, press [F12] to continue and then press [F8] to
start the process.
12. Follow the instructions on the Tester.
13. The seat automatically moves to various seat positions. When the seat remains stationary for a
few minutes, press [F12] to continue.
WM 729419 REMOVING AND INSTALLING SWITCH FOR MEMORY SEAT

PRELIMINARY WORK
1. Remove front door panel. → 705919 REMOVING AND INSTALLING FRONT DOOR PANEL

REMOVING SWITCH FOR MEMORY SEAT ADJUSTMENT
Information
Fig 1: Identifying Installation Position Of Switch For Memory Seat Adjustment
NOTE: Voltage peaks
1. Pull off electric plug connection for switch for memory seat adjustment.
2. Unscrew five fastening screws -1- on cover for door opener from the inside of the door panel.
Fig 3: Identifying Fastening Screws On Cover For Door Opener
3. Unscrew two fastening screws -2- on switch for memory seat adjustment.
4. Slide cover for door opener with switch up slightly -A- , pull it out of the bracket and then
remove it by pulling it forward -B- .
Fig 4: Removing Cover For Door Opener
5. Remove switch for memory seat adjustment -4- from cover for door opener -3- by pulling it
inwards.
Fig 5: Locating Seat Adjustment Switch

INSTALLING SWITCH FOR MEMORY SEAT ADJUSTMENT
1. Fit switch for memory seat adjustment -4- into cover for door opener -3- from inside.
Fig 1: Fitting Switch
2. Engage cover for door opener -3- with switch -4- from above -D- and position it in the door
panel -C- .
Fig 2: Positioning Cover
3. Tighten five fastening screws -1- on cover for door opener.
4. Tighten two fastening screws -2- on switch for memory seat adjustment.
Fig 3: Identifying Fastening Screws On Cover For Door Opener
5. Plug in electric plug connection for switch for memory seat adjustment.
Fig 4: Locating Electric Plug Connection

SUBSEQUENT WORK
1. Install front door panel. → Installing Front Door Panel
WM 729719 REMOVING AND INSTALLING MOTOR FOR ANGLE ADJUSTMENT

The angle adjustment motor cannot be replaced separately. It can only be replaced together with the
front seat frame. → 720955 REPLACING FRONT SEAT FRAME
Service Manual: 74 - SEAT UPHOLSTERIES, COVER -- 92A CAYENNE
WM 740819 REMOVING AND INSTALLING FRONT SEAT-SURFACE EXTENSION
WORK
FRONT SEAT

FRONT SEAT-SURFACE EXTENSION
1. Swivel seat-surface extension -1- upwards -arrow A- .
2. Move the slide -2- into the center of the seat-surface extension -arrow B- .
Fig 1: Positioning Seat-Surface Extension

3. Unclip fixing clips -1- for the cover all the way around.
4. Guide seat-surface extension out of the cover -2- and remove it.
Fig 2: Identifying Seat-Surface Extension Cover And Clip

FRONT SEAT-SURFACE EXTENSION
The seat-surface extension is installed in reverse order to removal .

WORK
FRONT SEAT
WM 740919 REMOVING AND INSTALLING SUCTION FAN FOR SEAT SURFACE

CAYENNE (3.0)) > INFORMATION > INSTALLATION POSITION
Fig 1: Identifying Installation Position Of Suction Fan For Seat Surface

FRONT SEAT

CAYENNE (3.0)) > REMOVING SUCTION FAN FOR SEAT SURFACE
1. Remove expansion rivet -1- .

Fig 1: Identifying Expansion Rivet
2. Disconnect electric plug connection -arrows- for suction fan.

Fig 2: Disconnecting Connector For Suction Fan
3. Unclip the suction fan together with the bracket and remove it by pulling it upwards.
Fig 3: Removing Suction Fan

CAYENNE (3.0)) > INSTALLING SUCTION FAN FOR SEAT SURFACE
Information
1. Position suction fan together with the bracket on the seat surface.
2. Clip in the bracket and secure the suction fan on the seat surface with an expansion rivet -1- .
Fig 1: Identifying Expansion Rivet
3. 31
Plug in electric plug connection -arrows- for suction fan.

Fig 2: Plugging In Connector For Suction Fan

FRONT SEAT
WM 741019 REMOVING AND INSTALLING PADDING FOR FRONT SEAT (CAYENNE,


Cushion clip Commercially Nr.130
pliers available tool

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TOOLS AND MATERIALS
Item Designation Explanation
-2- Cushion clip pliers Nr.130
-a- Cushion clips

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING PADDING FOR FRONT
SEAT
Information
If occupant detection components (installed for country equipment USA/Canada/Mexico) must be

replaced, the repair kit comprising padding, occupant detection control unit and pressure sensor mat
must always be replaced as a complete unit .
The spare parts are grouped in a repair kit (comprising padding -1-, occupant detection control
unit -2- and pressure sensor mat -3-), which must always be replaced as a complete unit .
1. Padding
2. Occupant detection control unit
3. Pressure sensor mat

Fig 1: Identifying Occupant Detection Repair Kit Contents
A mixed installation , e.g. "old" pressure sensor mat and "new" control unit, is not permitted .
The padding, pressure sensor mat and occupant detection control unit are calibrated together by the
manufacturer and must therefore only be replaced as a complete unit.
The occupant detection control unit does not have to be coded.
1. The seat padding is removed together with the seat cover. → 741319 REMOVING AND
INSTALLING COVER FOR FRONT SEAT

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING PADDING FOR FRONT
SEAT
1. The seat padding is installed together with the seat cover. → Installing Cover For Front Seat

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REPLACING PADDING FOR FRONT
SEAT
1. On vehicles with seat-surface extension: Remove padding for seat-surface extension.
2. Cut open cushion clips -circles- using side cutters and remove the cover from the padding.
Fig 1: Removing Cushion Clips
3. Fit the cover and align it with the contour of the padding.
Information
1. Fasten covering to the padding, starting from the middle .
2. Do so in the following sequence: middle, top/bottom, left/right .
4. Fasten the cover to the padding using cushion clip pliers Nr.130 and new cushion clips
-circles- .
Fig 2: Fitting Cushion Clips
WM 741055 REPLACING PADDING FOR FRONT SEAT (CAYENNE, CAYENNE GTS,



CAYENNE S DIESEL, CAYENNE (3.0)) > TOOLS AND MATERIALS
-a- Cushion clips

CAYENNE S DIESEL, CAYENNE (3.0)) > COMPONENT INFORMATION >
INSTALLATION POSITION OF PADDING FOR FRONT SEAT
Fig 1: Identifying Installation Position Of Padding For Front Seat

1. Remove cover for front seat. → 741319 REMOVING AND INSTALLING COVER FOR FRONT
SEAT
2. Remove front seat-surface extension. → 740819 REMOVING AND INSTALLING FRONT

SEAT-SURFACE EXTENSION

CAYENNE S DIESEL, CAYENNE (3.0)) > LOOSENING COVER FOR FRONT SEAT
1. Place padding for front seat on a clean surface.
2. Cut open cushion clips using side cutters and remove the cover from the padding.
Fig 1: Detaching Padding For Front Seat From Cover (Basic/Comfort)

Fig 2: Detaching Padding For Front Seat From Cover (Sport)

CAYENNE S DIESEL, CAYENNE (3.0)) > SECURING COVER FOR FRONT SEAT
1. Place cover on the padding for the front seat and align contour with the padding.
2. Secure the cover to the padding using cushion clip pliers Nr.130 and new cushion clips.
Fig 1: Securing Cover For Front Seat To Padding (Basic/Comfort)

Fig 2: Securing Cover For Front Seat To Padding (Sport)

1. Install front seat-surface extension. → 740819 REMOVING AND INSTALLING FRONT

2. Install cover for front seat. → Installing Cover For Front Seat
WM 741319 REMOVING AND INSTALLING COVER FOR FRONT SEAT (CAYENNE,


Wetting-off iron Special tool 9747
Knurling iron Special tool 9747/1
Bone burnisher Special tool 9747/2

Hot-air blower Commercially v.a.g 1416
available tool


securing torque ftlb.) 0.5 ftlb.)
seat-surface
extension to seat
Installing seat-surface extension

securing side torque ftlb.) 0.5 ftlb.)
bracket to seat
Securing bracket at the sides

1. Remove seat-surface extension fully.
3. Remove front seat trim panel. → 721619 REMOVING AND INSTALLING TRIM PANEL FOR
FRONT SEAT

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING COVER FOR FRONT
SEAT
Information
1. Unclip and remove plastic cover -1- on the seat frame.

Fig 1: Removing Plastic Cover
2. On vehicles with heated seats: Disconnect connector for seat heating.

Fig 2: Disconnecting Connector For Seat Heating
1. 2.1. Release electric plug connection for seat heating -1- (-a- ) and disconnect it
-A- .
2. 2.2. Release electric plug connection for seat heating for seat-surface extension -2-
(-b- ) and disconnect it -B- .
3. Press in expansion rivet pin -1- and pull out expansion rivet.
Fig 3: Detaching Rear Cover
4. Detach the cover at the rear -2- (-A- ).
5. Unscrew fastening screws -3- and pull the bracket -4- down out of the catches -B- .
Fig 4: Loosening Bracket At Sides
6. Disengage the cover at the sides -C- .

Fig 5: Disengaging Cover At Sides
7. Disengage the cover at the front -D- .

Fig 6: Disengaging Cover At Front
8. Press in expansion rivet pin -5- and pull out expansion rivet.
Fig 7: Detaching Cover At Sides
9. Disengage the cover at the rear -F- .
10. Disengage the cover at the sides -G- .
11. Disengage the cover at the rear -H- .

Fig 8: Disengaging Cover At Rear
12. Pull the cover forward between the padding for the seat and backrest -I- .
Fig 9: Pulling Cover Forward
13. Unscrew screws -1- and remove electric motor for seat-surface extension.
14. Unscrew screws -2- and remove seat-surface extension from the seat frame.
Fig 10: Identifying Seat-Surface Extension Screws
15. Remove cover for seat together with the padding and seat-surface extension from the seat
frame.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING COVER FOR FRONT
SEAT
Information
Fasten covering to the padding, starting from the middle .
Do so in the following sequence: middle, top/bottom, left/right .
Information
Installation is performed in reverse order. Pay particular attention to the following:
1. Tighten fastening screws to Tightening torque 7.5 Nm (5.5 ftlb.) +/-0.5 Nm (+/-0.5 ftlb.) .
2. Tighten four fastening screws on the seat-surface extension to Tightening torque 7.5 Nm (5.5
ftlb.) +/- 0.5 Nm (+/-0.5 ftlb.) .

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > SUBSEQUENT WORK > REMOVING
CREASES IN SEAT COVER (LEATHER)
NOTE: Risk of damage to cover if excessive heat is applied.
Creases in cover
=>If creases have formed, only short partial warming with the hot-air gun is permissible.
=>The hot-air temperature of 50 °C must always be observed.
1. If creases have formed, partially heat the affected areas of the cover with the hot-air gun and
smooth out the cover using the special tools.
Wetting-off iron 9747
Knurling iron 9747/1
Bone burnisher 9747/2
Hot-air blower v.a.g 1416

SUBSEQUENT WORK
1. Install front seat trim panel. → Installing Front Seat Trim Panel
WM 741355 REPLACING COVER FOR FRONT SEAT (CAYENNE, CAYENNE GTS,


cushion clip Commercially Nr.130

CAYENNE S DIESEL, CAYENNE (3.0)) > COMPONENT INFORMATION >
Fig 1: Identifying Installation Position Of Cover For Front Seat

1. Remove cover for front seat. → 741319 REMOVING AND INSTALLING COVER FOR FRONT
SEAT
2. Remove front seat-surface extension. → 740819 REMOVING AND INSTALLING FRONT


CAYENNE S DIESEL, CAYENNE (3.0)) > LOOSENING COVER FOR FRONT SEAT
1. Place padding for front seat on a clean surface.
Fig 1: Detaching Padding For Front Seat From Cover (Basic/Comfort)

Fig 2: Detaching Padding For Front Seat From Cover (Sport)

CAYENNE S DIESEL, CAYENNE (3.0)) > SECURING COVER FOR FRONT SEAT
1. Place cover on the padding for the front seat and align contour with the padding.
2. Secure the cover to the padding using cushion clip pliers Nr.130 and new cushion clips.
Fig 1: Securing Cover For Front Seat To Padding (Basic/Comfort)

Fig 2: Securing Cover For Front Seat To Padding (Sport)

1. Install front seat-surface extension. → 740819 REMOVING AND INSTALLING FRONT

2. Install cover for front seat. → Installing Cover For Front Seat
WM 7413N0 ELIMINATING SYMPTOMS IN BODY INTERIOR: REWORKING SEAT

COVER ON "SEAT WITH ACTIVE VENTILATION (I-NO. 4D3)" (SPOTS ON SEAT
COVER/SY0411) (CAYENNE TIP, CAYENNE MAN, CAYENNE S, CAYENNE TURBO,
CAYENNE GTS, CAYENNE S HYBRID, CAYENNE TURBO S, CAYENNE DIESEL,
CAYENNE S DIESEL, CAYENNE TIP (3.0)) > GENERAL INFORMATION > SYMPTOM
Under certain conditions, dark spots can appear near the holes (edge of holes) on vehicles with
equipment "Seat with active ventilation (I-no. 4D3)".

CAYENNE S DIESEL, CAYENNE TIP (3.0)) > GENERAL INFORMATION > CAUSES
AND REMEDIAL ACTION > CAUSE
Information
On perforated seat covers, the pre-dyed color can become darker near the holes (edge of holes) as a
result of dampness or rain water.
This can look like spots under certain lighting conditions and when viewed from certain angles.
=>These spots are not damaged areas on the seat cover and do not therefore constitute defects
from the point of view of the warranty.
=>It is a known fact that perforated leather becomes darker following contact with water.

CAYENNE S DIESEL, CAYENNE TIP (3.0)) > GENERAL INFORMATION > CAUSES
AND REMEDIAL ACTION > REMEDIAL ACTION
Requirements:
Seat heating and seat ventilation must be switched off .
Avoid direct sunlight.
Do not remove water stains or damp spots using leather cleaner or care products .
Procedure:
Wipe off the complete seat surface and backrest surface using a clean, fine-pore sponge and
distilled water . Make sure that the water does not soak right through to the back of the
perforated leather.
Leave the seat cover to dry completely at room temperature and away from direct sunlight.
Do not switch on seat heating and seat ventilation .
Once the seat cover is dry, rub it down with a dry, lint-free cloth.
=> This procedure for carrying out the remedial action is also described in the Driver's Manual.
Information
Please provide your customer with the following information:
Description of how to carry out remedial action .
Let your customer know that these spots are perfectly normal and are not defects on the seat
cover from the point of view of the warranty .

CAYENNE S DIESEL, CAYENNE TIP (3.0)) > TOOLS AND MATERIALS
Distilled water
Clean, fine-pore sponge
Clean, lint-free cloth
WM 741619 REMOVING AND INSTALLING SUCTION FAN FOR BACKREST SURFACE

> COMPONENT INFORMATION
Fig 1: Identifying Installation Position Of Suction Fan For Backrest Surface

WORK
1. Remove cover for backrest. → 722619 REMOVING AND INSTALLING COVER FOR
BACKREST

SUCTION FAN FOR BACKREST SURFACE
1. Detach cover for rear backrest at the top -arrow- .

Fig 1: Disengaging Cover
2. Disconnect electric plug connection for suction fan -arrows- .

Fig 2: Disconnecting Connector For Suction Fan
3. Remove fastenings for suction fan.

Fig 3: Identifying Expansion Rivets
1. 3.1. Press plastic pins -1- through the expansion rivets -2- using a suitable mandrel.
2. 3.2. Remove expansion rivets -2- by pulling them towards the rear.
4. Pull suction fan -1- out of the rubber flange (air guide) -2- (-arrow- ) and remove it by pulling
it towards the rear.
Fig 4: Removing Suction Fan

SUCTION FAN FOR BACKREST SURFACE
Information
1. Position suction fan -1- on the backrest frame and insert it into the rubber flange (air guide)
-2- (-arrow- ).
Fig 1: Positioning Suction Fan
2. Secure the suction fan on the backrest frame with two plastic expansion rivets -2- .
Fig 2: Identifying Expansion Rivets
1. 2.1. Fit expansion rivets -2- .
2. 2.2. Fit plastic pins -1- on the expansion rivets -2- and press them through using a
mandrel.
3. Plug in electric plug connection for suction fan -arrows- .

Fig 3: Plugging In Connector For Suction Fan
4. Attach cover for rear backrest at the top -arrow- .

Fig 4: Attaching Cover

WORK
1. Install cover for backrest. → Installing Cover For Backrest
WM 741719 REMOVING AND INSTALLING PADDING FOR FRONT BACKREST



E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TOOLS AND
MATERIALS
-a- Cushion clips

PADDING FOR FRONT BACKREST
1. The backrest padding is removed together with the backrest cover. → 741919 REMOVING
AND INSTALLING COVER FOR FRONT BACKREST

PADDING FOR FRONT BACKREST
1. The backrest padding is installed together with the backrest cover. → Installing Cover For
Front Backrest
WM 741755 REPLACING PADDING FOR FRONT BACKREST (CAYENNE, CAYENNE



FRONT BACKREST

CAYENNE S DIESEL, CAYENNE (3.0)) > REPLACING PADDING FOR FRONT
BACKREST
1. Cut open cushion clips -circles- using side cutters and remove the cover from the padding.
Fig 1: Detaching Backrest Cover From Padding
2. Fit the cover and align it with the contour of the padding.
Information
1. Fasten covering to the padding, starting from the middle .
2. Do so in the following sequence: middle, top/bottom, left/right .
3. Fasten the cover to the padding using cushion clip pliers Nr.130 and new cushion clips
-circles- .
Fig 2: Fastening Backrest Cover To Padding

FRONT BACKREST
WM 741919 REMOVING AND INSTALLING COVER FOR FRONT BACKREST



Hot-air gun Commercially v.a.g 1416
available tool

E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TOOLS AND
MATERIALS
-a- Cushion clips

WORK
1. Remove headrest. → 728019 REMOVING AND INSTALLING HEADREST
3. Remove front seat trim panel, without storage tray under seat. → 721619 REMOVING AND
INSTALLING FRONT SEAT TRIM PANEL
4. Remove cover for backrest. → 722619 REMOVING AND INSTALLING COVER FOR
BACKREST

COVER FOR FRONT BACKREST
Information
1. Disengage cover from the cut-out for the backrest cover all the way around -arrow- .
2. Pull out plastic rivets -1- .

Fig 1: Detaching Cover From Cut-Out For Backrest Cover
3. Disengage restraining strap -1- for the cover at the left and right.
4. Unclip rear seat cover -2- by pulling it downwards.
5. Loosen fastening screws -3- for ISOFIX clips -4- .

Fig 2: Identifying Restraining Strap Screws
6. Pull the bottom of the cover forward between the backrest and seat -A- .
Fig 3: Loosening Cover For Backrest
7. Release electric plug connection for seat heating (if installed) -1- (-a- ) and disconnect it -A- .
Fig 4: Disconnecting Connector For Seat Heating
8. Cut tie-wrap and guide out electric wire harness for seat heating.
9. Pull padding out between the seat and backrest -A- .

Fig 5: Removing Padding
10. Carefully guide out the top of the cover at the guides for the headrest.
11. Carefully lift padding with cover up and remove it -B- .

COVER FOR FRONT BACKREST
Information
Fasten covering to the padding, starting from the middle .
Do so in the following sequence: middle, top/bottom, left/right .
Information
1. Pull the cover and padding over the upper part and side bolsters -A- .
2. Pull the cover and padding back between the seat surface and backrest -B- .
3. Carefully guide in the top of the cover at the guides for the headrest.
Fig 1: Fastening Backrest Cover To Padding
4. Plug in electric plug connection for seat heating (if installed) -1- (-A- ) until the connector
engages securely.
5. Guide in wire harness for heated seats and secure with a tie-wrap.
Fig 2: Plugging In Connector For Seat Heating
6. Fit plastic rivets -1- .

Fig 3: Engaging Cover In Cut-Out For Backrest Cover
7. Engage the cover in the cut-out for the backrest cover all the way around -arrow- .
8. Engage restraining strap -1- for the cover at the left and right.
9. Clip in rear seat cover -2- .
10. Tighten fastening screws -3- for ISOFIX clips -4- .

Fig 4: Identifying Restraining Strap And Screws

WORK > REMOVING CREASES IN SEAT COVER (LEATHER)
Creases in cover
smooth out the cover using the special tool.
Hot-air gun v.a.g 1416

WORK > SUBSEQUENT WORK
1. Install headrest. → 728019 REMOVING AND INSTALLING HEADREST
2. Install cover for backrest. → Installing Cover For Backrest
3. Install front seat trim panel. → Installing Front Seat Trim Panel
WM 741955 REPLACING COVER FOR FRONT BACKREST (CAYENNE, CAYENNE



Hot-air blower Commercially v.a.g 1416
available tool

1. Remove cover for front backrest. → 741919 REMOVING AND INSTALLING COVER FOR
FRONT BACKREST

CAYENNE S DIESEL, CAYENNE (3.0)) > LOOSENING COVER FOR FRONT
BACKREST
1. Place padding for front backrest on a clean surface.
Fig 1: Detaching Padding For Front Backrest From Cover (Basic/Comfort)

Fig 2: Detaching Padding For Front Backrest From Cover (Sport)

CAYENNE S DIESEL, CAYENNE (3.0)) > SECURING COVER FOR FRONT BACKREST
1. Place cover on the padding and align contour of the padding.
2. Use cushion clip pliers Nr.130 and new cushion clips to secure the cover on the padding in
the specified sequence.
Fig 1: Securing Cover On Padding For Front Backrest (Basic/Comfort)

Fig 2: Securing Cover On Padding For Front Backrest (Sport)

Creases in cover
smooth out the cover using the special tools.

Hot-air blower v.a.g 1416

WORK
1. Install cover for front backrest. → Installing Cover For Front Backrest
WM 744919 REMOVING AND INSTALLING PADDING FOR 1/3-SPLIT FOLDING REAR

SEAT (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S,
REMOVING PADDING FOR 1/3-SPLIT FOLDING REAR SEAT
Fig 1: Identifying Padding On 1/3-Split Folding Rear Seat
Information
Fastening grommets on the locking mechanism for the padding on the seat frame will be damaged
irreparably during removal. Always replace the fastening grommets during installation.
1. Pierce the fastening grommets -1- on the underside of the seat frame -2- with a screwdriver
so that the locking mechanism no longer locks.
Fig 2: Loosening Fastening Grommets
2. Unclip the retaining eyelets -1- on the padding -2- with a strong upward jerk -arrows- to
remove them from the fastening grommets -3- .
Fig 3: Removing Padding For 1/3-Split Folding Rear Seat
3. Disconnect electric plug connection for 1/3-split folding rear backrest.

Fig 4: Electric Plug Connections For 1/3-Split Folding Rear Seat
1. 3.1. Release electric plug connection -1- for wire harness for seat heating -a- and
pull it off -A- .
2. 3.2. Release electric plug connection -2- for seat heating connection point -b- and
pull it off -B- .
3. 3.3. Release electric plug connection -3- on wire harness for side airbag -c- and pull
it off -C- .
4. Remove the padding for the 1/3-split folding rear seat together with the wire harness.

INSTALLING PADDING FOR 1/3-SPLIT FOLDING REAR SEAT
1. Connect the existing electric plug connections.

1. 1.1. Plug in electric plug connection -1- for seat heating -A- and lock it -a- .
2. 1.2. Plug in electric plug connection -2- for seat heating connection point -B- and
lock it -b- .
3. 1.3. Plug in electric plug connection -3- for side airbag -C- and lock it -c- .
Information
Fastening grommets on the locking mechanism for the padding on the seat frame will
be damaged irreparably during removal. Always replace the fastening grommets
during installation.
2. Fit new fastening grommets -3- .

Fig 2: Installing Padding
3. Position the padding -1- for the 1/3-split folding rear seat.
Check that the padding and the carpet inlay on the belt lock are seated correctly.
4. Clip in the retaining eyelets -2- on the padding -1- at the front by pressing them firmly
-arrows- into the fastening grommets -3- .
The retaining eyelets must engage securely in the fastening grommets.

REMOVING PADDING FOR 2/3-SPLIT FOLDING REAR SEAT
Fig 1: Identifying 2/3-Split Folding Rear Seat
Information
Fastening grommets on the locking mechanism for the padding on the seat frame will be damaged
irreparably during removal. Always replace the fastening grommets during installation.
1. Pierce the fastening grommets -1- on the underside of the seat frame -2- with a screwdriver
so that the locking mechanism no longer locks.
Fig 2: Loosening Fastening Grommets
2. Unclip the retaining eyelets -1- on the padding -2- with a strong upward jerk -arrows- at the
front to remove them from the brackets -3- .
Fig 3: Removing Padding For 2/3-Split Folding Rear Seat
3. Release the existing electric plug connections -1, 2- (-a, b- ) and pull them off -A, B- .
4. Remove the padding for the 2/3-split folding rear seat together with the wire harness.

INSTALLING PADDING FOR 2/3-SPLIT FOLDING REAR SEAT
1. Plug in existing electric plug connections -1, 2- for the 2/3-split folding seat -A, B- and lock
them -a, b- .
Fig 1: Installing Electric Plug Connections For 2/3-Split Folding Rear Seat
Information
Fastening grommets on the locking mechanism for the padding on the seat frame will be
damaged irreparably during removal. Always replace the fastening grommets during
installation.
2. Fit new fastening grommets -3- .
3. Position the padding -2- for the 2/3-split folding rear seat.
Check that the padding and the carpet inlay around the belt locks are seated correctly.
4. Clip in the retaining eyelets -1- on the padding -2- at the front by pressing them down firmly
-arrows- into the fastening grommets -3- .
Fig 2: Installing Padding For 2/3-Split Folding Rear Seat
The retaining eyelets must engage securely in the fastening grommets.
WM 745019 REMOVING AND INSTALLING COVER FOR 1/3-SPLIT FOLDING REAR

TOOLS


COVER FOR 1/3-SPLIT FOLDING REAR SEAT

REMOVING COVER FOR 1/3-SPLIT FOLDING REAR SEAT
Fig 1: Identifying Cover On 1/3-Split Folding Rear Seat

1. Place the padding for the 1/3-split folding rear seat on a clean surface with the top side down.
2. Remove seat cover.
1. 2.1. Cut the cushion clips -2- using side cutters → Cutting cushion clips .
Fig 2: Cutting Cushion Clips
2. 2.2. Start with the outer cushion clips -1- .

Fig 3: Identifying Cover For 1/3-Split Folding Rear Seat - Step 1
3. 2.3. Fold up the seat cover -1- at the outside -A- .

Fig 4: Removing Cover For 1/3-Split Folding Rear Seat - Step 2
4. 2.4. Cut open the inner clips in the specified sequence -2 - 6- .

Fig 5: Removing Cover For 1/3-Split Folding Rear Seat - Step 3
5. 2.5. Pull the seat cover -1- down off the padding -B- .
6. 2.6. Remove the remaining pieces of cushion clips.

INSTALLING COVER FOR 1/3-SPLIT FOLDING REAR SEAT
1. Install seat cover.
1. 1.1. Place the seat cover on the padding -A- and align with the contour of the
padding.
Fig 1: Securing Cover For 1/3-Split Folding Rear Seat - Step 1
2. 1.2. Using cushion clip pliers Nr.130 -4- , fit new cushion clips -2- in the specified
sequence -2 - 5- to fasten the seat cover to the padding → Fitting cushion clips .
2. Fasten cover for 1/3-split folding rear seat at the outside.
1. 2.1. Pull the outside of the seat cover over the padding -B- .
2. 2.2. Using cushion clip pliers Nr.130 , fasten the seat cover at the fastening points
-1- on the padding from below with new cushion clips.
Fig 4: Identifying Cover For 1/3-Split Folding Rear Seat - Step 2

1. Install padding for 1/3-split folding rear seat. → 744919 REMOVING AND INSTALLING

TOOLS



REMOVING COVER FOR 2/3-SPLIT FOLDING REAR SEAT
Fig 1: Identifying 2/3-Split Folding Rear Seat

1. Place the padding for the 2/3-split folding rear seat on a clean surface with the top side down.
2. Remove seat cover.
1. 2.1. Cut the cushion clips -2- using side cutters.

2. 2.2. Start with the outer cushion clips -1- on the cover -2- .
Fig 3: Identifying Cover For 2/3-Split Folding Rear Seat Clips - Step 1
3. 2.3. Fold up the seat cover at the outside.
4. 2.4. Cut open the inner clips in the specified sequence -1 - 6- on the cover -7- .
Fig 4: Identifying Cover For 2/3-Split Folding Rear Seat Clips - Step 2
5. 2.5. Pull the seat cover down off the padding.
6. 2.6. Remove the remaining pieces of cushion clips.

INSTALLING COVER FOR 2/3-SPLIT FOLDING REAR SEAT
1. Install seat cover -1- .
1. 1.1. Place the seat cover -1- on the padding -A- and align it with the contour of the
padding -B- .
Fig 1: Installing Seat Cover
2. 1.2. Fasten seat cover to the padding using cushion clip pliers Nr.130 -4- and new
cushion clips -2- .
3. 1.3. Secure the new cushion clips on the seat cover -7- and padding in the specified
sequence -1 - 6- .
4. 1.4. Pull the outside of the seat cover -7- over the padding -A- .
2. Secure the outside of the seat cover -2- to the padding from below with new cushion clips
using cushion clip pliers Nr.130 at the fastening points -1- .

1. Install padding for 2/3-split folding rear seat. → 744919 REMOVING AND INSTALLING

TECHNICAL VALUES

on side airbag torque
(rear)

FOLDING REAR SEAT
2. Remove headrest.
3. Remove seat cushion on 1/3-split folding seat. → 744919 REMOVING AND INSTALLING

REMOVING PADDING FOR 1/3-SPLIT FOLDING REAR BACKREST
Fig 1: Identifying 1/3-Split Folding Rear Backrest
1. Unclip rear trim panel at the top -1- at the retaining clips -2- .

Fig 3: Removing Electric Plug Connections For 1/3-Split Folding Rear Backrest
pull it off -A- .
pull it off -B- .
it off -C- .
4. 2.4. Unclip the holder -4- at the seat frame -5- .
3. Unclip electric wire harness -1- for the seat backrest at the brackets -2- .
Fig 4: Identifying Wire Harness Mounting On Seat Frame
4. Loosen Velcro fasteners -1, 3- at the bottom of the backrest cover -2- (-A-) .
Fig 5: Loosening Backrest Cover At Bottom
5. Insert a suitable tool -1- into the gap -2- at the bottom of the backrest frame and carefully
lever out the backrest cover piping -3- over the entire length of the backrest.
Fig 6: Loosening Backrest Cover
6. Carefully slide the backrest cover -1- over the covers -2- on the headrest support.
Fig 7: Identifying Backrest Cover (Top)
7. Unscrew fastening screw -4- on side airbag -2- .

Fig 8: Identifying Side Airbag On Backrest Frame
8. Slide the side airbag holder -1- up and take it out of the guide -3- .
9. Loosen the fastenings -1- securing the cover to the side airbag holder -2- at the front and
rear.
Fig 9: Identifying Cover On Airbag
10. Remove the padding for the 1/3-split folding rear backrest together with the cover and wire
harness.

INSTALLING PADDING FOR 1/3-SPLIT FOLDING REAR BACKREST
1. Position the padding for the 1/3-split folding rear backrest together with the cover and wire
harness on the seat frame.
2. Secure the backrest cover -1- to the side airbag holder -2- at the front and rear.
3. Fit side airbag to the backrest frame.
1. 3.1. Guide the holder -1- for the side airbag -2- into the guide -3- .
ftlb.) .
4. Carefully pull the backrest cover -1- over the covers -2- on the headrest guide.
5. Connect the existing electric plug connections.

Fig 4: Connecting Electric Plug Connections For 1/3-Split Folding Backrest
lock it -b- .
4. 5.4. Clip the holder -4- for the electric plug connections onto the seat frame -5- .
6. Clip in the wire harness -1- at the holders -2- on the seat frame.
7. Carefully fold the backrest cover to the rear -arrows- and insert the piping -2- over the entire
length into the guide -3- on the backrest frame → Seat piping .
Fig 6: Securing Rear Backrest Cover
8. Check that the piping -2- on the backrest cover -1- engages securely in the guide -5- .
Fig 7: Checking Seat Piping
9. Pull the rear backrest cover -1- down -A- and close the Velcro fasteners -2, 3- .
Fig 8: Securing Backrest Cover At Bottom
10. Clip in the rear trim panel at the top -1- at the retaining clips -2- (-arrow- ).
Fig 9: Fitting Trim Panel At Top

1. Install seat. → 724819 REMOVING AND INSTALLING 1/3-SPLIT FOLDING REAR SEAT
2. Install seat padding. → 744919 REMOVING AND INSTALLING PADDING FOR 1/3-SPLIT
FOLDING REAR SEAT
3. Install headrest.
WM 745219 REMOVING AND INSTALLING PADDING FOR 2/3-SPLIT FOLDING

TECHNICAL VALUES

Centre Tightening 50 Nm (37

three-point belt torque ftlb.)
(bottom)

1. Remove rear seat. → 724819 REMOVING AND INSTALLING 2/3-SPLIT FOLDING REAR
SEAT
2. Remove headrest.
3. Remove padding on 2/3-split folding seat. → 724819 REMOVING AND INSTALLING


REMOVING PADDING FOR 2/3-SPLIT FOLDING BACKREST
Information
The pictures shown in this document may differ from the original .
1. Unclip the rear trim panel at the top -1- from the seat backrest -2- using a suitable tool.
Fig 1: Identifying Rear Trim Panel (Top)
2. Loosen Velcro fasteners -1, 2- at the bottom of the backrest cover.

Fig 2: Identifying Rear Velcro Fasteners (Bottom)
3. Carefully lever the seat-belt guide -1- up out of the seat -2- using a suitable tool -A- and pull
it forward -B- .
Fig 3: Loosening Seat-Belt Guide
5. Loosen the seat belt -1- at the bottom.

Fig 5: Identifying Centre Seat Belt
1. 5.1. Unscrew fastening screw -2- on the seat belt.
2. 5.2. Unclip the fixing clips -3- for the seat belt on the seat frame -4- .
6. Carefully slide the backrest cover -1- forward over the covers -2- on the headrest support.

9. Loosen the fastenings securing the cover to the side airbag.

Fig 8: Identifying Seat Cover On Airbag
Fig 10: Identifying Wire Harness For 2/3-Split Folding Backrest
12. Pull out electric wire harness -1- together with the guide -2- on the inside of the seat frame
and unclip it at the holder -3- .
Fig 11: Identifying Electric Wire Harness
13. Remove the padding for the 2/3-split folding rear backrest together with the cover and wire
harness.

INSTALLING PADDING FOR 2/3-SPLIT FOLDING BACKREST > INSTALLING PADDING
1. Position the padding for the 2/3-split folding rear backrest together with the cover and wire
harness on the seat frame.
ftlb.) .
4. Clip in the electric wire harness -1- at the holder -3- on the inside of the seat frame and fit the
guide -2- on the seat frame.
Fig 3: Identifying Clipping In Holder For Wire Harness
them -a, b- .
6. Clip in the wire harness -1- at the brackets -2- on the seat frame.
8. Carefully fold the backrest cover -1- to the rear -arrows- and insert the piping -2- over the
entire length into the guide -3- on the backrest frame → Seat piping .
Fig 7: Securing Cover For 2/3-Split Folding Rear Backrest
10. Secure the seat belt -1- at the bottom.

1. 10.1. Screw in fastening screw -2- for the seat belt -1- and tighten to → Tightening
torque: 50 Nm (37 ftlb.) .
2. 10.2. Clip in fixing clips -3- for the seat belt on the seat frame -4- .
3. 10.3. Check that the seat belt is routed correctly.
11. Insert the seat belt guide -1- into the padding -2- (-A- ) and clip it in in a downward direction
-B- .
Fig 10: Inserting Seat Belt Guide
12. Pull the rear seat cover through in a downward direction and close the Velcro fasteners -1, 2- .
13. Clip the rear trim panel at the top -1- into the seat backrest -2- .

FOLDING REAR SEAT
3. Install seat cushion. → 744919 REMOVING AND INSTALLING PADDING FOR 2/3-SPLIT
FOLDING REAR SEAT

TOOLS


TECHNICAL VALUES

(rear)

COVER FOR 1/3-SPLIT FOLDING REAR BACKREST
FOLDING REAR SEAT
2. Remove headrest.
3. Remove seat cushion on 1/3-split folding seat. → 744919 REMOVING AND INSTALLING

REMOVING COVER FOR 1/3-SPLIT FOLDING REAR BACKREST
1. Unclip rear trim panel at the top -1- at the retaining clips -2- .

Fig 3: Disconnecting Electric Plug Connections For 1/3-Split Folding Rear Backrest
pull it off -A- .
pull it off -B- .
it off -C- .
4. 2.4. Unclip the holder -4- at the seat frame -5- .
4. Loosen Velcro fasteners -1, 3- at the bottom of the backrest cover -2- (-A-) .
Fig 5: Loosening Backrest Cover At Bottom

9. Loosen the fastenings -1- securing the cover to the side airbag holder -2- at the front and
rear.
10. Remove backrest cover.
1. 10.1. Cut the cushion clips -2- using a suitable tool, e.g. side cutters. → Cutting
cushion clips
2. 10.2. Cut open the cushion clips in the specified sequence -1-4- from the outside in.
Fig 11: Removing Cushion Clips
3. 10.3. Slide the outside of the backrest cover over the padding mount -A- .
4. 10.4. Remove the backrest cover from the padding mount -B- .
5. 10.5. Remove the remaining pieces of the cushion clips.

INSTALLING COVER FOR 1/3-SPLIT FOLDING REAR BACKREST
1. Fit the cover.
Always use cushion clip pliers Nr.130 -4- and new cushion clips -2- to fasten the cover. →
Fitting cushion clips
1. 1.1. Place the cover -1- on the padding -A- and align with the contour of the
padding -B- .
Fig 2: Fitting Cover - Step 1
2. 1.2. Fasten the cover -4- using cushion clip pliers Nr.130 and new cushion clips in
the sequence shown -1-3- .
Fig 3: Fitting Cover - Step 2
ftlb.) .
5. Connect existing electric plug connections.

Fig 7: Connecting Electric Plug Connections For 1/3-Split Folding Backrest
lock it -b- .
4. 5.4. Clip the holder -4- for the electric plug connections onto the seat frame -5- .
6. Clip in the wire harness -1- at the holders -2- on the seat frame.
Fig 9: Securing Rear Backrest Cover
9. Pull the rear backrest cover -1- down -A- and close the Velcro fasteners -2, 3- .
Fig 11: Securing Backrest Cover At Bottom
10. Clip in the rear trim panel at the top -1- at the retaining clips -2- (-arrow- ).
Fig 12: Fitting Trim Panel At Top

1. Install seat. → 724819 REMOVING AND INSTALLING 1/3-SPLIT FOLDING REAR SEAT
FOLDING REAR SEAT

TOOLS


TECHNICAL VALUES

Centre Tightening 50 Nm (37

three-point belt torque ftlb.)
(bottom)

1. Remove rear seat. → 724819 REMOVING AND INSTALLING 2/3-SPLIT FOLDING REAR
SEAT
2. Remove headrest.
3. Remove padding on 2/3-split folding seat. → 724819 REMOVING AND INSTALLING


REMOVING COVER FOR 2/3-SPLIT FOLDING REAR BACKREST
Information
1. Unclip the rear trim panel at the top -1- from the seat backrest -2- using a suitable tool.

3. Carefully lever the seat-belt guide -1- up out of the seat -2- using a suitable tool -A- and pull
it forward -B- .
Fig 4: Loosening Seat-Belt Guide
5. Loosen the seat belt -1- at the bottom.

1. 5.1. Unscrew fastening screw -2- on the seat belt.
2. 5.2. Unclip the fixing clips -3- for the seat belt on the seat frame -4- .
7. Unscrew fastening screw -4- on the side airbag -2- .

9. Loosen the fastenings securing the cover to the side airbag.

Fig 9: Identifying Seat Cover On Airbag
12. Pull out electric wire harness -1- together with the guide -2- on the inside of the seat frame
and unclip it at the holder -3- .
Fig 12: Identifying Electric Wire Harness
13. Remove backrest cover.
1. 13.1. Fold the backrest cover -4- outwards -arrows- .

Fig 13: Removing Seat Cover
2. 13.2. Cut the cushion clips -2- in the specified sequence -1 - 3- using a suitable tool,
e.g. side cutters. → Cutting cushion clips
3. 13.3. Remove the backrest cover from the padding mount.
4. 13.4. Remove the remaining pieces of the cushion clips.

INSTALLING COVER FOR 2/3-SPLIT FOLDING REAR BACKREST
1. Fit the cover.
Always use cushion clip pliers Nr.130 -4- and new cushion clips -2- to fasten the cover. →
Fitting cushion clips
1. 1.1. Place the seat cover -1- on the padding -A- and align it with the contour of the
padding -B- .
Fig 2: Securing Cover - Step 1
2. 1.2. Fasten the seat cover -4- using cushion clip pliers Nr.130 and new cushion
clips in the sequence shown -1 - 3- .
Fig 3: Securing Cover - Step 2
3. 1.3. Pull the outside of the seat cover to the rear -arrows- .
ftlb.) .
4. Clip in the electric wire harness -1- at the holder -3- on the inside of the seat frame and fit the
guide -2- on the seat frame.
Fig 6: Identifying Holder For Wire Harness
them -a, b- .
6. Clip in the wire harness -1- at the brackets -2- on the seat frame.
Fig 10: Securing Cover For 2/3-Split Folding Rear Backrest
10. Secure the seat belt -1- at the bottom.

1. 10.1. Screw in fastening screw -2- for the seat belt -1- and tighten to → Tightening
2. 10.2. Clip in fixing clips -3- for the seat belt on the seat frame -4- .
3. 10.3. Check that the seat belt is routed correctly.
11. Insert the seat belt guide -1- into the padding -2- (-A- ) and clip it in in a downward direction
-B- .
Fig 13: Inserting Seat Belt Guide Into Padding
13. Clip the rear trim panel at the top -1- into the seat backrest -2- .

FOLDING REAR SEAT
FOLDING REAR SEAT
WM 745519 REMOVING AND INSTALLING ARMREST WITH COVER (REAR) (EXCEPT

VALUES
Armrest to Tightening 8 Nm (6 ftlb.) +/-0.8 Nm

backrest torque (+/-0.5 ftlb.)

ARMREST WITH COVER
Fig 1: Identifying Armrest With Cover
1. Fold the armrest down fully.
2. Unclip the retaining clips -1- for the rear trim panel -2- for the armrest from the brackets -3-
on the backrest -4- on the 2/3-split folding seat using a suitable tool.
Fig 2: Identifying Rear Armrest Cover
3. Remove trim panel.
4. Remove armrest.
1. 4.1. Loosen fastening screws -1- on the armrest -2- .
2. 4.2. Unscrew locking lugs -3- on the armrest from the holders -4- at the
load-through provision in a downward direction -A- .
3. 4.3. Remove the armrest -2- by pulling it towards the front -B- .

ARMREST WITH COVER
1. Install armrest -1- .

Fig 1: Installing Armrest
1. 1.1. Position the armrest -1- in the load-through provision -2- (-A- ).
2. 1.2. Insert the locking lugs -3- into the guides -4- (-B- ).
3. 1.3. Screw in fastening screws -5- and tighten to → Tightening torque: 8 Nm (6

ftlb.)+/-0.8 Nm (+/- 0.5 ftlb.) .
2. Fit the rear trim panel -2- into the load-through provision -4- and clip the fastening clamps -1-
into the guides -3- .
Fig 2: Identifying Rear Armrest Cover, Clamps And Guides
WM 745619 REMOVING AND INSTALLING LOAD-THROUGH PROVISION (EXCEPT

VALUES
Load-through Tightening 18 Nm (13 +/-1 Nm (+/- 0.5

provision to seat torque ftlb.) ftlb.)
frame

WORK > PRELIMINARY WORK FOR REMOVING AND INSTALLING LOAD-THROUGH
PROVISION
Remove rear seat. 724819 REMOVING AND INSTALLING 2/3-SPLIT FOLDING REAR SEAT and
724819 REMOVING AND INSTALLING 1/3-SPLIT FOLDING REAR SEAT
LOAD-THROUGH PROVISION
Fig 1: Identifying Load-Through Provision Components

2. Fold the load-through provision fully forward.
3. Unclip side trim panel -1- from the holder -2- at the load-through provision -A- and lift it up
and out -B- .
Fig 3: Removing Trim Panel On Load-Through Provision
4. Lever the rear piping -1- at the bottom out of the guide -2- along its entire length using a
suitable tool -3- (-arrow- ).
Fig 4: Removing Outer Piping On Load-Through Provision
5. Release the inner piping -1- on the load-through provision -2- along its entire length using a
suitable tool -3- .
Fig 5: Removing Inner Piping On Load-Through Provision
6. With safety clips: Remove load-through provision -3- .

Fig 6: Removing Load-Through Provision (Pin With Safety Clip)
1. 6.1. Pull out the safety clips -1, 2- on the guide pins -4- .
2. 6.2. Slide the load-through provision -3- on the guide pins -4- by pushing it to the
left -A- .
3. 6.3. Pull the load-through provision -3- forward and remove it -B- .
7. With threaded joint: Remove load-through provision.

Fig 7: Removing Load-Through Provision (Screwed)
2. 7.2. Slide the load-through provision -3- on the guide pin -2- by pushing it to the left
-A- .
3. 7.3. Pull the load-through provision -3- forward and remove it -B- .

LOAD-THROUGH PROVISION
1. With safety clips: Install load-through provision -1- .

Fig 1: Installing Load-Through Provision (Pin With Safety Clip)
1. 1.1. Insert the load-through provision -1- into the vehicle -A- .
2. 1.2. Slide the load-through provision -1- onto the pin -2- by pushing it fully to the
right -B- .
3. 1.3. Fit the safety clips -3, 4- on the pin -2- .
2. With threaded joint: Install load-through provision.

Fig 2: Installing Load-Through Provision (Threaded Joint)
1. 2.1. Insert the load-through provision -1- into the vehicle -A- .
2. 2.2. Slide the load-through provision -1- on the guide pin -2- by pushing it to the
right -B- .
3. 2.3. Tighten fastening screw -3- to → Tightening torque: 18 Nm (13 ftlb.)+/-1 Nm

(+/-0.5 ftlb.) .
3. Fit the inner piping -1- on the load-through provision -2- along its entire length.
Fig 3: Fitting Inner Piping On Load-Through Provision
4. Fit the outer piping -1- on the load-through provision into the guide -2- along its entire length
until it engages securely.
Fig 4: Installing Outer Piping On Load-Through Provision
5. Slide the side trim panel -1- onto the seat from above -A- and clip it into the bracket -2- (-B-
).
Check that the trim panel is seated correctly.

Fig 5: Installing Side Trim Panel

WORK > SUBSEQUENT WORK FOR REMOVING AND INSTALLING LOAD-THROUGH
PROVISION
1. Install rear seat. 724819 REMOVING AND INSTALLING 2/3-SPLIT FOLDING REAR SEAT
and 724819 REMOVING AND INSTALLING 1/3-SPLIT FOLDING REAR SEAT
Service Manual: 7X - BODY-EQUIPMENT INSIDE - GENERAL -- 92A CAYENNE
WM 7X00IN TECHNICAL VALUES (CAYENNE, CAYENNE GTS, CAYENNE TURBO S,
CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) >
TECHNICAL VALUES
Fastening screw Item 5 Tightening 1.5 Nm (1 ftlb.)

at front of torque
dashboard
Removing dashboard

at side of torque
dashboard
Removing dashboard

at top of torque
dashboard
Removing dashboard

Door panel mounting

Door panel mounting



bottom

point to body

luggage net torque
cover

luggage net torque
cover at the
sides

TECHNICAL VALUES > TECHNICAL VALUES -70- DASHBOARD

at front of torque
dashboard
Removing dashboard

at side of torque
dashboard
Removing dashboard

at top of torque
dashboard
Removing dashboard

TECHNICAL VALUES > TECHNICAL VALUES -70- FRONT DOOR

Door panel mounting

Door panel mounting


TECHNICAL VALUES > TECHNICAL VALUES -70- REAR DOOR


bottom

TECHNICAL VALUES -70- LUGGAGE COMPARTMENT TRIM

point to body

TECHNICAL VALUES -70- BRACKET FOR LUGGAGE NET COVER

luggage net torque
cover

luggage net torque
cover at the
sides

Service Manual: 46 - BRAKES - BRAKE MECHANICS -- 92A CAYENNE
WM 4650TW TECHNICAL DATA/BRAKE WEAR LIMITS > TECHNICAL VALUES
Service brake Hydraulic

(footbrake) with dual-circuit brake
grey cast iron system with
brake discs brake-circuit
(standard brake) division per axle.
with PSM Vacuum brake
(Porsche Stability booster, internally
Management) as ventilated brake
standard discs with
six-piston
aluminum
monobloc fixed-
calliper brake on
front axle and
four-piston
aluminum
monobloc fixed-
calliper brake on
rear axle.
PSM Porsche Stability

Management
(PSM) as
standard with the
functions
Anti-lock Brake
System (ABS),
Anti-Slip
Regulation
(ASR), Engine
Drag Torque
Control (EDTC),
Automatic Brake
Differential
(ABD), brake
force boosting,
brake system
pre-filling.
Tandem brake 9/10 Zoll

booster Ø
(vacuum)
Boost ratio 8
Brake master 28.57 mm

cylinder Ø
Brake-circuit 24/12 mm
division
Brake disc Ø, 350 mm

front

rear
Brake disc 34 mm
thickness, front
Brake disc 28 mm
thickness, rear
Thickness 0.01 mm
tolerance of
brake disc, max.
Effective brake 285.2 mm

disc Ø, front

disc Ø, rear
Piston Ø in front 6 x 36 mm
brake calliper
Piston Ø in rear 4 x 32 mm
brake calliper
Brake pad area, 448 cm2

front

rear
Total brake pad 648 cm2

area

PCCB brake system with
discs with PSM brake-circuit
(Porsche Stability division per axle.
Management) as Vacuum brake
standard booster, internally
ventilated brake
discs with
six-piston
aluminum
monobloc fixed-
calliper brake on
front axle and
four-piston
aluminum
monobloc fixed-
calliper brake on
rear axle. The
brake callipers
are painted
yellow for visual
differentiation.

Management
(PSM) as
standard with the
functions
Anti-lock Brake
System (ABS),
Anti-Slip
Regulation
(ASR), Engine
Drag Torque
Control (EDTC),
Automatic Brake
Differential
(ABD), brake
force boosting,
brake system
pre-filling.

booster Ø
(vacuum)
Boost ratio 8/7

cylinder Ø
division

front

rear
Brake disc 38 mm
thickness, front
Brake disc 30 mm
thickness, rear
Thickness 0.01 mm
tolerance of
brake disc, max.
Effective brake 323 mm

disc Ø, front
disc Ø, rear
brake calliper
brake calliper

front

rear

area
Pad thickness, Wear limit 2 mm approx. 9.7 mm

front

rear
Brake disc New 34 mm

thickness, front

thickness, rear
Brake disc Only as-new 33.6 mm

minimum brake discs may
thickness after be reworked!Only
machining, front rework the brake
disc
symmetrically,
evenly from both
sides!

machining, rear rework the brake
disc
symmetrically,
evenly from both
sides!
Brake disc wear 32 mm

dimension, front

dimension, rear
Peak-to-valley 0.006 mm
surface
roughness of
brake disc after
machining, max.
Thickness 0.02 mm
tolerance of
brake discs after
machining, max.
Lateral runout of 0.03 mm

brake disc, max.

wheel hub, max.

brake disc when
installed, max.
Pushrod play Not adjustable
Parking brake Drum brake

(foot-operated acting
parking brake) mechanically on
both rear wheels
Parking-brake Wear limit 211 210 mm

drum Ø mm
Brake shoe width 30 mm
Brake pad Wear limit 1 mm 3 mm

thickness

front

rear
Brake disc New 38 mm +0.1 mm -0.1 mm

thickness, front

thickness, rear
Brake disc wear Minimum brake mm(Read value

limit, front disc thickness on brake disc
(wear limit) is hub) XX.X
stamped on the
brake disc hub.
Example: Min.
Th. 37.7 mm

limit, rear disc thickness on brake disc
stamped on the
brake disc hub.
Example: Min.
Th. 29.7 mm
Peak-to-valley New 0.006 mm

surface
roughness of
brake disc
Wear limit: Wear limit: Values and

Surface changes Connected procedure for:
in front and rear surface fracture > 46 51 02
brake discs 1 cm2 and/or Checking front
surface PCCB brake
roughness of discs/46 54 02
brake disc > 80 Checking rear
micrometer. PCCB brake
Replace PCCB discs.
brake discs on
both sides of the
axle.

brake disc, max.

wheel hub, max.

brake disc when
installed, max.

both rear wheels

drum Ø mm

thickness
WM 4650TW TECHNICAL DATA/BRAKE WEAR LIMITS > TECHNICAL VALUES >

TECHNICAL DATA - 18-INCH BRAKE SYSTEM (CAYENNE BASIC MODEL/CAYENNE
DIESEL (EXCEPT FOR USA))

(Porsche Stability booster,
Management) as internally
standard ventilated brake
discs with
six-piston
aluminum
monobloc fixed-
calliper brake on
front axle and
four-piston
aluminum
monobloc fixed-
calliper brake on
rear axle.

Management
(PSM) as
standard with the
functions
Anti-lock Brake
System (ABS),
Anti-Slip
Regulation
(ASR), Engine
Drag Torque
Control (EDTC),
Automatic Brake
Differential
(ABD), brake
force boosting,
brake system
pre-filling.

booster Ø
(vacuum)
Boost ratio 8

cylinder Ø
division

front

rear
Brake disc 34 mm
thickness, front
Brake disc 28 mm
thickness, rear
Thickness 0.01 mm
tolerance of
brake disc, max.

disc Ø, front

disc Ø, rear
brake calliper
brake calliper

front

rear

area

TECHNICAL DATA - PCCB (CAYENNE BASIC MODEL/CAYENNE S/CAYENNE
DIESEL/CAYENNE DIESEL S/CAYENNE HYBRID)

ventilated brake
discs with
six-piston
aluminum
monobloc fixed-
calliper brake on
front axle and
four-piston
aluminum
monobloc fixed-
calliper brake on
rear axle. The
brake callipers
are painted
yellow for visual
differentiation.

Management
(PSM) as
standard with the
functions
Anti-lock Brake
System (ABS),
Anti-Slip
Regulation
(ASR), Engine
Drag Torque
Control (EDTC),
Automatic Brake
Differential
(ABD), brake
force boosting,
brake system
pre-filling.

booster Ø
(vacuum)
Boost ratio 8/7

cylinder Ø
division

front

rear
Brake disc 38 mm
thickness, front
Brake disc 30 mm
thickness, rear
Thickness 0.01 mm
tolerance of
brake disc, max.

disc Ø, front
disc Ø, rear
brake calliper
brake calliper

front

rear

area
WM 4650TW TECHNICAL DATA/BRAKE WEAR LIMITS > TECHNICAL VALUES > TEST
VALUES AND WEAR LIMITS FOR 18-INCH BRAKE SYSTEM (CAYENNE BASIC
MODEL/CAYENNE DIESEL (EXCEPT FOR USA))
Information
Depending on the extent of wear on cast iron brake discs, two condition criteria can make replacement
necessary:
Formation of cracks at advanced stage on the brake disc friction surfaces .
Minimum brake disc thickness is not retained due to wear (material erosion due to friction) . →
46500200 CHECKING FRONT BRAKE DISCS (WEAR ASSESSMENT) → 46530250 CHECKING
REAR BRAKE DISCS (WEAR ASSESSMENT)
Pad thickness, Wear limit 2 mm approx. 9.7

front mm

rear mm

thickness, front

thickness, rear

disc
symmetrically,
evenly from both
sides!
disc
symmetrically,
evenly from both
sides!

dimension, front

dimension, rear
surface
roughness of
brake disc after
machining, max.
Thickness 0.02 mm
tolerance of
brake discs after
machining, max.

brake disc, max.

wheel hub, max.

brake disc when
installed, max.

both rear wheels

drum Ø mm

thickness
Possible complaints
Damage due to lack of use (rusting). This causes vibrations in the steering wheel, noises and
brake pedal pulsation.
Brake disc becomes distorted as a result of serious driving.

Too much lateral runout when new brake discs are fitted on dirty or distorted wheel hubs.
Procedure
Check brake disc for cracks, minimum thickness, lateral runout, thickness tolerance, flatness and
surface roughness.
If necessary, (depending on the actual brake disc thickness and the brake disc wear limit) machine
the brake disc using one of the disc brake dressing machines approved by Porsche.
The brake disc must only be reworked symmetrically, i.e. evenly from both sides! Read the
operating instructions for the disc brake dressing machine!
VALUES AND WEAR LIMITS FOR PCCB (CAYENNE BASIC MODEL/CAYENNE
S/CAYENNE DIESEL/CAYENNE DIESEL S/CAYENNE HYBRID)
Information
The following condition criteria can make replacement necessary depending on the wear of the PCCB
brake discs:
Surface changes in the brake disc friction surfaces at an advanced stage .
Minimum brake disc thickness is not retained due to wear (material erosion due to friction) .
Information
The PCCB brake disc must not be machined.

front

rear

thickness, front

thickness, rear
Brake disc wear Minimum brake mm (Read

limit, front disc thickness value on brake
(wear limit) is disc hub) XX.X
stamped on the
brake disc hub.
Example: Min.
Th. 37.7 mm

limit, rear disc thickness value on brake
stamped on the
brake disc hub.
Example: Min.
Th. 29.7 mm

surface
roughness of
brake disc

in front and rear surface fracture 46 51 02
brake discs > 1 cm2 and/or Checking front
surface PCCB brake
Replace PCCB discs.
brake discs on
both sides of the
axle.

brake disc, max.

wheel hub, max.

brake disc when
installed, max.

both rear wheels

drum Ø mm

thickness
Possible complaints
Procedure
Check brake disc for minimum thickness, lateral runout, thickness tolerance, flatness and surface
roughness.
WM 4601IN OVERVIEW OF BRAKE SYSTEMS > FRONT AXLE

Steel variant PCCB variant
Size 18"/350 mm 18"/360 mm 19"/390 mm 19"/390 mm 20"/410 mm

from 11/11
20"/420 mm
Brake calliper 6-piston 18" 6-piston 18" 6-piston 19" 6-piston 19" 6-piston 20"
wheel wheel wheel wheel wheel
Brake disc 350 mm x 34 360 mm x 36 390 mm x 38 390 mm x 38 410 mm x 38

diameter/thickness mm mm mm mm mm from
11/11420 mm x
40 mm
Cayenne X Optional
Cayenne Diesel X Optional

(except for USA)
Cayenne S X Optional
Cayenne Diesel X Optional

(USA only) and
Diesel S
Cayenne Hybrid X Optional
Cayenne GTS X Optional
Cayenne Turbo X Optional
WM 4601IN OVERVIEW OF BRAKE SYSTEMS > REAR AXLE
Size 17"/18"/330 mm 19"/358 mm 19"/20"/370 mm
Brake calliper 4-piston 17" wheel 4-piston 18" wheel 4-piston 19" wheel
Brake disc 330 mm x 28 mm 358 mm x 28 mm 370 mm x 30 mm

diameter/thickness
Cayenne X Optional
Cayenne Diesel (except X Optional

for USA)
Cayenne S X Optional
Cayenne Diesel (USA X Optional

only) and Diesel S
Cayenne Hybrid X Optional
Cayenne GTS X Optional
Cayenne Turbo X Optional
WM 4601IN OVERVIEW OF BRAKE SYSTEMS IN THE CAYENNE AS OF MODEL YEAR

2011 > FRONT AXLE
Steel Variant PCCB Variant
Size 18"/350 mm 18"/360 mm 19"/390 mm 19"/390 mm 20"/410 mm

from 11/11
20"/420 mm
Brake calliper 6-piston 18" 6-piston 18" 6-piston 19" 6-piston 19" 6-piston 20"
wheel wheel wheel wheel wheel
Brake disc 350 mm x 34 360 mm x 36 390 mm x 38 390 mm x 38 410 mm x 38

diameter/thickness mm mm mm mm mm from
11/11420 mm x
40 mm
V6 X Optional
V6 Diesel X Optional
V6 Hybrid X Optional
V8 X Optional
V8 GTS X As at 09/11 Optional
V8 Turbo X Optional
WM 4601IN OVERVIEW OF BRAKE SYSTEMS IN THE CAYENNE AS OF MODEL YEAR

2011 > REAR AXLE
Size 17"/18"/330 mm 19"/358 mm 19"/20"/370 mm
Brake calliper 4-piston 17" wheel 4-piston 18" wheel 4-piston 19" wheel
Brake disc 330 mm x 28 mm 358 mm x 28 mm 370 mm x 30 mm

diameter/thickness
V6 X Optional
V6 Diesel X Optional
V6 Hybrid X Optional
V8 X Optional
V8 GTS X As at 11/11 Optional
V8 Turbo X Optional
WM 460519 REMOVING AND INSTALLING BRAKE PEDAL > TOOLS

Release Tool VW Tool T10189
WM 460519 REMOVING AND INSTALLING BRAKE PEDAL > TECHNICAL VALUES
WM 460519 REMOVING AND INSTALLING BRAKE PEDAL > PRELIMINARY WORK >
PRELIMINARY WORK FOR REMOVING AND INSTALLING BRAKE PEDAL
1. Move the driver's seat all the way back.
2. Remove dashboard bracket. → 516819 REMOVING AND INSTALLING DASHBOARD

BRACKET
WM 460519 REMOVING AND INSTALLING BRAKE PEDAL > REMOVING BRAKE

PEDAL
Information
Fig 1: Identifying Brake Pedal And Shaft
1. Brake pedal
2. Brake pedal shaft
1. Disengage brake push rod from the brake pedal mounting using Release Tool T10189 .
Observe the following procedure for this purpose:
Fig 2: Identifying Release Tool T10189

Fig 3: Identifying Brake Pedal Release Tool
1. 1.1. Release Tool T10189 -1- must be positioned in such a way that the fork is at
the correct position in the brake pedal mounting (inset shows fork engaged; view
looking away from direction of travel).
2. 1.2. Release Tool T10189 must be positioned in such a way that it is located in the
right mold of the support and is perpendicular to the vehicle floor. Deflection point of
force (bend in the release tool T10189) is right over the recess in the mounting
saddle -arrow- .
Fig 4: Levering Out Brake Pedal
3. 1.3. When pressing Release Tool T10189 in direction of travel, the brake pedal
mounting is pressed apart and the ball of the push rod is released. At the same time,
pull the brake pedal away from the direction of travel and release the brake pedal
from the push rod.
Fig 5: Releasing Push Rod From Brake Pedal

Fig 6: Identifying Push Rod
2. Pull out the lock -1- at the left of the brake pedal shaft -2- (-arrow- ).
Fig 7: Removing Brake Pedal Lock
3. Using a hammer, press the brake pedal shaft -2- out by a few millimetres with short blows
from left to right.
4. Insert a screwdriver under the head of the brake pedal shaft -1- (right side). Carefully lever the
brake pedal shaft -1- towards the centre of the vehicle (cardan tunnel) and out of the brake
pedal -2- (-arrow- ).
Fig 8: Pressing Out Brake Pedal Shaft
WM 460519 REMOVING AND INSTALLING BRAKE PEDAL > INSTALLING BRAKE

PEDAL
Information
Do not grease or spray the brake pedal shaft (bearing pin) .
Use new lock nuts .
Observe correct Tightening Torques → 4X - CHASSIS - GENERAL -- 92A CAYENNE Tightening

Torques for brake mechanism - section on "Technical values" .
Tightening Torque for brake pedal shaft (bearing pin): 20 ± 3 Nm/15 ± 2 ft. lb. .
1. Insert brake pedal into the vehicle.
2. Press the brake pedal shaft -1- fully into the brake pedal -1- (-arrow- ).
Fig 1: Pressing In Brake Pedal Shaft
3. When pushing in the brake pedal shaft -1- , make sure that the cut-out -2- on the brake pedal
shaft -1- fits into the guide -3- on the holder -4- .
Fig 2: Identifying Brake Pedal Shaft, Guide And Holder
4. Slide the lock -1- at the left onto the brake pedal shaft -2- (-arrow- ).
Fig 3: Fitting Brake Pedal Lock
5. Position brake pedal -1- on the push rod -2- for the brake booster.
Fig 4: Positioning Brake Pedal On Push Rod
6. Press brake pedal -1- fully -arrow- until the push rod -2- engages with an audible click in the
holder -3- on the brake pedal.
Fig 5: Fitting Brake Pedal
WM 460519 REMOVING AND INSTALLING BRAKE PEDAL > SUBSEQUENT WORK >
SUBSEQUENT WORK FOR REMOVING AND INSTALLING BRAKE PEDAL
1. Fit dashboard bracket. → 516819 REMOVING AND INSTALLING DASHBOARD BRACKET
WM 461019 REMOVING AND INSTALLING MOUNTING SADDLE > TECHNICAL

VALUES
Screw securing Tightening 2 Nm (1.5 ft.

heat shield to Torque lb.)
left longitudinal
member
No. 1: Pedals M8 x 20 thread Tightening 23 Nm (17 ft. +/-3 Nm (+/- 2 ft.

(pedal bearing Torque lb.) lb.)
block) to
assembly plate
No. 2: Brake M8 thread Tightening 26 Nm (19 ft. +/-3 Nm (+/- 2 ft.
booster to Torque lb.) lb.)
pedals
WM 461019 REMOVING AND INSTALLING MOUNTING SADDLE > PRELIMINARY

WORK FOR REMOVING AND INSTALLING MOUNTING SADDLE
1. Remove left wheel housing liner. → 505619 REMOVING AND INSTALLING FRONT WHEEL
HOUSING LINER
2. Remove brake pedal. → 460519 REMOVING AND INSTALLING BRAKE PEDAL
3. Remove left cross panel. → 508119 REMOVING AND INSTALLING CROSS PANEL
4. Remove engine guard. → 108019 REMOVING AND INSTALLING ENGINE GUARD
5. Loosen relay carrier. → 978309 LOOSENING AND SECURING RELAY CARRIER
WM 461019 REMOVING AND INSTALLING MOUNTING SADDLE > REMOVING

MOUNTING SADDLE
Fig 1: Identifying Mounting Saddle Installation Position
1. Remove relay carrier at the right -2- next to the brake pedal.
Fig 2: Removing Relay Carrier
1. 1.1. Remove fastening screw -1- for the relay carrier -2- at the right next to the
brake pedal.
2. 1.2. Pull the relay carrier down and to the rear -A- and remove it from the lower
guide.
3. 1.3. Pull the upper guide -3- for the relay carrier up -B- out of the bracket -4- on the
mounting saddle.
2. Remove fastening nuts -1- for the brake booster under the dashboard.
Fig 3: Identifying Brake Booster Nuts
3. Unclip cable duct cover from main wire harness against the direction of travel -arrow- and cut
the tie-wraps (three in cable duct and three on the left of the cable duct).
Fig 4: Opening Cable Duct
4. Unclip fixing clips -1- for the cable duct -2- on the mounting saddle using a suitable tool, e.g.
pointed-nose pliers.
Fig 5: Identifying Clips On Cable Duct
5. Unscrew the top fastening screws -1- for the mounting saddle in the plenum panel.
Fig 6: Identifying Mounting Saddle Screws (Top)
6. Unscrew fastening screw -1- for the mounting saddle at the bottom of the plenum panel, under
the brake booster.
Fig 7: Identifying Mounting Saddle Screw In Plenum Panel (Bottom)
7. Unscrew fastening screws -1- for the heat shield -2- at the left of the primary catalytic
converter on the longitudinal member.
Fig 8: Identifying Heat Shield Fastening Screws, Left
8. Unscrew the bottom fastening screw -1- for the mounting saddle through the opening in the
wheel housing.
Fig 9: Identifying Mounting Saddle Screw At Bottom
9. Remove mounting saddle from the vehicle.
WM 461019 REMOVING AND INSTALLING MOUNTING SADDLE > INSTALLING

MOUNTING SADDLE
1. Fit mounting saddle in the vehicle.
2. Tighten fastening screws -1- at the bottom. Tightening Torque 23 Nm (17 ft. lb.) +/-3 Nm
(+/-2 ft. lb.)
Fig 1: Identifying Screw For Mounting Saddle At Bottom
3. Tighten fastening screws -1- for the heat shield -2- at the left of the longitudinal member.
Tightening Torque 2 Nm (1.5 ft. lb.)
Fig 2: Identifying Heat Shield, Left
4. Tighten fastening screw -1- for the mounting saddle at the left under the brake booster.
Tightening Torque 23 Nm (17 ft. lb.) +/-3 Nm (+/-2 ft. lb.)
Fig 3: Identifying Mounting Saddle Screw In Plenum Panel At Bottom
5. Tighten the top fastening screws -1- for the mounting saddle in the plenum panel. Tightening
Torque 23 Nm (17 ft. lb.) +/-3 Nm (+/-2 ft. lb.)
Fig 4: Identifying Mounting Saddle Screws At Top
6. Pre-fit tie-wraps -1- in the cable duct -2- .

Fig 5: Identifying Pre-Fitting Tie-Wraps In Cable Duct
7. Clip in fixing clips -1- from the cable duct -2- at the mounting saddle.
Fig 6: Identifying Cable Duct Clips
8. Secure main wire harness in the cable duct and clip in cover.
Fig 7: Identifying Main Wire Harness In Cable Duct
9. Secure main wire harness on the cable duct.

Fig 8: Identifying Main Wire Harness On Cable Duct
10. Tighten the fastening nuts -1- for the brake booster under the dashboard. Tightening Torque
26 Nm (19 ft. lb.) +/-3 Nm (+/-2 ft. lb.)
Fig 9: Identifying Brake Booster Fastening Nuts
11. Fit the relay carrier.

Fig 10: Fitting Relay Carrier At Right
1. 11.1. Insert the guide -3- for the relay carrier at the right next to the brake pedal from
above -B- and into the holder -4- .
2. 11.2. Press the relay carrier -2- down into the guide -A- .
3. 11.3. Fit fastening screw -1- .
WM 461019 REMOVING AND INSTALLING MOUNTING SADDLE > SUBSEQUENT

WORK > SUBSEQUENT WORK FOR REMOVING AND INSTALLING MOUNTING
SADDLE
1. Install brake pedal. → 460519 REMOVING AND INSTALLING BRAKE PEDAL
2. Install left cross panel. → 508119 REMOVING AND INSTALLING CROSS PANEL
3. Secure relay carrier. → 978309 LOOSENING AND SECURING RELAY CARRIER
4. Install wheel housing liner at the left. → 505619 REMOVING AND INSTALLING FRONT
WHEEL HOUSING LINER
5. Install engine guard. → 108019 REMOVING AND INSTALLING ENGINE GUARD

WM 463402 CHECKING FRONT BRAKE PADS (PCCB) > INFORMATION >
INFORMATION ON CHECKING BRAKE PADS
Procedure During Intermediate Maintenance:
Visually inspect the brake pads for wear. There Is No Need To Remove The Wheels Unless The
Brake Fluid Needs To Be Changed At The Same Time .
Outside of brake pad: Visual inspection through the cut-outs in the rim.
Inside of brake pad: Visual inspection from below with vehicle raised.
Without an aid, the inner brake pad is not or is only partly visible on the rear axle (with the wheel fitted).
On vehicles with a stone guard on the lower wishbone, this must be removed to get a better view of the
brake pads.
A mirror can be used as an aid -arrow- .
Fig 1: Checking Brake Pads
Procedure During Maintenance:

Raise the vehicle → 4X00IN LIFTING THE VEHICLE .
NOTE: Removing/fitting wheels
Risk of damage to (ceramic) brake discs
→ Use two Assembly Pins when removing and fitting the wheel.
→ Carefully guide the wheel towards the wheel hub, thereby preventing any heavy impact on the
(ceramic) brake disc.
Screw the two assembly aids (Assembly Pins) -1- , instead of two wheel bolts, into the wheel hub before
removing/fitting the wheel. During removal, first remove the three remaining wheel bolts and remove the
wheel carefully without touching the brake discs.
Remove wheel. Use assembly aids (Assembly Pins) -1- . → 440519 REMOVING AND INSTALLING
WHEEL .
Fig 2: Identifying Assembly Aids (Assembly Pins)

Check the brake pad thickness for wear. If in doubt following a visual inspection, you may have to
measure the thickness.
WM 463402 CHECKING FRONT BRAKE PADS (PCCB) > CHECKING > CHECKING
THICKNESS OF THE DISC BRAKE PADS
WARNING: Installation of brake pads with the wrong brake pad quality
Longer braking distance
More wear on brake pads
→ Only use the type-specific brake pads listed .
→ Replace the brake pads when the brake pad wear indicator light comes on, but no later than when
there is a residual pad thickness of 2 mm on each axle.
→ Replace the brake discs on each axle upon reaching the wear limits.
Information
plug connection) must also be replaced .
Replacing the warning contact can be avoided by replacing the brake pads no later than when the
pad thickness is 2.5 mm -arrows- .
Fig 1: Checking Thickness Of Brake Pads
Warning contacts must be replaced if the core of the line is worn .
However, if only the plastic part of the warning contact is worn, there is no need to replace it .
Raise the vehicle → PRELIMINARY WORK - section on "Preliminary work".
WHEEL .
1. Visually inspect the brake pads for wear.
WM 463402 CHECKING FRONT BRAKE PADS (PCCB) > SUBSEQUENT WORK
Fit wheel. Use assembly aids (Assembly Pins) -1- . → 440519 REMOVING AND INSTALLING WHEEL .
Fit wheel. → 440519 REMOVING AND INSTALLING WHEEL .
WM 463456 REPLACING FRONT BRAKE PADS (PCCB) > TOOLS
Piston Reset Commercially Nr. 144

Tool (replaces Available Tool
P83)
Assembly Pin VW Tool T10439 For holding the
brake calliper
WM 463456 REPLACING FRONT BRAKE PADS (PCCB) > PRELIMINARY WORK
Information
Do not open the brake system .
Do not loosen the brake hose from the brake calliper when loosening the brake calliper .
The core of the warning contact wire must not be left exposed! It does not matter if the insulation is
worn .
If necessary, remove a little brake fluid from the reservoir by suction in order to prevent an overflow
when the disc brake pads are pushed back .
Raise the vehicle.
→ 4X00IN LIFTING THE VEHICLE .
Remove wheel. Use assembly aids (Assembly Pins) -1- .
→ 440519 REMOVING AND INSTALLING WHEEL .

WM 463456 REPLACING FRONT BRAKE PADS (PCCB) > REMOVING FRONT BRAKE
PADS
1. Expose lines.
Information
1. To gain better access for removal of the brake calliper, turn the steering fully either to the
right or left .
1. 1.1. Remove fastening screws -1, 2- for holders -3, 4- for the brake hydraulic lines.
Fig 1: Identifying Hydraulic Line Holders
2. 1.2. Pull the brake pad wear indicator line out of the brake calliper.
3. 1.3. Disconnect plug connection for speed sensor.
Information
Protect the paintwork on the brake calliper from damage using a suitable cloth.
2. Carefully press the brake pads back using water pump pliers. Remove a little brake fluid from
the reservoir by suction if necessary in order to prevent an overflow!
Information
1. Do not open the brake system .
2. Do not loosen the brake hose from the brake calliper when loosening the brake calliper .
3. The core of the warning contact wire must not be left exposed! It does not matter if the
insulation is worn .
4. If necessary, remove a little brake fluid from the reservoir by suction in order to prevent
an overflow when the disc brake pads are pushed back .
3. Partially remove brake calliper. Use removal/installation aid for brake calliper Assembly Pin
T10439 .
Fig 2: Identifying Assembly Pin For Brake Calliper
Information
1. Never use an impact bolter to loosen and tighten the brake calliper on the wheel carrier .
1. 3.1. Remove upper fastening screw on the brake calliper -arrow- and insert
Assembly Pin.
Fig 3: Inserting Upper Assembly Pin
2. 3.2. Remove lower fastening screw on the brake calliper -arrow- and insert
Assembly Pin.
Fig 4: Inserting Lower Assembly Pin
3. 3.3. Pull the brake calliper as far as required out of installation position until the brake
calliper engages in the cut-outs on the Assembly Pins → Brake calliper tool fitted .
Carefully guide brake line and brake hose along with calliper in the process.
Fig 5: Identifying Brake Calliper Tool Fitted
4. Fit the brake piston between the disc brake pads on the brake calliper using Piston Reset
Tool (Replaces P83) Nr. 144 , and press the pads back evenly → Pressing back brake pads
. Remove a little brake fluid from the reservoir by suction if necessary in order to prevent an
overflow!
Fig 6: Pressing Back Brake Pads
5. If You Intend To Re-Use The Brake Pads, Mark The Relevant Installation Position!
Carefully slide a commercially available screwdriver between the brake pad/brake calliper and
lever the brake pad out by turning the screwdriver slightly. When doing this, make sure not to
damage the dust boots on the brake pistons -arrows- .
Fig 7: Removing Brake Pads
6. Remove pad retaining springs.
WM 463456 REPLACING FRONT BRAKE PADS (PCCB) > INSTALLING FRONT BRAKE
PADS
Information
Never use an impact bolter to loosen and tighten the brake calliper on the wheel carrier .
Visually inspect the thread for the brake calliper and blow it out carefully if necessary using
compressed air. Use goggles!
Replace screws .
Observe correct Tightening Torques → 4X00IN TIGHTENING TORQUES FOR THE BRAKE
HYDRAULIC SYSTEM .

→ Replace the brake discs on each axle as soon as the brake pad wear limit is reached.
WARNING: Old mounting parts fitted on the brake calliper
Reduced braking effect
Risk of damage to the brake calliper
→ Fit new pad retaining springs
→ Fit new fastening screws
Information
The back of the pad backing plates must not be greased .
Check disc brakes for wear. For details of wear limits see → 465102 CHECKING FRONT PCCB
BRAKE DISCS (WEAR ASSESSMENT) .
Disc brakes must be clean and free of grease .
worn .
Use new repair kit .
HYDRAULIC SYSTEM .
1. Fit new pad retaining springs.
2. Place disc brake pad onto the sealing surfaces of the pad retaining springs -arrows- .
Fig 1: Fitting Brake Pad
3. Press brake pad into the brake calliper with slight pressure and slide it onto the pad retaining
pins -arrows- .
Fig 2: Pressing Brake Pad Into Brake Calliper
4. Fit disc brake pad -arrow- .

Fig 3: Fitting Disc Brake Pad
WM 463456 REPLACING FRONT BRAKE PADS (PCCB) > SUBSEQUENT WORK
1. Fit the brake calliper.
→ 473919 REMOVING AND INSTALLING FRONT BRAKE CALLIPER (PCCB)
2. Position disc brake pads by operating the brake several times.
3. Check the brake fluid level and correct it if necessary.
4. Fit wheel. Use assembly aids (Assembly Pins) -1- . → 440519 REMOVING AND INSTALLING
WHEEL
WM 463456 REPLACING FRONT BRAKE PADS (PCCB) > INFORMATION > BEDDING
IN THE BRAKE PADS
New brake pads require a bedding-in period of approx. 200 km (124 miles)! Only then do they achieve
their best friction and wear coefficient! During this period, the brakes should only be subjected to full
stress at high speed in emergencies!
WM 463502 CHECKING REAR BRAKE PADS (PCCB) > INFORMATION >

brake pads.
WHEEL .
WM 463502 CHECKING REAR BRAKE PADS (PCCB) > CHECKING > CHECKING
THICKNESS OF REAR BRAKE PADS
brake pads.
WHEEL .
WM 463502 CHECKING REAR BRAKE PADS (PCCB) > SUBSEQUENT WORK
WM 463502 CHECKING REAR BRAKE PAD (PCCB) > INFORMATION > INFORMATION
ON CHECKING BRAKE PADS
brake pads.

WHEEL .
WM 463502 CHECKING REAR BRAKE PAD (PCCB) > CHECKING > CHECKING
THICKNESS OF REAR BRAKE PADS
Procedure during intermediate maintenance:
Visually inspect the brake pads for wear. There is no need to remove the wheels unless the brake
fluid needs to be changed at the same time .
brake pads.
Procedure during maintenance:
WHEEL .
WM 463502 CHECKING REAR BRAKE PAD (PCCB) > SUBSEQUENT WORK
WM 463556 REPLACING REAR BRAKE PADS (PCCB) > INFORMATION > NOTE ON
PICTURES SHOWN
Information
WM 463556 REPLACING REAR BRAKE PADS (PCCB) > PRELIMINARY WORK
Lift the vehicle.
Remove the wheel. Use assembly aids (Assembly Pins) -1- .

Information
worn .
1. Partially remove the brake calliper.
→ 474119 REMOVING AND INSTALLING REAR BRAKE CALLIPER (PCCB)
WM 463556 REPLACING REAR BRAKE PADS (PCCB) > REMOVING REAR DISC
BRAKE PADS
The core of the warning contact wire must not be left exposed! It does not matter if the insulation is worn!
when the disc brake pads are pushed back.
1. Screw the two assembly aids (Assembly Pins) -1- , instead of two wheel bolts, into the wheel
hub before removing/fitting the wheel. During removal, first remove the three remaining wheel
bolts and remove the wheel carefully without touching the brake discs.
2. Then (after removing the wheel), remove the two assembly aids (Assembly Pins) -1- again.
Information
3. Carefully press the brake pads back using water pump pliers.
4. Release and unclip the connector for the brake pad wear indicator and remove it from the
holder -arrow- .
Fig 2: Locating Cable Connector
1. Never use an impact bolter to loosen and tighten the brake calliper on the wheel bearing
housing .
Information
5. Get the transmission jack ready for the brake calliper and loosen the brake calliper → see Fig
3.
Fig 3: Removing Brake Calliper
6. Place the brake calliper on the transmission jack → Setting down brake calliper (shown as an
example) .
Fig 4: Setting Down Brake Calliper
7. Carefully slide a commercially available screwdriver between the brake pad/brake calliper and
Fig 5: Removing Rear-Axle Brake Pads
WM 463556 REPLACING REAR BRAKE PADS (PCCB) > INSTALLING REAR DISC
BRAKE PADS
Information
Check disc brakes for wear. For details of wear limits see → 465302 CHECKING REAR BRAKE
DISCS (WEAR ASSESSMENT) .
worn .
HYDRAULIC SYSTEM .
2. Place the disc brake pad onto the sealing surfaces of the pad retaining springs.
3. Press the brake pad into the brake calliper with slight pressure and slide it onto the pad
retaining pins. -arrows-
Fig 2: Locating Front Axle Brake Pad
4. Fit the disc brake pad. -direction arrow-

Fig 3: Fitting Front Axle Brake Pad
5. Fit the brake calliper and check that the brake hose is routed correctly (do not twist the brake
hose!).
WM 463556 REPLACING REAR BRAKE PADS (PCCB) > SUBSEQUENT WORK
1. Fit the wheel. Use assembly aids (Assembly Pins) -1- . → 44051900 REMOVING AND
INSTALLING WHEEL
WM 463556 REPLACING REAR BRAKE PADS (PCCB) > INFORMATION > BEDDING IN
THE BRAKE PADS
WM 463602 CHECKING THICKNESS OF FRONT BRAKE PADS > INFORMATION >

brake pads.
Remove wheels → 440519 REMOVING AND INSTALLING WHEEL .
WM 463602 CHECKING THICKNESS OF FRONT BRAKE PADS > CHECKING >

CHECKING THICKNESS OF BRAKE PADS

Information
Replacement of the warning contact can be avoided by replacing the brake pads no later than
when the pad thickness is 2.5 mm -Arrows- .
Remove wheel. → 440519 REMOVING AND INSTALLING WHEEL .
WM 463602 CHECKING THICKNESS OF FRONT BRAKE PADS > SUBSEQUENT

WORK
Fit the wheel → 440519 REMOVING AND INSTALLING WHEEL .
WM 463619 REMOVING AND INSTALLING FRONT DISC BRAKE PADS > TOOLS
Piston Commercially Nr. 144

Resetting Available Tool
Fixture
(replaces P83)
Assembly Pin VW Tool T10439
WM 463619 REMOVING AND INSTALLING FRONT DISC BRAKE PADS >

INFORMATION > NOTE ON PICTURES SHOWN
Information

PRELIMINARY WORK
Lift the vehicle.

WM 463619 REMOVING AND INSTALLING FRONT DISC BRAKE PADS > REMOVING
FRONT DISC BRAKE PADS
Information

worn .
Information
3. Partially remove the brake calliper. Check the following while doing this:
Information
right or left .
1. 3.1. Remove the holders -1, 2- for the brake hydraulic lines from the wheel bearing
housing -3- .
Fig 2: Mounting For Hydraulic Lines
2. 3.2. Pull the brake pad wear indicator line out of the brake calliper.
Information
5. Use removal/assembly aid for brake callipers Assembly Pin T10439 .

Fig 3: Identifying Assembly Pin On Brake Calliper
Information
6. Remove top fastening screw on the brake calliper and insert Assembly Pin -top direction
arrow- .
Fig 4: Removing Brake Calliper Screws
7. Remove bottom fastening screw on the brake calliper and insert Assembly Pin -bottom
direction arrow- .
Fig 5: Identifying Assembly Pin For Brake Calliper Fitted
8. Pull the brake calliper as far as required out of installation position until the brake calliper
engages in the cut-outs on the Assembly Pins. Carefully guide the brake line and brake hose
along as well!
Fig 6: Pulling Brake Calliper
9. Fit the brake piston between the brake pads on the brake calliper using Piston Resetting
Fixture (Replaces P83) Nr. 144 and press the pads back evenly -arrows- . Remove a little
brake fluid from the reservoir by suction if necessary in order to prevent an overflow!
10. If You Intend To Re-Use The Brake Pads, Mark The Relevant Installation Position .
Carefully slide a commercially available screwdriver between the brake pad/brake calliper and
Fig 8: Removing Brake Pads With Brake Calliper
WM 463619 REMOVING AND INSTALLING FRONT DISC BRAKE PADS > INSTALLING
FRONT DISC BRAKE PADS > INSTALLING DISC BRAKE PADS
Information
Replace screws .
HYDRAULIC SYSTEM .

1. Fit new pad retaining springs. → 465002 CHECKING FRONT BRAKE DISCS (WEAR
ASSESSMENT)
2. Place the brake pad onto the sealing surfaces of the pad retaining springs -arrows- .
retaining pins -arrows- .
Fig 2: Locating Brake Pad
4. Fit the disc brake pad. -direction arrow-


SUBSEQUENT WORK
→ 473919 REMOVING AND INSTALLING FRONT BRAKE CALLIPER
INSTALLING WHEEL

SUBSEQUENT WORK > BEDDING IN THE BRAKE PADS
New brake pads require a bedding-in period of approx. 200 km (125 miles) Only then do they achieve
WM 463802 CHECKING THICKNESS OF REAR BRAKE PADS > INFORMATION >

brake pads.
Fig 1: Checking Rear Brake Pads
Procedure during maintenance:
Remove wheels → 44051900 REMOVING AND INSTALLING WHEEL .
WM 463802 CHECKING THICKNESS OF REAR BRAKE PADS > CHECKING

THICKNESS OF BRAKE PADS > CHECKING THICKNESS OF REAR BRAKE PADS
Information
when the pad thickness is 2.5 mm -arrows- .
Fig 1: Checking Brake Pad Thickness
Remove wheel. → 44051900 REMOVING AND INSTALLING WHEEL .
WM 463802 CHECKING THICKNESS OF REAR BRAKE PADS > SUBSEQUENT WORK
Install wheel. → 44051900 REMOVING AND INSTALLING WHEEL .
WM 463819 REMOVING AND INSTALLING REAR BRAKE PADS > INFORMATION >
NOTE ON PICTURES SHOWN
Information
WM 463819 REMOVING AND INSTALLING REAR BRAKE PADS > PRELIMINARY

WORK
Information
worn .
Lift the vehicle.

WM 463819 REMOVING AND INSTALLING REAR BRAKE PADS > REMOVING REAR
BRAKE PAD > REMOVING REAR DISC BRAKE PADS
Information
holder -arrow- .
Information
housing .
Information
3.
example) .
WM 463819 REMOVING AND INSTALLING REAR BRAKE PADS > INSTALLING >
INSTALLING REAR DISC BRAKE PADS
Information
worn .
HYDRAULIC SYSTEM .
Fig 2: Locating Brake Pad
4. Fit the brake pad. -direction arrow-

hose!).
→ 474119 REMOVING AND INSTALLING REAR BRAKE CALLIPER
WM 463819 REMOVING AND INSTALLING REAR BRAKE PADS > SUBSEQUENT

WORK
INSTALLING WHEEL
BEDDING IN THE BRAKE PADS
WM 463656 REPLACING FRONT DISC BRAKE PADS > TOOLS

Piston Reset Commercially Nr. 144
Tool (replaces Available Tool
P83)

brake calliper
WM 463656 REPLACING FRONT DISC BRAKE PADS > PRELIMINARY WORK
Information
worn .
Raise the vehicle.

WM 463656 REPLACING FRONT DISC BRAKE PADS > REMOVING AND INSTALLING
FRONT DISC BRAKE PADS > REMOVING FRONT DISC BRAKE PADS
1. Expose lines.
Information
right or left .
2. 1.2. Detach line for brake pad wear indicator from brake calliper.
Information
Information
T10439 .
Information
Assembly Pin.
Assembly Pin.
4. Fit the brake piston between the disc brake pads on the brake calliper using Piston Reset
Tool (Replaces P83) Nr. 144 and press the pads back evenly → Pressing back brake pads .
Remove a little brake fluid from the reservoir by suction if necessary in order to prevent an
overflow!
5. If you intend to re-use the brake pads, mark the relevant installation position! Carefully
slide a commercially available screwdriver between the brake pad/brake calliper and lever the
brake pad out by turning the screwdriver slightly. When doing this, make sure not to damage
the dust boots on the brake pistons -arrows- .
WM 463656 REPLACING FRONT DISC BRAKE PADS > REMOVING AND INSTALLING
FRONT DISC BRAKE PADS > INSTALLING FRONT DISC BRAKE PADS
Information
Replace screws .
HYDRAULIC SYSTEM .

Information
Check disc brakes for wear. For details of wear limits, see → 465002 CHECKING FRONT BRAKE
The core of the warning contact wire must not be left exposed! Worn insulation is not important .
Use a new repair kit .
HYDRAULIC SYSTEM .
2. Place disc brake pad onto the sealing surfaces of the pad retaining springs -arrows- .
pins -arrows- .

WM 463656 REPLACING FRONT DISC BRAKE PADS > SUBSEQUENT WORK
1. Fit brake calliper. → 473919 REMOVING AND INSTALLING FRONT BRAKE CALLIPER
WHEEL
WM 463656 REPLACING FRONT DISC BRAKE PADS > INFORMATION > BEDDING IN
THE BRAKE PADS
WM 463802 CHECKING THICKNESS OF REAR BRAKE PADS > INFORMATION >

brake pads.
Remove wheels → REMOVING WHEEL - section on "Removing".
WM 463802 CHECKING THICKNESS OF REAR BRAKE PADS > CHECKING

THICKNESS OF BRAKE PADS > CHECKING THICKNESS OF REAR BRAKE PADS

Information
when the pad thickness is 2.5 mm -Arrows- .
WM 463802 CHECKING THICKNESS OF REAR BRAKE PADS > SUBSEQUENT WORK
Fit the wheel → INSTALLING WHEEL - section on "Installing".
NOTE ON PICTURES SHOWN
Information
WM 463819 REMOVING AND INSTALLING REAR BRAKE PADS > PRELIMINARY

WORK
Information
worn .
Lift the vehicle.

WM 463819 REMOVING AND INSTALLING REAR BRAKE PADS > REMOVING REAR
BRAKE PAD > REMOVING REAR DISC BRAKE PADS
Information
holder -arrow- .
Information
housing .
Information
3.
example) .
WM 463819 REMOVING AND INSTALLING REAR BRAKE PADS > INSTALLING >
INSTALLING REAR DISC BRAKE PADS
Information
worn .
HYDRAULIC SYSTEM .
Fig 1: Locating Front Axle Brake Pad
4. Fit the brake pad. -direction arrow-

hose!).
WM 463819 REMOVING AND INSTALLING REAR BRAKE PADS > SUBSEQUENT

WORK
INSTALLING WHEEL
BEDDING IN THE BRAKE PADS
WM 463856 REPLACING REAR DISC BRAKE PADS > PRELIMINARY WORK
Raise the vehicle.

Information
worn .
1. Partially remove brake calliper.
WM 463856 REPLACING REAR DISC BRAKE PADS > REMOVING AND INSTALLING
REAR DISC BRAKE PADS > REMOVING REAR DISC BRAKE PADS
The core of the warning contact wire must not be left exposed! Worn insulation is not important!
when the disc brake pads are pushed back!
Information
2. Release and unclip connector for the brake pad wear indicator and remove it from the holder
-arrow- .

Information
housing .
Information
3. Get the transmission jack ready for the brake calliper and loosen the brake calliper -arrows- .
4. Place the brake calliper on the transmission jack.
damage the dust boots on the brake pistons -arrow- .
WM 463856 REPLACING REAR DISC BRAKE PADS > REMOVING AND INSTALLING
REAR DISC BRAKE PADS > INSTALLING REAR DISC BRAKE PADS
Information
worn .
HYDRAULIC SYSTEM .
2. Place disc brake pad on the sealing surfaces of the pad retaining springs -arrows- .
pins -arrows- .

hose!).
WM 463856 REPLACING REAR DISC BRAKE PADS > SUBSEQUENT WORK
WHEEL
WM 463856 REPLACING REAR DISC BRAKE PADS > INFORMATION > BEDDING IN
THE BRAKE PADS
WM 465002 CHECKING FRONT BRAKE DISCS (WEAR ASSESSMENT) > TOOLS

Adapter Plate Special Tool 9510/1
Dial Gauge Set Commercially Nr. 147-1

With Ball Joint Available Tool
Arm
WM 465002 CHECKING FRONT BRAKE DISCS (WEAR ASSESSMENT) > TECHNICAL

VALUES
Brake Discs Maximum Crack 0.5 x a mm

Length
Brake Discs Maximum Crack 1 mm

Width
Brake Discs Maximum Crack 1.5 mm

Depth
WM 465002 CHECKING FRONT BRAKE DISCS (WEAR ASSESSMENT) >

INFORMATION
Information

INFORMATION > INFORMATION ON WEAR ASSESSMENT
Normally, brake disc replacement is necessary after the thickness falls below the minimum. In rare,
isolated cases (of very high loads for long periods) replacement may be necessary due to crack
formation. To a certain extent these cracks may be rated as not important. A description is given in the
following sections of when to replace brake discs.
Cracks occur as a result of material fatigue due to frequent and extreme thermal expansion fluctuations.
Particularly in cases of very high loads for long periods, these thermal expansion fluctuations produce
internal stresses. The result may be cracks in the friction surface. These cracks allow relaxation of the
friction disc, so that the speed at which the cracks develop is very slow.
Cracks run from the centre of the friction surface to the (inner and outer) edges of the brake disc. As
different vehicle types have different brake disc sizes, differences arise for the maximum crack length
limits.
Maximum crack length limit is calculated as follows:
0.5 x a (-a- = width of friction surface in mm).
Fig 1: Identifying Brake Disc Friction Surface Width
Larger cracks impair braking comfort and reduce brake disc strength, therefore making brake disc
replacement necessary as a precaution.
Irrespective of the crack length, the brake disc must be replaced if the crack has extended as far as the
outer and/or inner edge of the disc.
INFORMATION > BEDDING IN THE BRAKE PADS AND BRAKE DISCS
their best friction and wear coefficient. During this period, the brakes should be subjected to full stress
when travelling at high speed only in emergencies. The slightly reduced braking effect must be
compensated for by increased pressure on the brake pedal. The same also applies after replacing or
machining brake discs.
WM 465002 CHECKING FRONT BRAKE DISCS (WEAR ASSESSMENT) > CHECKING >
CHECKING FRONT BRAKE DISCS - EVALUATING CRACKS
Different vehicle types have different brake disc sizes. This produces differences for the maximum crack
length limits.

The length of a crack can be measured with a steel rule, for example. → Brake discs
Fig 2: Checking Brake Disc Cracks
Information
As a precaution, brake discs must be replaced when:
the → Maximum crack length: 0.5 x a mm (a = friction surface width in mm) is exceeded!
the → Maximum crack width: 1 mm is exceeded!
the → Maximum crack depth: 1.5 mm is exceeded!
CHECKING FRONT BRAKE DISC - MINIMUM THICKNESS
Information
Normally, brake discs are used until the maximum wear dimension is reached. → WM 4650TW
TECHNICAL DATA/BRAKE WEAR LIMITS Only in a few exceptional cases is it advisable to skim the
brake discs (if there is deep scoring or corrosion of the friction surface). In this case only the disc brake
dressing machines approved by Porsche AG are to be used .
Only as new brake discs may be reworked!
Only rework the brake discs symmetrically, evenly from both sides!
As the pressure force of a brake piston on the brake pad varies in magnitude, different areas of wear
arise on the friction surface. The brake disc can basically be divided into two areas of wear:
-A- Outer and inner wear area.
-B- Central wear area.

Fig 1: Identifying Front Brake Disc Minimum Thickness Wear Areas
The central wear area -B- is the area with the highest degree of wear.
Fig 2: Identifying Central Wear Areas
Measure the brake discs using a suitable micrometer at least three different places (-A, B, C- ),
offset by 120°.
Fig 3: Measuring Brake Discs Using Suitable Micrometer
CHECKING LATERAL RUNOUT (BRAKE DISC/WHEEL HUB) AND THICKNESS
TOLERANCE
Information
Fasten dial gauge set with ball joint arm to wheel bearing housing.
Two adapters are used for checking lateral runout. The brake disc and wheel hub can be measured with
these.
Brake disc lateral runout
1. Remove wheel → 440519 REMOVING AND INSTALLING WHEEL
2. Adapter Plate 9510/1 must be fitted and tightened to Tightening Torque 160 Nm (118 ft. lb.).
→ Adapter plate on wheel hub
Fig 1: Identifying Adapter Plate On Wheel Hub
3. Fit adapter Dial Gauge Set With Ball Joint Arm Nr. 147-1 at a suitable position on the wheel
bearing housing. → Dial gauge on brake disc
Fig 2: Installing Dial Gauge On Brake Disc
4. Fit the dial gauge with some preload and measure the lateral runout at the greatest external
diameter of the brake disc.
Wheel hub lateral runout
Information
The front face of the wheel hub must not be corroded. If necessary, clean with fine emery cloth.
Measure the wheel hub lateral runout at the front face of the wheel hub. You should always
measure the external and internal diameters of the wheel bolt area.
1. Remove brake disc. → 465019 REMOVING AND INSTALLING FRONT BRAKE DISC
bearing housing. Fit the dial gauge with some preload. → Dial gauge on wheel hub
Fig 3: Installing Dial Gauge On Wheel Hub
Brake disc thickness tolerance
For details of brake disc thickness tolerance, see Technical data/brake wear limits →. 4650TW
TECHNICAL DATA/BRAKE WEAR LIMITS
Measure the thickness tolerance using a suitable micrometer screw at approx. 8 places within the
braking surface.
WM 465019 REMOVING AND INSTALLING FRONT BRAKE DISC > TOOLS

brake calliper
WM 465019 REMOVING AND INSTALLING FRONT BRAKE DISC > TECHNICAL

VALUES
No. 4: Cable M8 x 14 thread Tightening 20 Nm (15 ft.

holder to Torque lb.)
front-axle wheel
carrier
No. 5: Brake M6 x 12 thread Tightening 9 Nm (6.5 ft.

hose holder to Torque lb.)
front-axle wheel
carrier
No. 6: Fastening M12 x 1.5 thread Tightening 15 Nm (11 ft.

screw securing (always replace Torque lb.)
brake disc to screws and lock
wheel hub nuts after
removal)
Threaded M14 x 1.5 x 115 Tightening 140 Nm (104 ft.

connection thread (always Torque lb.)
securing brake replace screws
calliper to and lock nuts
front-axle after removal)
18-inch wheel
carrier

19-inch wheel
carrier and
PCCB
WM 465019 REMOVING AND INSTALLING FRONT BRAKE DISC > PRELIMINARY

WORK
1. Raise the vehicle → 4X00IN LIFTING THE VEHICLE .
2. Remove wheel. Use assembly aids (Assembly Pins) -1- . → 440519 REMOVING AND
INSTALLING WHEEL .
WM 465019 REMOVING AND INSTALLING FRONT BRAKE DISC > PRELIMINARY

WORK > REMOVING FRONT BRAKE DISC
NOTE: Removal of brake calliper
Paint defects on brake calliper
→ Proceed with care when setting back the brake pads.
→ Protect brake calliper from paint defects using a suitable cloth.
1. Expose lines.
Information
1. To gain better access for assembly work, it is a good idea to turn the wheels fully either to
the right or left!
Fig 1: Identifying Brake Calliper Hydraulic Line Holders
2. 1.2. Pull line for brake pad wear indicator out of the brake calliper.
Information
Information
T10439 .
Assembly Pin.
Assembly Pin.
4. Unscrew fastening screw -arrow- and remove brake disc.

Fig 6: Locating Brake Disc Fastening Screw
WM 465019 REMOVING AND INSTALLING FRONT BRAKE DISC > INSTALLING

FRONT BRAKE DISC
Information
Always replace the brake calliper fastening screws following removal!
Do not confuse right and left brake discs during assembly!
1. Check that all parts are in perfect condition (visual inspection) and replace them if necessary.
2. Clean the levelling and centering surfaces on the brake disc and wheel hub.
3. Apply a very thin coat of Optimoly TA to the centering surface on the wheel hub.
Observe specified tightening torques:
Brake disc to wheel hub: Tightening Torque 15 Nm (11 ft. lb.)
Brake calliper to wheel bearing housing (18-inch brakes): Tightening Torque 140 Nm (104 ft.
lb.)
Brake calliper to wheel bearing housing (19-inch brakes): Tightening Torque 140 Nm (104 ft.
lb.)
Brake hose bracket to wheel bearing housing: Tightening Torque 9 Nm (6.5 ft. lb.)
Cable holder to wheel bearing housing: Tightening Torque 20 Nm (15 ft. lb.)
WM 465019 REMOVING AND INSTALLING FRONT BRAKE DISC > SUBSEQUENT

WORK
WHEEL .
WM 465019 REMOVING AND INSTALLING FRONT BRAKE DISC > SUBSEQUENT

WORK > INFORMATION ON BEDDING IN NEW BRAKE PADS
New brake pads require a slightly longer bedding-in period for PCCB brake discs than cast iron brake
discs.
In general, the following applies: New brake pads must be worn in (bedding-in period). Their optimum
braking effect is therefore not reached until after a few hundred kilometers. The slightly reduced braking
effect must be compensated for by increased pressure on the brake pedal. The same also applies after
changing brake discs.
WM 4650TW TECHNICAL DATA/BRAKE WEAR LIMITS > TECHNICAL VALUES

(Porsche Stability booster, internally
Management) as ventilated brake
standard discs with
six-piston
aluminum
monobloc fixed-
calliper brake on
front axle and
four-piston
aluminum
monobloc fixed-
calliper brake on
rear axle.

Management
(PSM) as
standard with the
functions
Anti-lock Brake
System (ABS),
Anti-Slip
Regulation
(ASR), Engine
Drag Torque
Control (EDTC),
Automatic Brake
Differential
(ABD), brake
force boosting,
brake system
pre-filling.

booster Ø
(vacuum)
Boost ratio 8/7

cylinder Ø
division

front

rear
Brake disc 36 mm
thickness, front
Brake disc 28 mm
thickness, rear
Thickness 0.01 mm
tolerance of
brake disc, max.

disc Ø, front

disc Ø, rear
brake calliper
brake calliper

front

rear

area

ventilated brake
discs with
six-piston
aluminum
monobloc fixed-
calliper brake on
front axle and
four-piston
aluminum
monobloc fixed-
calliper brake on
rear axle. The
brake callipers
are painted
yellow for visual
differentiation.

Management
(PSM) as
standard with the
functions
Anti-lock Brake
System (ABS),
Anti-Slip
Regulation
(ASR), Engine
Drag Torque
Control (EDTC),
Automatic Brake
Differential
(ABD), brake
force boosting,
brake system
pre-filling.

booster Ø
(vacuum)
Boost ratio 8/7

cylinder Ø
division

front

rear
Brake disc 38 mm
thickness, front
Brake disc 30 mm
thickness, rear
Thickness 0.01 mm
tolerance of
brake disc, max.
disc Ø, front

disc Ø, rear
brake calliper
brake calliper

front

rear

area

front

rear

thickness, front

thickness, rear

disc
symmetrically,
evenly from both
sides!

disc
symmetrically,
evenly from both
sides!

dimension, front

dimension, rear
surface
roughness of
brake disc after
machining, max.
Thickness 0.02 mm
tolerance of
brake discs after
machining, max.

brake disc, max.

wheel hub, max.

brake disc when
installed, max.

both rear wheels

drum Ø mm

thickness

front

rear

thickness, front

thickness, rear

limit, front disc thickness on brake disc
stamped on the
brake disc hub.
Example: Min.
Th. 37.7 mm

limit, rear disc thickness on brake disc
stamped on the
brake disc hub.
Example: Min.
Th. 29.7 mm

surface
roughness of
brake disc

in front and rear surface fracture > 46 51 02
brake discs 1 cm2 and/or Checking front
surface PCCB brake
Replace PCCB discs.
brake discs on
both sides of the
axle.

brake disc, max.

wheel hub, max.

brake disc when
installed, max.

both rear wheels

drum Ø mm

thickness

TECHNICAL DATA - 18-INCH BRAKE SYSTEM (CAYENNE S/CAYENNE DIESEL
(U.S.A. ONLY)/CAYENNE DIESEL S/CAYENNE HYBRID)

(Porsche Stability booster,
Management) as internally
standard ventilated brake
discs with
six-piston
aluminum
monobloc fixed-
calliper brake on
front axle and
four-piston
aluminum
monobloc fixed-
calliper brake on
rear axle.

Management
(PSM) as
standard with the
functions
Anti-lock Brake
System (ABS),
Anti-Slip
Regulation
(ASR), Engine
Drag Torque
Control (EDTC),
Automatic Brake
Differential
(ABD), brake
force boosting,
brake system
pre-filling.

booster Ø
(vacuum)
Boost ratio 8/7

cylinder Ø
division

front
rear
Brake disc 36 mm
thickness, front
Brake disc 28 mm
thickness, rear
Thickness 0.01 mm
tolerance of
brake disc, max.

disc Ø, front

disc Ø, rear
brake calliper
brake calliper

front

rear

area

TECHNICAL DATA - PCCB (CAYENNE BASIC MODEL/CAYENNE S/CAYENNE
DIESEL/CAYENNE DIESEL S/CAYENNE HYBRID)

ventilated brake
discs with
six-piston
aluminum
monobloc fixed-
calliper brake on
front axle and
four-piston
aluminum
monobloc fixed-
calliper brake on
rear axle. The
brake callipers
are painted
yellow for visual
differentiation.

Management
(PSM) as
standard with the
functions
Anti-lock Brake
System (ABS),
Anti-Slip
Regulation
(ASR), Engine
Drag Torque
Control (EDTC),
Automatic Brake
Differential
(ABD), brake
force boosting,
brake system
pre-filling.

booster Ø
(vacuum)
Boost ratio 8/7

cylinder Ø
division

front

rear
Brake disc 38 mm
thickness, front
Brake disc 30 mm
thickness, rear
Thickness 0.01 mm
tolerance of
brake disc, max.
disc Ø, front

disc Ø, rear
brake calliper
brake calliper

front

rear

area
VALUES AND WEAR LIMITS FOR 18-INCH BRAKE SYSTEM (CAYENNE S/CAYENNE
DIESEL (U.S.A. ONLY)/CAYENNE DIESEL S/CAYENNE HYBRID)
Information
Depending on the extent of wear on cast iron brake discs, two condition criteria can make replacement
necessary:
Formation of cracks at advanced stage on the brake disc friction surfaces .
Minimum brake disc thickness is not retained due to wear (material erosion due to friction) . →
46500200 CHECKING FRONT BRAKE DISCS (WEAR ASSESSMENT) → 46530250 CHECKING
REAR BRAKE DISCS (WEAR ASSESSMENT)

front mm

rear mm

thickness, front

thickness, rear

disc
symmetrically,
evenly from both
sides!

disc
symmetrically,
evenly from both
sides!

dimension, front

dimension, rear
surface
roughness of
brake disc after
machining, max.
Thickness 0.02 mm
tolerance of
brake discs after
machining, max.

brake disc, max.

wheel hub, max.

brake disc when
installed, max.

both rear wheels

drum Ø mm

thickness
Possible complaints
Damage due to lack of use (rusting). This causes vibrations in the steering wheel, noises and
brake pedal pulsation.
Brake disc becomes distorted as a result of serious driving.
Procedure
Check brake disc for cracks, minimum thickness, lateral runout, thickness tolerance, flatness and
surface roughness.
If necessary, (depending on the actual brake disc thickness and the brake disc wear limit) machine
the brake disc using one of the disc brake dressing machines approved by Porsche.
The brake disc must only be reworked symmetrically, i.e. evenly from both sides! Read the
operating instructions for the disc brake dressing machine!
VALUES AND WEAR LIMITS FOR PCCB (CAYENNE BASIC MODEL/CAYENNE
S/CAYENNE DIESEL/CAYENNE DIESEL S/CAYENNE HYBRID)
Information
The following condition criteria can make replacement necessary depending on the wear of the PCCB
brake discs:
Surface changes in the brake disc friction surfaces at an advanced stage .
Minimum brake disc thickness is not retained due to wear (material erosion due to friction) .
Information
The PCCB brake disc must not be machined.

front

rear

thickness, front

thickness, rear

limit, front disc thickness value on brake
stamped on the
brake disc hub.
Example: Min.
Th. 37.7 mm

limit, rear disc thickness value on brake
stamped on the
brake disc hub.
Example: Min.
Th. 29.7 mm

surface
roughness of
brake disc

in front and rear surface fracture 46 51 02
brake discs > 1 cm2 and/or Checking front
surface PCCB brake
Replace PCCB discs.
brake discs on
both sides of the
axle.

brake disc, max.

wheel hub, max.

brake disc when
installed, max.

both rear wheels

drum Ø mm

thickness
Possible complaints
Procedure
Check brake disc for minimum thickness, lateral runout, thickness tolerance, flatness and surface
roughness.
WM 465102 CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) >
CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) > NOTE ON
PICTURES SHOWN
Information

CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) > GENERAL
INFORMATION ON PCCB BRAKE DISCS
The brake discs have wear indicator plates in the friction surfaces. The wear indicator plates (six on
each brake disc) are arranged close to the outer diameter, offset by 120 ° -arrows- at three points. The
three wear indicator plates on each friction surface (3 on the inside and 3 on the outside) are positioned
directly opposite each other. Each wear indicator is approx. 2 cm2 . The wear indicators are barely
visible on new brake discs.
Fig 1: Locating Brake Discs Wear Indicators

The minimum brake disc thickness (wear dimension) is stamped on the brake-disc chamber (e.g. Min.
Th. 37.7 mm).

CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) > BASIC
INFORMATION
Checking involves the following: Information
1. Visual inspection for surface changes in the brake disc friction surfaces and wear indicators.
Indication of wear: Connected surface fracture > 1 cm2-arrow- , without adding up smaller
fractures → 465102 CHECKING FRONT PCCB BRAKE DISCS (WEAR ASSESSMENT) -
section on "Checking".
Fig 1: Locating Brake Discs Surface Fracture
2. Check surface roughness (Rk) of brake discs (max. 80 μm permitted) since this affects braking
comfort (noises), braking behavior/pedal pressure and brake-pad service life → 465102
CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) - section on "Checking".
Fig 2: Identifying Surface Roughness Of PCCB Brake Disc
3. Check brake discs for minimum thickness -X- . The minimum brake disc thickness (e.g. Min.
Th. 37.7 mm) is stamped on the brake-disc chamber → 465102 CHECKING FRONT PCCB
BRAKE DISC (WEAR ASSESSMENT) - section on "Checking".
Fig 3: Identifying Minimum Thickness Of PCCB Brake Disc
4. Check brake discs for edge damage -see pictureFig 4- (damage due to improper use) →
465102 CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) - section on
"Checking".
Fig 4: Identifying PCCB Brake Disc Damage Edge

CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) > GENERAL
INFORMATION ON REPLACING WORN PCCB BRAKE DISCS
Three criteria governing the condition of the parts can make replacement necessary depending
on the wear of PCCB brake discs:
1. Surface changes in the brake disc friction surfaces (material fatigue/wear) at an advanced
stage (indication of wear: connected friction surface damage > 1 cm2 ).
2. Surface roughness of the brake disc friction surfaces too great (roughness depends on
mileage and load).
3. Brake disc minimum thickness is not attained due to wear (material erosion due to friction).
1. In practice, all three forms of brake disc erosion usually occur.
2. Only in rare cases (as a result of long-term motor-racing brake loads/very high
temperatures on the friction surfaces), surface changes can progress so quickly that the
brake discs may need to be changed earlier than planned.
3. Brake discs that have turned blue at the brake-disc chamber and/or brake callipers that
have turned a strong brown color are clear indications of high loads over a long period of
time, e.g. on the race circuit.

CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) > REPLACING
BRAKE DISCS (INSTRUCTIONS/DECISION-MAKING AID)
When replacing brake discs as a result of wear (see wear assessment) both brake discs must be
replaced on an axle!
Irrespective of wear, a brake disc change may be necessary due to edge damage on the brake disc
friction surfaces! In this case, only one brake disc can be replaced if the friction surface of the other
PCCB brake disc is still 'as new' → 465102 CHECKING FRONT PCCB BRAKE DISC (WEAR
ASSESSMENT) - section on "Checking".
The wear indicator plates (six on each brake disc) are arranged close to the outer diameter, offset by
120 ° -arrows- at three points. The three wear indicator plates on each friction surface (3 on the inside
and 3 on the outside) are positioned directly opposite each other. Each wear indicator is approx. 2 cm2 .
The wear indicators are barely visible on new brake discs.
Fig 1: Locating Wear Indicators
Th. 37.7 mm).

CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) > CRACKS (STRESS-
RELIEF MICROSTRUCTURE) IN THE BRAKE DISC FRICTION SURFACE
Cracks in the brake disc friction surfaces must be regarded differently to cracks in grey cast-iron brake
discs. These cracks are not regarded as wear criteria for PCCB brake discs and may even be present
on new brake discs, depending on the manufacturer.
Fig 1: Identifying Stress-Relief Microstructure In PCCB Brake Disc Friction Surfaces
Information
Due to the composition of different materials in the friction layer and support body, the friction
surfaces (even when new) are coated with an uncritical crack pattern (stress-relief microstructure).
Individual relaxation cracks sometimes run along the perforated bores .
The stress-relief microstructure results from the way in which the brake disc surface is
manufactured and does not pose a risk to safety. There is also no danger of the friction layers
flaking off from the support body, since the friction layers are almost free of internal stresses as a
result of the stress-relief microstructure .
The stress-relief microstructure is sometimes clearly visible in new brake discs and the brake disc
chamber side and the side that is opposite to the chamber can differ significantly from one another
.

CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) > INFORMATION
CONCERNING BORES (PERFORATIONS) IN THE BRAKE DISC FRICTION SURFACE
Observe the following warning when cleaning or exposing the bores in the brake disc friction surface!
Fig 1: Identifying Bores (Perforations) In Brake Disc Friction Surface

NOTE: Work cannot be carried out on the bores in the brake disc friction surface
Damage to brake discs
→ Clean the bores on PCCB brake discs with high-pressure cleaning equipment if necessary. Observe
the relevant environmental and safety regulations.
→ Do not machine the bores. Drilling or counter-sinking is not permitted.

CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) > COATING ON THE
PCCB BRAKE DISCS (POTENTIAL CAUSES)
The coating on the PCCB brake discs arises as a result of a high load and high temperatures, for
example on a racing circuit. Check the following in such cases:

Ventilation (brake cooling): all components are present, secured correctly and undamaged.
Brake pad quality: If the vehicle is used for race-track driving, use appropriate brake pads.
The perforation bores -see pictureFig 1- in the brake discs must not be blocked. Unblock them if
necessary. → 465102 CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) - section
on "Information".
In the event of brake pad wear, the brake discs can still be used provided the brake discs satisfy all
wear criteria (see also GENERAL INFORMATION ON REPLACEMENT OF PCCB BRAKE DISCS
DUE TO WEAR ). The perforation bores -see pictureFig 1- must not be blocked.

CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) > INFORMATION ON
BEDDING IN NEW BRAKE PADS
discs.
In general, the following applies: New brake pads must be broken in (bedding-in period), their optimum
a brake disc change.

CHECKING PCCB BRAKE DISCS (WEAR ASSESSMENT) > VISUAL INSPECTION OF
THE SURFACES OF THE BRAKE DISC FRICTION SURFACES (INDICATION OF
WEAR)
Information
The friction surface changes occur due to material fatigue as a result of extremely high thermal
load. These disc temperatures, which occur above all in racing conditions, cause a progressive
material fatigue .
Effects on driving: The surface change worsens the smoothness of braking, decreases the disc
strength and increases the brake pad wear and therefore makes a precautionary parts
replacement necessary .
The following illustrations (PCCB brake disc wear appearance) are to be used for damage assessment.

CHECKING PCCB BRAKE DISCS (WEAR ASSESSMENT) > PCCB BRAKE DISC
WEAR APPEARANCE
1. Friction surfaces after normal brake load while driving on roads. No surface fractures present -
Brake discs do not need to be replaced!

Fig 1: Identifying PCCB Brake Disc Wear Appearance
2. Friction surfaces after a long journey and occasional high load. Isolated cases of connected
surface fractures less than 1 cm2-arrow- .
No replacement necessary as the connected surface fractures are < 1 cm2 !

Fig 2: Locating PCCB Surface Fractures
3. End of service life of friction surface or after highest load on a racing circuit.
Replace brake discs if the connected friction surface damage is > 1 cm2-arrow- . To do this,
follow the instructions provided under → 465102 CHECKING FRONT PCCB BRAKE DISC
(WEAR ASSESSMENT) - section on "Information".
Fig 3: Locating PCCB Friction Surface Damage
The best way to detect a surface fracture is by checking the wear indicators. Based on the
wear indicators, this means that at least one wear indicator -arrow- must have a surface
fracture of > 50% (damage > 1 cm2 /entire surface of a wear indicator with a surface area of
approx. 2 cm2 ).
Fig 4: Locating PCCB Surface Fracture On Wear Indicator

CHECKING PCCB BRAKE DISCS (WEAR ASSESSMENT) > EVALUATION OF
SURFACE ROUGHNESS RK (MAX. 80 MICROMETERS PERMITTED)
Information
An increase in surface roughness impairs smoothness of braking (rubbing, shaking in steering

wheel, scraping noises) and increases brake pad wear .
With a roughness (Rk) value of > 80 μm (> 80 micrometers), a precautionary parts replacement is
required .
The assessment is carried out visually, based on the diagram. Two illustrations of the same peak-to-
valley surface roughness (views 1 and 2) help to make a better assessment.
1. Brake discs that are OK:
1. 1.1. Surface roughness (Rk) = 6 μm -see picture- (view 1)Fig 1

Fig 1: Identifying PCCB Surface Roughness 6 Micrometers (View 1)
Surface roughness (Rk) = 6 μm -see picture- (view 2)Fig 2
New brake disc. Illustration is used for better classification.
The early stages of roughness are indicated by burnt-out carbon fibres on the
surface of an otherwise intact, semi-matt surface.
The surface feels smooth.



In the advanced stages of fibre burnout and the initial destruction of the Si and SiC
'matrix', the depressions have become more pronounced. Large sections of the
surface are still intact, the depressions form an even, fine-grained pattern.
The surface still feels matt, however, and the roughness is not yet pronounced.
Fig 4: Identifying PCCB Surface Roughness 56 Micrometers (View -2)
No replacement necessary!

Borderline disc, which can still just be evaluated as OK. As a result of more
advanced damage to the surface, the depressions are larger, and above all deeper,
compared with the previous surface condition.
On the one hand, the more extensive roughness is noticeable (only when a
comparison is made); on the other hand, however, like before, "only" depressions are
observed.
Replacement not yet necessary!

2. Worn brake discs:


Worn surface. Advanced wear has led to a situation where only the remains of the
original surface are left.
It is clear that the roughness is caused not only by depressions but also by bumps.
Replace brake discs! To do this, follow the instructions → 465102 CHECKING

FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) - section on "Information".
In general, the following applies: Brake discs must be replaced if the surface
roughness (Rk) is > 80 μm!
3. Worn brake discs (special cases):
1. 3.1. Surface roughness (Rk) = 108 μm, as for previous disc, but with some of the
original friction surface remaining -arrow- .
Replace brake discs! To do this, follow the instructions → 465102 CHECKING

FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) - section on "Information".
Fig 9: Identifying PCCB Surface Roughness (108 Micrometers)
2. 3.2. Surface roughness (Rk) = 72 μm. Borderline disc, identified by the roughness,
but also by the indication of wear and connected surface fractures -arrows- , > 1
cm2 .
Replace brake discs! To do this, follow the instructions provided under → 465102
CHECKING FRONT PCCB BRAKE DISC (WEAR ASSESSMENT) - section on
"Information".
Fig 10: Identifying Defective PCCB Brake Disc

CHECKING PCCB BRAKE DISCS (WEAR ASSESSMENT) > CHECKING BRAKE DISCS
FOR MINIMUM THICKNESS
Information
For perforated brake discs, the minimum thickness -X- must always be measured on the inner or
outer friction surface track -arrows- .
Wear limit: The minimum brake disc thickness is stamped on the brake-disc chamber (e.g. Min. Th.
37.7 mm) .
Measure the brake thickness -X- with a suitable micrometer screw gauge or a brake disc gauge
around the inner or outer friction surface tracks -arrows- .

CHECKING PCCB BRAKE DISCS (WEAR ASSESSMENT) > CHECKING BRAKE DISCS
FOR EDGE DAMAGE
Information
Irrespective of wear, a brake disc change may be necessary due to edge damage on the brake
disc friction surfaces .
In such cases, only one brake disc may need to be replaced if the friction surface of the other
PCCB brake disc is still perfectly OK .
Fig 1: Checking PCCB Brake Disc Edge Damage
Max. permissible width/depth = 2 mm
Max. permitted length = 10 mm
Max. 3 damaged edge areas permissible
WM 465119 REMOVING AND INSTALLING FRONT BRAKE DISC (PCCB) > TOOLS

brake calliper
WM 465119 REMOVING AND INSTALLING FRONT BRAKE DISC (PCCB) >

TECHNICAL VALUES
No. 4: Cable M8 x 14 thread Tightening 20 Nm (15 ft.

holder to Torque lb.)
front-axle wheel
carrier
No. 5: Brake M6 x 12 thread Tightening 9 Nm (6.5 ft.

hose holder to Torque lb.)
front-axle wheel
carrier

removal)

19-inch wheel
carrier and
PCCB

PRELIMINARY WORK
INSTALLING WHEEL .

PRELIMINARY WORK > REMOVING FRONT BRAKE DISC (PCCB)

1. Expose lines.
Information
the right or left!
Information
Information
T10439 .
Assembly Pin.
Assembly Pin.


INFORMATION > EXPLANATION OF TWO-PART BRAKE DISC
The PCCB brake discs consist of two parts on the front and rear axles. The brake disc -1- is
screwed to the brake disc hub -2- with 10 screws (M6) -3- .
Only the complete brake disc is available as a spare part (disc + brake disc hub)!
Do not separate the brake disc hub -2- and brake disc -1- .
Do not attempt to turn the screws -3- . The screws are prevented from turning by compression in
the bush.
Changing the Tightening Torque of the screws -3- will have negative effects on the noise
produced.
Fig 1: Identifying Two-Part Brake Disc

INSTALLING FRONT BRAKE DISC > INSTALLING FRONT BRAKE DISC (PCCB)
Information
Brake calliper to wheel bearing housing: Tightening Torque 140 Nm (104 ft. lb.)
Brake hose bracket to wheel carrier: Tightening Torque 9 Nm (6.5 ft. lb.)
Cable holder to wheel carrier: Tightening Torque 20 Nm (15 ft. lb.)

SUBSEQUENT WORK
WHEEL .

SUBSEQUENT WORK > INFORMATION ON BEDDING IN NEW BRAKE PADS
discs.
WM 465119 REMOVING AND INSTALLING FRONT PCCB BRAKE DISC > TOOLS

brake calliper
WM 465119 REMOVING AND INSTALLING FRONT PCCB BRAKE DISC >

Information

PRELIMINARY WORK
INSTALLING WHEEL .

PRELIMINARY WORK > REMOVING FRONT BRAKE DISC (PCCB)

1. Expose lines.
Information
the right or left!
Fig 1: Identifying Brake Calliper Hydraulic Line Holders
Information
Information
T10439 .
Assembly Pin.
Assembly Pin.


INFORMATION > EXPLANATION OF TWO-PART BRAKE DISC
1. The PCCB brake discs consist of two parts on the front and rear axles. The brake disc -1- is
screwed to the brake-disc chamber -2- with screws (M6) -3- .

2. Only the complete brake disc is available as a spare part (disc + brake-disc chamber)!
3. Do not separate the brake-disc chamber -2- and brake disc -1- . In addition, the screws -3-
must not be turned and should not need to be turned. The screws are prevented from turning
by compression in the bushing.
4. It is essential that the Tightening Torque of the screws is not changed (do not turn the screws)
as this can have a negative effect on the sound behavior.
1 Brake disc
2 Brake-disc chamber
3 Screw
WM 465119 REMOVING AND INSTALLING FRONT PCCB BRAKE DISC > INSTALLING
FRONT BRAKE DISC > INSTALLING FRONT BRAKE DISC (PCCB)
Information

Brake disc to wheel hub:
Brake calliper to wheel bearing housing:
Brake hose bracket to wheel carrier:
Cable holder to wheel carrier:

SUBSEQUENT WORK
INSTALLING WHEEL

discs.
WM 465302 CHECKING REAR BRAKE DISCS (WEAR ASSESSMENT) > TOOLS

Adapter Plate Special Tool 9510/1
Dial Gauge Set Commercially Nr. 147-1

with Ball Joint Available Tool
Arm
WM 465302 CHECKING REAR BRAKE DISCS (WEAR ASSESSMENT) > TECHNICAL

VALUES
Brake discs Maximum crack 0.5 x a mm

length
Brake discs Maximum crack 1 mm

width
Brake discs Maximum crack 1.5 mm

depth
WM 465302 CHECKING REAR BRAKE DISCS (WEAR ASSESSMENT) >

Information

INFORMATION > BRAKE DISC WEAR ASSESSMENT - GENERAL
Normally, brake disc replacement is necessary after the thickness falls below the minimum. In rare,
isolated cases (of very high loads for long periods) replacement may be necessary due to crack
formation. To a certain extent these cracks may be rated as not important. A description is given in the
following sections of when to replace brake discs.
Cracks occur as a result of material fatigue due to frequent and extreme thermal expansion fluctuations.
Particularly in cases of very high loads for long periods, these thermal expansion fluctuations produce
internal stresses. The result may be cracks in the friction surface. These cracks allow relaxation of the
friction disc, so that the speed at which the cracks develop is very slow.
Cracks run from the centre of the friction surface to the (inner and outer) edges of the brake disc. As
different vehicle types have different brake disc sizes, differences arise for the maximum crack length
limits.
Larger cracks impair braking comfort and reduce brake disc strength, therefore making brake disc
replacement necessary as a precaution.
INFORMATION > BEDDING IN THE BRAKE PADS AND BRAKE DISCS
their best friction and wear coefficient. During this period, the brakes should be subjected to full stress
when travelling at high speed only in emergencies. The slightly reduced braking effect must be
compensated for by increased pressure on the brake pedal. The same also applies after replacing or
machining brake discs.
WM 465302 CHECKING REAR BRAKE DISCS (WEAR ASSESSMENT) > CHECKING

REAR BRAKE DISCS (EVALUATING CRACKS)
Different vehicle types have different brake disc sizes. This results in differences in terms of maximum
crack length limits.
Fig 1: Identifying Rear Brake Discs Friction Surface Width

The length of a crack can be measured with a steel rule, for example. → Brake discs
Fig 2: Measuring Rear Brake Discs Friction Surface Cracks
Information
As a precaution, brake discs must be replaced when:
the → Maximum Crack Length: 0.5 x a mm (a = friction surface width in mm) is exceeded!
the → Maximum Crack Width: 1 mm is exceeded!
the → Maximum Crack Depth: 1.5 mm is exceeded!

REAR BRAKE DISCS (EVALUATING CRACKS) > CHECKING REAR BRAKE DISCS
(MINIMUM THICKNESS)
Information
Normally, brake discs are used until the maximum wear dimension is reached. → WM 4650TW
TECHNICAL DATA/BRAKE WEAR LIMITS Only in a few exceptional cases is it advisable to skim the
brake discs (if there is deep scoring or corrosion of the friction surface). In this case only the disc brake
dressing machines approved by Porsche AG are to be used .
Only as new brake discs may be reworked!
Only rework the brake discs symmetrically, evenly from both sides!
As the pressure force of a brake piston on the brake pad varies in magnitude, different areas of wear
arise on the friction surface. The brake disc can basically be divided into two areas of wear:
-A- Outer and inner wear area.
-B- Central wear area.

Fig 1: Identifying Rear Brake Discs Wear Areas A And B (Minimum Thickness)
The central wear area -B- is the area with the highest degree of wear.
Fig 2: Identifying Rear Brake Discs Wear Areas B (Minimum Thickness)
Measure the brake discs using a suitable micrometer at least three different places (-A, B, C- ),
offset by 120°.
Fig 3: Measuring Brake Discs Using Suitable Micrometer

REAR BRAKE DISCS (EVALUATING CRACKS) > CHECKING LATERAL RUNOUT
(BRAKE DISC/WHEEL HUB) AND THICKNESS TOLERANCE
Information
Fasten dial gauge set with ball joint arm to wheel bearing housing.
Two adapters are used for checking lateral runout. The brake disc and wheel hub can be measured with
these.
Brake disc lateral runout
1. Remove wheel → 440519 REMOVING AND INSTALLING WHEEL
2. Adapter Plate 9510/1 must be fitted and tightened to Tightening Torque 160 Nm (118 ft. lb.).
→ Adapter plate on wheel hub
Fig 1: Identifying Adapter Plate On Wheel Hub
bearing housing. → Dial gauge on brake disc
Fig 2: Fitting Adapter Dial Gauge Set With Ball Joint
4. Fit the dial gauge with some preload and measure the lateral runout at the greatest external
diameter of the brake-disc.
Wheel hub lateral runout
Information
The front face of the wheel hub must not be corroded. If necessary, clean with fine emery cloth.
Measure the wheel hub lateral runout at the front face of the wheel hub. You should always
measure the external and internal diameters of the wheel bolt area.
1. Remove brake disc. → 465319 REMOVING AND INSTALLING REAR BRAKE DISC
bearing housing. Fit the dial gauge with some preload. → Dial gauge on wheel hub
Fig 3: Measuring Wheel Hub Lateral Runout Using Dial Gauge
Brake disc thickness tolerance
For details of brake disc thickness tolerance, see Technical data/brake wear limits →. 4650TW
TECHNICAL DATA/BRAKE WEAR LIMITS
Measure the thickness tolerance using a suitable micrometer screw at approx. 8 places within the
braking surface.
WM 465319 REMOVING AND INSTALLING REAR BRAKE DISC > TOOLS

PIWIS Tester II Special Tool 9818
WM 465319 REMOVING AND INSTALLING REAR BRAKE DISC > TECHNICAL

VALUES

removal)
No. 10: ABS M6 x 12 thread Tightening 8 Nm (6 ft. lb.)

cable holder to Torque
rear-axle wheel
carrier

rear-axle wheel after removal)
carrier
WM 465319 REMOVING AND INSTALLING REAR BRAKE DISC > PRELIMINARY

WORK
INSTALLING WHEEL .
WM 465319 REMOVING AND INSTALLING REAR BRAKE DISC > REMOVING REAR
BRAKE DISC
1. PIWIS Tester II 9818 must be connected and started.
1. 1.1. Select Parking brake.
2. 1.2. Select Drive links/checks.
3. 1.3. Move to installation position.
-arrow- .
1. Paint defects on brake calliper
3. Evenly set back brake pads a little using water pump pliers.
4. Detach the brake calliper on the wheel carrier and suspend it at a suitable place in the wheel
housing or set it down carefully (do not open the brake hydraulic system!).

5. Unscrew fastening screw -B- and remove brake disc.

Fig 3: Locating Brake Disc Screws
WM 465319 REMOVING AND INSTALLING REAR BRAKE DISC > INSTALLING REAR
BRAKE DISC
Information
Replace brake calliper fastening screws each time they are removed .
Do not confuse left and right brake discs during assembly!
2. Clean the flat and centering surfaces on the brake disc and wheel hub.
WM 465319 REMOVING AND INSTALLING REAR BRAKE DISC > SUBSEQUENT

WORK
WHEEL .
Information
When replacing the brake discs and/or brake shoes, the brake shoes for the electronic parking
brake (EPB) must be ground down. The routine is initiated using the Porsche System Tester.
→ 468350 REWORKING PARKING-BRAKE SHOES
It is not necessary to grind down the brake discs if you are simply removing/installing the
brake discs.
1. Set the brake discs to the basic setting if necessary and calibrate the system . → WM
468316 ADJUSTING AND CALIBRATING BRAKE SHOES
2. Connect and start the Porsche System Tester. Follow the instructions on the Porsche System
Tester.
1. 2.1. Adjust parking-brake shoes. → 468316 ADJUSTING AND CALIBRATING

PARKING-BRAKE SHOES
2. 2.2. Rework parking-brake shoes.
→ 468350 REWORKING (GRINDING) PARKING-BRAKE SHOES
3. 2.3. Adjust and calibrate the parking-brake shoes.
→ 468316 ADJUSTING AND CALIBRATING PARKING-BRAKE SHOES
WM 465402 CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) >

INFORMATION ON CHECKING PCCB BRAKE DISCS > NOTE ON PICTURES SHOWN
Information

INFORMATION ON CHECKING PCCB BRAKE DISCS > GENERAL INFORMATION ON
PCCB BRAKE DISCS
The brake discs have wear indicator plates in the friction surfaces. The wear indicator plates (six on
each brake disc) are arranged close to the outer diameter, offset by 120 ° -arrows- at three points. The
three wear indicator plates on each friction surface (3 on the inside and 3 on the outside) are positioned
directly opposite each other. Each wear indicator is approx. 2 cm2 . The wear indicators are barely
visible on new brake discs.
Fig 1: Locating PCCB Brake Discs Wear Indicators
Th. 29.7 mm).

INFORMATION ON CHECKING PCCB BRAKE DISCS > BASIC INFORMATION
Checking involves the following tasks: Information
1. Visual inspection for surface changes in the brake disc friction surfaces and wear indicators.
Indication of wear: Connected surface fracture > 1 cm2-arrow- , without adding up smaller
fractures → 465402 CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) -
Fig 1: Locating Brake Disc Surface Fracture
2. Check surface roughness Rk of brake discs (max. 80 μm permitted) since this affects braking
comfort (noises), braking behavior/pedal pressure and brake-pad service life → 465402
CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) - section on "Checking".
Fig 2: Identifying Surface Roughness Of PCCB Brake Disc
3. Check brake discs for minimum thickness -X- . The minimum thickness of the brake disc
(example: Min. Th. 29.7 mm) is stamped on the brake disc hub → 465402 CHECKING REAR
PCCB BRAKE DISC (WEAR ASSESSMENT) - section on "Checking".
4. Check brake discs for edge damage -arrow- (damage due to improper use) → 465402
CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) - section on "Checking".
Fig 4: Identifying PCCB Brake Disc Edge Damage

INFORMATION ON CHECKING PCCB BRAKE DISCS > GENERAL INFORMATION ON
REPLACING WORN PCCB BRAKE DISCS
Three criteria governing the condition of the parts can make replacement necessary depending
on the wear of PCCB brake discs:
1. Surface changes in the brake disc friction surfaces (material fatigue/wear) at an advanced
stage (indication of wear: connected friction surface damage > 1 cm2 ).
2. Surface roughness of the brake disc friction surfaces too great (roughness depends on
mileage and load).
3. Brake disc minimum thickness is not attained due to wear (material erosion due to friction).
1. In practice, all three forms of brake disc erosion usually occur.
2. Only in rare cases (as a result of long-term motor-racing brake loads/very high
temperatures on the friction surfaces), surface changes can progress so quickly that the
brake discs may need to be changed earlier than planned.
3. Brake discs that have turned blue at the brake-disc chamber and/or brake callipers that
have turned a strong brown color are clear indications of high loads over a long period of
time, e.g. on the race circuit.

INFORMATION ON CHECKING PCCB BRAKE DISCS > REPLACING BRAKE DISCS
(DECISION-MAKING AID)
When replacing brake discs as a result of wear (see 465402 CHECKING REAR PCCB BRAKE DISC
(WEAR ASSESSMENT) ) both brake discs must be replaced on an axle!
Irrespective of wear, a brake disc change can be necessary on the brake disc friction surfaces due to
edge damage! In this case, only one brake disc can be replaced if the friction surface of the other PCCB
brake disc is still 'as new' → 465402 CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) -
The wear indicator plates (six on each brake disc) are arranged close to the outer diameter, offset by
120 ° -arrows- at three points. The three wear indicator plates on each friction surface (3 on the inside
and 3 on the outside) are positioned directly opposite each other. Each wear indicator is approx. 2 cm2 .
The wear indicators are barely visible on new brake discs.
Fig 1: Locating Brake Disc Wear Indicators

The minimum brake disc thickness (wear dimension) is stamped on the brake disc hub (example: Min.
Th. 29.7 mm).

INFORMATION ON CHECKING PCCB BRAKE DISCS > CRACKS (STRESS-RELIEF
MICROSTRUCTURE) IN THE BRAKE DISC FRICTION SURFACE
Cracks in the brake disc friction surfaces must be regarded differently to cracks in grey cast-iron brake
discs. These cracks are not regarded as wear criteria for PCCB brake discs and may even be present
on new brake discs, depending on the manufacturer.
Fig 1: Identifying Cracks (Stress-Relief Microstructure) In Brake Disc Friction Surfaces
Information
Due to the composition of different materials in the friction layer and support body, the friction
surfaces (even when new) are coated with an uncritical crack pattern (stress-relief microstructure).
Individual relaxation cracks sometimes run along the perforated bores .
The stress-relief microstructure results from the way in which the brake disc surface is
manufactured and does not pose a risk to safety. There is also no danger of the friction layers
flaking off from the support body, since the friction layers are almost free of internal stresses as a
result of the stress-relief microstructure .
The stress-relief microstructure is sometimes clearly visible in new brake discs and the brake disc
chamber side and the side that is opposite to the chamber can differ significantly from one another
.

INFORMATION ON CHECKING PCCB BRAKE DISCS > INFORMATION CONCERNING
BORES (PERFORATIONS) IN THE BRAKE DISC FRICTION SURFACE
Observe the following warning when cleaning or exposing the bores in the brake disc friction surface!

NOTE: Work cannot be carried out on the bores in the brake disc friction surface
Damage to brake discs
→ Clean the bores on PCCB brake discs with high-pressure cleaning equipment if necessary. Observe
the relevant environmental and safety regulations.
→ Do not machine the bores. Drilling or counter-sinking is not permitted.

INFORMATION ON CHECKING PCCB BRAKE DISCS > COATING ON THE PCCB
BRAKE DISCS (POSSIBLE CAUSES)
The coating on the PCCB brake discs arises as a result of a high load and high temperatures, for
example on a racing circuit. Check the following in such cases:
Fig 1: Identifying Coating On The PCCB Brake Discs

Ventilation (brake cooling): All components are present, secured correctly and undamaged.
Brake pad quality: If the vehicle is used for race-track driving, use appropriate brake pads.
The perforation bores → Bores (perforations) in brake disc friction surface in the brake discs must
not be blocked.
Unblock them if necessary. → 465402 CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT)
- section on "Information".
In the event of brake pad wear, the brake discs can still be used provided the brake discs satisfy all
wear criteria → 465402 CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) - section
on "Information". The perforation bores → Bores (perforations) in brake disc friction surface must
not be blocked.

INFORMATION ON CHECKING PCCB BRAKE DISCS > INFORMATION ON BEDDING
IN NEW BRAKE PADS
discs.
In general, the following applies: New brake pads must be broken in (bedding-in period), their optimum
a brake disc change.

CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) > VISUAL INSPECTION
OF THE SURFACES OF THE BRAKE DISC FRICTION SURFACES (INDICATION OF
WEAR)
Information
The friction surface changes occur due to material fatigue as a result of extremely high thermal
load. These disc temperatures, which occur above all in racing conditions, cause a progressive
material fatigue .
Effects on driving: The surface change worsens the smoothness of braking, decreases the disc
strength and increases the brake pad wear and therefore makes a precautionary parts
replacement necessary .
The following illustrations (PCCB brake disc wear appearance) are to be used for damage assessment.

CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) > PCCB BRAKE DISC
WEAR APPEARANCE
1. Friction surfaces after normal brake load while driving on roads. No surface fractures present -
Fig 1: Identifying PCCB Brake Disc Wear Appearance
2. Friction surfaces after a long run and occasional higher load. Isolated cases of connected
surface fractures less than 1 cm2-arrow- .
No replacement necessary as the associated surface fractures are < 1 cm2 !

Fig 2: Locating PCCB Surface Fractures
3. End of service life of friction surface or after highest load on a racing circuit.
Replace brake discs if the connected friction surface damage is > 1 cm2-arrow- . To do this,
follow the instructions → 465402 CHECKING REAR PCCB BRAKE DISC (WEAR
ASSESSMENT) - section on "Information".
Fig 3: Identifying Connected Friction Surface Damage
The best way to detect a surface fracture is by checking the wear indicators. Based on the
wear indicators, this means that at least one wear indicator -arrow- must have a surface
fracture of > 50% (damage > 1 cm2 /entire surface of a wear indicator with a surface area of
approx. 2 cm2 ).
Fig 4: Locating PCCB Surface Fracture On Wear Indicator

CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) > EVALUATION OF
SURFACE ROUGHNESS RK (MAX. 80 MICROMETERS PERMITTED)
Information
An increase in surface roughness impairs smoothness of braking (rubbing, shaking in steering

wheel, scraping noises) and increases brake pad wear .
With a roughness (Sr) value of > 80 μm (> 80 micrometer), a precautionary parts replacement is
required .
The assessment is carried out visually, based on the diagram. Two illustrations of the same peak-to
valley surface roughness (views 1 and 2) help to make a better assessment.
1. Brake discs that are OK:
1. 1.1. Surface roughness (Rk) = 6 μm -see illustration- (view 1)Fig 1

Fig 1: Locating PCCB Surface Roughness 6 Micrometers (View 1)
Surface roughness (Rk) = 6 μm -see illustration- (view 2)Fig 2
New brake disc. Illustration is used for better classification.
The early stages of roughness are indicated by burnt-out carbon fibres on the
surface of an otherwise intact, semi-matt surface.
The surface feels smooth.



In the advanced stages of fibre burnout and the initial destruction of the Si and SiC
'matrix', the depressions have become more pronounced. Large sections of the
surface are still intact, the depressions form an even, fine-grained pattern.
The surface still feels matt, however, and the roughness is not yet pronounced.

Borderline disc, which can still just be evaluated as OK. As a result of more
advanced damage to the surface, the depressions are larger, and above all deeper,
compared with the previous surface condition.
On the one hand, the more extensive roughness is noticeable (only when a
comparison is made); on the other hand, however, like before, "only" depressions are
observed.
Replacement not yet necessary!

2. Worn brake discs:


Worn surface. Advanced wear has led to a situation where only the remains of the
original surface are left.
It is clear that the roughness is caused not only by depressions but also by bumps.
Replace brake discs! To do this, follow the instructions → 465402 CHECKING REAR
PCCB BRAKE DISC (WEAR ASSESSMENT) - section on "Information".
3. Worn Brake Discs (Special Cases):
1. 3.1. Surface roughness Rk = 108 μm, as for previous disc, but with some of the
original friction surface remaining -arrow- .
Fig 9: Identifying Worn Brake Disc
2. 3.2. Surface roughness (Rk) = 72 μm. Borderline disc, identified by the roughness,
but also by the indication of wear and connected surface fractures -arrows- , > 1
cm2 .
Fig 10: Identifying PCCB Brake Disc Surface Roughness

CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) > CHECKING MINIMUM
THICKNESS OF BRAKE DISCS
Information
For perforated brake discs, the minimum thickness -X- must always be measured on the inner or
outer friction surface track -arrows- .
Wear limit: The minimum brake disc thickness is stamped on the brake-disc chamber (e.g. Min. Th.
29.7 mm) .
Measure the brake disc thickness -X- using a suitable micrometer screw or brake disc gauge
around the inner or outer friction surface tracks -arrows- .

CHECKING REAR PCCB BRAKE DISC (WEAR ASSESSMENT) > CHECKING BRAKE
DISCS FOR EDGE DAMAGE
Information
Irrespective of wear, a brake disc change can be necessary on the brake disc friction surfaces due
to edge damage .
In such cases, only one brake disc may need to be replaced if the friction area surface of the other
PCCB brake disc is still completely OK .
The following criteria apply to edge damage assessment:

Fig 1: Identifying PCCB Brake Disc Edge Damage
Max. permissible width/depth = 2 mm (0.08 inches)
Max. permitted length = 10 mm (0.39 inches)
Max. 3 damaged edge areas permissible
WM 465419 REMOVING AND INSTALLING REAR BRAKE DISC (PCCB) > TOOLS

WM 465419 REMOVING AND INSTALLING REAR BRAKE DISC (PCCB) > TECHNICAL
VALUES

removal)
No. 10: ABS M6 x 12 thread Tightening 8 Nm (6 ft. lb.)

cable holder to Torque
rear-axle wheel
carrier

carrier
WM 465419 REMOVING AND INSTALLING REAR BRAKE DISC (PCCB) >

PRELIMINARY WORK
INSTALLING WHEEL .
WM 465419 REMOVING AND INSTALLING REAR BRAKE DISC (PCCB) > REMOVING
REAR BRAKE DISC (PCCB) > REMOVING AND INSTALLING REAR BRAKE DISC
(PCCB)
1. 1.1. Select parking brake.
2. 1.2. Select Maintenance/repair.

-arrow- .
3. Set the brake pads back slightly and evenly using water pump pliers.


Fig 3: Locating Brake Disc Fastening Screws

EXPLANATION OF TWO-PART BRAKE DISC
The PCCB brake discs consist of two parts on the front and rear axles. The brake disc -1- is
screwed to the brake disc hub -2- with 10 screws (M6) -3- .
Only the complete brake disc is available as a spare part (disc + brake disc hub)!
Do not separate the brake disc hub -2- and brake disc -1- .
Do not attempt to turn the screws -3- . The screws are prevented from turning by compression in
the bush.
Changing the Tightening Torque of the screws -3- will have negative effects on the noise
produced.
WM 465419 REMOVING AND INSTALLING REAR BRAKE DISC (PCCB) > INSTALLING
REAR BRAKE DISC > INSTALLING REAR BRAKE DISC (PCCB)
Information
4. Installation is performed in reverse order
5. Connect and start the Porsche System Tester.

SUBSEQUENT WORK
WHEEL .

discs.
WM 465419 REMOVING AND INSTALLING REAR PCCB BRAKE DISC > TOOLS
WM 465419 REMOVING AND INSTALLING REAR PCCB BRAKE DISC >

WM 465419 REMOVING AND INSTALLING REAR PCCB BRAKE DISC > PRELIMINARY
WORK
INSTALLING WHEEL .
WM 465419 REMOVING AND INSTALLING REAR PCCB BRAKE DISC > REMOVING
REAR PCCB BRAKE DISC > REMOVING AND INSTALLING REAR BRAKE DISC
(PCCB)
1. 1.1. Select parking brake.
2. 1.2. Select Maintenance/repair.

-arrow- .
3. Set the brake pads back slightly and evenly using water pump pliers.



EXPLANATION OF TWO-PART BRAKE DISC
1. The PCCB brake discs consist of two parts on the front and rear axles. The brake disc -1- is
screwed to the brake-disc chamber -2- with screws (M6) -3- .
Fig 1: Identifying PCCB Brake Discs

2. Only the complete brake disc is available as a spare part (disc + brake-disc chamber)!
3. Do not separate the brake-disc chamber -2- and brake disc -1- . In addition, the screws -3-
must not be turned and should not need to be turned. The screws are prevented from turning
by compression in the bushing.
4. It is essential that the Tightening Torque of the screws is not changed (do not turn the screws)
as this can have a negative effect on the sound behavior.
1 Brake disc
2 Brake-disc chamber
3 Screw
WM 465419 REMOVING AND INSTALLING REAR PCCB BRAKE DISC > INSTALLING
REAR BRAKE DISC > INSTALLING REAR BRAKE DISC (PCCB)
Information
4. Installation is performed in reverse order
Brake disc to wheel hub:
Brake calliper to wheel bearing housing:
Cable holder to wheel bearing housing:
5. Connect and start the Porsche System Tester.

SUBSEQUENT WORK
INSTALLING WHEEL

discs.
WM 466119 REMOVING AND INSTALLING ACTUATOR FOR ELECTRIC PARKING

BRAKE > TECHNICAL VALUES
Actuator For Tightening 2 Nm (1.5 ft.

Parking Brake Torque lb.)

BRAKE > PRELIMINARY WORK
Remove trim panel under dashboard. → REMOVING TRIM PANEL UNDER DASHBOARD - section on
"Removing"

BRAKE > REMOVING ACTUATOR FOR ELECTRIC PARKING BRAKE
Fig 1: Identifying Electric Parking Brake Actuator Installation Position
1. Unscrew and remove two fastening screws -2- and remove actuator for electric parking brake
-1- .
Fig 2: Identifying Actuator For Electric Parking Brake

BRAKE > INSTALLING ACTUATOR FOR ELECTRIC PARKING BRAKE
1. Fit actuator for electric parking brake -1- and tighten two fastening screws -2- to →
Tightening Torque: 2 Nm (1.5 ft. lb.) .
Fig 1: Identifying Actuator For Electric Parking Brake
1. The indicator light in the parking brake actuator must be ON when you close it.
2. The indicator light in the parking brake actuator must be OFF when you open it.
3. Check for locking and release noises from the electric parking brake actuators when you
actuate them.

BRAKE > SUBSEQUENT WORK
Install trim panel under dashboard. → INSTALLING TRIM PANEL UNDER DASHBOARD - section on
"Installing"

BRAKE (EPB) > TECHNICAL VALUES
Actuator For Tightening 2 Nm (1.5 ft.

Parking Brake Torque lb.)

BRAKE (EPB) > PRELIMINARY WORK
Remove trim panel under dashboard. → REMOVING TRIM PANEL UNDER DASHBOARD - section on
"Removing"

BRAKE (EPB) > REMOVING ACTUATOR FOR ELECTRIC PARKING BRAKE
Fig 1: Identifying Electric Parking Brake Actuator Installation Position
1. Unscrew two fastening screws -2- and remove actuator for electric parking brake -1- .
Fig 2: Identifying Electric Parking Brake Actuator Fastening Screws

BRAKE (EPB) > INSTALLING ACTUATOR FOR ELECTRIC PARKING BRAKE
1. Fit actuator for electric parking brake -1- and tighten two fastening screws -2- to →
Fig 1: Identifying Installing Actuator For Electric Parking Brake
2. Perform a function test.
1. The indicator light in the parking brake actuator must be ON when you close it.
2. The indicator light in the parking brake actuator must be OFF when you open it.
3. Check for locking and release noises from the electric parking brake actuators when you
actuate them.

BRAKE (EPB) > SUBSEQUENT WORK
Install trim panel under dashboard. → INSTALLING TRIM PANEL UNDER DASHBOARD - section on
"Installing"
WM 466219 REMOVING AND INSTALLING CONTROL UNIT FOR ELECTRIC PARKING

BRAKE > TOOLS


BRAKE > PRELIMINARY WORK
1. If the control unit for the electric parking brake has to be replaced, the values must be read out
before removal using PIWIS Tester II 9818 . → 466255 REPLACING CONTROL UNIT FOR
ELECTRIC PARKING BRAKE .
2. Remove side trim panel for rear luggage compartment at the right. → REMOVING SIDE TRIM
PANEL FOR REAR LUGGAGE COMPARTMENT - section on "Removing"

BRAKE > REMOVING AND INSTALLING CONTROL UNIT FOR ELECTRIC PARKING
BRAKE > REMOVING CONTROL UNIT FOR ELECTRIC PARKING BRAKE
Fig 1: Identifying Installation Position Of Control Unit For Electric Parking Brake

Information
NOTE: Voltage peaks
1. Unscrew the two fastening screws -1- .

Fig 2: Identifying Control Unit For Electric Parking Brake
2. Release plug connection -1- and disconnect it -2- .


BRAKE > REMOVING AND INSTALLING CONTROL UNIT FOR ELECTRIC PARKING
BRAKE > INSTALLING CONTROL UNIT FOR ELECTRIC PARKING BRAKE
1. Connect plug connection -2- and lock it -1- .

Fig 1: Connecting Control Unit For Electric Parking Brake Plug Connection
2. Place control unit for electric parking brake in installation position.
3. Secure the control unit with the two fastening screws -1- .
Fig 2: Identifying Control Unit For Electric Parking Brake Screws

BRAKE > SUBSEQUENT WORK
1. If the control unit for the electric parking brake was replaced, the values must be written using
PIWIS Tester II 9818 . Replace control unit for electric parking brake. → 466255 REPLACING
CONTROL UNIT FOR ELECTRIC PARKING BRAKE .
2. Remove side trim panel for rear luggage compartment at the right. → INSTALLING SIDE TRIM
PANEL FOR REAR LUGGAGE COMPARTMENT - section on "Installing"
WM 466255 REPLACING CONTROL UNIT FOR ELECTRIC PARKING BRAKE > TOOLS

WM 466255 REPLACING CONTROL UNIT FOR ELECTRIC PARKING BRAKE >

TECHNICAL VALUES
Current Rating Nominal value 40 A
WM 466255 REPLACING CONTROL UNIT FOR ELECTRIC PARKING BRAKE >

CODING AND CALIBRATING CONTROL UNIT
NOTE: Voltage drop
battery.
Information
Tester releases.
CONTROL UNIT FOR ELECTRIC PARKING BRAKE .
ignition.
4. Select Parking brake in the control unit overview .
6. Automatic coding must then be selected. Press [F12] to start coding.
continue.
8. Drive links/checks must be selected.
9. Move to installation position and press [F12] to continue.
10. Press [F8] to start the function and follow the instructions on the Tester.
11. Select Check parking brake basic setting in the Maintenance/repairs menu and press
[F12] to continue.
12. Follow the instructions on the Tester and press [F12] to continue.
13. Complete the following steps on vehicles with steel brakes. Do not perform the Bedding in
function on vehicles with PCCB.
1. 13.1. Select the Bedding in function, then press [F12].
2. 13.2. Follow the instructions on the Tester and press [F8] to start the function.
3. 13.3. Follow the instructions on the Tester.
14. Select Calibrate parking brake distance sensor function and press [F12] to continue.
1. 14.1. Follow the instructions on the Tester and press [F12] to continue.
2. 14.2. Start the calibration process by pressing [F8].
3. 14.3. Follow the instructions on the Tester.
15. Read out the fault memory and erase it if necessary. Return to the overview of all control
units.
16. Check electric parking brake operation by pressing the parking brake operating button. The
LED in the button may flash after the first function test.
1. 16.1. If the LED in the button starts flashing after the first function test:
1. 16.1.1. Perform a further function test. Check electric parking brake

operation by actuating the lever.
17. Perform a test drive, check the function of the electric parking brake by actuating the lever and
read out the fault memory.
WM 468316 ADJUSTING AND CALIBRATING BRAKE SHOES > TECHNICAL VALUES

Actual Displayed on the Control value 000 mm

dimension Tester! Actual
gap dimension at
left and right
measured
between the
shoe and drum in
millimetres.
Required Displayed on the Control value +2.2 mm +/-0.3 mm

dimension Tester! Required
dimension
between the
shoe and drum in
millimetres.
Adjustment Must be Control value 000 mm

dimension calculated! Value
(in millimetres)
by which the
adjustment
device must be
turned.
Adjustment 1 click Control value 0.15 mm

device corresponds to
WM 468316 ADJUSTING AND CALIBRATING BRAKE SHOES > ADJUSTING AND

CALIBRATING PARKING-BRAKE SHOES
Information
The electric parking brake with asbestos-free brake pads must never be adjusted in such a way
that the pad has to grind free during operation . → 468350 GRINDING DOWN PARKING-BRAKE
SHOES
Adjustments must only be carried out at the two rear wheel adjustment devices .
Make sure that the EPB cables are routed and guided correctly .
In the event of unfavorable tolerances, the brake pads may prevent the brake disc from turning freely. If
this happens, the brake pads must be pressed back slightly and uniformly using water pump pliers.
1. Raise the vehicle. → 4X00IN LIFTING THE VEHICLE
2. Remove rear wheels. → 440519 REMOVING AND INSTALLING WHEEL
3. Release the EPB so that the brake discs can turn freely.
4. Move the brake shoes into installation position using the Porsche System Tester. Select
>>Parking brake<< in the control unit overview. Select >>Drive links/checks>>All<< >>Move to
installation position<<.
5. Adjust brake shoes on both sides. To do this, turn the relevant brake disc with the opening to
the adjustment device position. Using a screwdriver, adjust the adjustment device until the
brake disc can no longer be turned. The subsequent torque of the brake disc must be greater
than 100 Nm (74 ft. lb.). Then loosen 17 (+/- 1) clicks of the adjustment device (brake discs
must be able to turn freely).
6. Using the Porsche System Tester, select >>Parking brake<< in the control unit overview.
Select >>Maintenance/repairs<< >>Check parking brake basic setting<<.
It may be necessary to fine-tune the adjustment device after selecting >>Check parking brake
basic setting<<.
Actual Displayed on Control value 000 mm

dimension the Tester!
Actual gap
dimension at
left and right
measured
between the
shoe and drum
in millimetres.
Required Displayed on Control value +2.2 mm +/-0.3 mm

dimension the Tester!
Required
dimension
between the
shoe and drum
in millimetres.
Adjustment Must be Control value 000 mm

dimension calculated!
Value (in
millimetres) by
which the
adjustment
device must be
turned.
Adjustment dimension = required dimension - actual dimension (required dimension

minus actual dimension)
Fig 1: Calibrating Parking-Brake Shoes

Fig 2: Adjusting Parking-Brake Shoes
→ Control value: 0.15 mm
Corresponds to 1 click on the adjustment device
Information
A calculated value in the positive range means: Turn adjustment device towards A - loosen.
A calculated value in the negative range means: Turn adjustment device towards B - tighten.
Adjustment dimension = required dimension - actual dimension (required dimension

minus actual dimension)
Example:
Actual dimension: 2.6 mm
Required dimension: 2.0 mm (+/- 0.3 mm)
Adjustment dimension = required dimension - actual dimension
Adjustment dimension = 2.0 mm - 2.6 mm
Adjustment dimension = -0.6 mm
-0.6 mm: 0.15 mm = - 4 clicks (0.15 mm corresponds to one click!)
Adjustment dimension = -0.6 mm: This means that the gap dimension is too big and the
adjustment device must be adjusted towards B - tighten.
7. Grind parking-brake shoes (not PCCB!) → 468350 REWORKING (GRINDING)

PARKING-BRAKE SHOES .
8. Calibrate the EPB using the Porsche System Tester. To do this, select >>Parking brake<< in
the control unit overview. Select >>Maintenance/repairs<< >>Calibration<<.
9. To check the function of the EPB, actuate the EPB button several times (press 2-3 times) and
make sure that the actuators open and close on both sides.
Position disc brake pads by operating the brake several times.
10. Fit wheels → INSTALLING WHEEL - section on "Installing".
WM 468350 REWORKING (GRINDING) BRAKE SHOES > REWORKING (GRINDING)

PARKING-BRAKE SHOES
Information
Grinding applies only to vehicles with steel brakes. PCCB brake discs/brake shoes do not need to be
ground down.
Grinding must be performed after setting the brake shoes to the basic setting.
The brake shoes must be ground down prior to calibration.
It is not necessary to grind down the brake shoes if you are simply removing/installing the brake discs
→ 465319 REMOVING AND INSTALLING REAR BRAKE DISC , → 468356 REPLACING BRAKE
SHOES .
NOTE: Each time the brake discs and/or brake shoes are replaced, the electric parking
brake (EPB) must be ground down after first setting the brake shoes to the basic setting →
468316 SETTING AND CALIBRATING PARKING-BRAKE SHOES . The electric parking
brake will only function fully after it has been ground down and calibrated. This involves
driving the vehicle eight times from standstill to 10 km/h (6 mph) up to max. 20 km/h (12 mph)
for a distance of 20 meters. If the distance in meters is not sufficient for several consecutive
cycles, you can perform a reset with the vehicle after every cycle and drive on the same
stretch of road several times!
The >>Grind brake shoes<< routine is initiated using the Porsche System Tester.
1. Select >>Parking brake<< in the control unit overview. Select >>Maintenance/repairs<<

>>Grinding<<. Follow the instructions on the Porsche System Tester.
2. Once the brake shoes have been ground down correctly, the EPB must be calibrated. →
468316 ADJUSTING PARKING-BRAKE SHOES
WM 468350 GRINDING DOWN PARKING-BRAKE SHOES (EPB) > REWORKING

(GRINDING) PARKING-BRAKE SHOES
Information
Grinding applies only to vehicles with steel brakes. PCCB brake discs/brake shoes do not need to be
ground down.
Grinding must be performed after setting the brake shoes to the basic setting.
The brake shoes must be ground down prior to calibration.
It is not necessary to grind down the brake shoes if you are simply removing/installing the brake discs
→ 465319 REMOVING AND INSTALLING REAR BRAKE DISC , → 468356 REPLACING BRAKE
SHOES .
NOTE: Each time the brake discs and/or brake shoes are replaced, the electric parking
brake (EPB) must be ground down after first setting the brake shoes to the basic setting →
468316 SETTING AND CALIBRATING PARKING-BRAKE SHOES . The electric parking
brake will only function fully after it has been ground down and calibrated. This involves
driving the vehicle eight times from standstill to 10 km/h (6 mph) up to max. 20 km/h (12 mph)
for a distance of 20 meters. If the distance in meters is not sufficient for several consecutive
cycles, you can perform a reset with the vehicle after every cycle and drive on the same
stretch of road several times!
The >>Grind brake shoes<< routine is initiated using the Porsche System Tester.
1. Select >>Parking brake<< in the control unit overview. Select >>Maintenance/repairs<<

>>Grinding<<. Follow the instructions on the Porsche System Tester.
2. Once the brake shoes have been ground down correctly, the EPB must be calibrated. →
468316 ADJUSTING PARKING-BRAKE SHOES
WM 468356 REPLACING BRAKE SHOES > PRELIMINARY WORK
2. Remove wheel. → 440519 REMOVING AND INSTALLING WHEEL
3. Remove brake disc. → 465319 REMOVING AND INSTALLING REAR BRAKE DISC
WM 468356 REPLACING BRAKE SHOES > INFORMATION > NOTE ON PICTURES
SHOWN
WM 468356 REPLACING BRAKE SHOES > REMOVING BRAKE SHOES
Information
It is not necessary to grind down the parking-brake shoes if the parking-brake shoes are not replaced.
Set the brake shoes to the basic setting if necessary and calibrate the brakes → WM 468316
ADJUSTING AND CALIBRATING BRAKE SHOES .
Mark the parking-brake shoes and adjustment device according to their installation position .
Secure the adjustment device to prevent it from turning .
1. Brake Shoes
2. Adjustment Device
3. Compression Springs
4. Tension Springs
Fig 1: Component Overview Of Parking Brake
1. Loosen adjustment device -2- with a screwdriver. → Adjustment device

Fig 2: Identifying Adjustment Device
WARNING: Preloaded or pressurized components
1. Risk of injury (e.g. crushing or bruising) when removing and installing springs.
→ Do not reach into the danger area.
→ Relieve the tension on components before starting work.
→ Secure components to prevent them from loosening suddenly.
→ Wear protective gloves and goggles.
→ Be very careful when working on the brake system.
2. Remove compression springs -3- . → Compression springs

Fig 3: Compressing Brake System Springs
3. Disengage both tension springs -4- . → Tension springs

Fig 4: Locating Brake System Tension Springs
4. Remove brake shoes with adjustment device -1 and 2- .
5. Secure actuator for parking brake with a tie-wrap -arrow- .

Fig 5: Securing Actuator For Parking Brake With Tie-Wrap
WM 468356 REPLACING BRAKE SHOES > INSTALLING BRAKE SHOES
1. Brake Shoes
2. Adjustment Device
3. Compression Springs
4. Tension Springs
Fig 1: Component Overview Of Parking Brake
Align the entire unit in the middle.
1. Remove tie-wrap at actuator for parking brake.
2. Insert brake shoes with adjustment device -1 and 2- .
WARNING: Preloaded or pressurized components
1. Risk of injury (e.g. crushing or bruising) when removing and installing springs.
→ Relieve the tension on components before starting work.
→ Secure components to prevent them from loosening suddenly.
→ Wear protective gloves and goggles.
→ Be very careful when working on the brake system.

3. Engage both tension springs -4- .
4. Install compression springs -3- and plug in speed sensor connector again.
WM 468356 REPLACING BRAKE SHOES > SUBSEQUENT WORK
1. Install brake disc. → 465319 REMOVING AND INSTALLING REAR BRAKE DISC
2. Adjust and calibrate the brake shoes. → WM 468316 ADJUSTING AND CALIBRATING
BRAKE SHOES
Always grind down the brake shoes during adjustment and calibration.
3. Fit wheel. → 440519 REMOVING AND INSTALLING WHEEL
WM 468519 REMOVING AND INSTALLING SPREADER DEVICE > TECHNICAL

VALUES
No. 1: Actuator Tightening 20 Nm (15 ft. +60° (+44 ft. lb.)

to wheel carrier Torque lb.)
No. 6: Brake M6 x 12 thread Tightening 8 Nm (6 ft. lb.)

carrier to rear Torque
wheel carrier
WM 468519 REMOVING AND INSTALLING SPREADER DEVICE > PRELIMINARY

WORK
1. Remove wheel. → REMOVING WHEEL - section on "Removing"
2. Move electric parking brake (EPB) into >>installation position<< using the Porsche System
Tester. To do this, select >>Parking brake<< in the control unit overview. Select >>Drive
links/checks<< >>All<< >>Move to installation position<<.
3. Remove brake calliper and hang it at a suitable place in the wheel arch. → REMOVING REAR
BRAKE CALLIPER - section on "Removing"
4. Remove brake disc. → 465419 REMOVING AND INSTALLING REAR BRAKE DISC (PCCB) -
5. Remove brake shoes. → 468356 REPLACING BRAKE SHOES - section on "Removing"
WM 468519 REMOVING AND INSTALLING SPREADER DEVICE > REMOVING

SPREADER DEVICE (EPB) > REMOVING SPREADER DEVICE FOR EPB
Information
The spreader device (actuator) is located on the rear-axle wheel bearing housing instead of the
mechanical spreader device with the parking-brake cable.
1. Actuator
2. Tie-wrap - prevents twisting
Fig 1: Identifying EPB Actuator
1. Release electric plug connection -2- at the actuator -1- (-a- ) and pull it off -A- .
Fig 2: Removing Plug Connection For Actuator
2. Unclip wire harness -4- from the retaining clip -3- .
3. If the actuator has to be re-used, secure it in the brake shoe mountings with a tie-wrap to
prevent it from twisting! -arrow-
Fig 3: Identifying Servo Motor Lock
4. Loosen fastening screws -arrows- on the actuator.

Fig 4: Locating Actuator Fastening Screws
5. Loosen fastening screws -1- on the brake cover plate.

Fig 5: Identifying Screws On Brake Cover Plate
6. Turn the wheel hub so that the actuator can be removed carefully. → Removing actuator
Fig 6: Securing Wheel Hub Actuator
WM 468519 REMOVING AND INSTALLING SPREADER DEVICE > INSTALLING

SPREADER DEVICE (EPB) > INSTALLING SPREADER DEVICE FOR EPB
Information
If new brake discs and/or new brake shoes are installed on the vehicle, they must be worn in before
calibration (not PCCB!). → 468350 REWORKING PARKING-BRAKE SHOES
If a new actuator was installed, it must be confirmed in the Porsche System Tester.
>>Control unit overview<< >>Parking brake<< >>Drive links/Tests<< >>Confirm actuator

replacement<< .
1. NOTE: Do not twist brake shoe mountings when installing the actuator!
2. If using the same actuator again:
1. 2.1. Clean the spreader device carefully so as not to damage the dust boots.
2. 2.2. Visually inspect the dust boots for cracks.

3. Tighten fastening screws on the spreader device to the specified tightening torque. Tightening
Torque 20 Nm (15 ft. lb.) +60° (+44 ft. lb.)
Fig 1: Locating Actuator Screws
4. Tighten fastening screws on the brake cover plate to the specified tightening torque.
Tightening Torque 8 Nm (6 ft. lb.)
Fig 2: Identifying Brake Cover Plate Screws
5. Plug in electric plug connection -2- for the actuator -1- (-A- ) and lock it -a- .
6. Clip wire harness -4- into the retaining clip -3- (-B- ).
WM 468519 REMOVING AND INSTALLING SPREADER DEVICE > SUBSEQUENT

WORK
Information

replacement<< .
1. Install brake shoes. → 468356 REPLACING BRAKE SHOES - section on "Installing"
2. Fit brake calliper. → INSTALLING REAR BRAKE CALLIPER - section on "Installing"
3. Fit wheel. → INSTALLING WHEEL - section on "Installing"
4. Adjust, grind down and calibrate the electric parking brake (EPB) using the Porsche System
Tester. → 468316 ADJUSTING PARKING-BRAKE SHOES → - section on "Installing"
WM 468519 REMOVING AND INSTALLING SPREADER DEVICE (EPB) >
SPREADER DEVICE (EPB)
1. Remove the wheel. → REMOVING WHEEL - section on "Removing"
2. Move electric parking brake (EPB) into >>installation position<< using the Porsche System
Tester. To do this, select >>Parking brake<< in the control unit overview. Select >>Drive link
tests<< >>All<< >>Move to installation position<<.
3. Remove brake calliper and hang it at a suitable place in the wheel arch. → REMOVING REAR
BRAKE CALLIPER - section on "Removing"
4. Remove brake disc. → 465419 REMOVING AND INSTALLING REAR BRAKE DISC (PCCB) -
5. Remove brake shoes. → 468356 REPLACING BRAKE SHOES - section on "Removing"
WM 468519 REMOVING AND INSTALLING SPREADER DEVICE (EPB) > REMOVING

Information
The spreader device (actuator) is located on the rear-axle wheel bearing housing instead of the
mechanical spreader device with the parking-brake cable.
1. Actuator
2. Tie-wrap - prevents twisting

Fig 1: Identifying EPB Actuator
1. Release electric plug connection -2- at the actuator -1- (-a- ) and pull it off -A- .
Fig 2: Removing Plug Connection For Actuator
2. Unclip wire harness -4- from the retaining clip -3- .
3. If the actuator -1- has to be reused, secure it in the brake shoe mountings with a tie-wrap -2-
to prevent it from twisting!
Fig 3: Securing Actuator To Prevent From Twisting
4. Remove the fastening screws on the actuator -arrows- .

Fig 4: Locating Actuator Fastening Screws
5. Loosen fastening screws -1- on the brake cover plate.

Fig 5: Identifying Brake Cover Plate Screws
6. Turn the brake cover plate so that the actuator can be removed -arrow- .
Fig 6: Removing Actuator
WM 468519 REMOVING AND INSTALLING SPREADER DEVICE (EPB) > INSTALLING

Information

replacement<< .
1. Note: Do not twist the brake shoe mountings when installing the actuator!
2. If using the same actuator again:
1. 2.1. Clean the spreader device carefully so as not to damage the dust boots.
2. 2.2. Visually inspect the dust boots for cracks.
3. Tighten fastening screws on the spreader device to the specified tightening torque. → 4X00IN
TIGHTENING TORQUES FOR BRAKE MECHANICS
Fig 1: Locating Fastening Screws On Actuator
4. Tighten fastening screws on the brake cover plate to the specified tightening torque. → 4X00IN
TIGHTENING TORQUES FOR REAR AXLE
Fig 2: Identifying Screws On Brake Cover Plate
5. Plug in electric plug connection -2- for the actuator -1- (-A- ) and lock it -a- .
Fig 3: Installing Actuator Electric Plug Connection
6. Clip wire harness -4- into the retaining clip -3- (-B- ).
WM 468519 REMOVING AND INSTALLING SPREADER DEVICE (EPB) >

Information

replacement<< .
1. Install brake shoes. → 468356 REPLACING BRAKE SHOES - section on "Installing"
2. Fit the brake calliper. → INSTALLING REAR BRAKE CALLIPER - section on "Installing"
3. Fit wheel. → INSTALLING WHEEL - section on "Installing"

4. Adjust, grind down and calibrate the electric parking brake (EPB) using the Porsche System
Tester. → 468316 ADJUSTING PARKING-BRAKE SHOES → - section on "Installing"
Service Manual: 47 - BRAKES - HYDRAULIC BRAKE SYSTEM, REGULATOR -- 92A CAYENNE
WM 470107 BLEEDING THE BRAKE SYSTEM (CAYENNE, CAYENNE GTS, CAYENNE
Bleeder screw M10 x 1 thread Tightening 14 Nm (10.5 +/-2 Nm (+/-1.5

on brake torque ftlb.) ftlb.)
calliper

DIESEL, CAYENNE (3.0)) > CHECKING BRAKE FLUID LEVEL
Information
The brake fluid level must not exceed the MAX mark.
Observe brake fluid quality. Use only new DOT 4 brake fluid.
This brake fluid is available under the following part numbers: Quantity supplied: 1 liter =
000.043.203.66; 30 liters = 000.043.203.67.
Fig 1: Identifying Brake Fluid Reservoir Installation Position
1. Visually check the brake fluid level. The brake fluid level must be between the MIN and MAX
markings -1- . The brake fluid reservoir is located under the left plenum panel cover.
Fig 2: Identifying Min/Max Markings For Brake Fluid

DIESEL, CAYENNE (3.0)) > BLEEDING THE BRAKE SYSTEM > BLEEDING THE
BRAKE SYSTEM (AND REPLACING HYDRAULIC UNIT)
Information
000.043.203.66; 30 liters = 000.043.203.67.
There are two bleeder valves on the brake calliper. Brake fluid must be drained at both bleeder
valves. Observe specified sequence: Bleed the outer bleeder valve first.
1. Open the cap -1- on the reservoir -2- .

Fig 1: Identifying Cap On Brake Fluid Reservoir
2. Connect a bleeding device to the reservoir -2- .
3. Switch on the bleeding device. Bleeding pressure is approx. 2.0 bar.
4. A second mechanic is required. Continuously pump the brake pedal slowly during the bleeding
process.
1. 4.1. Continue changing the brake fluid at the brake callipers. Observe the sequence
specified on the Porsche System Tester: Front left/Front right/Rear right/Rear left.
5. Open each bleeder valve until clear, bubble-free brake fluid emerges.
6. Use a transparent hose and a collecting bottle to check the escaping brake fluid for
cleanliness, absence of air bubbles and to determine the amount of brake fluid used.
1. 6.1. Only when replacing the hydraulic unit:
Bleed the secondary circuit using the Porsche System Tester. To do this, select
>>PSM>>Maintenance/repairs>>Bleeding hydraulic unit<< in the control unit

overview.
7. Then bleed the right-hand side of the vehicle manually again: Front right/Rear right.
8. Tighten bleeder valves to the specified tightening torque Tightening torque 14 Nm (10.5
ftlb.) +/-2 Nm (+/-1.5 ftlb.) and remove bleeder hoses.
9. Switch off the bleeding device and remove the adapter at the reservoir. The brake fluid level in
the reservoir must be between the MIN and MAX markings after filling and bleeding the vehicle
-1- . Correct the brake fluid level if necessary.
10. Remove the Porsche System Tester.
WM 470855 CHANGING THE BRAKE FLUID (EXCEPT CAYENNE, CAYENNE GTS,

CAYENNE S DIESEL, CAYENNE (3.0)) > CHECKING BRAKE FLUID LEVEL
Information
The brake fluid level must not exceed the MAX mark.
000.043.203.66; 30 liters = 000.043.203.67.
Fig 1: Identifying Installation Position Of Brake Fluid Reservoir
1. Visually check the brake fluid level. The brake fluid level must be between the MIN and MAX
markings -1- . The brake fluid reservoir is located under the left plenum panel cover.
WM 470855 CHANGING THE BRAKE FLUID (EXCEPT CAYENNE, CAYENNE GTS,

CAYENNE S DIESEL, CAYENNE (3.0)) > CHANGING THE BRAKE FLUID
Information
The brake fluid change interval is two years using Super DOT 4 brake fluid.
000.043.203.66; 30 liters = 000.043.203.67.
Drain brake fluid from every brake calliper at both bleeder valves.
There are two bleeder valves on the brake calliper. Brake fluid must be drained at both bleeder
valves. Observe specified sequence: Bleed the outer bleeder valve first.
1. Open the cap -1- on the reservoir -2- .

Fig 1: Identifying Brake Fluid Reservoir
2. Connect bleeding device to the reservoir -2- .
3. Switch on the bleeding device. Bleeding pressure is approx. 2.0 bar.
4. Continue changing the brake fluid at the brake callipers. Observe the sequence specified on
the Porsche System Tester: Front left/Front right/Rear right/Rear left.
5. Open each bleeder valve until clear, bubble-free brake fluid emerges and until the
corresponding change quantity per brake calliper is reached (approx. 250 cm3 ).
6. Use a transparent hose and a collecting bottle to check the escaping brake fluid for
cleanliness, absence of air bubbles and to determine the amount of brake fluid used.
7. Tighten the bleeder valves to the specified tightening torque → WM 4X00IN TIGHTENING
TORQUES FOR BRAKE HYDRAULICS
8. Switch off the bleeding device and remove the adapter at the reservoir. The brake fluid level in
the reservoir must be between the MIN and MAX markings after filling and bleeding the vehicle
-1- . Correct the brake fluid level if necessary.
WM 470855 REPLACING BRAKE FLUID FOR THE CLUTCH SYSTEM (HYBRID)

(CAYENNE TIP "PLATINUM EDITION", CAYENNE TIP (3.0) "PLATINUM EDITION",
CAYENNE DIESEL "PLATINUM EDITION", CAYENNE S HYBRID) > TOOLS

Brake filling and Workshop WE 1096
bleeding device equipment
ATE

CAYENNE DIESEL "PLATINUM EDITION", CAYENNE S HYBRID) > INSTALLATION
OVERVIEW
Information
The brake fluid for the clutch system must be replaced every 2 years during vehicle maintenance.
Fig 1: Identifying Installation Position Of Clutch Slave Cylinder

CAYENNE DIESEL "PLATINUM EDITION", CAYENNE S HYBRID) > PRELIMINARY
WORK
1. Remove engine-bay guard.
→ 108019 REMOVING AND INSTALLING ENGINE-BAY GUARD (UNDERBODY

PANELLING) .

CAYENNE DIESEL "PLATINUM EDITION", CAYENNE S HYBRID) > CHANGING
HYDRAULIC FLUID
Information
The PIWIS Tester II 9818 instructions take precedence and in the event of a discrepancy these are the
instructions that must be followed. Deviations may occur with later software versions.
When changing the hydraulic fluid, the clutch system does not have to be bled using PIWIS Tester II.
However, the air/leak test must be carried out and clutch adaptation must be performed using PIWIS
Tester II.
1. Brake filling and bleeding device ATE WE 1096 must be connected.

2. The bleeder valve is located between the engine and drive motor at the bottom left.
3. Pull the dust boot -1- off the bleeder valve and attach the breather hose.
Fig 1: Identifying Installation Position Of Bleeder Valve
4. Brake filling and bleeding device ATE WE 1096 must be switched on.
5. Open the bleeder valve. Drain change quantity of 0.25 liters into the collection container.
6. Then close the bleeder valve.
7. Brake filling and bleeding device ATE WE 1096 must be switched off.
8. Carry out air/leak test.
PIWIS Tester II 9818 must be switched on.
1. 8.1. [Select DIAGNOSTICS.]
2. 8.2. Select vehicle model.
3. 8.3. [DME] must now be selected. Then select [MAINTENANCE/REPAIRS] and

press [F12] to confirm.
4. 8.4. You now have the option of creating a V ehicle A nalysis L og ("VAL" ).
5. 8.5. [CLUTCH ACTUATOR AND DECOUPLER] must now be selected. Then press
[F12] to confirm.
6. 8.6. Read instructions relating to HV batteries!
7. 8.7. [Check hydraulic system for air/leaks] must now be selected. Then press [F12] to
confirm.
9. Perform clutch adaptation.
PIWIS Tester II 9818 must be connected and switched on until it is ready for operation.
1. 9.1. [Select DIAGNOSTICS.]
2. 9.2. Select vehicle model.
3. 9.3. [DME] must now be selected. Then select [MAINTENANCE/REPAIRS] and

press [F12] to confirm.
4. 9.4. You now have the option of creating a V ehicle A nalysis L og ("VAL" ).
5. 9.5. [CLUTCH ACTUATOR AND DECOUPLER] must now be selected. Then press
[F12] to confirm.
6. 9.6. Read instructions relating to HV batteries!
7. 9.7. [Clutch adaptation] must be selected. Then press [F12] to confirm.
10. Adjust fill level in the reservoir to the MAX marking.

CAYENNE DIESEL "PLATINUM EDITION", CAYENNE S HYBRID) > SUBSEQUENT
WORK
1. Fit engine-bay guard.
→ 108019 REMOVING AND INSTALLING ENGINE-BAY GUARD (UNDERBODY

PANELLING) .
WM 471519 REMOVING AND INSTALLING BRAKE MASTER CYLINDER (CAYENNE,


bonnet stay Special tool 9704

No. 1: Brake M8 thread Tightening 23 Nm (17 +/-2 Nm (+/- 1.5

master cylinder torque ftlb.) ftlb.)
to brake booster
Brake pressure Tightening 18 Nm (13 +/-2 Nm (+/- 1.5

pipe to brake torque ftlb.) ftlb.)
master cylinder

PRELIMINARY WORK FOR REMOVING AND INSTALLING BRAKE MASTER
CYLINDER
1. Open the bonnet and secure it in service position using bonnet stay 9704 .
2. Remove left cross panel. → 508119 REMOVING AND INSTALLING CROSS PANEL
3. Loosen relay carrier. → 978309 LOOSENING AND SECURING RELAY CARRIER

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING BRAKE MASTER
CYLINDER
Information
Before disconnecting the brake lines, place a clean absorbent cloth underneath.
Close off brake lines with a suitable plug immediately after disconnecting.
Information
In the event of assembly work at the hydraulic connections, all electric plug connections in the area
of the connection point must always be connected. This prevents the inside of the plug
connections from being splashed with brake fluid or water.
Clean any plug connections that have become dirty or damp during removal and fitting using a
lint-free cloth, for example.
Brake fluid on electrical contacts (even thinned brake fluid) leads to corrosion and may cause
faults in the system.
Remove any escaping brake fluid immediately; rinse with water and dry thoroughly if necessary.
Information
The pictures shown in this document may differ from the original.
Fig 1: Identifying Installation Position Of Brake Master Cylinder

Fig 2: Identifying Brake Master Cylinder Components
1. Release sieve filter -1- using a suitable tool -2- and remove it from the brake fluid reservoir
-3- .
Fig 3: Removing Sieve Filter In Brake Fluid Reservoir
2. Drain brake fluid from the brake fluid reservoir -3- using a suitable tool, e.g. a double-action
hand pump.
3. Remove brake lines from the brake master cylinder -3- .

Fig 4: Removing Brake Master Cylinder
1. 3.1. Removing union nuts -2- .
2. 3.2. Pull brake lines out of the bores.
3. 3.3. Immediately close off brake lines and bores in the brake master cylinder -3-
using suitable stoppers.
4. Release electric plug connection -1- for the brake fluid level indicator and disconnect it -arrow
A- .
5. Release and disconnect electric plug connection for the brake light switch. → 943619
REMOVING AND INSTALLING BRAKE LIGHT SWITCH
Information
If the brake master cylinder is to be replaced, first remove the brake fluid reservoir and then
unscrew the fastening nuts for the brake master cylinder (see section entitled "REPLACING
BRAKE MASTER CYLINDER ", ff.).
6. Remove fastening nuts -1- for the brake master cylinder -2- on the brake booster -3- .
Fig 5: Identifying Fastening Nuts, Brake Master Cylinder And Brake Booster
7. Carefully remove the brake master cylinder -1- and brake fluid reservoir -2- from the brake
booster -3- and set them down on a suitable surface.
Fig 6: Identifying Brake Master Cylinder, Brake Fluid Reservoir And Brake Booster

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REPLACING BRAKE MASTER
CYLINDER
Information
If the brake master cylinder is to be replaced, first remove the brake fluid reservoir and then unscrew the
fastening nuts for the brake master cylinder.
Information
When replacing the brake master cylinder or the brake fluid reservoir, the latter is not repositioned until
the brake master cylinder has been installed.
1. Remove brake light switch. → 943619 REMOVING AND INSTALLING BRAKE LIGHT
SWITCH
2. Unscrew fastening screw -1- for the brake fluid reservoir -2- on the brake master cylinder -3-
.
Fig 1: Identifying, Brake Master Cylinder And Break Fluid Reservoir Screws
3. Lever out the brake fluid reservoir -1- using a suitable tool -2- and remove it from the brake
master cylinder -3- .
Fig 2: Removing Brake Fluid Reservoir
4. Remove rubber seals -1- from the brake master cylinder -2- and replace them.
Fig 3: Identifying Rubber Seals On Brake Master Cylinder

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING BRAKE MASTER
CYLINDER
1. Carefully insert the brake master cylinder -1- together with the brake fluid reservoir -2- into
the brake booster -3- .
Fig 1: Identifying Brake Master Cylinder, Brake Fluid Reservoir And Brake Booster
2. Fit fastening nuts -1- for the brake master cylinder -2- at the brake booster -3- . Tightening
torque 23 Nm (17 ftlb.) +/-2 Nm (+/-1.5 ftlb.)
Fig 2: Identifying Brake Master Cylinder Nuts
3. If the brake master cylinder was replaced, press the brake fluid reservoir -2- into the brake
master cylinder -2- (-arrow- ).
Fig 3: Fitting Brake Fluid Reservoir
1. 3.1. Fit fastening screw -1- for the brake fluid reservoir -2- on the brake master
cylinder -3- .
Fig 4: Identifying Brake Master Cylinder And Brake Fluid Reservoir Screw
4. Fit brake lines -2- on the brake master cylinder -3- . Tightening torque 18 Nm (13 ftlb.) +/-2
Nm (+/-1.5 ftlb.)
Fig 5: Fitting Brake Master Cylinder
5. Connect electric plug connection -1- for the brake fluid level indicator -arrow A- and lock it.
6. Fit the brake light switch if necessary. → Installing Brake Light Switch
7. Insert sieve filter -1- into the brake fluid reservoir -3- .
Fig 6: Inserting Sieve Filter In Brake Fluid Reservoir

SUBSEQUENT WORK FOR REMOVING AND INSTALLING BRAKE MASTER
CYLINDER
1. Install left cross panel. → Installing Cross Panel
2. Change the brake fluid. → 470107 BLEEDING THE BRAKE SYSTEM
3. Bonnet stay 9704 can now be removed. Then move the bonnet to its normal position.
WM 473919 REMOVING AND INSTALLING FRONT BRAKE CALLIPER (CAYENNE,


assembly pins VW tool T10439

Threaded M14 x 1.5 x 115 Tightening 140 Nm (104

connection thread (always torque ftlb.)
18-inch wheel
carrier

19-inch wheel
carrier and
PCCB
Brake pressure M10 x 1 thread Tightening 14 Nm (10.5 +/-1 Nm (+/- 0.5

calliper
No. 4: Threaded M6 x 12 thread Tightening 9 Nm (6.5 ftlb.)

connection torque
securing brake
hose bracket to
wheel carrier
No. 5: Threaded M8 x 14 thread Tightening 20 Nm (15

connection torque ftlb.)
securing cable
holder to wheel
carrier

2. Remove wheel. Use assembly aids (assembly pins) -1- . → 440519 REMOVING AND
INSTALLING WHEEL .
Fig 1: Identifying Assembly Aids (Threaded Bolts For Fitting Wheel)

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING FRONT BRAKE
CALLIPER
Information
To gain better access for removal of the brake calliper, turn the steering fully either to the right or
left.
Fig 1: Identifying Front Brake Calliper
1. Release and unclip connector for the brake pad wear indicator -arrow- .
Fig 2: Removing Connector For Brake Pad Wear Indicator
2. Disconnect plug connection for speed sensor.
Information
Do not bend the brake lines.
1. Detach brake line holders at the wheel carrier.
2. For easier access to the holders, turn in the wheel carrier as required.
4. Remove holders -1, 2- for the hydraulic lines on the wheel bearing housing -3- .
5. Loosen brake line on the brake calliper. Collect brake fluid in a suitable container. Close off
openings of the brake line and brake calliper using suitable stoppers.
Information
1. Never use an impact bolter to loosen and tighten the brake calliper on the wheel carrier.
6. Carefully remove brake calliper from the wheel carrier -arrows- .

Fig 4: Removing Brake Calliper From Wheel Carrier
7. If new brake pads are fitted, read the information under "Removing and installing disc brake
pads" → 463619 REMOVING AND INSTALLING FRONT BRAKE PADS

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING FRONT BRAKE
CALLIPER
Information
Never use an impact bolter to loosen and tighten the brake calliper on the wheel carrier.
Replace screws.
Observe correct tightening torques → 4X00IN TIGHTENING TORQUES FOR THE BRAKE
HYDRAULIC SYSTEM .
Check that all parts are in perfect condition (visual inspection) and replace them if necessary.
The assembly pins T10439 → Brake calliper tool can be used to make it easier to install the brake
calliper.
Fig 1: Identifying Brake Calliper Tool
1. Fit brake calliper.
1. 1.1. Carefully fit the brake calliper and screw in assembly pin in the top thread only
by hand.
Fig 2: Identifying Assembly Pin For Brake Calliper (Top)
2. 1.2. Screw in bottom brake calliper screws several turns by hand (this protects the
thread!).
3. 1.3. Remove assembly pin and screw in top brake calliper screw several turns by
hand (this protects the thread!).
4. 1.4. Screw in both brake calliper screws fully and tighten to the specified tightening
torque.
Brake calliper to wheel bearing housing (18-inch): Tightening torque 140 Nm (104
ftlb.)
Brake calliper to wheel bearing housing (19-inch): Tightening torque 140 Nm (104
ftlb.)
Information
1. Secure brake line holders at the wheel carrier.
2. Fit brake line at the brake calliper. Tightening torque 14 Nm (10.5 ftlb.) +/-1 Nm (+/-0.5 ftlb.)
3. Fit holders -1, 2- for the hydraulic lines on the wheel bearing housing -3- .
Brake hose bracket to wheel bearing housing: Tightening torque 9 Nm (6.5 ftlb.)
Cable holder to wheel bearing housing: Tightening torque 20 Nm (15 ftlb.)
4. Fit plug connection for speed sensor.
5. Fit brake pad wear indicator.

1. Bleed the brake system.
→ 470107 BLEEDING THE BRAKE SYSTEM
pads" → Installing Front Disc Brake Pads
4. Fit wheel. Use assembly aids (assembly pins) -1- . → Installing Wheel .

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > SUBSEQUENT WORK > BEDDING IN
THE BRAKE PADS
WM 473919 REMOVING AND INSTALLING FRONT BRAKE CALLIPER (PCCB)


assembly pins VW tool T10439

VALUES

19-inch wheel
carrier and
PCCB

connection torque
securing brake
hose bracket to
wheel carrier

securing cable
holder to wheel
carrier

WORK
INSTALLING WHEEL .

FRONT BRAKE CALLIPER
Information
To gain better access for removal of the brake calliper, turn the steering fully either to the right or
left.
Fig 1: Identifying Front Brake Calliper
1. Release and unclip connector for the brake pad wear indicator -arrow- .
Fig 2: Removing Connector For Brake Pad Wear Indicator
2. Disconnect plug connection for speed sensor.
Information
1. Detach brake line holders at the wheel carrier.
4. Remove holders -1, 2- for the hydraulic lines on the wheel bearing housing -3- .
5. Loosen brake line on the brake calliper. Collect the brake fluid in a suitable container. Close off
the openings of the brake line and brake calliper using suitable stoppers.
Information
6. Carefully remove brake calliper from the wheel carrier -arrows- .

pads" → 463456 REPLACING FRONT BRAKE PADS (PCCB)

FRONT BRAKE CALLIPER
Information
Replace screws.
HYDRAULIC SYSTEM .
Check that all parts are in perfect condition (visual inspection) and replace them if necessary.
The assembly pins T10439 → Brake calliper tool can be used to make it easier to install the brake
calliper.
Fig 1: Identifying Brake Calliper Tool
1. 1.1. Carefully fit the brake calliper and screw in assembly pin only in the top thread
by hand (this protects the thread!).
Fig 2: Identifying Assembly Pin For Brake Calliper (Top) Fitted
2. 1.2. Screw in bottom brake calliper screws several turns by hand (this protects the
thread!).
3. 1.3. Remove assembly pin and screw in top brake calliper screw several turns by
hand (this protects the thread!).
4. 1.4. Screw in both brake calliper screws fully and tighten to the specified tightening
torque. Tightening torque 140 Nm (104 ftlb.)
Information
1. Secure brake line holders at the wheel carrier.
2. Fit brake line at the brake calliper.
3. Fit holders -1, 2- for the hydraulic lines on the wheel bearing housing -3- .
Brake hose bracket to wheel bearing housing: Tightening torque 9 Nm (6.5 ftlb.)

4. Fit plug connection for speed sensor.
5. Fit brake pad wear indicator.

WORK
1. Bleed the brake system. → 470107 BLEEDING THE BRAKE SYSTEM
pads" → Installing Front Brake Pads

WORK > BEDDING IN THE BRAKE PADS
WM 474119 REMOVING AND INSTALLING REAR BRAKE CALLIPER (CAYENNE,


carrier

calliper
No. 4: Brake line M6 x 12 thread Tightening 8 Nm (6 ftlb.)

holder to torque
rear-axle brake
calliper
No. 10: ABS M6 x 12 thread Tightening 8 Nm (6 ftlb.)

cable holder to torque
rear-axle wheel
carrier

INSTALLING WHEEL .

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR BRAKE
CALLIPER
Fig 1: Locating Brake Calliper Connector
-arrow- .
3. Loosen fastening screw -B- on the holder for the brake pad wear indicator cable and brake
line from the brake calliper.
4. Disconnect brake line -A- at the brake calliper and collect brake fluid in a suitable container.
Fig 3: Locating Brake Line Holder
5. Close off the brake line and bore on the brake calliper using a suitable stopper.
Information
housing.
6. Remove brake calliper from the wheel carrier -A- .


TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR BRAKE
CALLIPER
Information
2. Visually inspect the thread for the brake calliper and blow it out carefully if necessary
using compressed air. Use goggles!
3. Replace screws.
4. Observe correct tightening torques → 4X00IN TIGHTENING TORQUES FOR THE

BRAKE HYDRAULIC SYSTEM .
2. Fit brake calliper. Tightening torque 85 Nm (63 ftlb.)
Information
1. Make sure that the brake line is not twisted. A twisted brake line can damage the bellows
at the drive shaft while driving.
4. Fit holder for the brake pad wear indicator cable and brake line on the brake calliper.
Brake hose bracket to brake calliper Tightening torque 8 Nm (6 ftlb.)
5. Clip in connector for brake pad wear indicator.

3. If new brake pads are fitted, see section "Removing and installing brake pads". → 463856
REPLACING REAR DISC BRAKE PADS
WM 474119 REMOVING AND INSTALLING REAR BRAKE CALLIPER (PCCB)

VALUES

carrier

calliper

holder to torque
rear-axle brake
calliper

rear-axle wheel
carrier

WORK
INSTALLING WHEEL .

REAR BRAKE CALLIPER
Fig 1: Identifying Brake Calliper
-arrow- .
Fig 2: Locating Cable Connector
3. Loosen fastening screw -B- on the holder for the brake pad wear indicator cable and brake
line from the brake calliper.
4. Disconnect brake line -A- at the brake calliper and collect brake fluid in a suitable container.
Fig 3: Locating Brake Line Holder
5. Close off the brake line and bore on the brake calliper using a suitable stopper.
Information
housing.
6. Remove brake calliper from the wheel carrier -A- .


REAR BRAKE CALLIPER
Information
Replace screws.
HYDRAULIC SYSTEM .
2. Fit brake calliper. Tightening torque 85 Nm (63 ftlb.)
Information
1. Make sure that the brake line is not twisted. A twisted brake line can damage the bellows
at the drive shaft while driving.
4. Fit holder for brake pad wear indicator cable and brake line.
Brake hose bracket to brake calliper Tightening torque 8 Nm (6 ftlb.)
5. Clip in connector for brake pad wear indicator.

WORK
3. If new brake pads are fitted, see section "Removing and installing brake pads". → 463556
REPLACING REAR BRAKE PADS (PCCB)

WORK > BEDDING IN THE BRAKE PADS
WM 477019 REMOVING AND INSTALLING BRAKE BOOSTER (CAYENNE, CAYENNE


release tool VW tool T10189

No. 2: Brake M8 thread Tightening 26 Nm (19 +/-3 Nm (+/-2

booster to torque ftlb.) ftlb.)
pedals

WORK FOR REMOVING AND INSTALLING BRAKE BOOSTER
1. Remove brake master cylinder. → 471519 REMOVING AND INSTALLING BRAKE MASTER
CYLINDER
2. Remove trim panel under dashboard at the left. → 701919 REMOVING AND INSTALLING

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING BRAKE BOOSTER
Information
During assembly work on hydraulic connections, the electric plug connections on the hydraulic unit
must always be connected. This prevents the plug connections on the hydraulic unit or in the
connector inside from being splashed with brake fluid or water.
Damp connectors must be wiped dry before disconnection.
Brake fluid on electrical contacts (even thinned brake fluid) causes corrosion and can result in
faults in the system.
Information
Close off the brake lines using suitable stoppers.

Place a cloth under the brake booster to soak up emerging brake fluid.
Fig 1: Identifying Installation Position Of Brake Booster
A. Brake booster
Fig 2: Identifying Brake Booster Components

1. Carefully pull the vacuum line -1- out of the brake booster -2- .
Fig 3: Identifying Vacuum Line On Brake Booster
2. Lever the push rod out of the brake pedal using the release tool T10189 . → 460519
REMOVING AND INSTALLING BRAKE PEDAL
3. Remove fastening nuts -1- from the brake booster under the dashboard.
Fig 4: Removing Brake Booster Fastening Nuts
Information
Make sure not to damage the push rod boot when removing the brake booster.
The seal between the brake booster and body must always be replaced.
4. Remove the brake booster.
1. 4.1. Hold brake lines aside carefully ahead of the brake booster.
2. 4.2. Carefully remove the brake booster from the engine compartment.

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING BRAKE BOOSTER
1. Hold the brake lines aside carefully ahead of the brake booster.
2. Fit the brake booster carefully.
3. Fit and tighten fastening nuts -1- for the brake booster under the dashboard. Tightening
torque 26 Nm (19 ftlb.) +/-3 Nm (+/-2 ftlb.)
Fig 1: Identifying Brake Booster Fastening Nuts
4. Fit the brake booster push rod on the brake pedal.
1. 4.1. Press the brake pedal forward until the ball joint engages in the mounting. →
Installing Brake Pedal
5. Carefully fit the vacuum line -1- into the brake booster -2- .

WORK FOR REMOVING AND INSTALLING BRAKE BOOSTER
1. Install brake master cylinder. → Installing Brake Master Cylinder
2. Fit trim panel under dashboard at the left. → 701919 REMOVING AND INSTALLING TRIM
PANEL UNDER DASHBOARD
WM 477601 CHECKING VACUUM PUMP (EXCEPT CAYENNE, CAYENNE GTS,


tester Special tool 9160/1

Information
The vacuum pump creates the necessary vacuum for the following components and functions:
The variable intake system on naturally aspirated engines (secondary load).
Sports flap exhaust system (secondary load).
The tank leakage test on US vehicles (secondary load).
Wastegate control on turbo vehicles (secondary load).
Brake booster (main load - large connection)
Defects in the specified systems can be caused by a defective vacuum pump. To avoid replacing
components based on suspected defects and repeat repairs, the function of the vacuum pump must be
checked.
The vacuum pump -1- is fitted at the rear of the right cylinder head on V-engines.
Fig 1: Identifying Vacuum Pump (Mechanical)

Fig 2: Identifying Vacuum Pump With Connections
1. Vacuum pump
2. Screw, M6 x 25
3. Sealing ring
4. Sealing ring
5. Secondary load connection

CAYENNE S DIESEL, CAYENNE (3.0)) > CHECKING VACUUM PUMP
Information
This check mainly involves examining the secondary load connection due to problems. The main
connection (brake booster) is not checked. Defects in the main connection would be apparent
immediately due to increasing pedal forces during braking (similar to a defective brake booster).
1. Expose the secondary load connection of the vacuum pump -5- . Different preliminary work is
required, depending on the model and equipment variant.
1. Vacuum pump
2. Screw, M6 x 25
3. Sealing ring
4. Sealing ring
2. Connect vacuum gauge tester 9160/1 to the secondary load connection.
3. Set vacuum gauge tester 9160/1 to vacuum (lever in open position).
4. Start engine and run it at idle speed with slightly changing revs.
5. The vacuum pump must create a vacuum of at least 500 mbar or 0.5 bar.
6. If the vacuum is not maintained, i.e. the pointer moves towards 0, the vacuum pump is
defective. Replace the vacuum pump. For details, see → 477619 REMOVING AND
INSTALLING VACUUM PUMP
7. This defect can cause engine oil to get into the vacuum system. In this case, the lines and
switching valves must be checked visually and replaced if necessary or cleaned with solvent
naphtha.
WM 477619 REMOVING AND INSTALLING VACUUM PUMP (CAYENNE, CAYENNE

Vacuum pump M6 x 25 thread Tightening 10 Nm (7.5 +/-1 Nm (+/-0.5

(mechanical) torque ftlb.) ftlb.)

1. Remove cross panel. → 508119 REMOVING AND INSTALLING CROSS PANEL

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING VACUUM PUMP
Information
Fig 1: Identifying Installation Position Of Vacuum Pump

1. Vacuum pump
2. Screw, M6 x 25
3. Sealing ring
4. Sealing ring
1. Loosen the clamp -1- on the vacuum line -2- and pull off the vacuum pump -3- .
Fig 3: Identifying Clamp On Vacuum Line
2. Disconnect vacuum line -1- from the vacuum pump -2- .

Fig 4: Identifying Vacuum Line From Vacuum Pump
3. Remove vacuum pump -1- .

Fig 5: Identifying Vacuum Pump Screws
2. 3.2. Turn vacuum pump to the side -1- and remove it.

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING VACUUM PUMP
1. Vacuum pump
2. Screw, M6 x 25
3. Sealing ring
4. Sealing ring
1. Carefully loosen and lever off sealing rings -3, 4- using a suitable tool.
2. Clean contact surfaces of sealing rings -3, 4- and fit new sealing rings -3, 4- .
3. Install vacuum pump.
1. 3.1. Clean mounting point before installation.
2. 3.2. Install vacuum pump -1- .
Align driver for vacuum pump -1- and position vacuum pump -1- .
Fig 2: Identifying Vacuum Pump Mounting Screws
3. 3.3. Tighten screws -2- . Tightening torque 10 Nm (7.5 ftlb.) +/-1 Nm (+/-0.5 ftlb.)
4. Connect vacuum line -2- to the vacuum pump -3- and lock the clamp -1- .
Fig 3: Identifying Vacuum Line To Vacuum Pump
5. Connect vacuum line -1- to the vacuum pump -2- .

Fig 4: Identifying Vacuum Line On Vacuum Pump

1. Install cross panel. → Installing Cross Panel
2. Check engine-oil level and top up if necessary. → 170101 CHECKING ENGINE-OIL LEVEL
USING THE PIWIS TESTER
WM 477619 REMOVING AND INSTALLING (MECHANICAL) VACUUM PUMP 3.0

(CAYENNE TIP (3.0) "PLATINUM EDITION", CAYENNE S HYBRID, CAYENNE TIP (3.0))
> REMOVING AND INSTALLING (MECHANICAL) VACUUM PUMP > REMOVING
(MECHANICAL) VACUUM PUMP
1. Unclip rear engine cover and remove it from the engine.
The mechanical vacuum pump is located at the front left of the cylinder head → Installation
position of vacuum pump .
2. Loosen the fastening screw -2- and move the line bracket -1- and lines aside so that the
fastening screws on the vacuum pump are easily accessible.
3. Pull the vacuum line -5- off the vacuum pump.
Information
1. When removing the vacuum pump, always check that the rotor of the vacuum pump is
not twisted when taking it out. Mark the position of the rotor immediately after removal
with a marker, for example.
4. Loosen three fastening screws -4- on the vacuum pump -3- and remove the vacuum pump.
WM 477619 REMOVING AND INSTALLING (MECHANICAL) VACUUM PUMP 3.0

(CAYENNE TIP (3.0) "PLATINUM EDITION", CAYENNE S HYBRID, CAYENNE TIP (3.0))
> REMOVING AND INSTALLING (MECHANICAL) VACUUM PUMP > INSTALLING
(MECHANICAL) VACUUM PUMP
1. Replace the vacuum pump seal. Fit the new seal at the correct position on the vacuum pump.
2. Align the rotor of the vacuum pump according to the marking you made.
3. Insert the vacuum pump with the seal evenly into the fitting bores of the cylinder head.
4. Fit the vacuum pump using the three fastening screws.
5. Fit the vacuum line and check that the vacuum line is seated correctly.
WM 477619 REMOVING AND INSTALLING VACUUM PUMP 3.6 (CAYENNE TIP

"PLATINUM EDITION", CAYENNE TIP, CAYENNE MAN) > TECHNICAL VALUES

Vacuum pump M6 x 25 thread Tightening 10 Nm (7.5 +/-1 Nm (+/-0.5

"PLATINUM EDITION", CAYENNE TIP, CAYENNE MAN) > PRELIMINARY WORK
1. Remove rear profile seal for front lid. → 553319 REMOVING AND INSTALLING SEAL FOR
FRONT LID
2. Remove both wiper arms. → 922519 REMOVING AND INSTALLING WIPER ARM
4. Remove wiper linkage. To do this, complete Steps 1-4 in → 921519 REMOVING AND
INSTALLING WIPER MOTOR .
5. Remove front cover (engine compartment). → 700219 REMOVING AND INSTALLING FRONT
COVER (ENGINE COMPARTMENT)
6. Remove left and right cross panel. → 508119 REMOVING AND INSTALLING CROSS PANEL
8. Remove engine guard by loosening the screws -arrows- under the transmission.
Fig 1: Locating Engine Guard Screws

9. Remove protective plate.
1. 9.1. Remove nuts -2- from the protective plate -1- .
2. 9.2. Lower the vehicle.
3. 9.3. Remove screw -3- from the protective plate.
4. 9.4. Remove protective plate.

Fig 2: Identifying Protective Plate With Mounting Screws

"PLATINUM EDITION", CAYENNE TIP, CAYENNE MAN) > REMOVING AND
INSTALLING VACUUM PUMP > REMOVING VACUUM PUMP
1. Remove center cross panel -3- .
1. 1.1. Disconnect lines -4- from the brackets -5- .
2. 1.2. Loosen fastening screws -1- and nuts -2- .
3. 1.3. Carefully pull out the cross panel in an upward direction.

Fig 1: Identifying Centre Cross Panel Screws
2. Pull the vacuum line off the vacuum pump using a sufficient amount of force.
Information
Check the position of the screws and the screw length when removing and installing the
vacuum pump. The screw at the top right in direction of travel is short, the other two screws
are long.
3. Loosen the upper screws -2- on the vacuum pump -1- .

4. Carefully move the coolant hoses behind the vacuum pump -1- aside using a wooden block (5
cm wide) -2- and loosen the lower fastening screw -3- on the vacuum pump.
Fig 3: Identifying Wooden Block Position
Information
1. When you remove the V6 vacuum pump, the sealing ring can remain on the drive shaft at
the engine side. If this happens, the sealing ring must be removed from the drive shaft
and inserted into the rotor of the vacuum pump at the correct position at the lower edge
of the chamfer -1- .
Fig 4: Identifying Vacuum Pump Assembly
Information
1. When removing the V6 vacuum pump, always check that the rotor of the vacuum pump
is not twisted when taking it out. Mark the position of the rotor immediately after removal
with a marker, for example -arrows- !
2. When replacing the vacuum pump, move the rotor of the new vacuum pump to the exact
same position and also mark the position of the rotor.
Fig 5: Locating Rotor Position Marked
5. Remove the vacuum pump carefully by pulling it to the rear.

"PLATINUM EDITION", CAYENNE TIP, CAYENNE MAN) > REMOVING AND
INSTALLING VACUUM PUMP > INSTALLING VACUUM PUMP
1. Fit the sealing ring -1- at the correct position in the vacuum pump so that it is flush with the
lower edge of the chamfer in the rotor.
Fig 1: Identifying Vacuum Pump Sealing Ring
2. Align the rotor according to the marking you made -arrows- . → Rotor position marked
Fig 2: Locating Rotor Position Marked
Information
1. Once you have inserted the vacuum pump, it must not be pulled back any more.
Otherwise, you will have to check the sealing ring again to ensure that it is seated
correctly.
3. Insert the vacuum pump -3- with the seal -4- evenly into the fitting bores of the cover piece
-1- .
Information
Check the position of the screws and the screw length when removing and installing the
vacuum pump. The screw at the top right in direction of travel is short, the other two screws
are long.
4. Fit the vacuum pump -3- using three screws -2- . Use the wooden block again if necessary
when tightening the lower screw.
Fastening screws securing vacuum pump to plenum panel wall: Tightening torque 10 Nm
(7.5 ftlb.) +/-1 Nm (+/- 0.5 ftlb.) .
Fig 3: Identifying Vacuum Pump Components
5. Fit the vacuum line and check that the vacuum line is seated correctly.
6. Fit center cross panel -3- .
1. 6.1. Insert cross panel in installation position.
2. 6.2. Fit fastening screws -1- and nuts -2- .
3. 6.3. Clip lines -4- into the brackets -5- .

Fig 4: Identifying Centre Cross Panel Components

"PLATINUM EDITION", CAYENNE TIP, CAYENNE MAN) > SUBSEQUENT WORK
1. Install protective plate.
1. 1.1. Fit and tighten screw -3- on the protective plate -1- .
2. 1.2. Raise the vehicle.
3. 1.3. Fit and tighten nuts -2- on the protective plate -1- .
Fig 1: Identifying Protective Plate, Nuts And Screws
2. Install engine guard and tighten screws -arrows- .

Fig 2: Locating Engine Guard Screws
3. Install cross panel at the left and right. → Installing Cross Panel
4. Install front cover (engine compartment). → 700219 REMOVING AND INSTALLING FRONT
5. Install wiper linkage. To do this, complete Steps 6-12 in → 921519 REMOVING AND
INSTALLING WIPER MOTOR .
7. Install both wiper arms. → Installing Wiper Arms
8. Install rear profile seal for front lid. → Installing Front Lid Seal
WM 477619 REMOVING AND INSTALLING V8/TURBO/GTS VACUUM PUMP

(CAYENNE S, CAYENNE TURBO, CAYENNE GTS, CAYENNE TURBO S) >
VACUUM PUMP
1. Remove cross panel. → 508119 REMOVING AND INSTALLING CROSS PANEL

(CAYENNE S, CAYENNE TURBO, CAYENNE GTS, CAYENNE TURBO S) > REMOVING
VACUUM PUMP
Information

Fig 2: Identifying Vacuum Pump, Fastening Screws, Sealing Ring, Sealing Ring
1. Vacuum pump
2. Fastening screws
3. Sealing ring
4. Sealing ring
1. Loosen clamp -1- on vacuum line -2- for brake booster at the vacuum pump -3- .
Pull off vacuum line.

Fig 3: Identifying Vacuum Pump Line Clamp
2. Pull vacuum line -1- off the vacuum pump -2- for automatic transmission.
Fig 4: Identifying Vacuum Supply Line
3. Remove vacuum pump.
1. 3.1. Detach and remove the vacuum pump -1- .
Remove the vacuum pump -1- by unscrewing the screws -2- . Turn the vacuum
pump to the side and guide it past the fuel low-pressure line.

(CAYENNE S, CAYENNE TURBO, CAYENNE GTS, CAYENNE TURBO S) > INSTALLING
VACUUM PUMP
1. Vacuum pump
2. Fastening screws
3. Sealing ring
4. Sealing ring
1. Replace sealing rings -2, 3- on vacuum pump -1- .
Carefully loosen and lever off the sealing rings -2, 3- using a suitable tool. Clean contact
surface of sealing rings -2, 3- and fit new sealing rings -2, 3- .
Fig 2: Identifying Replacing Sealing Rings On Vacuum Pump
2. Install vacuum pump.
1. 2.1. Clean mounting point before installation.
2. 2.2. Fit and secure the vacuum pump -1- .
Align driver for vacuum pump -1- and fit the vacuum pump -1- . Screw in and tighten
screws -2- .
Observe the correct tightening torque. → 4X00IN TIGHTENING TORQUES FOR

BRAKE HYDRAULICS
3. Fit vacuum line -2- for brake booster onto the vacuum pump -3- and secure the clamp -1- .
Fig 4: Identifying Vacuum Pump, Line And Break Booster
4. Connect vacuum supply hose -1- to the vacuum pump -2- .

Fig 5: Identifying Vacuum Supply Hose To Vacuum Pump

VACUUM PUMP
1. Fit the cross panel. → Installing Cross Panel
2. Check engine-oil level and top up if necessary. → 170117 CHANGING ENGINE OIL AND OIL
FILTER
WM 477719 REMOVING AND INSTALLING VACUUM LINE FOR BRAKE BOOSTER

CAYENNE TIP (3.0)) > PRELIMINARY WORK > PRELIMINARY WORK FOR REMOVING
AND INSTALLING VACUUM LINE FOR BRAKE BOOSTER
1. Remove alarm siren. → 966519 REMOVING AND INSTALLING ALARM SIREN
2. Remove the right cross panel. → 508119 REMOVING AND INSTALLING CROSS PANEL
CAYENNE TIP (3.0)) > REMOVING VACUUM LINE FOR BRAKE BOOSTER
Fig 1: Identifying Installation Position Of Vacuum Line For Brake Booster
1. Carefully pull the vacuum line -1- out of the brake booster -2- .
2. Release electric plug connection -1- from the vacuum control valve -2- (-a- ) and pull it off
-A- .
Fig 3: Removing Electric Plug Connection From Vacuum Control Valve
3. Unclip vacuum line -1- from the retaining clip -2- in a downward direction.
Fig 4: Identifying Clip On Brake Booster Vacuum Line
4. Carefully pull the vacuum line -1- with the rubber boot -2- up out of the bulkhead -3- .
Fig 5: Identifying Rubber Boot On Vacuum Line For Brake Booster
5. Carefully guide the vacuum line to the right and out of the plenum panel.
6. Loosen clamp -1- on vacuum line -2- for brake booster at the vacuum pump -3- .
Pull off vacuum line.

Fig 6: Identifying Vacuum Pump Line And Clamp

CAYENNE TIP (3.0)) > INSTALLING VACUUM LINE FOR BRAKE BOOSTER
1. Carefully guide the vacuum line into the plenum panel from the right.
2. Clip the vacuum line -1- into the retaining clip -2- in the plenum panel.
Fig 1: Identifying Clip On Brake Booster Vacuum Line
3. Plug in electric plug connection -1- for the vacuum control valve -2- (-A- ) and lock it -a- .
Fig 2: Installing Electric Plug Connection On Vacuum Control Valve
Information
The two O-rings on the vacuum line at the vacuum pump must always be replaced.
4. Fit vacuum line -2- for brake booster onto the vacuum pump -3- and secure the clamp -1- .
Fig 3: Identifying Vacuum Pump Line For Brake Booster
5. Carefully press the vacuum line -1- with the rubber boot -2- into the bulkhead -3- .
Fig 4: Identifying Rubber Boot On Vacuum Line For Brake Booster
6. Carefully fit the vacuum line -1- into the brake booster -2- .

CAYENNE TIP (3.0)) > SUBSEQUENT WORK > SUBSEQUENT WORK FOR REMOVING
AND INSTALLING BRAKE BOOSTER VACUUM LINE
1. Fit alarm siren. → 966519 REMOVING AND INSTALLING ALARM SIREN
2. Fit the right cross panel. → Installing Cross Panel

Service Manual: 4X - CHASSIS - GENERAL -- 92A CAYENNE
WM 4X00IN COMPONENT ARRANGEMENT - LEVELLING SYSTEM (EXCEPT
E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0))
The Cayenne models feature a levelling system with fully supporting air suspension on both axles and
the electronically regulated damping system Porsche Active Suspension Management (PASM).
The air suspension with level control makes it possible to actively adapt the ground clearance of the
Cayenne to the current driving situation or to the vehicle load.
Depending on the load, various vehicle ride heights with various suspension characteristics can be
achieved by increasing or decreasing the air volume. The amount of air needed for each air-spring strut
is determined by means of a control unit and provided via an air supply consisting of a compressor, a
solenoid valve unit and pressure accumulator.
Fig 1: Overview Of Air Suspension System Component Arrangement
Description of
No. component Qty. Position
-1- Air-spring strut, front axle 2 Wheel housing/lower

control arm
-2- Air-spring strut, rear axle 2 Air spring mounting/wheel

bearing housing, bottom
-3- Level sensors 4 Upper control arm/front
axleUpper control arm,
front/rear axle
-4- Body acceleration sensors 3 Front wheel housing

(2x front and 1x rear) (right/left), right luggage
compartment (integrated in
levelling system/PASM
control unit!)
-5- Compressor and valve 1 Centre underbody, right

unit
-6- Pressure accumulator 1 Centre underbody, left
-7- Levelling system control 1 Luggage compartment,

unit/PASM right
-8- PASM switch unit 1 Centre console
WM 4X00IN WHEEL RIM PAINT COLORS (CAYENNE, CAYENNE GTS, CAYENNE

DIESEL, CAYENNE (3.0)) > WHEEL RIM PAINT COLORS
18-inch Cayenne
Fig 1: Identifying Wheel Rim Cayenne (18-Inch)
Color code/option Designation Note Order No.
8Z8 Brilliant Silver C1J
18-inch Cayenne S III

Fig 2: Identifying Wheel Rim Cayenne S (18-Inch)
8Z8 Brilliant Silver C1Q
19-inch Cayenne Turbo

Fig 3: Identifying Wheel Rim Cayenne Turbo (19-Inch)
88Z Brilliant Chrome C8K
19-inch Cayenne Design II

Fig 4: Identifying Wheel Rim Cayenne Design II (19-Inch)
88Z Brilliant Chrome F09
20-inch Cayenne Sport Design II

Fig 5: Identifying Wheel Rim Cayenne Sport Design (20-Inch)
88Z Brilliant Chrome CN7
20-inch RS Spyder Design

Fig 6: Identifying Wheel Rim RS Spyder Design (20-Inch)
EP8 Decorative Silver/Titanium CP5
21-inch 911 Turbo II

Fig 7: Identifying Wheel Rim 911 Turbo (21-Inch)
OC6 Dark Titanium CZ4
21-inch Cayenne Sport Edition

Fig 8: Identifying Wheel Rim Cayenne Sport Edition (21-Inch)
M7Z GT Silver Metallic CK0
Painted wheel Wheel painted in CNE

custom colour
Painted wheel Wheel painted High-gloss CQ1

Black
21-inch Turbo
Fig 9: Identifying Wheel Rim Turbo Design (21-Inch)
OC6 Dark Titanium High-gloss turned and C7T

polished finish
WM 4X00IN BRAKE DISC MEASUREMENT SHEET (CAYENNE, CAYENNE GTS,

CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION > BRAKE DISC
MEASUREMENT SHEET
Information
Notes on checking and measurement points can be found in:
Technical data relating to the tests . → 4650TW TECHNICAL DATA/BRAKE WEAR LIMIT
Description of Tests 1-3, front . → 465002 CHECKING FRONT BRAKE DISCS (WEAR
ASSESSMENT)
Description of Tests 1-3, rear . → 465302 CHECKING REAR BRAKE DISCS (WEAR
ASSESSMENT)
A copy or print-out of the data card shown here can be used to document the measured result. The data
cards cannot be ordered.
1. Make a copy or print-out of the data card shown here.
Information
1. Actual values that are identical in all versions are already entered!
2. These values may change in the course of further development . Check them if
necessary and add the new values as required. → 4650TW TECHNICAL DATA/BRAKE
WEAR LIMIT
2. Before taking measurements (Test 1 to Test 3), enter the general data, vehicle type and the
missing nominal values (new brake disc thickness/brake disc wear limit) in the data card.
3. Carry out measurements (actual status) and enter the values in the data card.
4. If brake discs are to be replaced, carry out Test 2 with the new discs again and enter the latest
values in a new data card.
Measuring prerequisites
Note the labor operation numbers.
Measuring brake discs: 80 time units per axle.
Brake disc measurement
Customer: Rep. Order No.:
Street: Porsche VIN:
City: Reg. number:
Telephone: Date of first registration:
Vehicle type: Odometer reading [km/miles]:
Checked by: Date/Signature
Nominal values
Test 1 = Brake disc thickness
Front: Rear:
Brake disc thickness, new [mm]:
Front: Rear:
Wear limit [mm]:
Test 2 = Lateral runout
max.:
Brake disc installed [mm]
WM 4X00IN GENERAL INFORMATION ON TYRE PRESSURE MONITORING (TPM)

E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > GENERAL
INFORMATION ON TYRE PRESSURE MONITORING (TPM) > DESIGN AND
OPERATING PRINCIPLE > DESIGN
Fig 1: Identifying Design Of 3rd Generation TPM System
The 3rd generation TPM system consists of:
4 wheel electronics units screwed onto the wheels
4 TPM valves and
1 TPM control unit (KSG) with integrated central antenna (installed on the rear axle)
OPERATING PRINCIPLE > OPERATING PRINCIPLE
The 3rd generation TPM system operates on the principle of unidirectional communication between the
wheel electronics and control unit. This means that the wheel electronics can communicate with the
control unit, but the control unit cannot communicate with the wheel electronics.
The wheel electronics units send the currently measured tyre pressure, the direction of rotation, the
temperature of the air in the tyre and the remaining service life (of the battery) as well as a specific ID
from the wheel that is currently turning at specified intervals.
The wheel position is learned automatically from the side and axle specifications. The direction of
rotation of a wheel is detected by acceleration sensors in the wheel electronics (left/right detection). Axle
sensing (front axle/rear axle detection) is performed based on differentiated sound levels between the
front and rear axle, where the central antenna is fitted close to one axle (high level). The levels received
from the other axle are correspondingly low.

OPERATING PRINCIPLE > TRANSMISSION MODES
The wheel electronics units communicate with the control unit in various modes. Depending on the
current mode of a wheel electronics unit, it sends telegrams to the control unit at defined intervals.
Normal mode: Normal mode is active while the vehicle is driving (after Burst mode has ended).
Sleep mode: Sleep mode is activated as soon as the vehicle remains stationary for longer than 5
minutes. The wheel electronics then send no more telegrams. If the ignition is switched on while
the wheel electronics units are in Sleep mode, no tyre pressures are displayed (display in
instrument cluster: "-.-"). Tyre pressures are only displayed again when the vehicle is driving (see
Burst mode).
Burst mode: If the wheel electronics units are in Sleep mode and the vehicle is accelerated to
over 25 km/h (15 mph) from stationary, the wheel electronics units switch to Burst mode. The
wheel electronics units send their telegrams for 60 seconds at fast intervals.

E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TEACHING
TYRE PRESSURE MONITORING (TPM) > GENERAL INFORMATION
If a new set of wheels is used or wheel electronics units were replaced, the TPM system must be taught.
When teaching the TPM system, the control unit stores the wheel IDs of the wheel electronics units and
assigns a position to them.
New wheel electronics units can be taught by selecting a new set of wheels in the instrument cluster.
The system is then in learning mode and re-assigns the wheel IDs that are received.
But the system also detects a wheel change if the stored information does not correspond to the
information received. The control unit then displays a message on the instrument cluster prompting you
to select the newly fitted set of wheels.
The wheel electronics units can be taught while the vehicle is driving and while it is stationary. Teaching
while driving is recommended.

TYRE PRESSURE MONITORING (TPM) > TEACHING WHILE DRIVING
A procedure in PIWIS Tester II 9818 can be used to teach the wheel IDs while driving: >>Tyre Pressure
Monitoring (TPM) system << >>Maintenance/repairs<< >>Teach wheel IDs<< >>Teach wheel IDs while
driving<<.
The wheel IDs can also be taught without using the System Tester.
The following points must always be observed:
Allow an idle time of at least 5 minutes before teaching the wheel IDs (wheel electronics units are
then in Sleep mode).
Briefly accelerate the vehicle to over 25 km/h (15 mph) in order to teach the wheel IDs (wheel
electronics units are then in Burst mode).
Then continue driving at any speed (even < 25 km/h or 15 mph) for max. 10 minutes.
Teaching was successful if a pressure reading is displayed in the instrument cluster for all wheel
positions.

TYRE PRESSURE MONITORING (TPM) > TEACHING WHILE STATIONARY
Information
If the TPM system is to be taught while the vehicle is stationary, it is advisable to take note of the wheel
IDs and the position of all wheels and store the information together with the wheels. This can
significantly reduce the teaching time for the next wheel change.
The wheel IDs and position can be read out using PIWIS Tester II 9818 if this information is already
stored in the control unit. >>Tyre Pressure Monitoring (TPM) system<< >>Actual values and input
signals<<

TYRE PRESSURE MONITORING (TPM) > TEACHING WHILE STATIONARY > IF
WHEEL IDS ARE KNOWN
Allocation of wheel electronics units using PIWIS Tester II 9818 : >>Tyre Pressure Monitoring (TPM)
system<< >>Maintenance/repairs<< >>Teach wheel IDs<< >>Teach wheel IDs while vehicle is
stationary<< >>Wheel IDs known<<.

TYRE PRESSURE MONITORING (TPM) > TEACHING WHILE STATIONARY > IF
WHEEL IDS ARE UNKNOWN
Allocation of wheel electronics units using PIWIS Tester II 9818 : >>Tyre Pressure Monitoring (TPM)
system<< >>Maintenance/repairs<< >>Teach wheel IDs<< >>Teach wheel IDs while vehicle is
stationary<< >>Wheel IDs unknown<<.
Always observe the following procedure (instructions on the System Tester always take precedence!):
Allow an idle time of at least 5 minutes before teaching the wheel IDs (wheel electronics units are
then in Sleep mode).
As per instructions on the System Tester, pressure (at least 0.2 bar and approx. 5 seconds) at the
wheels must be reduced.
The wheel electronics registers the pressure difference (after 2 minutes at the latest) and switches
to Burst mode.
The control unit receives the telegrams from the activated wheel electronics unit and writes its
wheel ID to the specified position.
WM 4X00IN INFORMATION ON PSM (CAYENNE, CAYENNE GTS, CAYENNE TURBO S,

CAYENNE (3.0)) > INFORMATION ON PSM
PSM is an active control system for stabilizing the vehicle at the limit of driving dynamics. Sensors
continuously determine:
Vehicle speed
Direction of travel (steering angle)
Lateral acceleration
Longitudinal acceleration
Rotation rate
Information
The PSM (Porsche Stability Management) is automatically ready/switched on after each engine
start .
The vehicles are equipped with a new PSM generation with enhanced functions, which considerably
improve active safety.
Enhanced braking readiness
Brake assist function
Enhanced Trailer Stability Management
New ABS tuning for braking on loose surfaces
With enhanced braking readiness, the brake system builds up slight pressure when the accelerator is
released quickly and places the brake pads lightly on the brake discs. If the driver now presses the
brake, braking power can be achieved more quickly. This results in a shorter stopping distance.
Enhanced braking readiness always remains active, irrespective of whether PSM is on or off.
On identifying full braking - when a defined pedal pressure is exceeded - brake assist supplies the
required pressure for maximum deceleration via the PSM hydraulic unit. Brake assist can be deactivated
by switching off PSM.
Enhanced Trailer Stability Management is a support function of PSM for driving with a trailer. The system
detects swaying movements of the trailer and tries to minimize these through targeted braking. Trailer
Stability Management can be switched off by switching off PSM. When the driver presses the brake
pedal, Trailer Stability Management is activated even if PSM is switched off.
The ABS control strategy has been modified for braking on loose surfaces. A brake barrier, which helps
to reduce braking distance on gravel or snow for example, is created in front of the tires by blocking the
wheels short.

CAYENNE (3.0)) > INFORMATION ON PSM > SWITCHING OFF PSM
Press the PSM button. PSM switches off after a short delay.
When PSM is off, the PSM OFF warning light in the instrument panel and the indicator light in the switch
light up.
When braking, the vehicle is also stabilized when PSM is switched off!
One-sided wheel spin is also prevented when PSM is switched off!
PSM should always be switched on for normal driving.
In the following exceptional cases, it can be advantageous to switch off the PSM temporarily:
On a loose surface and in deep snow
When rocking the vehicle free
When using snow chains
On extremely rough ground (if one or more wheels have little or no road grip - engine performance
is reduced)

CAYENNE (3.0)) > INFORMATION ON PSM > SWITCHING ON PSM
Press the PSM button. PSM switches on after a short delay.
WM 4X00IN LIFTING THE VEHICLE (CAYENNE, CAYENNE GTS, CAYENNE TURBO S,

Rocker switch Time 10 s +5 s
Rocker switch Time 10 s +5 s

CAYENNE (3.0)) > LIFTING THE VEHICLE > PRELIMINARY WORK
WARNING: Vehicle can fall down
→ Do not place any solid objects under the raised vehicle.
→ Ensure that the lifting platform is prevented from lowering.
→ Remove solid objects before lowering the vehicle.
→ Raise the vehicle only at the jacking points provided.
→ The outer jacking points should be used primarily.
When driving onto the lifting platform, bear in mind the work that needs to be carried out. In other words:
if work has to be carried out in the front footwell, the vehicle should be positioned in such a way that the
front doors can be opened far enough.
If the vehicle is a Cayenne with air suspension/levelling system, also observe the following instructions:
Switch off the levelling system manually (see Switching Off The Levelling System ).
Information
If the vehicle was raised on the lifting platform when the levelling system was switched on, it will
automatically detect levelling platform mode and switch off the levelling system.
It is no longer possible to switch the levelling system on manually in lifting platform mode.
It will not be possible to carry out level adjustment, the component test or the drive link test.
Driving the vehicle a short distance at more than 7 km/h (4 mph) will resolve this .

CAYENNE (3.0)) > LIFTING THE VEHICLE > SWITCHING OFF THE LEVELLING
SYSTEM
Adjust vehicle to normal level.
Switch on ignition.
→ Time: 10 s+5 s Press rocker switch forward.
The message Control switched off appears in the variable control display of the instrument panel.

CAYENNE (3.0)) > LIFTING THE VEHICLE > SWITCHING ON THE LEVELLING
SYSTEM
Switch on ignition.
→ Time: 10 s+5 s Press rocker switch forward or
drive the vehicle. The levelling system comes on automatically.

Fig 1: Locating Jacking Points
WM 4X00IN SAFETY NOTES AND INFORMATION WHEN REPAIRING THE RUNNING

GEAR (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S


WARNING NOTES > FITTING CHASSIS COMPONENTS
Danger of injury
Loss of torque

WARNING NOTES > SPRING STRUTS/COIL SPRINGS
WARNING: Installation of incorrect or damaged coil springs
Different vehicle handling
Coil springs can break
→ Examine the components carefully before installation.
→ When installing new coil springs/spring struts, make sure they are assigned correctly.
→ Only use a suitable tool for removing and installing coil springs.
→ Do not weld or grind, or use a hammer close to the spring struts.

→ Do not apply colour markings to the coil springs.

WARNING NOTES > WHEELS AND TIRES
WARNING: High tyre seating pressure
Risk of squashing or bruising
→ Use a tyre filling cage.
Information
Newly mounted tires require a bedding-in period to remove the vulcanization layer .
Customers must be informed that the full performance of new tires is achieved only after a distance
of 100 to 200 km (60 to 120 miles) has been driven. Avoid extreme driving maneuvers
(acceleration, braking) during this time .

WARNING NOTES > WORKING ON VEHICLES WITH PSM
WARNING: Steering-angle sensor not calibrated or calibrated incorrectly
Unexpected vehicle handling
Steering-angle sensor does not function
Malfunction in steering-angle sensor
→ After working on wheel suspension parts, when replacing the steering-angle sensor and after
changing the wheel alignment values, calibrate the steering-angle sensor using PIWIS Tester II 9818 .
→ Keep the front wheels in straight-ahead position on the measuring platform during calibration.
→ On vehicles with electromechanical steering, also re-teach the electric steering lock settings.

WARNING NOTES > BRAKE SYSTEM
→ Only use the type-specific brake pads .
Information
Observe brake fluid quality. Use only new DOT 4 brake fluid .
The brake-fluid change interval using Super DOT4 brake fluid is two years .
This brake fluid is available under the following part numbers: Container quantity: 1 liter =
000.043.203.66. 30 liters = 000.043.203.67 .

WARNING NOTES > HANDLING AIRBAG SYSTEMS
Information
000.043.203.66. 30 liters = 000.043.203.67 .

WARNING NOTES > STEERING
Information
000.043.203.66. 30 liters = 000.043.203.67 .
WM 4X00IN TESTS/INSTRUCTIONS FOR ALL-WHEEL DRIVE (CAYENNE, CAYENNE

CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION > FINISH-BALANCING ON
THE VEHICLE
Electronic finish-balancing (static balancing) of the wheels on the vehicle (following stationary balancing)
is not necessary. Finish-balancing is generally permitted. The operating instructions and balancing
machine manufacturer's instructions must be observed!

CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION > FUNCTION TEST
The function test may only be carried out on a roller-type test stand approved for all-wheel drive
vehicles.

CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION > BRAKE TEST
Brake tests may only be carried out in the road driving program (High Range) on single-axle roller-type
test stands with all-wheel drive function. Requirements:
Transmission in neutral during test (before starting the rollers).

The following limit values must not be exceeded:
Test speed max. 7.5 km/h
Test duration: max. 20 seconds.
Observe specifications in the operating instructions provided by the relevant manufacturer of the axle
roller-type test stand!

CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION > EBP TEST
Information
Accelerator pedal must not be pressed.
All conditions must be valid for 1 second because only then is roller-type test stand mode detected!
Entry conditions for roller-type test stand mode in the EPB control unit
Ignition on.
VIN is entered correctly.
Vehicle is coded correctly.
Transmission disengaged: manual transmission at idle speed, PDK in neutral position "N".
Speed on front axle < 2.2 km/h
Speed on rear axle: < 12 km/h
The clutch pedal is no longer queried on the Cayenne.
Exit conditions for roller-type test stand mode in the EPB control unit
Ignition off.
CAN transmission information invalid.
Clutch not pressed or selector lever not in position "N".
Speed on all wheels: V < 2.2 km/h
Test procedure
Roller-type test stand detected.
Switch actuated to tightening direction.
Once the pad contact point is reached, the first actuator pauses until the second one reaches it.
Tighten both actuators (no time delay).
Balance the left and right wheel speed delta.
Exit roller-type test stand mode when the wheels are locking.
NOTE: The strategy is identical for grey cast-iron and PCCB brakes!

CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION > TOWING TIPTRONIC
VEHICLES
Information
When towing a vehicle, there is no power assistance available when the engine is stopped. As a result,
a lot more force has to be used when braking and steering. Always tow a vehicle at low speeds. See
also the information in the Driver's Manual.
Information
There is insufficient transmission lubrication when the engine is not running .
Move selector lever to position N.
Switch ignition on (otherwise steering lock will engage and brake light and indicator light will not
function).
Do not exceed a top speed of 50 km/h (30 mph).
Maximum towing distance is 50 km (30 miles).
If, owing to circumstances, the vehicle has to be towed with an axle raised, the cardan shaft of the axle
whose wheels are turning must be removed.
In the case of long towing distances, the vehicle must be transported on a trailer.
WM 4X00IN TIGHTENING TORQUES FOR ANTI-LOCK BRAKE SYSTEM (ABS)

VALUES
No. 1: Holder to M6 x 10 thread Tightening 10 Nm (7.5

hydraulic unit torque ftlb.)
Fastening screws Tightening 5 Nm (3.5

hydraulic unit
holder to body
No. 1, 2, 3, 6: M10/M12 thread Tightening 14 Nm (10.5 +/-1 Nm (+/- 0.5

Brake pressure torque ftlb.) ftlb.)
pipe to hydraulic
unit
No. 4, 5: Brake M12 thread Tightening 18 Nm (13 +/-2 Nm (+/- 1.5

pressure pipe to torque ftlb.) ftlb.)
hydraulic unit
Cap screws for M10 x 1 thread Tightening 14 Nm (10.5 +/-1 Nm (+/- 0.5
brake lines torque ftlb.) ftlb.)
No. 1: M6 thread Tightening 8 Nm (6 ftlb.)

Combination (always replace torque
sensor screws and lock
nuts after
removal)
Speed sensor to M6 x 16 thread Tightening 8 Nm (6 ftlb.)

front and rear torque
axles

VALUES > TIGHTENING TORQUES > HYDRAULIC UNIT
No. 1: Holder to M6 x 10 thread Tightening 10 Nm (7.5

hydraulic unit torque ftlb.)

screws securing torque
hydraulic unit
holder to body
Fig 1: Identifying Hydraulic Unit

VALUES > TIGHTENING TORQUES > HYDRAULIC UNIT LINES
No. 1, 2, 3, 6: M10/M12 thread Tightening 14 Nm (10.5 +/-1 Nm (+/- 0.5

Brake pressure torque ftlb.) ftlb.)
pipe to hydraulic
unit
No. 4, 5: Brake M12 thread Tightening 18 Nm (13 +/-2 Nm (+/- 1.5

pressure pipe to torque ftlb.) ftlb.)
hydraulic unit
Fig 1: Identifying ESP Connections

VALUES > TIGHTENING TORQUES > COMBINATION SENSOR
No. 1: M6 thread Tightening 8 Nm (6 ftlb.)

Combination (always replace torque
sensor screws and lock
nuts after
removal)
Speed sensor to M6 x 16 thread Tightening 8 Nm (6 ftlb.)

front and rear torque
axles
Fig 1: Identifying Combination Sensor
WM 4X00IN TIGHTENING TORQUES FOR BRAKE HYDRAULICS (EXCEPT CAYENNE,


front-axle 18-inch after removal)
wheel carrier

wheel carrier and
PCCB
Connecting line M10 x 1 thread Tightening 14 Nm (10.5 +/-1 Nm (+/- 0.5

to brake calliper torque ftlb.) ftlb.)

carrier
Bleeder screw on M10 x 1 thread Tightening 14 Nm (10.5 +/-2 Nm (+/- 1.5

brake calliper torque ftlb.) ftlb.)

calliper
Mounting for M6 x 14 thread Tightening 10 Nm (7.5

intermediate torque ftlb.)
piece
Vacuum pump Tightening 10 Nm (7.5 +/-1 Nm (+/- 0.5

(electric) torque ftlb.) ftlb.)
Vacuum pump M6 x 25 thread Tightening 10 Nm (7.5 +/-1 Nm (+/- 0.5


to brake booster
No. 2: Brake M8 thread Tightening 26 Nm (19 +/-3 Nm (+/- 2

booster to pedals torque ftlb.) ftlb.)

master cylinder
Brake pressure M10/M12 thread Tightening 14 Nm (10.5 +/-1 Nm (+/- 0.5

hose, distributor,
brake calliper

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > BRAKE
CALLIPER/BRAKE LINES/VACUUM PUMP

wheel carrier

wheel carrier and
PCCB


carrier


calliper

piece



MASTER CYLINDER/BRAKE BOOSTER

to brake booster
pedals

master cylinder

hose, distributor,
brake calliper
Fig 1: Overview Of Brake Booster/Brake Master Cylinder With Reservoir
WM 4X00IN TIGHTENING TORQUES FOR BRAKE MECHANICS (EXCEPT CAYENNE,

No. 2: Brake M6 x 12 thread Tightening 8 Nm (6 ftlb.)

cover plate to torque
front axle
No. 4: Cable M8 x 14 thread Tightening 20 Nm (15

holder to torque ftlb.)
front-axle wheel
carrier
No. 5: Brake M6 x 12 thread Tightening 9 Nm (6.5
hose holder to torque ftlb.)
front-axle wheel
carrier
No. 6: Fastening M12 x 1.5 thread Tightening 15 Nm (11

screw securing (always replace torque ftlb.)
removal)

piece
Deflector to body M8 x 20 thread Tightening 23 Nm (17

(tunnel) torque ftlb.)
No. 1: Actuator to Tightening 20 Nm (15 +60° (+44 ftlb.)

wheel carrier torque ftlb.)
No. 2: Screw M12 x 1.5 thread Tightening 15 Nm (11

plug for rear torque ftlb.)
brake disc

holder to torque
rear-axle brake
calliper

carrier to rear torque
wheel carrier

removal)
No. 8: Cable Tightening 8 Nm (6 ftlb.)

holder to control torque
arm

rear-axle wheel
carrier
No. 1: Pedals M8 x 20 thread Tightening 23 Nm (17 +/-3 Nm (+/- 2

(pedal bearing torque ftlb.) ftlb.)
block) to
assembly plate
No. 2: Tightening 10 Nm (7.5 +/-1.5 Nm

Accelerator pedal torque ftlb.) (+/-1.0 ftlb.)
to pedal block
No. 3: Clutch Thread Tightening 15 Nm (11 +/-1 Nm (+/- 0.5
to pedal block
Cold air bulkhead Tightening 8 Nm (6 ftlb.) +/-1.5 Nm (+/-1

torque ftlb.)
No. 1: Clutch M8 x 25 thread Tightening 23 Nm (17 +/-2 Nm (+/- 1.5

slave cylinder to torque ftlb.) ftlb.)
transmission
No. 2: Ventilation Thread Tightening 6 Nm (4.5 +/-1 Nm (+/- 0.5

valve to clutch torque ftlb.) ftlb.)
slave cylinder

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > TIGHTENING
TORQUES FOR FRONT AXLE

front axle

front-axle wheel
carrier

front-axle wheel
carrier

removal)

piece

Fig 1: Overview Of Front Brake System

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > TIGHTENING
TORQUES FOR REAR AXLE
Tightening torques for rear axle
No. 1: Actuator Tightening 20 Nm (15 +60° (+44 ftlb.)

to wheel carrier torque ftlb.)

brake disc

line holder to torque
rear-axle brake
calliper

wheel carrier
No. 7: M12 x 1.5 thread Tightening 15 Nm (11

Fastening screw (always replace torque ftlb.)
securing brake screws and lock
disc to wheel nuts after
hub removal)

arm

rear-axle wheel
carrier
Fig 1: Overview Of Rear Brake System

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > PEDALS
(ACCELERATOR PEDAL/CLUTCH MASTER CYLINDER/CLUTCH SLAVE CYLINDER) >
PEDALS/ACCELERATOR PEDAL/CLUTCH MASTER CYLINDER
Brake booster/brake master cylinder in Tightening torques for brake hydraulics!

block) to
assembly plate
No. 2: Tightening 10 Nm (7.5 +/-1.5 Nm (+/-
Accelerator torque ftlb.) 1.0 ftlb.)
pedal to pedal
block

to pedal block
Cold air Tightening 8 Nm (6 ftlb.) +/-1.5 Nm (+/- 1

bulkhead torque ftlb.)
Fig 1: Overview Of Pedals

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > PEDALS
CLUTCH SLAVE CYLINDER

transmission

slave cylinder
Fig 1: Identifying Clutch Slave Cylinder
WM 4X00IN TIGHTENING TORQUES FOR BRAKE HYDRAULIC SYSTEM (CAYENNE,


wheel carrier

wheel carrier and
PCCB


carrier


calliper

piece



to brake booster

booster to pedals torque ftlb.) ftlb.)

master cylinder

hose, distributor,
brake calliper

CALLIPER/BRAKE LINES/VACUUM PUMP

wheel carrier
wheel carrier and
PCCB


carrier


calliper

piece



MASTER CYLINDER/BRAKE BOOSTER

to brake booster

pedals

master cylinder

hose, distributor,
brake calliper
Fig 1: Overview Of Brake Booster/Brake Master Cylinder With Reservoir
WM 4X00IN TIGHTENING TORQUES FOR BRAKE MECHANISM (CAYENNE, CAYENNE


front axle

front-axle wheel
carrier

front-axle wheel
carrier
removal)

piece

No. 1: Actuator to Tightening 20 Nm (15 +60° (+44 ftlb.)

wheel carrier torque ftlb.)

brake disc

holder to torque
rear-axle brake
calliper

wheel carrier

removal)

arm

rear-axle wheel
carrier

block) to
assembly plate
No. 2: Tightening 10 Nm (7.5 +/-1.5 Nm

Accelerator pedal torque ftlb.) (+/-1.0 ftlb.)
to pedal block

to pedal block
Cold air bulkhead Tightening 8 Nm (6 ftlb.) +/-1.5 Nm (+/-1
torque ftlb.)

transmission

slave cylinder

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > TIGHTENING
TORQUES FOR FRONT AXLE

front axle

front-axle wheel
carrier

front-axle wheel
carrier

removal)

piece


CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > TIGHTENING
TORQUES FOR REAR AXLE
Tightening torques for rear axle
No. 1: Actuator Tightening 20 Nm (15 +60° (+44 ftlb.)

to wheel carrier torque ftlb.)

brake disc

line holder to torque
rear-axle brake
calliper

wheel carrier
No. 7: M12 x 1.5 thread Tightening 15 Nm (11

Fastening screw (always replace torque ftlb.)
securing brake screws and lock
disc to wheel nuts after
hub removal)

arm

rear-axle wheel
carrier
Fig 1: Overview Of Rear Brake System

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > PEDALS
PEDALS/ACCELERATOR PEDAL/CLUTCH MASTER CYLINDER
Brake booster/brake master cylinder in Tightening torques for brake hydraulics!

block) to
assembly plate
No. 2: Tightening 10 Nm (7.5 +/-1.5 Nm (+/-

Accelerator torque ftlb.) 1.0 ftlb.)
pedal to pedal
block

to pedal block
Cold air Tightening 8 Nm (6 ftlb.) +/-1.5 Nm (+/- 1

bulkhead torque ftlb.)
Fig 1: Overview Of Pedals

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > PEDALS
CLUTCH SLAVE CYLINDER

transmission
slave cylinder
Fig 1: Identifying Clutch Slave Cylinder
WM 4X00IN TIGHTENING TORQUES FOR FRONT AXLE (CAYENNE, CAYENNE GTS,

No. 1: Threaded M14 x 1.5 x 150 Tightening 120 Nm (89 +180°

connection securing thread (always torque ftlb.)
suspension subframe replace screws
to body (front) and lock nuts
after removal)

suspension subframe replace screws
to body (rear) and lock nuts
after removal)
No. 1: Threaded M14 x 1.5 thread Tightening 150 Nm (111 +90°

connection securing (always replace torque ftlb.)
trailing arm to screws and lock
suspension subframe nuts after
removal)
No. 2: Threaded M10 x 70 thread Tightening 50 Nm (37 +180°
upper trailing arm to screws and lock
body nuts after
removal)
No. 3: Threaded M5 x 10 thread Tightening 9 Nm (6.5

connection securing torque ftlb.)
HBA system on
vehicles with steel
springs

level regulator on
vehicles with springs
No. 4: Threaded M14 x 1.5 thread Tightening 170 Nm (126

lower trailing arm to
suspension subframe

upper trailing arm to screws and lock
pivot bearing nuts after
removal)

lower trailing arm to screws and lock
removal)
No. 1: Threaded M6 x 16 thread Tightening 8 Nm (6 ftlb.)

connection securing torque
speed sensor to
wheel carrier

brake cover plate to
wheel carrier
No. 3: Threaded M14 x 1.5 x 115 Tightening 140 Nm (104

brake calliper to replace screws
wheel carrier and lock nuts
after removal)

wheel carrier 19" and and lock nuts
PCCB after removal)
brake hose bracket
to wheel carrier

cable holder to wheel
carrier

brake disc to wheel
hub
Wheel bearing to M12 x 1.25 Tightening 80 Nm (59 +120°

wheel carrier thread (always torque ftlb.)
replace screws
and lock nuts
after removal)

spring strut to trailing
arm
No. 2: Threaded M12 x 1.5 thread Tightening 60 Nm (44 +/-5 Nm (+/-3.5

connection securing torque ftlb.) ftlb.)
spring-strut mount to
piston rod
No. 2: Threaded M12 x 1.5 thread Tightening 70 Nm (52 +/-5 Nm (+/-3.5

connection securing torque ftlb.) ftlb.)
spring-strut mount to
piston rod (PASM
damper)
No. 3: Threaded M10 thread Tightening 60 Nm (44

spring strut to body
Threaded connection Tightening 10 Nm (7.5

securing air-guide torque ftlb.)
element to spring
strut

anti-roll bar to
suspension subframe
No. 2: Threaded M12 x 1.5 thread Tightening 110 Nm (81.5

anti-roll bar to
suspension/stabilizer
(connecting link)
Threaded connection Tightening 12 Nm (9
securing anti-roll bar torque ftlb.)
to anti-roll-bar mount
(hose clamp)

(connecting link) to
spring strut
No. 1: Threaded M10 thread Tightening 50 Nm (37 +90°

drive shaft to front
axle transmission
flange

drive shaft to front
axle transmission
flange

drive shaft to wheel screws and lock
hub nuts after
removal); grease
friction surface
of the nut with
aluminum paste
(do not put
grease on the
thread)

differential to replace screws
suspension subframe and lock nuts
after removal)
Threaded connection M14 x 1.5 x 49 Tightening 180 Nm (133

securing wheel to thread (do not torque ftlb.)
wheel hub grease screw)
Threaded connection M5 thread Tightening 4 Nm (3 ftlb.) +/-0.5 Nm

securing TPM valve (always replace torque (+/-0.5 ftlb.)
to wheel screws and lock
nuts after
removal);
counter at the
valve body,
make sure it
does not turn!
Threaded connection (Replace screws Tightening 4 Nm (3 ftlb.) +/-0.5 Nm
securing wheel and lock nuts torque (+/-0.5 ftlb.)
electronics to TPM after removal)
valve

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > SUSPENSION
SUBFRAME

securing replace screws
suspension and lock nuts
subframe to after removal)
body (front)

suspension and lock nuts
subframe to after removal)
body (rear)
Fig 1: Example Of Front Axle Suspension Subframe

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > TRAILING ARM

connection (always replace torque ftlb.)
securing trailing screws and lock
arm to nuts after
suspension removal)
subframe

securing upper screws and lock
trailing arm to nuts after
body removal)

securing HBA
system on
vehicles with
steel springs

securing level
regulator on
vehicles with
springs

securing lower
trailing arm to
suspension
subframe

securing upper screws and lock
pivot bearing removal)

securing lower screws and lock
pivot bearing removal)
Fig 1: Overview Of Steel Spring Strut 2
Fig 2: Overview Of Air-Spring Strut 1

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > WHEEL CARRIER
(PIVOT BEARING)

connection torque
securing speed
sensor to wheel
carrier

connection torque
securing brake
cover plate to
wheel carrier

calliper to wheel and lock nuts
carrier after removal)

carrier 19" and after removal)
PCCB

connection torque
securing brake
hose bracket to
wheel carrier

securing cable
holder to wheel
carrier

securing brake
disc to wheel
hub
Wheel bearing M12 x 1.25 Tightening 80 Nm (59 +120°

to wheel carrier thread (always torque ftlb.)
replace screws
and lock nuts
after removal)

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > SPRING STRUT

securing spring
strut to trailing
arm
No. 2: Threaded M12 x 1.5 thread Tightening 60 Nm (44 +/-5 Nm (+/- 3.5
connection torque ftlb.) ftlb.)
securing
spring-strut
mount to piston
rod
No. 2: Threaded M12 x 1.5 thread Tightening 70 Nm (52 +/-5 Nm (+/- 3.5
connection torque ftlb.) ftlb.)
securing
spring-strut
mount to piston
rod (PASM
damper)
No. 3: Threaded M10 thread Tightening 60 Nm (44
securing spring
strut to body
Threaded Tightening 10 Nm (7.5

securing
air-guide
element to
spring strut
Fig 1: Overview Of Steel Spring Strut - Shown Without PASM

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > ANTI-ROLL
BAR/SUSPENSION/STABILIZER

anti-roll bar to
suspension subframe

anti-roll bar to
(connecting link)
Threaded connection Tightening 12 Nm (9

securing anti-roll bar torque ftlb.)
to anti-roll-bar mount
(hose clamp)

spring strut
Fig 1: Overview Of Anti-Roll Bar

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > DRIVE SHAFT

securing drive
shaft to front axle
transmission
flange
securing drive
shaft to front axle
transmission
flange

securing drive screws and lock
shaft to wheel nuts after
hub removal); grease
friction surface of
the nut with
aluminum paste
(do not put
grease on the
thread)
Fig 1: Identifying Drive Shaft

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > DIFFERENTIAL

differential to and lock nuts
suspension after removal)
subframe
Fig 1: Identifying Front Axle Differential

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > WHEEL

connection thread (do not torque ftlb.)
securing wheel grease screw)
to wheel hub
Threaded M5 thread Tightening 4 Nm (3 ftlb.) +/-0.5 Nm

connection (always replace torque (+/-0.5 ftlb.)
securing TPM screws and lock
valve to wheel nuts after
removal); counter
at the valve body,
make sure it
does not turn!
Threaded (Replace screws Tightening 4 Nm (3 ftlb.) +/-0.5 Nm
connection and lock nuts torque (+/-0.5 ftlb.)
securing wheel after removal)
electronics to
TPM valve
WM 4X00IN TIGHTENING TORQUES FOR LEVELLING SYSTEM/PORSCHE DYNAMIC

CHASSIS CONTROL (PDCC) (CAYENNE, CAYENNE GTS, CAYENNE TURBO S,
No. 1: Line to valve Tightening 28 Nm (21

block torque ftlb.)

block torque ftlb.)

block torque ftlb.)

block torque ftlb.)
No. 5: Valve block to M6 thread Tightening 10 Nm (7.5

wheel housing torque ftlb.)
Reservoir mounting M6 thread Tightening 10 Nm (7.5

torque ftlb.)
No. 1/2: Cap screws M14 x 1.5 Tightening 28 Nm (21 +/-4 Nm (+/- 3
on flow distributor thread; items 1 torque ftlb.) ftlb.)
(fluid flow) and 2
No. 3: Banjo bolt on M14 x 1.5 Tightening 20 Nm (15 +4°

flow distributor (fluid thread; item 3 torque ftlb.)
flow)
No. 4: Flow M6 x 16 thread Tightening 10 Nm (7.5

distributor (fluid flow) torque ftlb.)
to front-axle
transmission
Cap screws M14 x 1.5/M16 x Tightening 28 Nm (21 +/-4 Nm (+/- 3

1.5 with rim torque ftlb.) ftlb.)
Cap screws M16/M18 with Tightening 32 Nm (24 +/-5 Nm (+/- 3.5

O-ring torque ftlb.) ftlb.)
Banjo bolts M14 Tightening 35 Nm (26 +/-5 Nm (+/- 3.5


No. 1: Threaded Tightening 12 Nm (9
anti-roll bar to
anti-roll-bar mount
(hose clamp)

spring strut

anti-roll bar to
(connecting link)
No. 4: Cap screws M14/M16 thread Tightening 28 Nm (21

torque ftlb.)
No. 5: Cap screws M14 x 1.5/M16 x Tightening 28 Nm (21 +/-4 Nm (+/- 3


anti-roll bar to
chassis subframe

anti-roll bar to
rear-axle chassis
subframe
No. 2/3: Threaded M12 x 1.5 thread Tightening 90 Nm (67 +90 angular
connection securing (always replace torque ftlb.) degrees
suspension/stabilizer screws and lock
to wheel nuts after
carrier/shock removal)
absorber strut
No. 4: Rear-axle M8 x 25 thread Tightening 23 Nm (17

valve block to torque ftlb.)
chassis subframe
Cover to rear-axle M6 thread Tightening 10 Nm (7.5

valve block torque ftlb.)
No. 5: Cap screws on M14/M16 thread Tightening 28 Nm (21


anti-roll bar torque ftlb.)

anti-roll bar to screws and lock
suspension/stabilizer nuts after
removal)

CAYENNE (3.0)) > TECHNICAL VALUES > PORSCHE DYNAMIC CHASSIS CONTROL
(PDCC) > VALVE BLOCK ON FRONT AXLE/RESERVOIR
No. 1: Line to Tightening 28 Nm (21




No. 5: Valve M6 thread Tightening 10 Nm (7.5

block to wheel torque ftlb.)
housing
Reservoir M6 thread Tightening 10 Nm (7.5

mounting torque ftlb.)
Fig 1: Identifying Front-Axle Valve Block With PDCC Lines

(PDCC) > FLOW DISTRIBUTOR ON FRONT AXLE/LINES
No. 1/2: Cap M14 x 1.5 thread; Tightening 28 Nm (21 +/-4 Nm (+/- 3
screws on flow items 1 and 2 torque ftlb.) ftlb.)
distributor (fluid
flow)
No. 3: Banjo bolt M14 x 1.5 thread; Tightening 20 Nm (15 +4°

on flow item 3 torque ftlb.)
distributor (fluid
flow)
No. 4: Flow M6 x 16 thread Tightening 10 Nm (7.5

distributor (fluid torque ftlb.)
flow) to front-axle
transmission
Cap screws M14 x 1.5/M16 x Tightening 28 Nm (21 +/-4 Nm (+/- 3

Cap screws M16/M18 with Tightening 32 Nm (24 +/-5 Nm (+/- 3.5
O-ring torque ftlb.) ftlb.)


Fig 1: Identifying PDCC Distributor With Lines

(PDCC) > FRONT-AXLE ANTI-ROLL BAR/SUSPENSION/STABILIZER
No. 1: Threaded Tightening 12 Nm (9

anti-roll bar to
anti-roll-bar mount
(hose clamp)

spring strut

anti-roll bar to
(connecting link)
No. 4: Cap screws M14/M16 thread Tightening 28 Nm (21

torque ftlb.)
No. 5: Cap screws M14 x 1.5/M16 x Tightening 28 Nm (21 +/-4 Nm (+/- 3


anti-roll bar to
chassis subframe
Fig 1: Overview Of Anti-Roll Bar/Suspension/Stabilizer

(PDCC) > REAR-AXLE ANTI-ROLL BAR/SUSPENSION/STABILIZER

anti-roll bar to
rear-axle chassis
subframe
No. 2/3: Threaded M12 x 1.5 thread Tightening 90 Nm (67 +90 angular
to wheel nuts after
absorber strut
No. 4: Rear-axle M8 x 25 thread Tightening 23 Nm (17

valve block to torque ftlb.)
chassis subframe
Cover to rear-axle M6 thread Tightening 10 Nm (7.5



anti-roll bar torque ftlb.)

removal)
Fig 1: Overview Of PDCC Anti-Roll Bar On Rear Axle With Connecting Link
WM 4X00IN TIGHTENING TORQUES FOR REAR AXLE (CAYENNE, CAYENNE GTS,

No. 1: Threaded M14 x 1.5 x 150 Tightening 120 Nm (89 +180 angular
connection securing thread (always torque ftlb.) degrees
chassis subframe to replace screws
body (front) and lock nuts
after removal)
chassis subframe to replace screws
body (rear) and lock nuts
after removal)
No 1.: Threaded M12 x 1.5 x 120 Tightening 90 Nm (67 +90 angular

lower trailing arm to replace screws
rear wheel carrier and lock nuts
(spring strut + after removal)
connecting link)
front upper trailing replace screws
arm to wheel carrier and lock nuts
after removal)
rear upper trailing replace screws
arm to wheel carrier and lock nuts
after removal)

front upper trailing replace screws
arm to chassis and lock nuts
subframe after removal)

rear upper trailing replace screws
arm to chassis and lock nuts
subframe after removal)
after removal)
chassis subframe and lock nuts
(front) after removal)

lower trailing arm to screws and lock
chassis subframe nuts after
(rear) removal)
No. 9: Threaded M6 thread Tightening 8 Nm (6 ftlb.)

front upper level
regulator

front upper HBA on
vehicles with steel
springs

holder to chassis
subframe (HBA on
vehicles with steel
springs)

holder to chassis
subframe (level
regulator)

tie rod to chassis screws and lock
subframe nuts after
removal)
No. 3: Threaded M16 x 1.5 thread Tightening 150 Nm (111 +90 angular
tie rod to wheel screws and lock
carrier nuts after
removal)
No. 1: Threaded M10 thread, Tightening 50 Nm (37 +180°

connection securing observe torque ftlb.)
spring strut to tightening
damper housing sequence! First
tighten the bolts
on the inside of
the vehicle

suspension/stabilizer replace screws
to wheel and lock nuts
carrier/shock after removal)
absorber strut
No. 3: Supporting Tightening 60 Nm (44 +/-5 Nm (+/- 3.5

mount to piston rod torque ftlb.) ftlb.)

(PASM damper)
Cover on concave M8 thread Pressing force +26 Nm (+19 +/-1 Nm (+/- 0.5
support ftlb.) ftlb.)

anti-roll bar to
rear-axle chassis
subframe

removal)
Threaded connection M12 x 1.5 thread Tightening 90 Nm (67 +90 angular
securing (always replace torque ftlb.) degrees
to wheel nuts after
absorber strut
No. 1: Threaded This is done Tightening 130 Nm (96

connection securing before installing torque ftlb.)
drive shaft to wheel the wheel
hub (1st step) bearing
housing/M24 x
1.5
thread/always
replace lock nut
following removal
No. 1: Threaded This is done with Tightening 460 Nm (340

connection securing the wheel torque ftlb.)
drive shaft to wheel bearing housing
hub (2nd step) fitted/M24 x 1.5
thread/always
replace lock nut
following removal

EPB servo motor to
wheel carrier

brake disc to wheel
hub

after removal)

brake line holder to
brake calliper

speed sensor to
wheel carrier

brake carrier to
wheel carrier
connection for screw torque ftlb.)
plug
No. 8: Threaded M6 thread Tightening 10 Nm (7.5

ABS cable holder to
front upper control
arm
No. 9: Wheel bearing M12 x 1.25 Tightening 80 Nm (59 +120°

to wheel carrier thread (always torque ftlb.)
replace screws
and lock nuts
after removal)

differential to chassis screws and lock
subframe nuts after
removal)

differential to chassis screws and lock
subframe nuts after
removal)
Threaded connection M14 x 1.5 x 49 Tightening 180 Nm (133

securing wheel to thread (do not torque ftlb.)
wheel hub grease screws)
Threaded connection M5 thread Tightening 4 Nm (3 ftlb.) +/-0.5 Nm (+/-

securing TPM valve (always replace torque 0.5 ftlb.)
to wheel screws and lock
nuts after
removal); counter
at the valve body,
make sure it
does not turn!
Threaded connection (Replace screws Tightening 4 Nm (3 ftlb.) +/-0.5 Nm (+/-

securing wheel and lock nuts torque 0.5 ftlb.)
electronics to TPM after removal)
valve

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > CHASSIS SUBFRAME
No. 1: Threaded M14 x 1.5 x 150 Tightening 120 Nm (89 +180 Angle
connection thread (always torque ftlb.) degrees
securing chassis replace screws
subframe to and lock nuts
body (front) after removal)
No. 2: Threaded M14 x 1.5 x 150 Tightening 120 Nm (89 +180 Angle
securing chassis replace screws
subframe to and lock nuts
body (rear) after removal)
Fig 1: Identifying Chassis Subframe

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > TRAILING ARM
No 1.: Threaded M12 x 1.5 x 120 Tightening 90 Nm (67 +90 angular

securing lower replace screws
trailing arm to and lock nuts
rear wheel after removal)
carrier (spring
strut +
connecting link)
securing front replace screws
upper trailing and lock nuts
arm to wheel after removal)
carrier
securing rear replace screws
arm to wheel after removal)
carrier

securing front replace screws
arm to chassis after removal)
subframe

securing rear replace screws
arm to chassis after removal)
subframe
wheel carrier after removal)
chassis after removal)
subframe (front)

securing lower screws and lock
chassis removal)
subframe (rear)

connection torque
securing front
upper level
regulator

connection torque
securing front
upper HBA on
vehicles with
steel springs
No. 10: M5 x 10 thread Tightening 5 Nm (3.5 ftlb.)

Threaded torque
connection
securing holder
to chassis
subframe (HBA
on vehicles with
steel springs)
No. 10: M5 x 10 thread Tightening 5 Nm (3.5 ftlb.)

Threaded torque
connection
securing holder
to chassis
subframe (level
regulator)
Fig 1: Overview Of Trailing Arm - Steel Suspension

Fig 2: Overview Of Trailing Arm - Air Suspension

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > TIE ROD

securing tie rod screws and lock
to chassis nuts after
subframe removal)
connection (always replace torque ftlb.) degrees
securing tie rod screws and lock
to wheel carrier nuts after
removal)
Fig 1: Overview Of Trailing Arm - Steel Suspension

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > SPRING STRUT
No. 1: Threaded M10 thread, Tightening 50 Nm (37 +180°

connection securing observe torque ftlb.)
spring strut to tightening
damper housing sequence! First
tighten the bolts
on the inside of
the vehicle

suspension/stabilizer replace screws
to wheel and lock nuts
carrier/shock after removal)
absorber strut


(PASM damper)
Cover on concave M8 thread Pressing force +26 Nm (+19 +/-1 Nm (+/- 0.5
support ftlb.) ftlb.)
Fig 1: Overview Of Steel Spring Strut
Fig 2: Overview Of Air-Spring Strut

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > ANTI-ROLL
BAR/SUSPENSION/STABILIZER

anti-roll bar to
rear-axle chassis
subframe

removal)
Threaded connection M12 x 1.5 thread Tightening 90 Nm (67 +90 angular

securing (always replace torque ftlb.) degrees
to wheel nuts after
absorber strut
Fig 1: Overview Of Anti-Roll Bar

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > DRIVE SHAFT
No. 1: Threaded This is done Tightening 130 Nm (96

connection before installing torque ftlb.)
securing drive the wheel bearing
shaft to wheel housing/M24 x
hub (1st step) 1.5 thread/always
replace lock nut
following removal
No. 1: Threaded This is done with Tightening 460 Nm (340

connection the wheel bearing torque ftlb.)
securing drive housing
shaft to wheel fitted/M24 x 1.5
hub (2nd step) thread/always
replace lock nut
following removal
Fig 1: Identifying Drive Shaft

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > WHEEL CARRIER

securing EPB
servo motor to
wheel carrier

securing brake
disc to wheel
hub

carrier after removal)

connection torque
securing brake
line holder to
brake calliper

connection torque
securing speed
sensor to wheel
carrier

connection torque
securing brake
carrier to wheel
carrier

connection for torque ftlb.)
screw plug
No. 8: Threaded M6 thread Tightening 10 Nm (7.5

securing ABS
cable holder to
front upper
control arm
No. 9: Wheel M12 x 1.25 Tightening 80 Nm (59 +120°

bearing to wheel thread (always torque ftlb.)
carrier replace screws
and lock nuts
after removal)
Fig 1: Overview Of Wheel Carrier

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > DIFFERENTIAL

securing screws and lock
differential to nuts after
chassis removal)
subframe

securing screws and lock
differential to nuts after
chassis removal)
subframe
Fig 1: Identifying Differential

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > WHEEL

connection thread (do not torque ftlb.)
securing wheel grease screws)
to wheel hub
Threaded M5 thread Tightening 4 Nm (3 ftlb.) +/-0.5 Nm

connection (always replace torque (+/-0.5 ftlb.)
securing TPM screws and lock
valve to wheel nuts after
removal); counter
at the valve body,
make sure it
does not turn!
Threaded (Replace screws Tightening 4 Nm (3 ftlb.) +/-0.5 Nm

connection and lock nuts torque (+/-0.5 ftlb.)
securing wheel after removal)
electronics to
TPM valve
WM 4X00IN TIGHTENING TORQUES FOR STEERING (CAYENNE, CAYENNE GTS,


securing steering screws and lock
gear to suspension nuts after
subframe removal)

securing tie rod to screws and lock
removal)
No. 3: Threaded M16 x 1.5 thread, Tightening 90 Nm (67

connection lock nut torque ftlb.)
securing tie rod to
tie-rod end

connection for heat torque ftlb.)
shield
No. 5: Threaded M18 x 1.5 thread, Tightening 100 Nm (74 +10°

connection axial joint torque ftlb.)
securing axial joint
to steering rack
No. 6: Expansion a/f 17 thread (a/f Tightening 32 Nm (24 +/-4 Nm (+/-3

hose to steering = wrench size 17) torque ftlb.) ftlb.)
gear
No. 7: Return line a/f 17 thread (a/f Tightening 32 Nm (24 +/-4 Nm (+/-3
to steering gear = wrench size 17) torque ftlb.) ftlb.)
Expansion/return M6 x 12 thread Tightening 9 Nm (6.5

hose to steering torque ftlb.)
gear
No. 8: Heat shield M6 x 16 thread Tightening 10 Nm (7.5

to steering gear torque ftlb.)

connection thread (only use torque + torque ftlb.)
securing steering screw once) angle
wheel to steering
column
No. 3: Threaded M8 x 32 thread; Tightening 20 Nm (15

connection observe torque ftlb.)
securing steering tightening
column to sequence!
assembly bracket Tighten
anti-clockwise
from 1 to 4,
starting with the
rear right
fastening screw.

connection screw frequency torque ftlb.)
securing steering strut to mounting
column to bracket after
frequency strut screwing on
steering column!
No. 5: Threaded Tightening 4 Nm (3 ftlb.)

connection torque
securing mount for
sealing ring/seal to
firewall

connection (only use screw torque ftlb.)
securing universal once)
joint to steering
gear
Contact bridge to Tightening 6 Nm (4.5

steering wheel torque ftlb.)
skeleton
Multi-functional Tightening 0.45 Nm

switch and front torque (0.25 ftlb.)
trim to main cover
Steering wheel Tightening 2 Nm (1.5

skeleton to main torque ftlb.)
cover
Paddles to steering Tightening 2.5 Nm (2

wheel skeleton torque ftlb.)
Back cover to Tightening 2.7 Nm (2

steering wheel torque ftlb.)
skeleton
No. 1: Hydraulic M8 x 35 thread Tightening 23 Nm (17

pump to engine torque ftlb.)
(support)
No. 2: Pulley to M8 x 16 thread Tightening 23 Nm (17

hydraulic pump torque ftlb.)
Intake pipe to M6 x 12 thread Tightening 10 Nm (7.5

Expansion hose to Tightening 32 Nm (24 +/-4 Nm (+/-3

hydraulic pump torque ftlb.) ftlb.)
Reservoir Tightening 10 Nm (7.5
torque ftlb.)
No. 2: Hydraulic Tightening 23 Nm (17

(support)
No. 3: Pulley to Tightening 23 Nm (17

Suction hose to Spring band Tightening

hydraulic pump clamp torque
Expansion hose to M6 Tightening 10 Nm (7.5 +/-1 Nm (+/-0.5


torque ftlb.)

(support)




torque ftlb.)

(support)




torque ftlb.)

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > STEERING 1

securing steering screws and lock
gear to suspension nuts after
subframe removal)

securing tie rod to screws and lock
removal)
No. 3: Threaded M16 x 1.5 Tightening 90 Nm (67

connection thread, lock nut torque ftlb.)
securing tie rod to
tie-rod end

connection for heat torque ftlb.)
shield
No. 5: Threaded M18 x 1.5 Tightening 100 Nm (74 +10°

connection thread, axial joint torque ftlb.)
securing axial joint
to steering rack
No. 6: Expansion a/f 17 thread (a/f Tightening 32 Nm (24 +/-4 Nm (+/- 3

hose to steering = wrench size torque ftlb.) ftlb.)
gear 17)
No. 7: Return line a/f 17 thread (a/f Tightening 32 Nm (24 +/-4 Nm (+/- 3
to steering gear = wrench size torque ftlb.) ftlb.)
17)
Expansion/return M6 x 12 thread Tightening 9 Nm (6.5

hose to steering torque ftlb.)
gear
No. 8: Heat shield M6 x 16 thread Tightening 10 Nm (7.5

to steering gear torque ftlb.)
Fig 1: Overview Of Steering Gear

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > STEERING WIRING 1

connection thread (only use torque + torque ftlb.)
securing screw once) angle
steering wheel
to steering
column

connection observe torque ftlb.)
securing tightening
steering column sequence!
to assembly Tighten
bracket anti-clockwise
from 1 to 4,
starting with the
rear right
fastening screw.

connection screw frequency torque ftlb.)
securing strut to mounting
steering column bracket after
to frequency screwing on
strut steering column!
No. 5: Threaded Tightening 4 Nm (3 ftlb.)

connection torque
securing mount
for sealing
ring/seal to
firewall

connection (only use screw torque ftlb.)
securing once)
universal joint to
steering gear
Fig 1: Overview Of Steering Column 1

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > STEERING WHEEL
Contact bridge Tightening 6 Nm (4.5 ftlb.)

to steering torque
wheel skeleton
Multi-functional Tightening 0.45 Nm (0.25

switch and front torque ftlb.)
trim to main
cover
Steering wheel Tightening 2 Nm (1.5 ftlb.)

skeleton to main torque
cover
Paddles to Tightening 2.5 Nm (2 ftlb.)

steering wheel torque
skeleton
Back cover to Tightening 2.7 Nm (2 ftlb.)

steering wheel torque
skeleton

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > HYDRAULIC PUMP
V8 4.8 DFI
No. 1: Hydraulic M8 x 35 thread Tightening 23 Nm (17

(support)
No. 2: Pulley to M8 x 16 thread Tightening 23 Nm (17

Intake pipe to M6 x 12 thread Tightening 10 Nm (7.5

Expansion hose Tightening 32 Nm (24 +/-4 Nm (+/- 3

to hydraulic torque ftlb.) ftlb.)
pump

torque ftlb.)
Fig 1: Overview Of Hydraulic Pump V8

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > HYDRAULIC PUMP
V6 3.0 TFSI

(support)


Expansion hose M6 Tightening 10 Nm (7.5 +/-1 Nm (+/- 0.5

pump

torque ftlb.)
Fig 1: Overview Of Hydraulic Pump V6 TFSI

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > POWER-STEERING
PUMP V6 3.0 DIESEL

(support)



pump

torque ftlb.)
Fig 1: Overview Of Hydraulic Pump - Diesel

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > CAYENNE V6 3.6 DFI

(support)


pump

torque ftlb.)
Fig 1: Overview Of Hydraulic Pump V6
WM 4X00IN WHEEL RIM PAINT COLORS (CAYENNE, CAYENNE GTS, CAYENNE

DIESEL, CAYENNE (3.0)) > WHEEL RIM PAINT COLORS
18-inch Cayenne
Fig 1: Identifying Wheel Rim Cayenne (18-Inch)
8Z8 Brilliant Silver C1J
18-inch Cayenne S III

Fig 2: Identifying Wheel Rim Cayenne S (18-Inch)
8Z8 Brilliant Silver C1Q
19-inch Cayenne Turbo

Fig 3: Identifying Wheel Rim Cayenne Turbo (19-Inch)
88Z Brilliant Chrome C8K
19-inch Cayenne Design II

Fig 4: Identifying Wheel Rim Cayenne Design (19-Inch)
88Z Brilliant Chrome F09
20-inch Cayenne Sport Design II

Fig 5: Identifying Wheel Rim Cayenne Sport Design (20-Inch)
88Z Brilliant Chrome CN7
20-inch RS Spyder Design

Fig 6: Identifying Wheel Rim RS Spyder Design (20-Inch)
EP8 Decorative Silver/Titanium CP5
21-inch 911 Turbo II

Fig 7: Identifying Wheel Rim 911 Turbo (21-Inch)
OC6 Dark Titanium CZ4
21-inch Cayenne Sport Edition

Fig 8: Identifying Wheel Rim Cayenne Sport Edition (21-Inch)
M7Z GT Silver Metallic CK0
Painted wheel Wheel painted in CNE

custom colour
Painted wheel Wheel painted High-gloss CQ1

Black
21-inch Turbo
Fig 9: Identifying Wheel Rim Turbo Design (21-Inch)
OC6 Dark Titanium High-gloss turned and C7T

polished finish
Service Manual: 27 - STARTER, POWER SUPPLY, CRUISE CONTROL -- 92A CAYENNE
WM 270419 REMOVING AND INSTALLING VOLTAGE CONVERTER FOR START/STOP
(ALL MODELS) > TOOLS

(ALL MODELS) > PRELIMINARY WORK
1. If a new control unit has to be installed, the values/coding must be read out using PIWIS
Tester II 9818 prior to removing the "old" control unit. → 270455 REPLACING VOLTAGE
CONVERTER FOR START/STOP .

COMPARTMENT

(ALL MODELS) > REMOVING VOLTAGE CONVERTER FOR START/STOP
Information

Fig 1: Identifying Voltage Converter For Start/Stop Installation Position
NOTE: Voltage peaks
1. Unscrew and remove fastening screw -1- and fastening nut -2- from the bracket for the
voltage converter.
Fig 2: Removing Voltage Converter From Bracket
2. Remove bracket with voltage converter from the dashboard bracket.
3. Release electric plug connection -3- (-a- ) and unplug it from the voltage converter.
Fig 3: Identifying Start/Stop Voltage Converter Connector

(ALL MODELS) > INSTALLING VOLTAGE CONVERTER FOR START/STOP
Information
1. Plug electric plug connection -3- into the voltage converter and lock it -a- .
2. Position bracket with voltage converter on the dashboard bracket.
3. Secure voltage converter for Start/Stop to the dashboard bracket using the fastening screw -1-
and fastening nut -2- .
Fig 2: Installing Bracket Fasteners

(ALL MODELS) > SUBSEQUENT WORK

COMPARTMENT
PIWIS Tester II 9818 . → 270455 REPLACING VOLTAGE CONVERTER FOR START/STOP .
WM 270455 REPLACING VOLTAGE TRANSFORMER FOR START/STOP (ALL

MODELS) > TOOLS


MODELS) > TECHNICAL VALUES

MODELS) > READING AND WRITING VALUES
NOTE: Voltage drop
battery.
Information
Tester releases.
3. Select the Gateway control unit in the overview and press [F12] to continue.
4. Select the DC/DC converter control unit.
9. Check the chassis number.
VOLTAGE CONVERTER FOR START/STOP .
11. Switch on ignition, select Maintenance/repairs , Control unit replacement , Write data and
press [F12] to continue. Then press [F8] to start.
The data that was read out is loaded.
12. The System Tester displays the message: Data has been written , press [F12] to continue.
WM 270519 REMOVING AND INSTALLING BATTERY SENSOR (ALL MODELS) >

TECHNICAL VALUES
Tolerance Tolerance
1 2
Terminal clamp to battery Tightening 6 Nm (4.5 ft.

terminal Torque lb.)
Ground line for battery to Tightening 20 Nm (15 ft.

body Torque lb.)

PRELIMINARY WORK
1. Remove battery cover. → ________271219 Removing and installing battery cover

REMOVING BATTERY SENSOR
NOTE: Using charging cables/jump leads directly on the vehicle battery.
Risk of damage to battery sensors.
→ Always connect charging cables/jump leads to the external power supply for jump-lead starting.
Information
Switch off all loads and remove the ignition key.
Do not disconnect the battery while the engine is running .
Disconnect and reconnect battery with extreme caution .
Do not rub the battery with a dry cloth .
Information
The battery sensor and battery ground strap form one unit and can only be replaced together.
2. Release electric plug connection on the battery sensor and disconnect it -arrow- .
Fig 1: Disconnecting Battery Sensor Connector
3. Disconnect ground line for battery. → 270619 REMOVING AND INSTALLING BATTERY
4. Open the service flap in the driver's footwell.
5. Unscrew fastening nut -1- and guide battery sensor with ground line -2- through the opening
-arrow- in the battery box.
6. Remove battery sensor with ground line -2- .
Fig 2: Locating Battery Sensor With Ground Line

INSTALLING BATTERY SENSOR
Information
After replacing the battery sensor, the battery sensor will be detected automatically by the gateway
control unit.
2. Tighten fastening nut securing ground line to the body. Tightening Torque 20 Nm (15 ft. lb.)
3. Tighten terminal clamp on ground line. Tightening Torque 6 Nm (4.5 ft. lb.)
4. Check that the rubber sleeve is seated correctly in the opening of the battery box.

SUBSEQUENT WORK
1. Install battery cover. → 271219 REMOVING AND INSTALLING BATTERY COVER
2. Follow work instructions after disconnecting the battery. → 2X00IN WORK INSTRUCTIONS
AFTER DISCONNECTING THE BATTERY
WM 270619 REMOVING AND INSTALLING BATTERY (ALL MODELS) > TECHNICAL

VALUES

value 1 2
Tightening 6 Nm (4.5
Terminal clamp to battery terminal
Torque ft. lb.)
Fastening screw securing battery in Tightening 23 Nm (17

battery housing Torque ft. lb.)
Fastening screw securing retaining Tightening 8 Nm (6 ft.

bracket to battery housing Torque lb.)
WM 270619 REMOVING AND INSTALLING BATTERY (ALL MODELS) > PRELIMINARY

WORK
1. Remove battery cover. → 271219 REMOVING AND INSTALLING BATTERY COVER
WM 270619 REMOVING AND INSTALLING BATTERY (ALL MODELS) > REMOVING

BATTERY
necessary.
WARNING: Static battery charge
Battery can explode
Electrical discharges
→ Do not rub the battery with a dry cloth.
Information
The battery is located in the battery box under the left front seat .
The vehicle must be supplied with external power at the jump-lead starting points so that the seat
can be moved even when the battery is fully discharged . → WM 2706IN EXTERNAL POWER
CONNECTION, JUMP-LEAD STARTING (ALL MODELS)
Fig 1: Identifying Battery Installation Position
Information
1. Release and disconnect electric plug connection at the battery sensor.

2. Risk of short circuit! First disconnect the negative cable, then the positive cable.
Fig 3: Disconnecting Cables
3. Unscrew the fastening screw -1- on the sheetmetal bracket and remove the battery mount.
4. Unscrew the screw for the battery mount -2- and remove the battery mount.
5. Pull the vent hose -3- off the battery.

Fig 4: Removing Battery Mount
6. Lift the battery up and out.
WM 270619 REMOVING AND INSTALLING BATTERY (ALL MODELS) > INSTALLING

BATTERY
Danger of injury
Loss of torque
→ Observe specified Tightening Torques.
Information
Make sure that the two ends of the vent hose are routed and inserted correctly .
1. The battery is installed in reverse order to removal.
2. Fit battery mount and secure with the fastening screw. Tightening Torque 23 Nm (17 ft. lb.)
3. Fit sheetmetal bracket and secure with the fastening screw. Tightening Torque 8 Nm (6 ft.
lb.)
4. Risk of short circuit! First connect the positive cable, then the negative cable. Tighten fastening
nuts. Tightening Torque 6 Nm (4.5 ft. lb.)
WM 270619 REMOVING AND INSTALLING BATTERY (ALL MODELS) > SUBSEQUENT

WORK
WM 270655 REPLACING BATTERY (ALL MODELS) > PRELIMINARY WORK
1. Remove and install battery. → 270619 REMOVING AND INSTALLING BATTERY
WM 270655 REPLACING BATTERY (ALL MODELS) > REPLACING AGM BATTERY
Information
The AGM (A bsorbent G lass M at) battery is a Maintenance-Free , Sealed battery.
This battery must not be opened. If the battery is opened, it must be replaced .
There is a Serial Number -A- and a Part Number -B- on the top right-hand side of the battery .
Fig 1: Identifying Serial Number And Part Number On Battery
3. Select the Gateway control unit in the Overview and press [F12] to continue.
4. Maintenance/Repairs must then be selected.
5. Change Battery must now be selected. Then press [F12] to continue.
6. Enter The Serial Number And Part Number and press [F12] to continue.
7. Enter the battery size and manufacturer and press [F12] to continue.
WM 270655 REPLACING BATTERY (ALL MODELS) > SUBSEQUENT WORK
WM 2706IN EXTERNAL POWER CONNECTION, JUMP-LEAD STARTING (ALL
MODELS) > INFORMATION
Information
If the battery is flat, jump leads can be used together with the battery of another vehicle to start the
car or to supply external power to the vehicle .
Both batteries must be 12 V batteries.
The capacity (Ah) of the battery supplying the power must not be significantly lower than that of the flat
battery.
WARNING: Live jump leads
Risk of electric shock
Risk of short circuit
→ Route the jump leads so that they do not become entangled in moving parts in the engine
compartment.
→ There must be no contact between the vehicles.
The flat battery must be properly connected to the vehicle electrical system.
1. Remove cover for jump-lead starting terminal.
2. Open protective cover on the positive terminal for jump-lead starting -+- .
Fig 1: Identifying Jump-Lead Starting Terminals
3. Connect the positive cable to the positive terminal for jump-lead starting -+- , then to the
positive terminal of the donor battery.
4. Connect the negative cable to the negative terminal of the donor battery first, then to the
ground point for jump-lead starting - .
5. Have the engine of the vehicle supplying the power run at a higher speed.
6. Start engine. Do not spend longer than 15 seconds trying to start the vehicle with the jump
leads - after 15 seconds have elapsed, wait for at least one minute.
7. Disconnect the two jump leads in reverse sequence when the engine is running.
8. Close protective cover.
9. Position the cover.
WM 270819 REMOVING AND INSTALLING E-BOX (CAYENNE S E-HYBRID) > TOOLS

Voltage Tester Workshop Equipment WE 1380
High-Voltage Cordon Workshop Equipment WE 1589
Insulated Tool Set Workshop Equipment WE 1593
WM 270819 REMOVING AND INSTALLING E-BOX (CAYENNE S E-HYBRID) >

TECHNICAL VALUES

value 1 2
Tightening 10.1 Nm
E-Box To High-Voltage Battery
Torque (7.5 ft. lb.)
Fastening Screws (M6 X 12) Securing

Tightening 10.1 Nm
Side Cover Plate To High-Voltage
Battery

Tightening 10.1 Nm
Top Cover Plate To High-Voltage
Battery
Fastening screws (M6 x 12) securing Tightening 10.1 Nm

top cover plate to high-voltage battery Torque (7.5 ft. lb.)

Torque ft. lb.)
Battery
Fastening Nuts Securing High-Voltage Tightening 5.9 Nm

Battery Control Unit To E-Box Torque (4.5 ft. lb.)
Fastening nuts securing cover for

Tightening 5.9 Nm
high-voltage battery control unit to
E-box
Fuse
Torque ft. lb.)
Fastening screws securing fuse carrier Tightening 10.1 Nm

cover to high-voltage battery Torque (7.5 ft. lb.)

PRELIMINARY WORK
1. Observe warning notes. → 2X00IN GENERAL WARNING NOTES FOR WORKING ON THE
HIGH-VOLTAGE VEHICLE ELECTRICAL SYSTEM
2. Remove high-voltage battery. → REMOVING HIGH-VOLTAGE BATTERY - section on

"Removing"
3. Set up a High-Voltage Cordon High-Voltage Cordon WE 1589 around the high-voltage

workstation.
Fig 1: Caution For Battery Restricted Area

REMOVING E-BOX
WARNING: High voltage
→ Work on the high-voltage battery may only be carried out by a high-voltage technician.
→ Always use insulated tools Insulated Tool Set WE 1593 when working on the high-voltage battery.
→ Observe general warning notes for working on the high-voltage vehicle electrical system. → 2X00IN
NOTE: Incorrect removal or fitting of safety-related screws for the high-voltage battery.
Risk of damage to rivet nuts
Risk of damage to screw heads
Risk of damage to high-voltage battery
→ Loosen and tighten fastening screws without using electric tools.
→ Only loosen and tighten fastening screws using special tool VAS 6883 Insulated Tool Set.
→ Be extremely careful when loosening fastening screws. See Note: → "Procedure For Loosening
Micro-Self-Locking Screws" .
→ Clean the threaded bores before fitting the fastening screws. See Note: → "Procedure For Cleaning
Threaded Bores On The High-Voltage Battery" .
→ Always use new fastening screws.
Information
Always use insulated tools Insulated Tool Set WE 1593 when working on the high-voltage battery and
a High-Voltage Cordon WE 1589 when working on a HV work bay.
Information
If the E-box for the high-voltage system Cannot Be Removed because the screw heads or rivet nuts
are damaged, for example, proceed as follows:
Stop working on the high-voltage battery immediately .
To find out what to do next, get in touch with your contact person at your importer's Technical
Competence Centre (TCC) .
Information
If the Cover On The Fuse Carrier for the high-voltage battery Cannot Be Removed because the
screw heads or rivet nuts are damaged, for example, proceed as follows:
Stop working on the high-voltage battery Immediately .
1. Remove fuse carrier cover.
1. 1.1. Loosen fastening screws -1- as described above.
2. 1.2. Push fuse carrier cover down and remove it.

Fig 1: Identifying Fuse Carrier Cover Screws
Information
Perform function test on voltage tester at the vehicle jump-start terminals using a reference
voltage.
2. Verify isolation from the power supply at the high-voltage battery fuse using voltage tester
Voltage Tester WE 1380 .
1. 2.1. Contact point -A- to contact point -B- .
2. 2.2. Contact point -A- to housing.
3. 2.3. Contact point -B- to housing.
4. 2.4. Check contact point -A- to contact point -B- again to prevent static charge.
Fig 2: Checking Absence Of Electric Charge
Information
Further steps may only be carried out if the measured voltage is less than 1 V. If this is not the
case, stop working on the system and contact Technical Support.
Information
Once absence of electric charge has been verified using the voltage tester, the fuse must be
replaced without any interruption to work.
3. Remove high-voltage battery fuse.
1. 3.1. Unscrew and remove fastening screws -3- for cap -1- and fuse -2- .
2. 3.2. Remove cap -1- together with fuse -2- .

Fig 3: Removing Fuse
3. 3.3. Unclip cap -1- from the fuse and re-insert it on the high-voltage battery to
protect exposed high-voltage contacts.
Fig 4: Installing Battery Cap
4. Remove high-voltage battery control unit.
1. 4.1. Loosen fastening nuts -1, 2- on the cover of the high-voltage battery control unit
and remove cover -3- .
2. 4.2. Remove spacers under the fastening nuts -1- .

Fig 5: Identifying Cover For High-Voltage Battery Control Unit
3. 4.3. Remove ground line -1- from the fastening bolt.

Fig 6: Identifying Ground Line
4. 4.4. Loosen fastening nuts -1- on the high-voltage battery control unit and pull off
high-voltage battery control unit -2- .
Fig 7: Identifying High-Voltage Battery Control Unit
5. 4.5. Release electric plug connection -1- at the high-voltage battery control unit
completely -arrows a- and disconnect it -arrow A- .
6. 4.6. Release electric plug connection -2- completely -arrow b- and disconnect it
-arrow B- .
7. 4.7. Remove high-voltage battery control unit.
Information
Procedure For Loosening Micro-Self-Locking Screws .
The covers on the high-voltage batteries are secured using fastening screws with high-strength
screw locking agent. However, these can be difficult to loosen as a result of certain
environmental conditions and depending on the service life of the vehicle.
To avoid breaking off or damaging fastening screws, always loosen the fastening screws as
follows:
1. Mark the fastening screw using a felt-tip pen and carefully loosen it by half (1/2) a
turn -arrow a- .
2. Screw the fastening screw in again by half (1/2) a turn -arrow b- .
3. Repeat Steps 1 and 2 at least five times (5x) until the loosening torque of the
fastening screw is reduced significantly. The fastening screw can then be turned
easily.
4. After Step 3, the torque should be much lower so that the fastening screw can be
loosened completely -arrow c- .
Fig 9: Loosening Fastening Screws
Information
If the Cover Plate for the high-voltage battery Cannot Be Removed because the screw
heads or rivet nuts are damaged, for example, proceed as follows:
1. Stop Working on the high-voltage battery Immediately .
2. To find out what to do next, get in touch with your contact person at your
importer's Technical Competence Centre (TCC) .
5. Remove top cover plate on the high-voltage battery
2. 5.2. Loosen fastening screws -1, 2- as described above.

Fig 10: Identifying Top Cover Plate On High-Voltage Battery
Do not remove top cover plate on the high-voltage battery.

Information
Procedure For Cleaning Threaded Bores (Blind Hole Bore) On The High-Voltage Battery
.
After loosening micro-self-locking fastening screws, it is important to remove the particles of

screw locking agent from the threaded bores.
1. All tasks that are necessary for cleaning the threaded bores must be carried out by hand
and the required personal protective gear must always be used .
2. Never use lubricant for cleaning the threaded bores .
3. When cleaning the threaded bores, always make sure that no remaining pieces of the
micro-encapsulated coating/metal chips get into the battery housing. Use a vacuum
cleaner to do this .
Fig 12: Identifying Tap Comparison
When cleaning the threaded bores (M6 and M8) on the high-voltage battery, always proceed
as follows:
1. Insert tap -1- (with spiral grooves) into the threaded bore.
2. Hold a vacuum cleaner with a plastic nozzle -3- at the threaded bore in such a way
that the remaining pieces of adhesive/metal chips will be removed.
3. Turn the tap back and forth by a quarter (1/4) to a half (1/2) a turn several times
-arrow- to extract the remaining adhesive/metal chips that are dislodged -2- .
Fig 13: Cleaning Threaded Bore
4. Repeat Step 3 several times until the threaded bore is completely cleaned.
Information
Procedure For Cleaning Threaded Bores (Through-Bore) On The Side Bar Of The
High-Voltage Battery .

as follows:
1. Stick two strips (50 x 80 mm) of fabric adhesive tape -4- on the inside of the bar on
the high-voltage battery using a plastic wedge. The bores must be completely
sealed.
2. Insert tap (with spiral grooves) -1- into the threaded bore.
that the remaining pieces of adhesive/metal chips -2- will be removed.
-arrow- to extract the remaining adhesive/metal chips that are dislodged.
5. Repeat Step 3 several times until the threaded bore is completely cleaned. Make
sure not to puncture the fabric adhesive tape.
6. Carefully remove fabric adhesive tape and always use a vacuum cleaner to remove
any loose particles at the same time.
6. Clean threaded bores -1- for the fastening points for the top cover plate as described above
Using An M6 X 1.0 Tap With Spiral Grooves .
Fig 16: Identifying Threaded Bores
Information
Carefully remove the top cover plate to prevent damage to the E-box wiring harness.
1. 6.1. Carefully lift up the top cover plate on the high-voltage battery and remove it.
Information
1. Stop Working On the high-voltage battery Immediately .
2. To find out what to do next, get in touch with your contact person at your importer's
Technical Competence Centre (TCC) .
7. Check seal on front cover plate and if it is damaged, replace the front cover plate.
1. 7.1. Loosen fastening screws (M6 x 12) -1- as described above.

Fig 17: Removing Front Cover Plate
2. 7.2. Carefully remove front cover plate on the high-voltage battery by pulling it to the
side.
3. 7.3. Clean the threaded bores -1- for the fastening points for the side cover plate as
described above Using An M6 X 1.0 Tap With Spiral Grooves .
8. Remove E-box.
1. 8.1. Loosen tie-wrap -1- on HV line.

Fig 19: Disconnecting HV Line
2. 8.2. Remove wiring harness -1- by pulling it up out of the guide -arrows- .
3. 8.3. Loosen fastening screws -1- for the E-box as described above.
Fig 21: Identifying E-Box Screws
4. 8.4. Carefully pull the E-box straight off the high-voltage battery and make sure not to
tilt the E-box when pulling it off the guide pins -1- .
Fig 22: Identifying E-Box Guide Pins
5. 8.5. Cover exposed terminals on the high-voltage battery -arrows- with adhesive
tape immediately after removing the E-box.
Fig 23: Identifying Battery Terminals
Information

as follows:
sealed.
9. Clean the threaded bores on the upper bar of the high-voltage battery as described above.
1. M8 Through-Bore
2. M8 Blind Hole Bore
3. M6 Through-Bore
4. Fabric Adhesive Tape
1. 9.1. Clean the threaded bores for the fastening points of the top cover plate -1, 2-
using An M8 X 1.25 Tap With Spiral Grooves .
2. 9.2. Clean the threaded bore for the upper fastening points of the E-box -3- using an
M6 X 1.0 Tap With Spiral Grooves .
10. Clean the threaded bores for the fastening points -1- of the E-box as described above.
Fig 27: Cleaning Threaded Bores

INSTALLING E-BOX
Information
a High-Voltage Cordon High-Voltage Cordon WE 1589 when working on a HV work bay.
Information
When fitting the cover, check that the E-box wiring harness is positioned correctly and is not squashed.
Information
Fastening screws and fastening nuts must not be re-used and must be replaced with new ones.
1. Install E-box.
1. 1.1. Remove adhesive tape from the battery terminals -arrows- .

Fig 1: Locating Battery Terminals
2. 1.2. Push E-box onto the guide pins -1- , making sure not to tilt the E-box and
position it flat on the high-voltage battery.
3. 1.3. Screw in and tighten fastening screws -1- on the E-box. → Tightening Torque:
10.1 Nm (7.5 ft. lb.)
4. 1.4. Position the wiring harness -1- at the top of the guide -arrows- and make sure
that the seal -2- is fitted correctly.
Fig 4: Positioning Wiring Harness
5. 1.5. Connect electric plug connection -1- on the E-box -A- until it engages securely.
Check that the wiring harness is routed behind the plug connection -1- as shown.
6. 1.6. Fasten tie-wrap -1- on HV line.

Fig 6: Locating HV Line
Information
When fitting the cover, check that the E-box wiring harness is positioned correctly and is not
squashed.
Information
The high-voltage battery cover must not be re-used and must be replaced by a new cover. The
new cover is supplied without warning signs. These must be ordered separately and affixed on
the cover.
2. Install cover plates on the high-voltage battery.
1. 2.1. Position side cover plate carefully on the high-voltage battery.
2. 2.2. Tighten fastening screws (M6 x 12) -1- . → Tightening Torque: 10.1 Nm (7.5 ft.
lb.)
Fig 7: Identifying Side Cover Plate Screws
3. 2.3. Carefully position top cover plate on the high-voltage battery.
lb.)
Tighten fastening screws (M6 x 12) -2- . → Tightening Torque: 10.1 Nm (7.5 ft.
lb.)
Fig 8: Identifying Top Cover Plate Screws
5. 2.5. Tighten fastening screws (M8 x 16) -1- . → Tightening Torque: 13 Nm (9.5 ft.
lb.)
3. Install high-voltage battery control unit.
1. 3.1. Connect electric plug connection -2- on the high-voltage battery control unit -b-
and lock it -B- .
2. 3.2. Connect electric plug connection -1- (-a- ) and lock it -A- .
Fig 10: Connecting Electric Plug Connections
3. 3.3. Position control unit -2- on the E-box and tighten fastening nuts -1- . →
Tightening Torque: 5.9 Nm (4.5 ft. lb.)
4. 3.4. Push ground line -1- onto the fastening bolts.

5. 3.5. Position spacers on the bolts under fastening nuts -2- .
6. 3.6. Position cover on high-voltage battery control unit -3- and tighten fastening nuts
-1, 2- . → Tightening Torque: 5.9 Nm (4.5 ft. lb.)
4. Remove cap -1- .

Fig 14: Identifying Battery Cap
5. Verify absence of electric charge at the exposed high-voltage contacts of the high-voltage
battery using a suitable voltage tester at contact points -A, B- .

Fig 15: Checking Electric Charge
The measurement also prevents voltages due to the build-up of static charge.
Information
Insert fuse without causing any interruption to work in order to prevent an electrostatic charge.
6. Install high-voltage battery fuse.
1. 6.1. Clip fuse into cap
2. 6.2. Position cap -1- together with fuse -2-
3. 6.3. Screw on fastening screws -3- for cap -1- and fuse -2- . → Tightening
Torque: 10 Nm (7.5 ft. lb.)
Fig 16: Identifying Fuse
7. Position fuse carrier cover and tighten fastening screws -1- . → Tightening Torque: 10.1 Nm
(7.5 ft. lb.)
Fig 17: Identifying Fuse Carrier Cover
Information
Stickers (Warning Of Dangerous Electrical Voltage)
The cover and possibly the front cover plate for the high-voltage battery must be replaced
while carrying out the work required for replacing the E-box.
The identification and warning stickers affixed to the cover and cover plate cannot be re-used.
Before re-installing the high-voltage battery, new stickers must be affixed to the new cover and
possibly to the new front cover plate at the same position and with the same text alignment as
on the removed cover plates.
The required safety marking warning sign 8R0.010.539.x must be selected according to the
relevant language and country version.
8. Affix warning signs to the high-voltage battery.
1. Warning Sign Pictograms
2. Indication Sticker For Lithium-Ion High-Voltage Battery
3. Safety Marking Warning Sign

Fig 18: Identifying Warning Sign Stickers

SUBSEQUENT WORK
1. Install high-voltage battery. → INSTALLING HIGH-VOLTAGE BATTERY - section on

"Installing"
WM 270819 REMOVING AND INSTALLING FUSE AT E-BOX (CAYENNE S E-HYBRID) >

TOOLS


PRELIMINARY WORK
2. Isolate the high-voltage system from the power supply and complete the relevant
documentation. → 2X00IN ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM
POWER SUPPLY/STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM (AFES)
3. Remove high-voltage battery. → INSTALLING HIGH-VOLTAGE BATTERY - section on

"Removing"
4. Set up a High-Voltage Cordon WE 1589 around the high-voltage workstation.


REMOVING FUSE AT E-BOX
Information
1. Open retaining clip -A- and carefully pull the fuse up and out -B- .

INSTALLING FUSE AT E-BOX

Information
Before installing the fuse, the seal must be checked for damage. If the seal is damaged, the fuse must
be replaced.
1. Carefully insert fuse -A- and lock it with the retaining clip -B- . Check that the retaining clip
locks correctly.
2. Check that the fuse is positioned correctly and fitted securely.

Fig 1: Installing Fuse

SUBSEQUENT WORK

"Installing"
2. Start the high-voltage system and complete the relevant documentation. → 2X00IN
ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER SUPPLY/STARTING
HIGH-VOLTAGE ELECTRICAL SYSTEM (AFES)
WM 270819 REMOVING AND INSTALLING HIGH-VOLTAGE BATTERY (CAYENNE S

E-HYBRID) > TOOLS
Workshop Crane Workshop

WE 1188
VAS 6100 Equipment
Workshop
Insulated Tool Set WE 1593
Equipment
Lifting tackle VW tool 3033

Adapter plate Special tool 9860
guide rod Special tool 9860/2

E-HYBRID) > TECHNICAL VALUES

value 1 2
Fastening bracket securing Tightening 23 Nm (17

high-voltage battery to body Torque ft. lb.)
Electric potential line to Tightening 17 Nm (13

high-voltage battery Torque ft. lb.)
Electric potential to body
Torque ft. lb.)
HV line from power Tightening 7 Nm (5 ft.

electronics to battery Torque lb.)
Mounting for cover for HV Lens-head screw Tightening 23 Nm (17

battery (micro-self-locking) Torque ft. lb.)

E-HYBRID) > PRELIMINARY WORK

HIGH-VOLTAGE ELECTRICAL SYSTEM
2. Carry out classification of high-voltage battery. → 2X00IN CLASSIFICATION OF

HIGH-VOLTAGE BATTERY
4. Drain low-temperature cooling system → 193817 DRAINING AND FILLING COOLANT

(INCLUDES BLEEDING) .
5. Remove luggage compartment cover. → 700619 REMOVING AND INSTALLING TRIM PANEL
FOR LUGGAGE COMPARTMENT (LUGGAGE COMPARTMENT COVER)
6. Remove side trim panel for rear luggage compartment. → REMOVING SIDE TRIM PANEL
FOR REAR LUGGAGE COMPARTMENT - section on "Removing"
7. Remove cover for rear lock support. → REMOVING COVER FOR REAR LOCK SUPPORT -

E-HYBRID) > REMOVING HIGH-VOLTAGE BATTERY
Fig 1: Identifying High-Voltage Battery Installation Position
Information
To prevent coolant from getting into the high-voltage battery and damaging the high-voltage battery, the
cooling system must only be disconnected at the specified position.
1. Release and pull off breather hoses for the cooling system -6- .
Fig 2: Disconnecting Breather Hoses
2. Release and disconnect high-voltage line for on-board charger -1- from the high-voltage
battery -3- .
3. Unscrew and disconnect high-voltage lines for the power electronics unit -2- from the
high-voltage battery -3- .
Fig 3: Disconnecting High-Voltage Lines
4. Electric plug connections for the hybrid or drive CAN -4- must be removed -a - from the
bracket and then released -b - and disconnected -c- .
5. Open cable duct -5- and remove high-voltage lines.
6. Unclip and remove cable duct -5- .

Fig 5: Removing Cable Duct
7. Remove equipotential bonding line -7- .
1. 7.1. Loosen fastening screw for equipotential bonding line at the body -9- .
2. 7.2. Loosen fastening screw for equipotential bonding line at the high-voltage battery
-8- .
3. 7.3. Remove equipotential bonding line.

Fig 6: Removing Equipotential Bonding Line
Information
The fastening screws for the cover on the high-voltage battery are micro-self-locking and must
not be re-used.
8. Unscrew fastening bracket for high-voltage battery -12- and screw in Guide Rod 9860/2 -10-
.
1. 8.1. First loosen the outer fastening screws.
2. 8.2. Guide Rod 9860/2 must then be screwed into the outer thread.
3. 8.3. Loosen inner fastening screws -11- .

Fig 7: Identifying Fastening Bracket
Information
Procedure for loosening micro-self-locking screws .
environmental influences and depending on the service life of the vehicle.
follows:
turn -arrow a- .
easily.
9. Unscrew and remove center fastening screws -13- from the high-voltage battery in order to fit
the adapter plates.
10. Position adapter plates -15- Adapter Plate 9860 and use fastening screws -14- to fit them on
the high-voltage battery.
Fig 10: Identifying Adapter Plates
11. Fit lifting tackle -16- Lifting Tackle 3033 on the adapter plates.
Information
Depending on the workshop crane used, lifting tackle may have to be attached first and then
secured to the adapter plates.
Fig 11: Identifying Lifting Tackle Tool (3033)
Information
Before removing the high-voltage battery, have a table or trolley and two plastic or rubber
blocks ready for lowering the high-voltage battery. The high-voltage battery must not be
lowered onto the floor to prevent damage to the water drains on the underside of the
high-voltage battery.
Information
When lifting out the battery, it is a good idea to get another person to guide the battery on the
crane.
12. Workshop Crane VAS 6100 WE 1188 must be engaged in the lifting tackle Lifting Tackle
3033 . Then lift it carefully at the center.
Fig 12: Lifting Vehicle Battery
13. Lift up the high-voltage battery and get another person to pull it towards the rear and lift it
carefully out of the luggage compartment pan.
Information
The battery must not be left hanging on the crane for a long time.
14. Lift the high-voltage battery up further, push the workshop crane forward slightly and turn it 90
degrees as soon as possible and guide the high-voltage battery out of the vehicle.
Fig 13: Lifting Out High-Voltage Battery
15. Lower the high-voltage battery onto the blocks on the prepared table or trolley.
WARNING: Danger of fire, explosion
1. Insulation fault as a result of coolant leaking into high-voltage battery
→ Always drain the high-voltage battery cooling lines completely before transporting/handling
16. Drain the cooling system completely using compressed air set to max. 2.5 bar .
Fig 14: Draining Cooling System
1. 16.1. Hold the coolant hose -18- in a suitable container -3- .
2. 16.2. Flush the coolant hose -17- using compressed air set to max. 2.5 bar until no
more coolant emerges at the coolant hose -18- .
Information
Close off/mask high-voltage connections on the high-voltage battery using suitable stoppers or
adhesive tape to prevent dirt and fluids from getting in.
17. Disconnect cooling lines -19- for the high-voltage battery -3- at the bayonet lock.
Fig 15: Disconnecting Cooling Line From Battery
18. Fit cooling system stoppers on cooling system connections on the old high-voltage battery and
secure with adhesive tape.

E-HYBRID) > INSTALLING HIGH-VOLTAGE BATTERY
Information
The contact surfaces of the equipotential bonding line must be checked prior to installation.
The contact surfaces must be clean and free of rust and grease.
Clean the contact surfaces using the contact surface cleaning set VAS 6410 if necessary.
Information
When connecting or screwing the high-voltage lines to the high-voltage battery connections, carefully
check the plug contacts and make sure that they are connected properly.
The connector pins on conventional plug connections must be checked before connecting them and the
plug connections must be inserted carefully.
Information
Check seal on connector for high-voltage lines for the power electronics unit before installation and
replace it if necessary
Information
Remove stoppers or adhesive tape from the high-voltage connection for the high-voltage battery and
check for dirt and fluid leaking in.
Information
Only a high-voltage battery designed specifically for the Cayenne S E-Hybrid may be used. High-voltage
batteries from other model lines (e.g. Panamera S E-Hybrid) must not be installed.
Information
When inserting the high-voltage battery into the vehicle, make sure that no lines or connectors are
trapped by the battery.
1. Guide Rods 9860/2 -1- must then be screwed into the outer thread.
Fig 1: Identifying Guide Rods
2. Clean the thread if you have not already done so.
Information
.

When cleaning the threaded bores (M6) on the high-voltage battery, always proceed as
follows:
Fig 4: Identifying Adapter Plate
6. Carefully lift the high-voltage battery into the vehicle with the help of another person.
Fig 6: Positioning High-Voltage Battery
7. Guide high-voltage battery -6- fully into the luggage compartment, turn it 90 degrees as soon
as possible and position outer thread of the fastening brackets for the high-voltage battery over
the luggage compartment pan onto the Guide Rods 9860/2 .
8. Get another person to guide the outer thread of the fastening brackets for the high-voltage
battery -7- into all the Guide Rods 9860/2 -1- . Carefully lower the high-voltage battery into
the luggage compartment pan.
Fig 7: Lowering High-Voltage Battery Into Vehicle
Information
The fastening screws for the fastening brackets are micro-self-locking and must not be
re-used.
9. Tighten fastening brackets for high-voltage battery. Tightening Torque 23 Nm (17 ft. lb.)
1. 9.1. Always screw in the inner fastening screws first.
2. 9.2. Guide Rod 9860/2 must be loosened from the outer threads.
3. 9.3. Tighten outer fastening screws.
Information
not be re-used.
10. Loosen fastening screws for the high-voltage battery and remove adapter plate together with
the lifting tackle. Screw fastening screws into the open threaded bores. Tightening Torque 23
Nm (17 ft. lb.)
11. Connect cooling system hoses and secure with hose clamps.
12. Install equipotential bonding line -8- .
1. 12.1. Secure equipotential bonding line -8- to the high-voltage battery -6- .
2. 12.2. Secure equipotential bonding line -8- to the body -9- . Tightening Torque 9
Nm (6.5 ft. lb.)
Fig 8: Securing Equipotential Bonding Line
13. Connect breather hoses for the cooling system and secure with hose clamps.
14. Fit cable duct, insert high-voltage lines and close the cable duct.
15. Plug in electric plug connections for the hybrid or drive CAN until they engage securely.
16. Insert electric plug connections into the bracket.
17. Plug in high-voltage lines for the power electronics unit -10- and secure with fastening screws.
18. Plug in high-voltage line for the on-board charger until it engages securely.
Fig 9: Fitting High-Voltage Lines

E-HYBRID) > SUBSEQUENT WORK
1. Install cover for rear lock support. → REMOVING COVER FOR REAR LOCK SUPPORT -
2. Install side trim panel for rear luggage compartment. → REMOVING SIDE TRIM PANEL FOR
REAR LUGGAGE COMPARTMENT - section on "Removing"
3. Install luggage compartment cover. → 700619 REMOVING AND INSTALLING TRIM PANEL
4. Fill low-temperature cooling system. → 193817 DRAINING AND FILLING COOLANT

(INCLUDES BLEEDING)
WM 270819 REMOVING AND INSTALLING HIGH-VOLTAGE BATTERY FUSE

(CAYENNE S E-HYBRID) > TOOLS

(CAYENNE S E-HYBRID) > TECHNICAL VALUES
Fuse Tightening Torque 10 Nm (7.5 ft. lb.)
Fuse carrier cover Tightening Torque 10.1 Nm (7.5 ft. lb.)

(CAYENNE S E-HYBRID) > PRELIMINARY WORK

"Removing"

workstation.

(CAYENNE S E-HYBRID) > REMOVING HIGH-VOLTAGE BATTERY FUSE
Information
Information
The covers on the high-voltage batteries are secured using fastening screws with high-strength screw
locking agent. However, these can be difficult to loosen as a result of certain environmental conditions
and depending on the service life of the vehicle.
To avoid breaking off or damaging fastening screws, always loosen the fastening screws as follows:
1. Mark the fastening screw using a felt-tip pen and carefully loosen it by half (1/2) a turn -arrow
a- .
3. Repeat Steps 1 and 2 at least five times (5x) until the loosening torque of the fastening screw
is reduced significantly. The fastening screw can then be turned easily.
4. After Step 3, the torque should be much lower so that the fastening screw can be loosened
completely -arrow c- .

Information
If the Cover On The Fuse Carrier for the high-voltage system Cannot Be Removed
because the screw heads or rivet nuts are damaged, for example, proceed as follows:
Information
voltage.
Information
Information
2. 3.2. Carefully remove cap -1- together with fuse -2- .

Information

as follows:
sealed.
4. Clean the screw threads of the fastening points as described above Using An M6 X 1.0 Tap
With Spiral Grooves .
5. Unclip cap -1- from fuse and insert it on the high-voltage battery again.

(CAYENNE S E-HYBRID) > INSTALLING HIGH-VOLTAGE BATTERY FUSE
Information
Fastening screws for the fuse and fuse carrier cover must not be re-used and must be replaced with new
fastening screws.
1. Remove cap.
2. Verify absence of electric charge at the open terminals of the high-voltage battery fuse using a
suitable voltage tester at contact points -A, B- .

Information
Information
Check seal on fuse carrier cover for damage. The cover must not be re-used if damaged and
must be replaced.
(7.5 ft. lb.) .

(CAYENNE S E-HYBRID) > SUBSEQUENT WORK

"Installing"
WM 270855 REPLACING HIGH-VOLTAGE BATTERY (CAYENNE S E-HYBRID) >

TOOLS
Insulated Tool Workshop

WE 1593
Set Equipment
Lifting Tackle VW Tool 3033

TECHNICAL VALUES

value 1 2
Fastening bracket to Lens-head screw (micro- 23 Nm (17

Contact force
high-voltage battery self-locking) ft. lb.)
Mounting For Cover For Lens-Head Screw Tightening 23 Nm (17

HV Battery (Micro-Self-Locking) Torque ft. lb.)
Mounting For Hollow Tightening 10 Nm (7.5

M6 x 14
Section To Battery Torque ft. lb.)

REPLACING HIGH-VOLTAGE BATTERY

"Removing"
2. Remove lifting tackle Lifting tackle 3033 and adapter plates Adapter Plate 9860 from the
3. Drain the cooling system completely using compressed air set to max. 2.5 Bar .

4. Remove the two coolant lines for the high-voltage battery and fit them on the new high-voltage
battery. Check that the lines are fitted and sealed correctly.
5. Fit suitable cooling system caps (from the new high-voltage battery) on the cooling system
connections -1- and high-voltage connections of the old high-voltage battery and secure with
adhesive tape.
Fig 2: Identifying Cooling System Connections
Information
re-used.
6. Unscrew fastening brackets -1- from the removed high-voltage battery and fit them on the new
high-voltage battery -2- . Contact Force 23 Nm (17 ft. lb.)
Fig 3: Identifying Fastening Brackets
7. Unscrew hollow section -1- from the removed high-voltage battery and fit it on the new
high-voltage battery -2- . Tightening Torque 10 Nm (7.5 ft. lb.)
Fig 4: Identifying Hollow Section
Information
8. Affix warning signs to the new high-voltage battery.

Fig 5: Warning Sign Stickers
9. Fit lifting tackle Lifting Tackle 3033 and adapter plates Adapter Plate 9860 on the

"Installing"
Information
not be re-used.
11. Screw fastening screws -1- into the high-voltage battery. Tightening Torque 23 Nm (17 ft.
lb.)
Fig 6: Identifying Screw Fastening Screws
12. Screw grub screws -1- into the center bores.

Fig 7: Identifying Grub Screws
WM 2708IN PACKAGING INSTRUCTIONS FOR HIGH-VOLTAGE BATTERY (CAYENNE

S E-HYBRID) > TOOLS
Workshop Workshop
WE 1188
Crane Equipment
Lifting Tackle VW tool 3033

S E-HYBRID) > PRELIMINARY WORK

"Removing"

S E-HYBRID) > PACKING HIGH-VOLTAGE BATTERY IN TRANSPORT BOX
WARNING: Danger of objects or loads falling down
→ Secure components to prevent them from falling down.
Information
Always wear safety gloves when packing the high-voltage battery.
1. Prepare the transport box -1- .
1. 1.1. Prepare cut pieces from honeycomb board. Set consists of two cover and floor
elements and six side elements
1. 1.1.1. Remove cover element -2- .
2. 1.1.2. Remove side elements -3- .
3. 1.1.3. Leave floor element -4- fitted.

Fig 1: Identifying Transport Box, Cover Element And Side Elements
2. 1.2. Remove large plastic bag from the upright box.
3. 1.3. Remove desiccant -2- from the upright box.
4. 1.4. Remove Vermiculite bag -1- from the upright box.

Fig 2: Identifying Vermiculite And Desiccant
→ Always drain the high-voltage battery cooling lines completely before

transporting/handling the high-voltage battery.
2. Drain the cooling system completely when it is outside of the vehicle using compressed air set
to max. 2.5 bar .
Information
Cooling line connections must be closed off to prevent fluid from leaking out during transport.
Coolant leaks and the resulting damage to the high-voltage battery can mean that repairs to
the high-voltage battery can no longer be carried out in certain cases.
3. Fit supplied cooling system caps on cooling system connections -1- and secure with adhesive
tape.
Fig 4: Identifying Cooling System Caps
4. Position adapter plates -1- Adapter Plate 9860 on the high-voltage battery and use fastening
screws -2- to fit them on the high-voltage battery.
Fig 5: Identifying Adapter Plates Screws
5. Fit lifting tackle -1- Lifting Tackle 3033 on the adapter plates -2- .
Fig 6: Identifying Lifting Tackle (3033)
Information
Set the workshop crane Workshop Crane WE 1188 to the fourth detent (500 kg).
6. Workshop Crane WE 1188 must be engaged in the lifting tackle Lifting Tackle 3033 . Then
lift it carefully at the center.
7. Centre transport box lengthways with respect to the workshop crane.
8. Place two honeycomb boards -1- at the short side of the box -x1- .
Information
Make sure not to damage the honeycomb boards when positioning the high-voltage battery.
9. Wrap a large plastic bag around the high-voltage battery and lower it until it is flush with the
two positioned honeycomb boards so that four honeycomb boards -x2- can be positioned at
the opposite side of the box.
Fig 7: Wrapping High-Voltage Battery
10. Remove workshop crane Workshop Crane WE 1188 with lifting tackle Lifting Tackle 3033
from the high-voltage battery.
11. Loosen and remove adapter plates Adapter Plate 9860 from the high-voltage battery.
Information
The threads in the high-voltage battery without fastening screws can remain open.
12. Insert the remaining four honeycomb boards -2- at the opposite side of the box for the
high-voltage battery E-box.
Information
If the remaining honeycomb boards cannot be inserted without damaging them, the
high-voltage battery must be lifted up again and re-aligned.
Fig 8: Identifying Honeycomb Boards
13. Centre the desiccant In the large plastic bag on the long sides of the box.
14. Fold over the large plastic bag and seal with commercially available adhesive tape.
Information
A large plastic bag must be wrapped around the sides. The fold of the bag must be centered
on the long side of the box.
15. Place Vermiculite bag diagonally in the corners of the box.
16. Fit honeycomb board cover element -1- on the high-voltage battery.
Fig 9: Identifying Honeycomb Board Cover Element
17. Place a copy of the test log -1- for classification of lithium-ion high-voltage batteries in the box.
Fig 10: Identifying Test Log
18. Fit cover on the box and seal with the supplied clips.
1. 18.1. Push in clips -A- and check that they engage correctly -B- .
Fig 11: Pushing Clips On Box
19. Affix labels -1, 2, 3, 4- to the transport box.
1. 19.1. Affix "Hazardous goods class 9" label -1- to one long side of the box.
2. 19.2. Affix "UN 3480, lithium-ion batteries" label -2- to one long side of the box to the
right of label -1- .
3. 19.3. Affix document bag -3- to one long side of the box to the right of label -2- .
4. 19.4. Affix "Item number" label -4- to one long side of the box to the right of label -3-
.
Fig 12: Identifying Transport Box Labels
20. Complete accompanying documentation and place it in the document bag together with
another copy of the test log for classification of lithium-ion high-voltage batteries.
Information
The original test log for classification of lithium-ion high-voltage batteries must be kept in the
Porsche Centre.
21. Affix "Item number" label -2- to one short side of the box.
Fig 13: Identifying Transport Box Item Number Label
WM 271219 REMOVING AND INSTALLING BATTERY COVER (ALL MODELS) >

TECHNICAL VALUES
Air vent to battery cover Tightening Torque 2 Nm (1.5 ft. lb.)

PRELIMINARY WORK
1. Loosen the left front seat and tilt it to the rear with lines connected. → 720119 REMOVING
AND INSTALLING FRONT SEAT

REMOVING AND INSTALLING BATTERY COVER
necessary.
Battery can explode
Information
Fig 1: Identifying Battery Position
Information
1. When removing the carpeted floor for the first time, cut along the perforation using a carpet
knife.
2. Unscrew screw -1- and remove air guide -2- .
3. Open the tension hooks -arrows- on the battery cover -3- using a suitable tool.
4. Remove battery cover -3- .

Fig 2: Removing Battery Cover
5. The battery cover -3- is installed in reverse order to removal.
6. Tighten screw -1- . Tightening Torque 2 Nm (1.5 ft. lb.)

SUBSEQUENT WORK
1. Install left front seat. → 720119 REMOVING AND INSTALLING FRONT SEAT
WM 272219 REMOVING AND INSTALLING GENERATOR (CAYENNE) > TECHNICAL

VALUES
Tolerance Tolerance
1 2
Fastening screw securing Tightening 20 Nm (15

generator to engine, M8 Torque ft. lb.)
Tightening 15 Nm (11 ft.

B+ line to generator, M8
Torque lb.)
WM 272219 REMOVING AND INSTALLING GENERATOR (CAYENNE) > PRELIMINARY
WORK
1. Before the generator can be removed, the battery must be disconnected and the terminal
covered. → DISCONNECTING THE BATTERY
2. Remove air box for throttle housing (intake manifold). → REMOVING AIR BOX FOR
THROTTLE HOUSING - section on "Removing"
3. Remove air cleaner housing lid. → 242455 REPLACING AIR-CLEANER ELEMENT
4. Remove belt tensioner. → REMOVING BELT TENSIONER - section on "Removing"
WM 272219 REMOVING AND INSTALLING GENERATOR (CAYENNE) > REMOVING

GENERATOR
Fig 1: Overview Of Generator
1. Release the connector -1- and unplug it -arrow A- (-arrow B- ).
2. Screw off fastening nut -2- and pull off the B+ line -3- (-arrow C- ).
Fig 2: Disconnecting Electric Connections On Generator
3. Unscrew fastening screws -3- and remove the generator to the side -arrow- . Press the
generator out of the bracket using a lever if necessary.
Fig 3: Removing Generator
4. Lift generator up and out. Press the upper cooling water hose aside if necessary.
WM 272219 REMOVING AND INSTALLING GENERATOR (CAYENNE) > INSTALLING

GENERATOR
Information
Before installing the new generator, tap the threaded bushes -1- out by approx. 4 mm .
Fig 1: Identifying Generator Bushes
1. Insert the generator -3- from above.
2. Place the generator in installation position -arrow- and secure with the fastening screws
-arrows 3- .. → Tightening Torque: 20 Nm (15 ft. lb.)
Fig 2: Securing Generator
3. Connect the B+ line -3- to the generator -arrow A- and secure with the fastening nut -2- . →
Tightening Torque: 15 Nm (11 ft. lb.)
4. Plug in connector -1- (-arrow B- ) until it engages securely.

Fig 3: Securing Electric Connections On Generator
WM 272219 REMOVING AND INSTALLING GENERATOR (CAYENNE) > SUBSEQUENT

WORK
1. Install the belt tensioner. → INSTALLING BELT TENSIONER - section on "Installing"
2. Install air cleaner housing lid. → 242455 REPLACING AIR-CLEANER ELEMENT
3. Install air box for throttle housing (intake manifold). → INSTALLING AIR BOX FOR THROTTLE
4. Connect the battery and carry out the work instructions. → CONNECTING THE BATTERY
WM 276019 REMOVING AND INSTALLING STARTER (V6) (CAYENNE GTS &

CAYENNE S) > TECHNICAL VALUES
Tolerance
Location Description Type Basic value Tolerance 1
2
Tightening 45 Nm (33 ft. +8 Nm (+6 ft.

Fastening screw for starter
Torque lb.) lb.)
Fastening nut securing B+ line Tightening 18 Nm (13 ft.
to starter Torque lb.)
Fastening nut securing terminal Tightening 10 Nm (7.5

50 line to starter Torque ft. lb.)

CAYENNE S) > PRELIMINARY WORK
1. Disconnect the battery → DISCONNECTING THE BATTERY .
2. Remove intake-air distributor. → REMOVING INTAKE-AIR DISTRIBUTOR
3. Remove vacuum reservoir. → REMOVING VACUUM RESERVOIR

CAYENNE S) > REMOVING STARTER
Fig 1: Identifying Installation Position Of Starter
1. Loosen screws on the rear cable guide. → Rear cable guide

Fig 2: Locating Rear Cable Guide
2. Screw off fastening nuts -1 and 2- on the electric connections at the starter.
3. Remove electric connections -3 and 4- (-arrow- ).

Fig 3: Fastening Nuts On Electric Connections At Starter
4. Unscrew and remove fastening screws -2- on the cable duct.
5. Disconnect connectors for injectors -1- on cylinder bank 1.

Fig 4: Identifying Cable Duct And Connectors For Injectors
6. Release connector on the rear knock sensor for cylinder bank 1 -1- and disconnect it.
Fig 5: Identifying Cable Plug For Knock Sensor
7. Carefully hold the cable duct to one side.
8. Unscrew and remove fastening screws -1- on the starter.

Fig 6: Identifying Starter Screws
9. Remove starter.
Fig 7: Removing Starter

CAYENNE S) > INSTALLING STARTER
Information
Tightening Torques, tightening sequence and assembly overviews for the engine and transmission:
Group 1: → 1X00IN TECHNICAL VALUES

Fig 1: Identifying Starter Installation Position
1. The starter is installed in reverse order to removal.
1. 1.1. Fastening nut securing terminal 50 to starter Tightening Torque 10 Nm (7.5 ft.
lb.)
2. 1.2. Fastening screws for starter Tightening Torque 45 Nm (33 ft. lb.) +8 Nm (+6 ft.
lb.)
3. 1.3. Fastening nut securing B+ line to starter Tightening Torque 18 Nm (13 ft. lb.)

CAYENNE S) > SUBSEQUENT WORK
1. Install vacuum reservoir. → 245419 REMOVING AND INSTALLING VACUUM RESERVOIR
2. Install intake-air distributor. → 244619 REMOVING AND INSTALLING INTAKE-AIR

DISTRIBUTOR
WM 276019 REMOVING AND INSTALLING STARTER (V8) (CAYENNE GTS, CAYENNE

S, CAYENNE TURBO & CAYENNE TURBO S) > TECHNICAL VALUES
Basic Tolerance
value 2
Fastening screw securing starter Tightening 45 Nm (33 +8 Nm (+6 ft.

to engine housing Torque ft. lb.) lb.)
Tightening 18 Nm (13
Fastening nut for B+ line
Torque ft. lb.)
Tightening 6.5 Nm (5 ft.

Fastening nut for electric line
Torque lb.)

S, CAYENNE TURBO & CAYENNE TURBO S) > PRELIMINARY WORK

BATTERY .
2. Remove fuel distributor pipe. → REMOVING FUEL DISTRIBUTOR PIPE (FUEL RAIL) -

S, CAYENNE TURBO & CAYENNE TURBO S) > REMOVING STARTER
Fig 1: Installation Position Of Starter
NOTE: Voltage peaks
1. Undo electric change-over valve.
1. 1.1. Pull electric change-over valve -1- off the holder -arrow- and set it aside with
the lines connected.
Fig 2: Removing Electric Change-Over Valve
2. Unscrew fastening nuts -2 and 3- on the starter and remove lines -4 and 5- (-arrow- ).
Fig 3: Removing Fastening Nuts On Starter

4. Remove the starter.
1. 4.1. Pull starter -7- towards the front in direction of travel -arrow A- and lift it up
-arrow B- .
2. 4.2. Remove line -8- (-arrow C- ).
3. 4.3. Lift the starter -7- up and remove it -arrow D- .


S, CAYENNE TURBO & CAYENNE TURBO S) > INSTALLING STARTER
1. Install the starter.
1. 1.1. Insert the starter -7- from above -arrow A- .
2. 1.2. Fit line -8- (-arrow B- ).
3. 1.3. Lower the starter -7- (-arrow C- ) and slide it into the engine housing -arrow
D- .
Fig 1: Installing Starter
2. Secure the starter with the fastening screws -6- and tighten to → Tightening Torque: 45 Nm
(33 ft. lb.) +8 Nm (+6 ft. lb.) .
Fig 2: Identifying Starter Fastening Screws
3. Position lines -4 and 5- on the starter -arrow- and secure with the fastening nuts -2 and 3- .
→ Tightening Torque: 18 Nm (13 ft. lb.) , → Tightening Torque: 6.5 Nm (5 ft. lb.)
Fig 3: Securing Electric Lines To Starter
4. Push electric change-over valve -1- onto the holder -arrow- .

Fig 4: Securing Electric Change-Over Valve

S, CAYENNE TURBO & CAYENNE TURBO S) > SUBSEQUENT WORK
1. Install fuel distributor pipe. → INSTALLING FUEL DISTRIBUTOR PIPE (FUEL RAIL) - section
on "Installing".
WM 276019 REMOVING AND INSTALLING STARTER (VR6) (CAYENNE) > TECHNICAL

VALUES

value 1 2
Fastening screw securing starter on Tightening 75 Nm (56

-6-
the transmission side, M12 Torque ft. lb.)
Fastening screw securing starter to Tightening 75 Nm (56

-8-
engine block, M12 Torque ft. lb.)
Fastening nut on solenoid switch, M6
Torque lb.)
Fastening nut for B+ line, M8 -1-
Torque ft. lb.)
WM 276019 REMOVING AND INSTALLING STARTER (VR6) (CAYENNE) >

PRELIMINARY WORK
1. Disconnect battery. → REMOVING BATTERY - section on "Removing"; → DISCONNECTING

THE BATTERY
2. Remove engine guard. → REMOVING ENGINE GUARD - section on "Removing"
WM 276019 REMOVING AND INSTALLING STARTER (VR6) (CAYENNE) > REMOVING

STARTER
WARNING: Working on the vehicle electrical system
Risk of burns
→ Disconnect the battery.
→ Prevent battery from reconnecting.
→ Cover the battery.
→ Remove ground terminal and cover the terminals.
→ Route electric lines without tensile strength.
→ Secure electric lines to existing lines/components.

Fig 1: Overview Of Starter
1. Open the press-studs -arrow- and remove the heat protection cover on the solenoid switch.
Fig 2: Identifying Press Studs For Heat Insulation Cover
2. Pull off protection cap -A- .
3. Screw off the fastening nut -1- and remove the line from the threaded bolt -B- .
4. Pull off protection cap -3- (-C- ).
5. Screw off the fastening nut -2- and remove the line from the threaded bolt -C- .
Fig 3: Disconnecting Lines On Starter
6. Unscrew the fastening screw -3- and pull line bracket away in a downward direction -A- .
7. Unscrew the fastening screw -4- .
8. Screw off the fastening nuts -5- and remove the holder -B- . To do this, turn the holder slightly
if necessary.
Fig 4: Identifying Starter Fasteners
9. Unscrew the fastening screw -6- on the transmission side of the starter.
Fig 5: Fastening Screw For Starter
11. Unscrew the lower fastening screw -8- on the starter.
12. Pull the line carefully downwards -A- and remove the starter -B- . Turn the starter if
necessary.
WM 276019 REMOVING AND INSTALLING STARTER (VR6) (CAYENNE) > INSTALLING

STARTER
Information
Before installing the starter, check the smooth operation of the thread for securing the starter.
Threads that do not open/close smoothly must be repaired before installing the starter .
1. Pull the line carefully downwards -A- and insert the starter -B- . Turn the starter if necessary
-C- .
Fig 1: Inserting Starter
2. Lift the starter forwards and screw in fastening screw -8- but do not tighten it.
3. Screw in the fastening screw -6- on the transmission side and tighten the two fastening
screws on the starter. → Tightening Torque: 75 Nm (56 ft. lb.) , → Tightening Torque: 75
Nm (56 ft. lb.)
Fig 2: Identifying Fastening Screw For Starter
4. Insert the holder -A- and screw on the fastening nuts -5- , but do not tighten them.
5. Screw in and tighten the fastening screw -4- , then tighten the fastening nuts -5- .
6. Place the protective tube in installation position -B- and secure with the fastening screw -3- .
7. Connect the line to the threaded bolt -A- and secure with the fastening nut -2- . → Tightening
Torque: 8 Nm (6 ft. lb.)
8. Fit protection cap -3- (-A- ).
9. Connect the line to the B+ connection -B- and secure with the fastening nut -1- . →
10. Fit protection cap on the B+ connection -C- .
Fig 4: Securing Lines On Starter
11. Place heat protection cover around solenoid switch -A- and secure with the press-studs -B- .
Fig 5: Pressing Studs For Heat Insulation Cover
12. Secure the line with the fastening screw -7- .

Fig 6: Screwing Down Line

SUBSEQUENT WORK
1. Install engine guard. → INSTALLING ENGINE GUARD - section on "Installing"
2. Connect the battery. → INSTALLING BATTERY - section on "Installing"; → CONNECTING

THE BATTERY
WM 278515 ADJUSTING CONTROL UNIT FOR DISTANCE MEASURING SENSOR (ALL

MODELS) > TOOLS

Wheel Alignment
Workshop
System ML 5000 WE 1272
Equipment
Porsche
Axle Alignment System

Workshop
With DSP508XF WE 1328
Equipment
Sensors
Adjustment Device
Workshop
With Reflector VAS WE 1362
Equipment
6430/1
Mirror For Adjustment Workshop
WE 1363
Device VAS 6430/3 Equipment
T-socket wrench for

Workshop
ACC sensor VAS WE 1364
Equipment
6190/2

MODELS) > PRELIMINARY WORK
The distance measuring sensor must be re-adjusted as part of the following tasks
1. Suspension was aligned and adjusted.
2. The distance measuring sensor (ACC sensor) control unit and/or the control unit holder was
removed, replaced and re-installed.
3. The lock carrier was loosened.
4. The front end is damaged.
5. Fault memory entry: ACC sensor incorrectly adjusted (D00004).
1. 5.1. The misalignment angle is outside of the range -1.5° to +1.5°.

MODELS) > PRELIMINARY WORK > TEST PREREQUISITES
1. The tread depth on one axle must not differ by more than 2 mm.
2. Air pressure of tires in accordance with regulations (regardless of "Comfort" or "Normal" air
pressure).
3. As with complete suspension alignment, make sure that there is no sliding base or turnplate at
the end stop during alignment.
1. 3.1. Take the track width and wheel base into consideration.
4. Check that vehicle weight corresponds to empty weight. Weight of the vehicle ready for driving
(completely full fuel tank and water tank for the windscreen washer/headlight cleaning system,
spare wheel, tool kit, jack) without driver.
5. Spare wheel, tool kit, jack must be located at the positions specified by the vehicle
manufacturer.
6. Vehicle aligned correctly, having been bounced and allowed to settle multiple times.
7. Check wheel suspension, steering and steering linkage for play and damage.
1. 7.1. Carry out repairs if necessary.
8. Adjust vehicles with levelling system (air spring) to normal level*.
1. 8.1. *Information: Engine/ignition off, doors closed, lock the vehicle.
2. 8.2. Wait for 15 seconds (air spring corrects vehicle).
3. 8.3. Unlock vehicle, open door and leave open during measurement, switch on
ignition.

MODELS) > PRELIMINARY WORK > DESIGN OF MEASURING SYSTEM
Information
Check that there is sufficient floor space between the vehicle and the adjustment device - the gap
between the adjustment device and vehicle must be approx. 120 cm.
The vehicle can be reversed onto the axle alignment platform if there is not enough floor space in front
of the measuring platform.
The vehicle must be positioned so that the front and rear axles are centered on turnplates/sliding plates.
Information
The procedure described here is for the wheel alignment system ML 5000 Porsche WE 1272 and the
axle alignment system with DSP508XF sensors WE 1328 .
Deviations can occur with other alignment systems.
1. Fit instrument holders onto the wheels on the rear axle.
2. Fit the rear sensors on the rear axle using the spoiler adapter (Beissbarth only, this sets the
sensors to a lower position).
3. Align the rear sensors on the rear axle using the spirit level and clamp the instrument holders
using the wing screws.
Information
Once the vehicle and adjustment tool are aligned, the vehicle and adjustment tool must no
longer be moved.
1. The vehicle is standing on turnplates/sliding plates that are released on one side ,
allowing the vehicle to be moved slightly .
2. If the vehicle is moved while taking measurements on the turnplates, the measurement
process must be repeated .
3. If the adjustment tool is moved following alignment, the measurement process must be
repeated .
4. Attach front sensors to the measuring mirror, align using the spirit level and clamp.
1. 4.1. Centre the adjustment tool.
2. 4.2. Set distance of adjustment tool and vehicle in accordance with the specifications
provided by the measuring equipment manufacturer.
3. 4.3. The distance between the left sensor and the vehicle -Bl- should be identical to
the distance between the right sensor and the vehicle -Br- .
Fig 1: Adjusting Device Setup
5. Switch on (initialize) the sensors.

MODELS) > PRELIMINARY WORK > PREPARATION FOR ADJUSTING DISTANCE
MEASURING SENSOR
1. Connect a battery charger with a current rating of at least 40 A to the external power feed
points.
2. Read out the fault memory using PIWIS Tester II 9818 , create a VAL if necessary → 0X03IN
CREATING VEHICLE ANALYSIS LOG (VAL) and correct any faults.
Fig 1: Identifying Diagnostic Socket

3. 3.3. Unlock vehicle, open door and leave open during the measurement, switch on
ignition.
4. Remove cover on sensor. → Removing cover

1. 4.1. Release cover at the top -arrows- .
2. 4.2. Fold cover forward and remove it.
5. Clean sensor and cover using a commercially available cleaning agent.
6. Fit the front sensors onto the adjustment device, align using spirit levels and clamp using the
wing screws, and switch them on (initialize).
7. The gap between the ACC adjustment device adjustment device with reflector VAS 6430/1
WE 1362 and the vehicle must be approx. 120 cm.
1. 7.1. Position the ACC adjustment device adjustment device with reflector VAS
6430/1 WE 1362 at a distance of 130 +/- 10 cm between the sensor lens and
mirror face mirror for adjustment device VAS 6430/3 WE 1363 .
the distance between the right spirit level and the vehicle -Br- .
8. On the adjustment device, move the mirror into position -2- so that it is aligned with the
marking (-A- number 2 on the rotary knob must point towards the vehicle).
Fig 4: Positioning Adjustment Device
Information
longer be moved.
allowing the vehicle to be moved .
repeated .
9. Release turnplates/sliding plates on One Side Of The Vehicle .
10. Open the corresponding menu (Use Operating Instructions For Measuring Platform) in
order to adjust the distance measuring sensor.
11. Before starting the adjustment process, use the laser beam -3- at the mirror on the adjustment
device (for switching on the laser beam >> see operating instructions for adjustment device) to
check that the laser beam strikes the sensor lens. Info:
1. 11.1. The adjustment device is aligned (positioned) correctly if the laser beam still
strikes the sensor lens even after the identical individual toe values have been set.
2. 11.2. If the laser beam does not strike the sensor lens, alignment of the adjustment
device must be repeated.
Fig 5: Identifying Laser Beam At Mirror
12. Align adjustment device at the side:
1. 12.1. The laser beam of the adjustment device must strike the center of the sensor
lens.
Fig 6: Aligning Adjustment Device
13. Use the adjusting screws -1, 2, 3, 4, 5- on the adjustment device to level the mirror's spirit
levels -A, B- .
Fig 7: Aligning Mirror's Spirit Levels
14. Use the crank -arrow- on the adjustment device to adjust the mirror so that the laser beam
(for switching on the laser beam >> see operating instructions for adjustment device) strikes
the center of the sensor lens on the vertical line.
Fig 8: Example Of Adjustment Bar Display
15. Turn the adjustment bar on the adjustment device to the side using the adjusting screw -5-
until the green indicator on the adjustment bar is displayed on the measuring platform screen.
Fig 9: Example Of Hunter Display

MODELS) > ADJUSTING CONTROL UNIT FOR DISTANCE MEASURING SENSOR
1. A battery charger with a current rating of at least 40 A must be connected to the external
power feed points.
2. Connect PIWIS Tester II 9818 to the vehicle and start it.
4. Select the required vehicle and select Adaptive Cruise Control control unit, then press [F12]
to continue.
5. In the Adaptive Cruise Control menu, select the Maintenance/Repairs submenu and press
[F12] to continue.
6. Follow the instructions on the Tester and, if necessary, adjust the sensor -1- using the
adjusting tool T-Socket Wrench For ACC Sensor VAS 6190/2 WE 1364 in line with the
Tester specifications.
Fig 1: Adjusting Screws For Distance Measuring Sensor
7. The process must be repeated until the message Adjustment Successful is displayed on the
Tester.

MODELS) > SUBSEQUENT WORK

2. PIWIS Tester II 9818 can now be disconnected from the vehicle.
3. Disconnect the battery charger.
4. Remove sensors and instrument holders.
Information
Before and after fitting the trim cover for the distance measuring sensor control unit, check the
following points:
1. The holder for the distance measuring sensor control unit must not show any signs of
deformation, which may have been caused, for example, by removing or installing the
trim cover for the distance measuring sensor control unit. If the holder for the distance
measuring sensor control unit is deformed, carefully push it back into shape .
2. If the trim cover is damaged or cracked, replace the trim cover .
3. After fitting the trim cover, check that it is seated correctly and securely .
5. Install cover on sensor and clip it in at the top -arrows- .

6. Perform a test drive and check operation of distance measuring sensor control unit.
7. Read out the fault memory of the distance measuring sensor (ACC) control unit and erase it if
necessary.
WM 278519 REMOVING AND INSTALLING CONTROL UNIT FOR DISTANCE

MEASURING SENSOR (ALL MODELS) > TECHNICAL VALUES

value 1 2
Holder for distance measuring

Internal Torx Tightening 8 Nm (6
sensor control unit to closing
screw, M6 x 12 Torque ft. lb.)
panel

MEASURING SENSOR (ALL MODELS) > REMOVING CONTROL UNIT FOR DISTANCE
MEASURING SENSOR


3. Release electric plug connection -arrow a- and disconnect it -arrow b- .

4. Unclip electric wire harness from holder for distance measuring sensor control unit.

Fig 3: Identifying Sensor Control Unit Screws
6. Remove holder together with control unit for distance measuring sensor.

MEASURING SENSOR (ALL MODELS) > INSTALLING CONTROL UNIT FOR
DISTANCE MEASURING SENSOR
Information
following points:
Tighten fastening screws. Tightening Torque 8 Nm (6 ft. lb.)

MEASURING SENSOR (ALL MODELS) > SUBSEQUENT WORK > SUBSEQUENT
WORK AFTER REMOVING AND INSTALLING CONTROL UNIT FOR DISTANCE
MEASURING SENSOR
If the distance measuring sensor control unit was removed and installed or replaced, the distance
measuring sensor control unit will need to be re-adjusted on a measuring platform using adjustment tool
VAS 6430 . → 278515 ADJUSTING CONTROL UNIT FOR DISTANCE MEASURING SENSOR .
WM 278555 REPLACING CONTROL UNIT FOR DISTANCE MEASURING SENSOR


(ALL MODELS) > TECHNICAL VALUES

(ALL MODELS) > READING AND WRITING VALUES
NOTE: Voltage drop
battery.
Information
Tester releases.
4. Select Adaptive cruise control control unit in the overview .
CONTROL UNIT FOR DISTANCE MEASURING SENSOR

WM 279019 REMOVING AND INSTALLING ELECTRIC MOTOR WITH DECOUPLER
(HYBRID MODULE) (CAYENNE S HYBRID) > PRELIMINARY WORK
1. Observe warning notes. → WM 2X00IN GENERAL WARNING NOTES FOR WORKING ON

THE HIGH-VOLTAGE VEHICLE ELECTRICAL SYSTEM (CAYENNE S E-HYBRID)
2. Isolate the high-voltage electrical system from the power supply and complete the relevant
POWER SUPPLY/STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM .
3. Remove the engine. → REMOVING V6 HYBRID ENGINE - section on "Removing".
4. Unscrew the transmission from the engine. → REMOVING TRANSMISSION - section on

"Removing".

(HYBRID MODULE) (CAYENNE S HYBRID) > REMOVING ELECTRIC MOTOR WITH
DECOUPLER (HYBRID MODULE)
The procedure is described in the document → 100127 REMOVING ENGINE FROM TRANSMISSION
AND MOUNTING ENGINE ON TRANSMISSION .

(HYBRID MODULE) (CAYENNE S HYBRID) > INSTALLING ELECTRIC MOTOR WITH

(HYBRID MODULE) (CAYENNE S HYBRID) > SUBSEQUENT WORK
1. Install transmission on engine. → INSTALLING TRANSMISSION - section on "Installing".
2. Start the high-voltage electrical system and complete the relevant documentation. → 2X00IN
HIGH-VOLTAGE ELECTRICAL SYSTEM .
3. Read about how to calibrate the electric motor in "Guided Fault Finding and the latest
Technical Information releases for special tasks to be performed after servicing and repairing
the Cayenne Hybrid".
WM 279119 REMOVING AND INSTALLING FUSE FOR POWER ELECTRONICS FOR

HIGH-VOLTAGE SYSTEM (CAYENNE S E-HYBRID) > TOOLS

HIGH-VOLTAGE SYSTEM (CAYENNE S E-HYBRID) > TECHNICAL VALUES
value 1 2
Cover on power electronics unit
Torque lb.)
Media shield to power electronics Tightening 7 Nm (5 ft.

unit Torque lb.)
Fuse for power electronics unit to Tightening 2 Nm (1.5

power electronics unit Torque ft. lb.)

HIGH-VOLTAGE SYSTEM (CAYENNE S E-HYBRID) > INFORMATION
Information
Further steps may only be carried out if the voltage measured at the power electronics is < 5 V. If this is
not the case, stop working on the system and contact Technical Support.
Fig 1: Identifying Power Electronics Unit Installation Position

HIGH-VOLTAGE SYSTEM (CAYENNE S E-HYBRID) > PRELIMINARY WORK
3. Disconnect the battery. → 978509 LOOSENING AND SECURING GROUND STRAP FOR
BATTERY
4. Remove engine compartment cover at the left. → 700219 REMOVING AND INSTALLING
5. If fitted: Remove acoustic simulator.

HIGH-VOLTAGE SYSTEM (CAYENNE S E-HYBRID) > REMOVING FUSE FOR POWER
ELECTRONICS UNIT
1. Unclip clips for high-voltage line at the media shield.
2. Unscrew media shield -1- .

Fig 1: Identifying Media Shield Screws
3. Release and disconnect high-voltage connector for air-conditioning compressor
1. 3.1. Release 1: Press red tab -a- and pull it -A-
2. 3.2. Release 2: Press black knob -b- and pull it off -B-
Fig 2: Disconnecting High-Voltage Connector
4. Check that power electronics unit for high-voltage system -1- is de-energized.
Information
Further steps may only be carried out if the voltage measured at the power electronics is < 5 V.
If this is not the case, stop working on the system and contact Technical Support.
Fig 3: Identifying High-Voltage System
5. Unscrew cover on power electronics unit -1- .

Fig 4: Identifying Power Electronics Unit Cover
6. Loosen fastening screws -1- on fuse for power electronics for the high-voltage system -2- and
remove fuse.
Fig 5: Identifying Power Electronics Unit Fuse

HIGH-VOLTAGE SYSTEM (CAYENNE S E-HYBRID) > INSTALLING FUSE FOR POWER
ELECTRONICS UNIT
1. Position fuse for power electronics unit for high-voltage system -2- and tighten fastening
screws -1- . Tightening Torque 2 Nm (1.5 ft. lb.)
Information
As soon as the cover on the power electronics unit is removed, it must be replaced by a new
cover for safety reasons.
2. Fit and secure cover on power electronics unit -1- . Tightening Torque 7 Nm (5 ft. lb.)
Fig 2: Installing Power Electronics Unit Cover
3. Plug in high-voltage connector for air-conditioning compressor at the power electronics unit
Information
Check that the HV connector is locked correctly. The hook (red) must be locked after
connecting the HV connector.
4. Fit and secure media protective plate. Tightening Torque 7 Nm (5 ft. lb.)
5. Clip high-voltage lines onto media protective plate.

HIGH-VOLTAGE SYSTEM (CAYENNE S E-HYBRID) > SUBSEQUENT WORK
1. If fitted: Install acoustic simulator.
2. Install engine compartment cover at the left. → INSTALLING FRONT TRIM PANEL (ENGINE
COMPARTMENT)
3. Connect the battery. → 978509 LOOSENING AND SECURING GROUND STRAP FOR
BATTERY
4. Start the vehicle again and complete the relevant documentation. → 2X00IN ISOLATING
HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER SUPPLY/STARTING
WM 279155 REPLACING POWER ELECTRONICS FOR HIGH-VOLTAGE SYSTEM


WE 1593
Set Equipment


(CAYENNE S E-HYBRID) > TEACHING POWER ELECTRONICS
NOTE: Voltage drop
battery.
Information
Tester releases.
Information
by the vehicle.
1. Switch off ignition and replace power electronics unit. → 279119 REMOVING AND
INSTALLING POWER ELECTRONICS FOR HIGH-VOLTAGE SYSTEM
2. Connect the PIWIS Tester to the vehicle and start the diagnostic application. Switch on ignition.
4. Select the On-Line Teaching Function menu on the Start page.
5. Vehicle must now be selected. Then press [F12] to continue. Vehicle data will be read out.
6. The vehicle identification number (VIN) is displayed. Change the vehicle identification number
if necessary.
7. Enter the repair order number and press [F12] to continue.
8. Enter the PPN user name and password and press [F12] to continue.
10. The Tester displays the message Login Successful . Press [F12] to continue.
11. Follow the instructions on the Tester and perform the teaching process.
12. Once the teaching process is completed successfully, the Tester shows the components that
were taught and the overall status of the vehicle, for example: Taught . Press [F12] to
continue.
13. Press [EXIT] To End The On-Line Teaching Function and select the Vehicle Type on the
Start page.
14. Select the High-Voltage Power Electronics control unit in the Overview .
15. Select the Codings/Adaptations menu and carry out the Automatic Coding function in
accordance with the instructions on the Tester.
16. Press [F7] Read All Fault Memories And Erase If Required and delete all faults.
17. Function test: Lock, open and start the vehicle using all remote controls (hand-held
transmitters).
WM 279219 REMOVING AND INSTALLING ELECTRIC MOTOR (CAYENNE S HYBRID)

> PRELIMINARY WORK

"Removing".

> REMOVING ELECTRIC MOTOR

> INSTALLING ELECTRIC MOTOR

> SUBSEQUENT WORK

(HYBRID MODULE) (CAYENNE S E-HYBRID) > TOOLS
Insulated Tool Set Workshop equipment WE 1593

(HYBRID MODULE) (CAYENNE S E-HYBRID) > PRELIMINARY WORK
3. Remove engine. → REMOVING V6 HYBRID ENGINE - section on "Removing".
4. Unscrew transmission from the engine. → REMOVING AUTOMATIC TRANSMISSION

(HYBRID MODULE) (CAYENNE S E-HYBRID) > REMOVING ELECTRIC MOTOR WITH

(HYBRID MODULE) (CAYENNE S E-HYBRID) > INSTALLING ELECTRIC MOTOR WITH

(HYBRID MODULE) (CAYENNE S E-HYBRID) > SUBSEQUENT WORK
1. Install transmission on engine. → 373519 REMOVING AND INSTALLING AUTOMATIC

TRANSMISSION .
3. Read about how to calibrate the electric motor in "Guided Fault Finding" and the latest
Technical Information releases for special tasks to be performed after servicing and repair
work.
WM 279319 REMOVING AND INSTALLING HIGH-VOLTAGE LINE BETWEEN

HIGH-VOLTAGE CHARGER AND HIGH-VOLTAGE BATTERY (CAYENNE S E-HYBRID)
> TOOLS

> PRELIMINARY WORK
4. Remove side trim panel for rear luggage compartment at the left. → REMOVING SIDE TRIM

> REMOVING HIGH-VOLTAGE LINE BETWEEN HIGH-VOLTAGE CHARGER AND
HIGH-VOLTAGE BATTERY > REMOVING HIGH-VOLTAGE LINE
Fig 1: Identifying High-Voltage Line Installation Position
1. Release high-voltage connector -1- from the high-voltage battery -2- and disconnect it.
2. Open cable duct -3- and remove right high-voltage line -4- .
Fig 2: Disconnecting High-Voltage Line
3. Unclipping high-voltage line
4. Release high-voltage connector -1- from the high-voltage charger -2- and disconnect it.
Fig 3: Disconnecting High-Voltage Connector From High-Voltage Charger

> INSTALLING HIGH-VOLTAGE LINE BETWEEN HIGH-VOLTAGE CHARGER AND

> SUBSEQUENT WORK
1. Install cover for rear lock support. → INSTALLING COVER FOR REAR LOCK SUPPORT -
2. Install side trim panel for rear luggage compartment at the left. → INSTALLING SIDE TRIM
WM 279319 REMOVING AND INSTALLING HIGH-VOLTAGE LINE FROM

BATTERY/HIGH-VOLTAGE CHARGER TO POWER ELECTRONICS/PTC AT THE
FRONT (CAYENNE S E-HYBRID) > TOOLS

FRONT (CAYENNE S E-HYBRID) > TECHNICAL VALUES
Tolerance Tolerance
1 2
High-voltage line cover to Fastening nut Tightening 9 Nm (6.5 ft.

body -4- Torque lb.)


FRONT (CAYENNE S E-HYBRID) > PRELIMINARY WORK
1. Read and comply with warning notes. → 2X00IN GENERAL WARNING NOTES FOR
WORKING ON THE HIGH-VOLTAGE ELECTRICAL SYSTEM .
3. Remove rear side trim panel at the left. → REMOVING SIDE TRIM PANEL FOR REAR
LUGGAGE COMPARTMENT - section on "Removing".
4. Remove cover for left underbody. → 519319 REMOVING AND INSTALLING COVER FOR
CENTER UNDERBODY .
5. Remove the lower fastening clamp from the heat shield next to the left front silencer.
6. Remove left front wheel.
7. Remove front wheel housing liner at the left. → 505619 REMOVING AND INSTALLING
8. Remove power electronics for high-voltage system. → 279119 REMOVING AND INSTALLING
POWER ELECTRONICS FOR HIGH-VOLTAGE SYSTEM

FRONT (CAYENNE S E-HYBRID) > REMOVING HIGH-VOLTAGE LINE FROM BATTERY
TO POWER ELECTRONICS
Fig 1: High-Voltage Line Routing Diagram
1. Release and disconnect high-voltage connector from auxiliary heater (front PTC) -1- .
3. Unscrew coolant line -3- .
4. Cut tie-wraps -4- and unscrew fastening screw for cable guides -5- .
5. Guide high-voltage line down through the gap opening on the heat shield -6- .
Fig 2: Disconnecting High-Voltage Line From Front PTC
6. Unscrew the three fastening nuts -1- for the high-voltage line (engine area).
1. 6.1. Cut the tie-wraps for the high-voltage line cover -arrow- and remove cover in a
downward direction.
Fig 3: Removing High-Voltage Line Cover
7. Unscrew universal joint at the steering column and set it aside. → 481519 REMOVING AND
INSTALLING STEERING COLUMN
8. Open the two corrugated tube clips and unclip the high-voltage lines from the two corrugated
tube holders -1- (left door sill area, center).
1. 8.1. Cut tie-wraps -arrow- .

Fig 4: Removing High-Voltage Line
9. Remove the two fixing clips -1- (left door sill area, rear).
10. Unclip the cable guides on the body (expanding anchor) three times -arrow- .
11. Unclip the high-voltage lines from the corrugated tube holder -1- (left door sill area, rear).
12. Remove high-voltage line in luggage compartment area.
1. 12.1. Unscrew coolant lines -1- and set them aside.

Fig 7: Removing Coolant Lines
2. 12.2. Unclip high-voltage line from battery to high-voltage charger -1 - .
3. 12.3. Unclip high-voltage line from power electronics to high-voltage charger -6- .
4. 12.4. Unscrew the three fastening nuts -2- for the high-voltage line cover -3- and
remove it.
5. 12.5. Open the cable duct -4- .
6. 12.6. Release and disconnect high-voltage connector for high-voltage line for
on-board charger -7- .
7. 12.7. Unscrew high-voltage lines from the battery -5- .
8. 12.8. Guide the rubber sleeve for the cable bushing for the high-voltage lines on the
body floor (luggage compartment area) down through the body floor -A- .
9. 12.9. Pull out the high-voltage lines in a downward direction -B- .


FRONT (CAYENNE S E-HYBRID) > INSTALLING HIGH-VOLTAGE LINE FROM
BATTERY TO POWER ELECTRONICS
Information
For correct longitudinal positioning in the vehicle, a plastic eyelet is fitted on the high-voltage wire
harness for the hybrid battery close to the line shielding in the luggage compartment. During installation,
this plastic eyelet must be attached to the center threaded bolt on the line shielding in the luggage
compartment.
1. Install high-voltage line in luggage compartment area.
1. 1.1. Push the high-voltage lines down through the opening in the luggage
compartment floor -A- .
2. 1.2. Coat the rubber sleeve with sliding compound and press it onto the body until
the rubber sleeve is positioned correctly.
3. 1.3. Push the plastic eyelet of the high-voltage line onto the fastening bolt. Fit the
cover -3- and secure with the three fastening nuts -2- . → Tightening Torque: 9
Nm (6.5 ft. lb.) .
4. 1.4. Plug high-voltage lines into the high-voltage battery -5- and secure them. →
270819 REMOVING AND INSTALLING HIGH-VOLTAGE BATTERY
5. 1.5. Plug in high-voltage line for the high-voltage charger -7- until it engages
securely.
6. 1.6. Place high-voltage lines in the cable duct -4- and fit cable duct.
7. 1.7. Clip in high-voltage line from battery to high-voltage charger -1- .
8. 1.8. Clip in high-voltage line from power electronics to high-voltage charger -6- .
Fig 1: Installing High-Voltage Line
9. 1.9. Screw on coolant line -1- .

Fig 2: Identifying Coolant Line Screws
2. Clip the two high-voltage lines into the corrugated tube holders -1- (left door sill area, rear).
1. 2.1. Close corrugated tube holders.

Fig 3: Installing High-Voltage Lines
3. Clip in the cable guides on the body (expanding anchor) three times -arrow- .
4. Install the high-voltage lines using the two fixing clips -1- (left door sill area, rear).
5. Clip the high-voltage lines into the two corrugated tube holders -1- (left door sill area, center).
2. 5.2. Secure the high-voltage line with a tie-wrap -arrow- .

6. Secure universal joint to the steering column. → 481519 REMOVING AND INSTALLING
STEERING COLUMN
7. Install high-voltage line in engine area.
1. 7.1. Fit high-voltage line cover and screw on the three fastening nuts -1- . →
2. 7.2. Secure the high-voltage line and cover using three tie-wraps -arrow- .
Fig 6: Installing High-Voltage Line Cover
8. Fit high-voltage line through the gap opening on the heat shield -6- into the wheel housing.
9. Secure cable guides using tie-wraps -4- and tighten fastening screw on the cable guides -5- .
10. Plug in electric plug connection -2- until it engages securely.
11. Plug in high-voltage connector for auxiliary heater (front PTC) -1- until it engages securely.
12. Screw on coolant line -3- .

Fig 7: Securing High-Voltage Line For Front PTC
Information
The plug connection and connector holder must be checked for wear and damage before
connecting the high-voltage lines.
The high-voltage lines are color-coded and must only be connected to the color-coded
connector holder.
The high-voltage lines can only be connected at one position. Check the connection position
before connecting the lines.

FRONT (CAYENNE S E-HYBRID) > SUBSEQUENT WORK
1. Install fuel tank. Install the left running board on the fuel tank and fit the two restraining straps
at the front left. → INSTALLING FUEL TANK - section on "Installing".
2. Fill the fuel tank. → 200317 DRAINING AND FILLING FUEL .
3. Install the lower fastening clamp on the heat shield next to the left front silencer.
4. Install cover for left underbody. → 519319 REMOVING AND INSTALLING COVER FOR
CENTRE UNDERBODY .
5. Install side trim panel at the rear right. → INSTALLING SIDE TRIM PANEL FOR REAR
LUGGAGE COMPARTMENT - section on "Installing".
7. Install front wheel housing liner at the left. → 505619 REMOVING AND INSTALLING FRONT
WHEEL HOUSING LINER
8. Install left front wheel.
WM 279319 REMOVING AND INSTALLING HIGH-VOLTAGE LINE FROM POWER

ELECTRONICS TO AIR-CONDITIONING COMPRESSOR (CAYENNE S E-HYBRID) >
TOOLS

PRELIMINARY WORK

REMOVING HIGH-VOLTAGE LINE FROM POWER ELECTRONICS TO
AIR-CONDITIONING COMPRESSOR
1. Unclip high-voltage line.

Fig 2: Identifying Media Shield
3. Release high-voltage connector at the power electronics unit and disconnect it.
2. 3.2. Release 2: Press black knob -b- and pull it off -B Removing
4. Release high-voltage line at the air-conditioning compressor and disconnect it.
5. Carefully remove high-voltage line.

INSTALLING HIGH-VOLTAGE LINE FROM POWER ELECTRONICS TO

SUBSEQUENT WORK
2. Install engine compartment cover at the left. → 700219 REMOVING AND INSTALLING

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S E-HYBRID) > TOOLS

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S E-HYBRID) > TECHNICAL
VALUES

value 1 2
Line bracket for high-voltage Fastening Tightening 8 Nm (6 ft.

line to electric motor screws - 3- Torque lb.)
High-voltage line to electric Tightening 20 Nm (15

Fastening nut -2-
motor Torque ft. lb.)
Connection box cover on Fastening Tightening 7 Nm (5 ft.

electric motor screws - 1- Torque lb.)

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S E-HYBRID) > PRELIMINARY
WORK

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S E-HYBRID) > REMOVING
HIGH-VOLTAGE LINE FROM POWER ELECTRONICS TO ELECTRIC MOTOR >
REMOVING HIGH-VOLTAGE LINE
Information
Always replace all three high-voltage lines if necessary.
Use new seals.
Use new screws.
Check contacts on the line connections for corrosion and clean them if necessary.
1. Unscrew and remove the four fastening screws -1- for the cover. Then lift up the cover and
swivel it to one side.
2. Unscrew and remove the three fastening nuts -2- for the high-voltage line contacts.
3. Unscrew and remove the fastening screws -3- for the high-voltage lines on the electric motor.
Fig 3: Identifying High-Voltage Contacts Nuts And Screws
4. Lift up high-voltage line -4- , turn it approx. 75 ° to the left and carefully pull it out of the electric
motor.
1. 4.1. Lift up high-voltage line -5- , turn it approx. 75 ° to the right and carefully pull it
out of the electric motor.
Fig 4: Removing High-Voltage Lines

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S E-HYBRID) > INSTALLING
INSTALLING HIGH-VOLTAGE LINE
Information
Use new seals.
Use new screws.
Information
The three high-voltage lines are coded differently.

Fig 1: Identifying High-Voltage Line And Electric Motor Coding
Make sure that the coding for the electric motor matches the coding for the line.
Information
Always replace the connection box cover seal for the electric motor after opening it.
1. Push the three high-voltage lines -6, 5, 4- one after the other into the electric motor, attach
them to the contacts and secure with the fastening screws -3- . → Tightening Torque: 8 Nm
(6 ft. lb.) .
2. Secure the contacts of the three high-voltage lines with the fastening nuts -2- . → Tightening
Fig 3: Identifying High-Voltage Line Contacts
3. Fit the cover for the electric motor and secure with the four fastening screws -1- . →
Fig 4: Fitting Electric Motor Cover

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S E-HYBRID) > SUBSEQUENT
WORK
1. Install engine. → INSTALLING V6 HYBRID ENGINE - section on "Installing".
WM 279319 REMOVING AND INSTALLING HIGH-VOLTAGE LINE FROM BATTERY TO

POWER ELECTRONICS (CAYENNE S HYBRID) > TECHNICAL VALUES
Tolerance Tolerance
1 2


POWER ELECTRONICS (CAYENNE S HYBRID) > PRELIMINARY WORK
CENTRE UNDERBODY .
6. Empty the fuel tank. → 200317 DRAINING AND FILLING FUEL .
7. Remove fuel tank. → REMOVING FUEL TANK - section on "Removing".
9. Remove left wheel housing liner.

POWER ELECTRONICS (CAYENNE S HYBRID) > REMOVING HIGH-VOLTAGE LINE
FROM BATTERY TO POWER ELECTRONICS
Fig 1: Overview Of High-Voltage Line
1. Disengage the holder -arrow- for the two high-voltage lines at the power electronics.
Fig 2: Disengaging High-Voltage Lines From Power Electronics
downward direction.
Fig 3: Removing High-Voltage Line In Engine Area

Fig 4: Removing High-Voltage Line In Centre Area
Fig 5: Removing High-Voltage Line In Rear Area
6. Unclip the two high-voltage lines from the corrugated tube holder -2- (left door sill area, rear).
remove it.
body floor (luggage compartment area) down through the body floor -2- .
3. 7.3. Pull out the high-voltage lines in a downward direction -3- .

Fig 7: Removing High-Voltage Line In Luggage Compartment Area

POWER ELECTRONICS (CAYENNE S HYBRID) > INSTALLING HIGH-VOLTAGE LINE
Information
compartment.
1. 1.1. Slide the high-voltage lines down through the opening on the luggage
compartment floor -2- .
2. 1.2. Coat the rubber sleeve with sliding compound and press it onto the body -1-
until the rubber sleeve is positioned correctly.
cover -3- and secure it with the three fastening nuts -4- . → Tightening Torque: 9
Nm (6.5 ft. lb.) .
Fig 1: Installing High-Voltage Line In Luggage Compartment Area
1. 2.1. Close the corrugated tube holder.

Fig 2: Installing High-Voltage Lines Into Corrugated Tubes
4. Install the two high-voltage lines with the two fixing clips -3- (left door sill area, rear).
Fig 3: Installing High-Voltage Line In Rear Area
5. Clip the two high-voltage lines into the two corrugated tube holders -2- (left door sill area,
center).
1. 5.1. Close the corrugated tube holders.

Fig 4: Installing High-Voltage Line In Centre Area
2. 6.2. Secure the high-voltage line and cover with three tie-wraps -arrow- .
Fig 5: Installing High-Voltage Line In Engine Area
7. Secure high-voltage lines to the power electronics with the holding claw.
Fig 6: Locating High-Voltage Lines To Power Electronics
Information
connector holder.

POWER ELECTRONICS (CAYENNE S HYBRID) > SUBSEQUENT WORK
1. Install the fuel tank. Install the left running board on the fuel tank and fit the two restraining
straps at the front left. → INSTALLING FUEL TANK - section on "Installing".
CENTRE UNDERBODY .

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S HYBRID) > TECHNICAL VALUES

value 1 2


Fastening nut -2-


ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S HYBRID) > PRELIMINARY WORK

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S HYBRID) > REMOVING
HIGH-VOLTAGE LINE FROM POWER ELECTRONICS TO ELECTRIC MOTOR
Information
Use new seals.
Use new screws.
1. Unscrew the four fastening screws -1- for the cover. Then lift up the cover and swivel it to one
side.
Fig 1: Removing Electric Motor Cover
2. Unscrew the three fastening nuts -2- for the high-voltage line contacts.
3. Unscrew the fastening screws -3- for the high-voltage lines on the electric motor
motor.

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S HYBRID) > INSTALLING
INSTALLING HIGH-VOLTAGE LINE ON POWER ELECTRONICS FOR ELECTRIC
MOTOR
Information
Use new seals.
Use new screws.
Information

Information
(6 ft. lb.) .
Fig 4: Installing Motor Cover

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S HYBRID) > SUBSEQUENT WORK
1. Install the engine. → INSTALLING V6 HYBRID ENGINE - section on "Installing".

ELECTRONICS TO AIR-CONDITIONING COMPRESSOR (CAYENNE S HYBRID) >
PRELIMINARY WORK
2. The high-voltage system must be isolated from the power supply. Isolate the high-voltage
system from the power supply and complete the relevant documentation. → 2X00IN
Information
The high-voltage lines and connector holder at the power electronics are color-coded
1. Release the high-voltage line -1- at the power electronics (rapid-action coupling) and unplug it.
Fig 1: Removing High-Voltage Lines From Power Electronics
2. Release the high-voltage line from the power electronics to the air-conditioning compressor
(rapid-action coupling) and unplug it.
Fig 2: Removing High-Voltage Line From Air-Conditioning Compressor
3. Take the high-voltage line from the power electronics to the air-conditioning compressor out of

Information
The plug connection and connector holder must be checked for wear and damage before connecting the
high-voltage lines.
The high-voltage lines are color-coded and must only be connected to the color-coded connector holder.
The high-voltage lines can only be connected at one position. Check the connection position before
connecting the lines.
1. Plug in the high-voltage line from the power electronics to the air-conditioning compressor
(rapid-action coupling) until the connector engages securely.
Fig 1: Connecting High-Voltage Line To Air-Conditioning Compressor
2. Plug the high-voltage line -1- into the power electronics until the connector engages securely.
Fig 2: Connecting High-Voltage Lines To Power Electronics
Replacing high-voltage line
Information
When replacing the high-voltage line, the cable must be routed differently because it now has a
different length and an additional tie-wrap holder must be fitted.
3. Plug in the high-voltage line from the power electronics to the air-conditioning compressor at
the air-conditioning compressor -2- (quick connector) until the connector engages securely.
4. Secure the high-voltage line to the line from the air-conditioning compressor with a tie-wrap
-3- .
Fig 3: Replacing High-Voltage Line

SUBSEQUENT WORK
WM 279419 REMOVING AND INSTALLING HIGH-VOLTAGE BATTERY CONTROL UNIT

High-Voltage Workshop
WE 1589
Cordon Equipment
Workshop
Equipment

Tolerance Tolerance
1 2
Tightening 5.9 Nm (4.5 ft.

HV battery control unit
Torque lb.)
Cover for HV battery control Tightening 5.9 Nm (4.5 ft.

unit Torque lb.)

1. If a new control unit has to be installed, the values must be read out using PIWIS Tester II
9818 before removing the "old" control unit. → 279455 REPLACING CONTROL UNIT FOR
HV BATTERY

"Removing"
5. Remove high-voltage battery fuse. → REMOVING HIGH-VOLTAGE BATTERY FUSE - section

on "Removing"

(CAYENNE S E-HYBRID) > REMOVING HIGH-VOLTAGE BATTERY CONTROL UNIT

Information
Fig 1: Caution For Restricted Area For Battery
1. Loosen fastening nuts -1, 2- on the cover of the HV battery control unit and remove cover -3-
.
Fig 2: Identifying HV Battery Control Unit Cover
2. Remove spacers under the fastening nuts -1- .
3. Remove ground line.

Fig 3: Removing Ground Line
4. Loosen fastening nuts -1- on the HV battery control unit and pull off HV battery control unit -2-
.
Fig 4: Removing Control Unit For HV Battery
5. Release electric plug connection -1- at the HV battery control unit completely -a- and
disconnect it -A- .
6. Release electric plug connection -2- completely -b- and disconnect it -B- .
7. Remove control unit for HV battery.
8. Clean screw thread at the fastening points carefully with a vacuum cleaner. Make sure that no
dirt gets into the battery housing. Only use a vacuum cleaner with a plastic nozzle.

(CAYENNE S E-HYBRID) > INSTALLING HIGH-VOLTAGE BATTERY CONTROL UNIT
Information
Information
1. Connect electric plug connection -2- on the HV battery control unit -b- and lock it -B- .
2. Connect electric plug connection -2- (-a- ) and lock it -A- .

3. Push control unit -2- onto the E-box and tighten fastening nuts -1- to → Tightening Torque:
5.9 Nm (4.5 ft. lb.) .
Fig 2: Identifying Control Unit For HV Battery
4. Position spacers on the bolts under fastening nuts -2- .
5. Position cover for HV battery control unit -3- and tighten fastening nuts -1, 2- to →
Tightening Torque: 5.9 Nm (4.5 ft. lb.) .
Fig 3: Identifying Cover For HV Battery Control Unit

1. Install high-voltage battery fuse. → INSTALLING HIGH-VOLTAGE BATTERY FUSE - section

on "Installing"

"Installing"
4. If the control unit was replaced, the "new" control unit must be adapted to suit the vehicle using
PIWIS Tester II 9818 . → 279455 REPLACING CONTROL UNIT FOR HV BATTERY
WM 279419 REMOVING AND INSTALLING CONTROL UNIT FOR HV BATTERY

(CAYENNE S HYBRID) > TOOLS

TORX Screwdriver Workshop
WE 1382
Set VAS 6633 Equipment

(CAYENNE S HYBRID) > PRELIMINARY WORK
Tester II 9818 prior to removing the "old" control unit. → 279455 REPLACING BATTERY
MANAGEMENT SYSTEM CONTROL UNIT .
4. Remove the high-voltage battery. → REMOVING HIGH-VOLTAGE BATTERY - section on

"Removing"

(CAYENNE S HYBRID) > REMOVING CONTROL UNIT FOR HV BATTERY
Fig 1: Identifying Control Unit For HV Battery Installation Position
WARNING: High voltage at the E-box
→ Work on the HV battery control unit may only be carried out by a high-voltage technician.
→ Always use insulated tools when working on the HV battery control unit.
→ Observe general warning notes for working on the high-voltage vehicle electrical system.
1. Unscrew the eight fastening screws -1- on the E-box cover and remove it.
Fig 2: Identifying E-Box Cover Screws
2. Loosen the two fastening screws -2- on the service disconnector mounting.
Fig 3: Identifying Service Mounting Screws
3. Cut tie-wrap -arrow- for the electric line.
4. Release and unplug the three electric connectors -1, 2, 3- on the HV battery control unit.
Fig 4: Removing Electric Connectors
5. Unscrew the two fastening screws -3- from the HV battery control unit using the TORX
Screwdriver Set VAS 6633 WE 1382 .
Fig 5: Identifying HV Battery Control Unit Screws
6. Lift up the HV battery control unit and release and unplug the electric connectors -4- and -5- .
Fig 6: Removing Connectors
7. Lift the HV battery control unit out of the E-box.

8. To replace the control unit, release and unplug the electric connector -6- on the HV battery
control unit and remove it together with the HV battery wire harness.

(CAYENNE S HYBRID) > INSTALLING CONTROL UNIT FOR HV BATTERY
1. Plug in electric connector -6- with the HV battery wire harness at the control unit until the
connector engages securely.
Fig 1: Installing HV Battery Control Unit And Electric Connectors
2. Insert the HV battery control unit into the E-box and plug in both connectors -4- and -5- until
they engage securely.
Fig 2: Installing HV Battery Control Unit
3. Position HV battery control unit in the E-box.
4. Secure the ground strap (cable shoe) to the HV battery control unit in the E-box.
1. 4.1. Secure the HV battery control unit and ground strap using the two fastening
screws -3- and the TORX Screwdriver Set VAS 6633 WE 1382 .
Fig 3: Securing HV Battery Control Unit
5. Secure the service disconnector mounting with the two fastening screws -2- .
Fig 4: Identifying Service Screws
6. Plug electric connectors -1, 2, 3- into the HV battery control unit until the connectors engage
securely.
Fig 5: Installing Electric Connectors
7. Fit tie-wrap for the electric line -arrow- .
8. Before positioning the E-box cover, check the line routing of the HV battery wire harness from
the E-box.
1. 8.1. The rubber sleeve -arrow- on the wire harness must be engaged properly in the
E-box housing.
Fig 6: Locating E-Box Wire Harness Sleeve
9. Fit E-box cover and secure with the eight fastening screws -1- .
Fig 7: Installing E-Box Cover

(CAYENNE S HYBRID) > SUBSEQUENT WORK
1. Install the high-voltage battery. → INSTALLING HIGH-VOLTAGE BATTERY - section on

"Installing".
3. If the control unit was replaced, the control unit must be adapted to the vehicle using PIWIS
Tester II 9818 . → 279455 REPLACING BATTERY MANAGEMENT SYSTEM CONTROL
UNIT .
4. If the fault memory was erased, the electric motor must be calibrated fully.
WM 279455 REPLACING HIGH-VOLTAGE BATTERY CONTROL UNIT (CAYENNE S

E-HYBRID) > TOOLS



E-HYBRID) > READING AND WRITING VALUES
NOTE: Voltage drop
battery.
Information
Tester releases.
ignition.
3. Select the High-voltage battery control unit in the overview .
5. Control unit replacement must now be selected. Then press [F12].
6. Read data must now be selected. Then press [F12].
HIGH-VOLTAGE BATTERY CONTROL UNIT .
13. Select the Calibrate phase angle function and follow the instructions on the Tester.
WM 279455 REPLACING CONTROL UNIT FOR HV BATTERY (CAYENNE S HYBRID) >

TOOLS

TECHNICAL VALUES

NOTE: Voltage drop
battery.
Information
Tester releases.
ignition.
BATTERY MANAGEMENT SYSTEM CONTROL UNIT .
WM 279519 REMOVING AND INSTALLING PILOT LINE CONNECTOR (CAYENNE S

HYBRID) > TOOLS
Hybrid Test Adapter Workshop

WE 1378
VAS 6558/1 Equipment
Workshop
Voltage Tester WE 1380
Equipment

Tolerance Tolerance
1 2
Crash panel to power Fastening screw Tightening 9 Nm (6.5 ft.

electronics -4- Torque lb.)


3. Open the loadspace floor.

HYBRID) > REMOVING PILOT LINE CONNECTOR
Information
In the event of queries or uncertainty regarding the terms "Electrically instructed person (Eip)", "high-
voltage technician (HVT)", "high-voltage expert" or the hybrid system, please contact the relevant
importer before starting any work.
1. Read out the fault memory using PIWIS Tester II 9818 .

2. The following work must only be carried out by a person who is at least trained and qualified as
a recognized high-voltage technician .
3. Switch off the ignition (term. 15) and make sure that it cannot be switched back on again. Then
remove the remote control from the ignition lock. On vehicles with "Keyless Entry and Go",
release the operating lever and pull it out of the ignition lock. Store the remote control and
operating lever in a safe place.
4. Remove service disconnector cover on the high-voltage battery.

Fig 1: Removing Service Disconnector Cover
5. Release the service disconnector by moving it to the right -1- and lift up the securing clip -2- .
Fig 2: Releasing Service Disconnector
6. Remove the service disconnector from the high-voltage battery.

Fig 3: Removing Service Disconnector
7. Release and unplug the pilot line connector.

Fig 4: Removing Pilot Line Connector
8. The lock -1- for the two high-voltage lines -2- opens.
The test log Verifying Absence Of Electric Charge and Restarting High-Voltage System
can be found under Standard forms in the PPN.
9. Release high-voltage lines -HV-- and -HV+- one after the other (rapid-action coupling) and
disconnect them from the battery.
10. Use the Hybrid test adapter VAS 6558/1 WE 1378 and the voltage tester WE 1380 to verify
the absence of electric charge at the two high-voltage contacts on the high-voltage battery.
1. 10.1. Carry out measurements in accordance with the test log.
11. Remove engine compartment cover at the left. → REMOVING FRONT TRIM PANEL (ENGINE
COMPARTMENT) - section on "Removing".
12. Remove crash panel from the power electronics.
1. 12.1. Unscrew the three fastening screws -4- .
2. 12.2. Unscrew fastening nut -5- .
3. 12.3. Remove crash panel.

Fig 6: Identifying Power Electronics Crash Panel
13. Release the high-voltage line -1- at the power electronics (rapid-action coupling) and unplug it
from the power electronics.
14. Open the securing clip for the high-voltage line -2- .
Fig 8: Opening High-Voltage Line Clip
15. Release the high-voltage lines -2, 3- at the power electronics (rapid-action coupling) and
unplug them from the power electronics.
16. Plug in the high-voltage line -1- for the air-conditioning compressor at the power electronics
(rapid action coupling) until the connector engages securely.
17. Use the Hybrid Test Adapter VAS 6558/1 WE 1378 and the Voltage Tester WE 1380 to
verify the absence of electric charge at the power electronics.
1. 17.1. Set the tester to volts and carry out measurements in accordance with the test
log.
18. Document the measurements and values in the test log stored under Standard forms in the
PPN "Verifying Absence Of Electric Charge" and place it in the vehicle documents folder.
20. Release the pilot line connector -1- at the power electronics (rapid-action coupling) and unplug
it.
Fig 10: Removing Pilot Line Connector And High-Voltage Lines For Electric Motor

HYBRID) > INSTALLING PILOT LINE CONNECTOR
1. A visual inspection must be carried out on all threaded connections on the high-voltage
components (battery, power electronics, electric motor and air-conditioning compressor).
Information
Always check the connections for the high-voltage lines and the connector holders before
plugging in the high-voltage lines.
1. If the Plug Contacts are deformed or damaged, stop working on the system and contact
Technical Support .
2. If the Plug Connections are deformed or damaged, stop working on the system and
contact Technical Support .
3. If the lines are deformed or damaged, stop working on the system and contact Technical
Support .
2. Check the outside of all high-voltage and electric potential lines for damage and check that the
connections are correct and that the lines are locked securely.
Information
connector holder.
3. Close the lock for the high-voltage line and connect and lock the pilot line connector -1- (rapid-
action coupling).
Fig 1: Connecting High-Voltage Lines And Pilot Line Connector
4. Release the high-voltage line -1- for the air-conditioning compressor at the power electronics
Fig 2: Removing High-Voltage Line For Air-Conditioning Compressor
Information
The high-voltage lines are colur-coded and must only be connected to the color-coded
connector holder.
5. Plug the high-voltage lines -3, 2, 1- into the power electronics one after the other until the
connectors engage securely.
6. Install crash panel on the power electronics.
1. 6.1. Fit the crash panel.
2. 6.2. Secure the crash panel with the three fastening screws -4- . → Tightening
3. 6.3. Secure the crash panel with the fastening nut -5- . → Tightening Torque: 9 Nm
(6.5 ft. lb.)
COMPARTMENT) - section on "Installing"
Information
Technical Support .
3. If the Lines are deformed or damaged, stop working on the system and contact Technical
Support .
Information
connector holder.
8. Fit the lock for the two high-voltage lines -2- and secure them to the pilot line connector.
Fig 5: Installing High-Voltage Lines On Power Electronics
9. Plug in the pilot line connector until it engages securely.

Fig 6: Plugging In Pilot Line Connector
10. Insert the service disconnector in the high-voltage battery.

Fig 7: Installing Service Disconnector
11. Lock the service disconnector -1- and close it -2-

Fig 8: Locking Service Disconnector
12. Fit service disconnector cover on the high-voltage battery.

Fig 9: Fitting Service Disconnector Cover

1. Read out the fault memory using PIWIS Tester II 9818 . If faults are present in the
high-voltage system, correct them according to the fault-finding strategy.
2. Create the test log under Standard forms in the PPN "Restarting high-voltage system" and
place it in the vehicle documents folder.
3. Close front and rear lid.
4. Proceed according to the current specifications in "Guided Fault Finding" and in the latest
the Cayenne Hybrid.
WM 279555 REPLACING PILOT LINES FOR CONNECTOR (SERVICE

DISCONNECTOR) (CAYENNE S E-HYBRID) > REMOVING SERVICE DISCONNECTOR
1. Unclip service disconnector.
2. Detach cover -1- using a small screwdriver -2- and remove it from the green housing -3- .
Fig 1: Detaching Service Disconnector Cover
3. Loosen fabric adhesive tape on the cable at the end of the connector and cut it off.
4. Release secondary lock using a small screwdriver.

Fig 2: Releasing Secondary Lock
Information
CAUTION: Risk of damage to locking lugs
5. Release pins -1- using press-out tool VAS 1978/35-2 -2- and pull them out carefully at the
cable -3- .
Fig 3: Pressing Pilot Lines Connector Pins
6. Release and pull off clips -1- on the old connector -2- using a thin screwdriver -3- .
Fig 4: Removing Pilot Lines Connector Clips

DISCONNECTOR) (CAYENNE S E-HYBRID) > INSTALLING SERVICE DISCONNECTOR
1. Prepare new service disconnector for installation.
1. 1.1. Release and pull off cover -1- on the new service disconnector -3- using a small
screwdriver -2- .
Fig 1: Installing Service Disconnector Cover
2. 1.2. Secure clips -1- on the new service disconnector -2- .

Fig 2: Securing Service Disconnector Clips
3. 1.3. Release secondary lock on the new service disconnector using a small
screwdriver.
Information
Check that the pins (upper locking lugs) are aligned correctly
If the locking lugs do not lock with an audible click, bend up the locking lugs at the pin first
using press-out tool
2. Press in pins in the following sequence until they engage securely.
1. 2.1. Red/lilac cable in pin 1
2. 2.2. Red/yellow cable in pin 2
3. 2.3. Green/black cable in pin 3
4. 2.4. Yellow/black cable in pin 4
3. Close secondary lock.
4. Fit black cap on the green connector until it engages securely on both sides.
5. Wrap new fabric tape around the cable.
6. Clip in service disconnector at the same position as before.
WM 279619 REMOVING AND INSTALLING CHARGING SOCKET (CAYENNE S

E-HYBRID) > TOOLS

Charging socket to body Tightening Torque 9.7 Nm (7.5 ft. lb.)

5. Release and disconnect high-voltage connector for PTC at the front, high-voltage battery and
charging socket at the high-voltage charger. → 279719 REMOVING AND INSTALLING
ON-BOARD CHARGER
6. Release and disconnect electric plug connection at the high-voltage charger. → 279719
REMOVING AND INSTALLING ON-BOARD CHARGER

E-HYBRID) > REMOVING CHARGING SOCKET
Fig 1: Identifying Charging Socket Installation Position
1. Release and disconnect electric plug connection -1- and unclip it from the body.
2. Unscrew fastening nuts -1- on charging socket -2- .

Fig 3: Loosening Charging Socket Nuts
3. Remove charging socket -1- by carefully turning it anti-clockwise -a- .

Fig 4: Removing Charging Socket
4. Cut tie-wrap -2- and pull water drain -1- off the charging socket.
Fig 5: Pulling Water Drain

E-HYBRID) > INSTALLING CHARGING SOCKET
Information
The high-voltage line for the charging socket must be routed behind the 12 V line.
Information
Make sure not to kink the water drain during installation.
1. Installation is performed in reverse order to removal. Tightening Torque 9.7 Nm (7.5 ft. lb.)

1. Plug in electric plug connection at the high-voltage charger until it engages securely. →
279719 REMOVING AND INSTALLING ON-BOARD CHARGER
2. Plug in high-voltage connectors for PTC at the front, high-voltage battery and high-voltage
charger until they engage securely. → 279719 REMOVING AND INSTALLING ON-BOARD
CHARGER
3. Install side trim panel for rear luggage compartment at the left. → REMOVING SIDE TRIM
WM 279719 REMOVING AND INSTALLING HIGH-VOLTAGE CHARGER (CAYENNE S

E-HYBRID) > TOOLS

Tolerance Tolerance
1 2
High-voltage charger to body
Torque ft. lb.)
Equipotential bonding line to Tightening 7 Nm (5 ft.

high-voltage charger Torque lb.)

6. Remove subwoofer. → REMOVING SUBWOOFER - section on "Removing"

E-HYBRID) > REMOVING HIGH-VOLTAGE CHARGER
Fig 1: Identifying High-Voltage Charger Installation Position
1. Disconnect low-temperature lines -1- and seal them on both sides.

Fig 2: Disconnecting Low-Temperature Lines
Information
Collect emerging coolant in a suitable container.
Information
High-voltage connectors are released using the red tab in 2 steps:
1. 1) Release 1: Press red tab -a- and pull it -A-
2. 2) Release 2: Press black knob -b- and pull it off -B-

2. Release and disconnect high-voltage line to PTC at the rear -2- using the red tab.
3. Release and disconnect high-voltage line to PTC at the front -1- using the red tab.
4. Release and disconnect high-voltage line to high-voltage battery -3- .


6. Release and disconnect high-voltage line to charging socket -1- .

Fig 6: Releasing High-Voltage Line
7. Screw off equipotential bonding line -1- at the high-voltage charger.

8. Loosen fastening screws for high-voltage charger and carefully remove high-voltage charger.
Fig 8: Removing High-Voltage Charger

E-HYBRID) > INSTALLING HIGH-VOLTAGE CHARGER
1. Installation is performed in reverse order to removal. Tightening Torque 10 Nm (7.5 ft. lb.)

1. Install subwoofer. → INSTALLING SUBWOOFER - section on "Installing"

Service Manual: 2X - ENGINE-ELECTRIC - GENERAL -- 92A CAYENNE
WM 2X00IN WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY
(CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) >
TECHNICAL VALUES
Ground line for Tightening 20 Nm (15

battery to body torque ftlb.)

DISCONNECTING THE BATTERY
Battery can explode
Information
Information
The battery is located under the driver's seat.
1. Detach and fold over carpet in front of the driver's seat. → 704119 REMOVING AND
INSTALLING CARPET
2. Screw off ground strap at the ground point in front of the driver's seat:
3. Risk of short circuit! Screw off the ground strap -2- at the ground point -1- under the driver's
seat in front of the battery box.
Fig 1: Identifying Ground Strap Point
4. Route or insulate the ground strap -2- so that all contact with a ground carrier (e.g. body,
battery terminal) is avoided.

CONNECTING THE BATTERY
1. Connect the battery
1. 1.1. Connect the ground strap -2- to the ground point -1- on the body in front of the
driver's seat and secure with the fastening nut. Tightening torque 20 Nm (15 ftlb.)
Fig 1: Identifying Ground Strap Point
2. Re-lay the carpet.

(CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > EFFECT
OF DISCONNECTION OR TOTAL DISCHARGE OF BATTERY ON ELECTRICAL
SYSTEMS IN THE VEHICLE AND THE PRECAUTIONS TO BE TAKEN
Information

(CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > EFFECT
OF DISCONNECTION OR TOTAL DISCHARGE OF BATTERY ON ELECTRICAL
SYSTEMS IN THE VEHICLE AND THE PRECAUTIONS TO BE TAKEN > CONTROL
UNIT MEMORIES
Values and faults stored in the control units can be deleted if the battery is disconnected or completely
discharged.
If possible, all fault memories should be checked and, if necessary, printed out before the battery is
disconnected .
Information
Supply voltage fault entry
The entry "supply voltage" may be stored in various control units if the battery has been completely
discharged.
Delete the "supply voltage" entry from the control units in question .
Information
Ready status
In some countries (presently the U.S.A. and Canada), after disconnecting the battery, it is necessary to
reach the Ready status by a test drive and/or by using the Porsche System Tester DME control module
menu). If in doubt about this, contact the relevant importer.
Information
2470 DME control module
With all DME systems, the engine must run for several minutes before the engine control module can
relearn the idle speed and mixture adaptation values!
After disconnection of the power supply, the idle speed might change or fluctuate briefly until the throttle
valve adjusting unit has been readapted.
The mixture adaptation is also lost.
After the battery is connected:
With the DME, it is necessary to carry out a learning and adaptation routine as described below:
Switch ignition on for 30 seconds without starting the engine .
Do not actuate accelerator pedal .
This completes the adaptation of the throttle valve adjusting unit.
Information
Tyre pressure monitoring system
When the battery is disconnected and connected, the tire pressure is first displayed as "- - - ".
Once the battery has been disconnected and work is complete, the vehicle must be driven for a
short distance .
The actual pressures will then be displayed again.
Information
4560 Steering angle sensor
The steering angle sensor must be re-initialised when the battery is disconnected and connected.
Turn wheels to straight-ahead position .
Switch ignition off and then on again twice .
Start engine .
From the straight-ahead position, turn steering wheel approx. 20° to the right, past the
straight-ahead position .
Drive the vehicle straight ahead for at least one second at a speed above 4 km/h (2.5 mph) .
The steering angle sensor segment is recognized again in this process.
Once the sensor has been successfully initialized, the fault code that is stored in the fault memory is
documented using the fault deletion counter.
The fault memory erases itself automatically.
The PSM indicator light in the instrument cluster goes out.
Information
6014 Motor for sunroof
The limit positions of the sunroof are deleted from the control unit when the battery is disconnected and
connected.
Switch on ignition .
Press the sunroof button for several seconds in direction of travel .
After approx. 10 seconds, the sunroof performs an automatic standardization process and resets
all positions .
Keep the button pressed during the standardization process .
Afterwards, the sunroof is standardized correctly.
Information
6452 Power windows
The limit positions of the power windows are deleted from the control unit when the battery is
disconnected and connected.
Perform the following procedure for all power windows:
Pull rocker switch and fully close window once .
Pull rocker switch once more .
The upper end position of the window is stored.
Press rocker switch and fully open window once .
Press rocker switch once more .
The lower end position of the window is stored.
Information
4815 Electrical steering column adjustment (ELVS)
The electrical steering column adjustment end positions (ELVS) are deleted when the battery is
The following buttons must be pressed in sequence in order to reinitializes electrical steering column
adjustment.
Press the extend button three times (extend towards the driver) .
Press the retract button once .
Press the extend button once (towards the driver) .
Press the up button once .
Press the down button once .
Once the buttons have been pressed correctly, the steering column automatically moves all axles and
stops at the center position (only works when the vehicle is stationary).
1. Carry out a test drive after connecting the battery.
WM 2X00IN ADAPTATIONS - CONTI DME (CAYENNE S, CAYENNE TURBO, CAYENNE

GTS, CAYENNE TURBO S) > INFORMATION
The following adaptations will be deleted automatically when you erase the fault memory (see
INFORMATION )
Mixture adaptation
Lambda adaptation
Camshaft adaptation
Knock adaptation
Map-controlled thermostat adaptation

GTS, CAYENNE TURBO S) > DELETING ADAPTATIONS > ALL ADAPTATIONS
Necessary after:
Replacing engine
How?
PIWIS Tester:
1. Preconditions:
1. 1.1. Engine off
2. 1.2. Ignition on
3. 1.3. Engine cold if possible
2. Select menu:
1. 2.1. DME
2. 2.2. Programming
3. 2.3. Automatic programming
3. Start function: [F8]
4. Adapt throttle valve (see below)

1)
The RBM data is also deleted here .

GTS, CAYENNE TURBO S) > DELETING ADAPTATIONS > DELETING ADAPTATIONS
SELECTIVELY (AFFECTED AREAS)
Fuel high-pressure adaptation
Necessary after:
Replacing high-pressure pump
All work that must be carried out as a result of high-pressure faults, e.g. electric fuel pump, control
unit for electric fuel pump...
Fuel high-pressure adaptation
Necessary after:
Replacing oil pump
Replacing oil pressure control valve
Mixture adaptation
Lambda adaptation
Necessary after:
Replacing high-pressure injectors
Correcting faults during load detection, mixture control, emissions measurement
Pressure sensors, intake manifold
Necessary after:
Replacing intake manifold pressure sensor
Replacing boost pressure sensor (Turbo only)
Boost pressure control (Turbo only)
Necessary after:
Replacing turbocharger
Correcting faults in boost pressure control system
How?
PIWIS Tester:
1. Preconditions:
1. 1.1. Engine off
2. 1.2. Ignition on
3. 1.3. Engine cold if possible
2. Select menu:
1. 2.1. DME
2. 2.2. Maintenance/repairs
3. 2.3. Delete adaptation values
3. Information on deleting adaptation values
4. Confirm with [F8]
5. Submenu of adaptation ranges
6. Select adaptation range and continue with [F12]
7. Switch off ignition (see also INFORMATION )

GTS, CAYENNE TURBO S) > OVERWRITING ADAPTATION VALUES > INFORMATION
Consequences of Tester adaptation if conditions for automatic adaptation are not met (violated boundary
condition):
For a fault entry in the load detection range (P0068 + P1069... P1077), the limits are extended in
order to prevent incorrect detections.
This extension is cancelled if an adaptation is performed when the conditions for automatic
adaptation are met, or after 15 warm-up cycles at the latest
(Warm-up cycle = coolant temperature increases by more than 23 °C (73 °F) after start-up and
reaches at least 73 °C (163 °F))
Following manual throttle valve adaptation when ambient conditions are not met, throttle valve
adaptation is carried out again automatically as soon as the ambient conditions are met.
There is NO 30-second waiting time here, but a slightly delayed engine start is possible once.
The ambient conditions for automatic adaptation are as follows:
Engine off and ignition on for > 30 seconds.
Accelerator pedal is not pressed.
Vehicle is stationary.
Power supply for throttle valve adjusting unit is OK.

Coolant temperature 5 °C... 100 °C (41 °F... 212 °F)
Intake air temperature 5 °C... 40 °C (41 °F... 104 °F)

GTS, CAYENNE TURBO S) > OVERWRITING ADAPTATION VALUES > THROTTLE
VALVE
after deletion or without deletion
Necessary after:
Re-programming DME control unit
Replacing DME control unit
Replacing throttle valve
How?
Ignition on > 30 seconds if the preconditions are met
or
PIWIS Tester:
1. Preconditions:
1. 1.1. Engine off
2. 1.2. Ignition on
2. Select menu:
1. 2.1. DME
3. 2.3. Adaptations
4. 2.4. Throttle valve adaptation
3. Go to Note: [F12]
5. Switch off ignition (see INFORMATION )

GTS, CAYENNE TURBO S) > OVERWRITING ADAPTATION VALUES > KICKDOWN
ACCELERATOR PEDAL MODULE (CAYENNE (92A) TIPTRONIC ONLY)
Necessary after:

Replacing accelerator pedal module
How?
PIWIS Tester:
1. Preconditions:
1. 1.1. Engine off
2. 1.2. Ignition on
2. Select menu:
1. 2.1. DME
3. 2.3. Adaptations
4. 2.4. Kickdown adaptation
4. Press accelerator pedal fully and release it again after 30 seconds

GTS, CAYENNE TURBO S) > OVERWRITING ADAPTATION VALUES > INFORMATION
The accelerator pedal must always be pressed after approx. 1.5 minutes since each adaptation step is
limited to 5 Nm.

GTS, CAYENNE TURBO S) > OVERWRITING ADAPTATION VALUES > TORQUE LOSS
Necessary after:
Re-programming PDK control unit
Necessary before:
Re-calibrating PDK
How?
Engine idling
1. Preconditions:
1. 1.1. Engine at operating temperature
2. Engine idling for 3 minutes without activating loads, press accelerator pedal once after approx.
1.5 minutes during this time
3. Engine idling for 3 minutes with air conditioning switched on, press accelerator pedal once
after approx. 1.5 minutes during this time
4. Engine idling for 3 minutes with air conditioning switched on and transmission range engaged,
press accelerator pedal once after approx. 1.5 minutes during this time
WM 2X00IN BASIC SAFETY INSTRUCTIONS FOR WORKING WITH LEAD-ACID

BATTERIES (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S,
CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > DANGERS CAUSED BY
ELECTROLYTE WHEN FILLING LEAD-ACID BATTERIES > DANGERS FOR PERSONS
Electrolyte is extremely caustic.
Avoid contact with caustic fluid.
Wear personal protective gear.
Rinse acid splashes in the eyes immediately with clean water. Then consult a doctor immediately
Neutralize acid splashes on the skin or clothing immediately with acid neutralizer or soap suds and
rinse again with plenty of water. Contact a doctor if necessary.
In the event of extensive skin contact with electrolyte, remove soaked clothing immediately and
wash the skin thoroughly in a shower. Then consult a doctor immediately.
If you drink electrolyte, rinse your mouth immediately with water. Drink water in small sips, do not
induce vomiting. Then consult a doctor immediately.
If you inhale acid mist, breathe in fresh air immediately. Contact a doctor if necessary.
Do not tilt the battery. Electrolyte can emerge from the vent openings.

ELECTROLYTE WHEN FILLING LEAD-ACID BATTERIES > DANGERS FOR THE
ENVIRONMENT
Electrolyte reacts with alkalis and water and generates a considerable amount of heat. Electrolyte
destroys paper, wood and textiles and has a corrosive reaction to metals. Electrolyte is a fluid that is
hazardous to water and causes ecological damage as a result of pH changes.
Absorb spilt electrolyte using binding material.
Neutralize spilt electrolyte with acid neutralizer.
Dilute small quantities and residual quantities with water and rinse it away.
Store electrolyte only in acid-resistant containers in the area reserved for pollutants and hazardous
substances.
Transport electrolyte only in securely locked containers.

CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > DANGERS WHEN
CHARGING LEAD-ACID BATTERIES > DANGERS FOR PERSONS
Highly inflammable hydrogen can be produced if batteries are overcharged or if the charge voltage is too
high. Danger of production of hydrogen gas (highly inflammable mixture).
Only charge lead-acid batteries in special battery rooms.
Fit forced ventilation systems in the room for excellent ventilation.
Keep ventilation openings free.
Keep clear of ignition sources.
Connect and disconnect the battery terminals only with the charger switched off in order to prevent
sparks.
Do not hold a naked flame or lit cigarette near a battery.
Only illuminate the inside of a battery with a torch.

SHORT CIRCUIT > DANGERS FOR PERSONS
A short circuit between the battery terminals as a result of conductive objects can cause a fire. Danger
due to arc, cable fire, terminal meltdown and electrostatic discharge.
Cover the battery terminals.
Disconnect the negative cable from the battery before working on the battery.
Keep electrically conductive objects clear of the battery terminals.
Only use work clothing and shoes approved by Porsche.

CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > PERSONAL
PROTECTIVE EQUIPMENT
The protective equipment required for workshop activities is compulsory. The following specific
protective equipment is also required for working with lead-acid batteries.
Protective goggles with side protection.
Acid/chemical-resistant protective gloves.

Acid-resistant rubber apron.
Industrial footwear with acid-resistant soles.
WM 2X00IN BATTERY TRICKLE CHARGING (CAYENNE, CAYENNE GTS, CAYENNE

TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) >
INFORMATION > BATTERY TRICKLE CHARGING
Information
When working or carrying out tests on the vehicle or when the vehicle is in the workshop, a battery
charger with a rated current of at least 40 A must be connected .
As soon as the vehicle is unlocked, e.g. the vehicle is in the workshop or salesroom, it must be
trickle charged with a battery charging device .
1. Open protective cover on positive terminal for jump-lead starting -+- (-arrow- ).
Fig 1: Opening Protective Cover On Positive Terminal
2. First, connect the positive cable from the charger to the positive terminal -+- .
3. Then connect the negative cable from the charger to the ground point for jump-lead starting - .
4. Read and follow the operating instructions for the charger.
5. Switch off all electrical loads.

6. Switch on the charger.
WM 2X00IN CLASSIFICATION OF HIGH-VOLTAGE BATTERY (CAYENNE S E-HYBRID)

> TOOLS
Workshop Workshop WE 1188

crane equipment
Diagnosis box Workshop WE 1587

equipment
High-voltage Workshop WE 1589

cordon equipment
wire mesh crate Workshop WE 1590

equipment
temperature Workshop WE 1591

gauge equipment
Warning sign Workshop WE 1594

(No equipment
unauthorized
access)

(No fire, naked equipment
flames or
smoking)

(Warning of equipment
dangerous
electrical
voltage)

(Warning of equipment
dangers
associated with
batteries)


> INFORMATION > INSTALLATION POSITION OF HIGH-VOLTAGE BATTERY

> INFORMATION > GENERAL WARNING NOTES
WARNING: Lithium-ion high-voltage battery in dangerous state
Risk of fire
Risk of explosion
→ Cancel classification immediately
→ Alert the fire services
→ Take steps to deal with the danger from fire/gas leaks
WARNING: Lithium-ion high-voltage battery in critical state
Danger of poisoning from emerging gases/fluids
→ If battery is in the vehicle: Move the vehicle to the quarantine location.
→ If battery is not in the vehicle: Place battery in wire mesh crate at quarantine location.
Health risks for persons with life-support systems.
→ All work on vehicles with a high-voltage vehicle electrical system must only be carried out by
electrically instructed persons (eip). The work must be done under the instruction of a high-voltage
technician (HVT).

> CLASSIFICATION OF HIGH-VOLTAGE BATTERY > HIGH-VOLTAGE BATTERY WITH
CLASSIFICATION IN VEHICLE

Risk of fire
Risk of explosion
→ If battery is in the vehicle: Move the vehicle to the quarantine location.
1. Complete the test log for classification of lithium-ion high-voltage batteries with general
information.
2. Perform an initial visual assessment as described in the test log.
1. 2.1. Work through and document the criteria as described in the test log.
3. Perform a functional and thermal assessment as described in the test log.
Information
The PIWIS Tester II 9818 instructions take precedence since the description may be different
with later Tester releases.
The procedure described here has been structured in general terms; different text or additions
may appear in PIWIS Tester II 9818 .
Information
1. If communication between the PIWIS Tester and HV battery control unit cannot be
established even after several attempts, contact Technical Support to find out how to
proceed .
1. 3.1. PIWIS Tester must be connected to the vehicle before starting the Tester. Switch
on ignition.
2. 3.2. Select "Vehicle" on the Tester --> Vehicle data is read out.
3. 3.3. Select "Control unit for high-voltage battery" on the "Overview" tab, press
[F12] and continue without creating a VAL.
4. 3.4. Switch to the "Maintenance and repairs" tab.
5. 3.5. Select "Battery classification" and press [F12] --> Follow instructions on the
Tester.
6. 3.6. Document the result shown on the Tester in the test log.
4. If the battery was not assessed as dangerous or critical , the battery can be removed.
Information
If fluid is leaking out, electrolyte can easily be distinguished from normal coolant by its pungent
smell. To check the vent line, first remove the protection cap and re-fit it after you have
checked the line.
5. After removing the battery, perform a detailed visual assessment as described in the test log.
Information
1. If the answer "Yes" was not given for any of the test criteria, the battery condition is not
critical .
6. Document the overall result in the test log and sign the test log.

> CLASSIFICATION OF HIGH-VOLTAGE BATTERY > HIGH-VOLTAGE BATTERY WITH
CLASSIFICATION OUTSIDE OF VEHICLE
Risk of fire
Risk of explosion
→ If battery is in the vehicle: Move vehicle to the quarantine location.
Information
When setting down a removed high-voltage battery, make sure to use suitable supports to prevent
damage to any water drains on the underside of the battery .
1. Complete the test log for classification of lithium-ion high-voltage batteries with general
information.
2. Perform an initial visual assessment as described in the test log.
3. Perform a thermal assessment as described in the test log.
1. 3.1. Stick adhesive strips -4- at the three measuring points -1- , -2- , -3- .
2. 3.2. Perform thermal measurement using temperature gauge WE 1591 -5- .
3. 3.3. Document the measurement result in the test log.

Fig 1: Measuring Points Of Thermal Measurement
Information
If fluid is leaking out, electrolyte can easily be distinguished from normal coolant by its pungent
smell. To check the vent line, first remove the protection cap and re-fit it after you have
checked the line.
4. Perform a detailed visual assessment as described in the test log.
5. Perform a detailed functional and thermal assessment as described in the test log.
1. 5.1. Diagnosis box WE 1587 must be connected to the battery.

Information
The PIWIS Tester II 9818 instructions take precedence since the description may be
different with later Tester releases.
The procedure described here has been structured in general terms; different text or
additions may appear in PIWIS Tester II 9818 .
Information
1. If communication between the PIWIS Tester and HV battery control unit cannot
be established even after several attempts, contact Technical Support to find
out how to proceed .
2. 5.2. PIWIS Tester II 9818 must then be connected to the diagnosis box WE 1587 .
3. 5.3. Diagnosis box WE 1587 must be connected to the power supply.
4. 5.4. Diagnosis box WE 1587 must then be switched on before pressing [F1] to
activate terminal 15 and [F2] to activate terminal 30. If not pre-set, press [F3] to
select a resistance value of 120 Ohm. PIWIS Tester must now be started.
5. 5.5. Select "Vehicle" on the Tester --> Vehicle data is read out.
6. 5.6. Select "Control unit for high-voltage battery" on the "Overview" tab, press
[F12] and continue without creating a VAL.
7. 5.7. Switch to the "Maintenance and repairs" tab.
8. 5.8. Select "Battery classification" and press [F12] --> Follow instructions on the
Tester.
9. 5.9. Document the result in the test log.
Information
1. If the answer "Yes" was not given for any of the test criteria, the battery condition is not
critical .
6. Document the overall result in the test log and sign the test log.

> QUARANTINE OF A HIGH-VOLTAGE BATTERY > QUARANTINE OF A
HIGH-VOLTAGE BATTERY IN THE VEHICLE
1. Move vehicle to the quarantine location and cordon it off in accordance with instructions using
high-voltage cordon High-voltage cordon WE 1589 and warning signs Warning sign (No
unauthorized access) WE 1594 , Warning sign (No fire, naked flames or smoking) WE
1595 , Warning sign (Warning of dangerous electrical voltage) WE 1596 , Warning sign
(Warning of dangers associated with batteries) WE 1597 .

> QUARANTINE OF A HIGH-VOLTAGE BATTERY > QUARANTINE OF A REMOVED
Information
A cross member can also be fitted on the battery. For quick handling, the adapter plate can also be fitted
on the battery with a cross member.
1. Adapter plate 9860 -1- must be positioned on the high-voltage battery and fitted to the
high-voltage battery using fastening screws -2- .
Fig 1: Securing Adapter Plates
2. Lifting tackle 3033 -1- can then be fitted to the adapter plates -2- .
Fig 2: Fitting Lift Tackle
Information
Set the workshop crane Workshop crane WE 1188 to the fourth detent (500 kg).
3. Workshop crane WE 1188 must be engaged in the lifting tackle 3033 . Then lift it carefully
at the center.
4. Using the workshop crane WE 1188 , slowly lower the suspended high-voltage battery into
the wire mesh crate WE 1590 -1- . When doing so, make sure that the high-voltage battery
-2- is sitting on the correct brackets -3- .
Fig 3: Positioning Wire Mesh Crate
5. Close the wire mesh crate and mark it according to instructions using high-voltage cordon
WE 1589 , warning signs Warning sign (No unauthorized access) WE 1594 , Warning
sign (No fire, naked flames or smoking) WE 1595 , Warning sign (Warning of dangerous
electrical voltage) WE 1596 , Warning sign (Warning of dangers associated with
batteries) WE 1597 .
WM 2X00IN FUNCTION TEST ON HIGH-VOLTAGE TEST ADAPTER (CAYENNE S

E-HYBRID) > TOOLS
high-voltage test Workshop WE 1585

adapter HVA 280 equipment
high-voltage test Workshop WE 1586

adapter HVR 40 equipment

E-HYBRID) > FUNCTION TEST ON HIGH-VOLTAGE TEST ADAPTER > FUNCTION
TEST ON HIGH-VOLTAGE TEST ADAPTER VAS 6558/9-6
Information
When checking the system using high-voltage test adapter HVA 280 WE 1585 , make sure not to
damage the pins in the socket of the test adapter.
Information
When taking measurements on the connectors, it is not clear which is the positive and which is the
negative terminal. For this reason, both pins on the connector must always be measured against the
respective socket on the test adapter. One of the pins must correspond to the value specified in the test
log. Follow the procedure shown in the graphics when taking measurements. The pins on the
connectors are shown correctly here.
1. Perform function test on the high-voltage test adapter High-voltage test adapter HVA 280 WE
1585 in accordance with the test log for verifying isolation from the power supply using a
multimeter. Set the multimeter to resistance (Ohm).
1. 1.1. Measure negative terminal for line A on negative socket.

Fig 1: Measuring Negative Terminal For Line On Negative Socket (Line A)
2. 1.2. Measure positive terminal for line A on positive socket.

Fig 2: Measuring Positive Terminal For Line On Positive Socket (Line A)
3. 1.3. Measure shielding for line A on shielded socket.

Fig 3: Measuring Shielding For Line On Shielded Socket (Line A)
4. 1.4. Measure negative terminal for line B on negative socket.

Fig 4: Measuring Negative Terminal For Line On Negative Socket (Line B)
5. 1.5. Measure positive terminal for line B on positive socket.

Fig 5: Measuring Positive Terminal For Line On Positive Socket (Line B)
6. 1.6. Measure shielding for line B on shielded socket.

Fig 6: Measuring Shielding For Line On Shielded Socket (Line B)

E-HYBRID) > FUNCTION TEST ON HIGH-VOLTAGE TEST ADAPTER > FUNCTION
TEST ON HIGH-VOLTAGE TEST ADAPTER VAS 6558/9-7
Information
When checking the system using high-voltage test adapter HVR 40 WE 1586 , make sure not to
damage the pins in the socket of the test adapter.
Information
When taking measurements on the connectors, it is not clear which is the positive and which is the
negative terminal. For this reason, both pins on the connector must always be measured against the
respective socket on the test adapter. One of the pins must correspond to the value specified in the test
log. Follow the procedure shown in the graphics when taking measurements. The pins on the
connectors are shown correctly here.
1. Perform function test on the high-voltage test adapter High-voltage test adapter HVR 40 WE
1586 in accordance with the test log for verifying isolation from the power supply using a
multimeter. Set the multimeter to resistance (Ohm).
1. 1.1. Measure negative terminal for line A on negative socket.

Fig 1: Measuring Negative Terminal For Line On Negative Socket (Line A)
2. 1.2. Measure positive terminal for line A on positive socket.

Fig 2: Measuring Positive Terminal For Line On Positive Socket (Line A)
3. 1.3. Measure shielding for line A on shielded socket.

Fig 3: Measuring Shielding For Line On Shielded Socket (Line A)
4. 1.4. Measure negative terminal for line B on negative socket.

Fig 4: Measuring Negative Terminal For Line On Negative Socket (Line B)
5. 1.5. Measure positive terminal for line B on positive socket.

Fig 5: Measuring Positive Terminal For Line On Positive Socket (Line B)
6. 1.6. Measure shielding for line B on shielded socket.

Fig 6: Measuring Shielding For Line On Shielded Socket (Line B)
WM 2X00IN GENERAL WARNING NOTES FOR WORKING ON THE HIGH-VOLTAGE

VEHICLE ELECTRICAL SYSTEM (CAYENNE S E-HYBRID) > TOOLS
Insulated tool set Workshop WE 1593

equipment
WM 2X00IN GENERAL WARNING NOTES FOR WORKING ON THE HIGH-VOLTAGE

VEHICLE ELECTRICAL SYSTEM (CAYENNE S E-HYBRID) > GENERAL WARNING
NOTES > GENERAL WARNING NOTES FOR WORKING ON THE HIGH-VOLTAGE
VEHICLE ELECTRICAL SYSTEM
→ Always use insulated tools Insulated tool set WE 1593 when working on the high-voltage battery.
→ 2X00IN GENERAL WARNING NOTES FOR WORKING ON THE HIGH-VOLTAGE ELECTRICAL

SYSTEM
Information
The workshop flow chart (see Standard documents) must be observed when working on high-voltage
vehicles.
Information
Information
Before starting to work on the high-voltage system or close to high-voltage components, a high-voltage
technician must isolate the high-voltage system from the power supply.
The document → 2X00IN ISOLATION FROM SUPPLY PRIOR TO PERFORMING MAINTENANCE

TASKS ON HYBRID VEHICLES describes the various types of work for which the high-voltage system
must be isolated from the power supply.
The test log Verifying absence of electric charge and Restarting high-voltage system can be found
under Standard forms in the PPN.
Information
Please note the following when de-energising the high-voltage system:
The high-voltage system must only be isolated from the power supply by a correspondingly
qualified person (High Voltage Technician - HVT) .
The high voltage technician ascertains that the system is de-energized and secures it to prevent
reactivation .
The system is secured to prevent reactivation by disconnecting the 12-volt service connector and
securing the system with a padlock. The high voltage technician must store the key for the padlock
in a safe place .
The high voltage technician identifies the vehicle as de-energized by attaching a corresponding
sign .
All work (e.g. maintenance, changing tires, convenience electronics) on vehicles with a
high-voltage system must only be carried out by an electrically instructed person (eip). The work
must be done under the instruction of a high-voltage technician .
Before working on the high-voltage system and carrying out any repair work to the body, a high
voltage technician must switch off the power to the system .
If the high-voltage system cannot be isolated from the power supply, further repairs must only be
carried out by a high voltage expert .
Persons with medical devices must not carry out any work on vehicles with a high-voltage system.
Medical devices include internal analgesic pumps, implanted defibrillators, pacemakers, insulin
pumps and hearing aids .
Information
Handling high-voltage lines:
Do not support yourself or your tools on high-voltage lines and their components .
Work involving metal-removing, deforming and sharp-edged tools in the vicinity of high-voltage
components and lines is prohibited .
Work involving heat sources such as welding, soldering, hot air and thermal bonding in the vicinity
of high-voltage components and lines is prohibited .
High-voltage lines must not be extensively bent or kinked .
In the event of queries or uncertainties, consult the relevant high voltage technician .
WM 2X00IN ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER

SUPPLY/STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM (CAYENNE S HYBRID) >
TOOLS
Hybrid test Workshop WE 1378

adapter VAS equipment
6558/1
voltage tester Workshop WE 1380
equipment

TECHNICAL VALUES
Crash panel to Fastening screw Tightening 9 Nm (6.5 ftlb.)

power - 4- torque
electronics
Crash panel to Fastening screw Tightening 9 Nm (6.5 ftlb.)

power - 5- torque
electronics

GENERAL WARNING NOTES > GENERAL WARNING NOTES FOR WORKING ON THE
HIGH-VOLTAGE SYSTEM
Information
Information
Before starting to work on the high-voltage system or close to high-voltage components, a high-voltage
technician must isolate the high-voltage system from the power supply.

Information
qualified person (high-voltage technician (HVT)) .
The high-voltage technician ascertains that the system is de-energized and secures it to prevent
reactivation .
The system is secured to prevent reactivation by getting the high-voltage technician to lock the
service disconnector .
The high-voltage technician identifies the vehicle as de-energized by attaching a corresponding

sign .
All work (e.g. maintenance, changing tires, comfort electrics) on vehicles with a high-voltage
system must only be carried out by an electrically instructed person (eip). The work must be done
under the instruction of a high-voltage technician (HVT) .
Before working on the high-voltage system and carrying out any repair work to the body, a
high-voltage technician must switch off the power to the system .
If the high-voltage system cannot be isolated from the power supply, do not continue working on
the system and contact Technical Support .
Information
Handling high-voltage cables:
Do not support yourself or your tools on high-voltage cables and their components .
components and cables is prohibited .
of high-voltage components and cables is prohibited .
High-voltage cables must not be extensively bent or kinked .
In the event of queries or uncertainties, consult the relevant high-voltage technician .

INFORMATION > ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER
SUPPLY
Information
Work for which the high-voltage system has to be isolated from the power supply:
All work on a hybrid vehicle must only be carried out by persons who are at least qualified as an
Eip (Electrically instructed person) .
When carrying out any work on a hybrid vehicle, the hybrid-specific components in the
activity/work area must be visually inspected .
The high-voltage cables must not be extensively bent or kinked .
Anything anomalous or unclear must be reported to the HVT (high-voltage technician) or HVE
(high-voltage expert) .
Working close to high-voltage components and high-voltage lines using cutting, deforming and
sharp-edged tools or heat sources, such as welding, soldering, hot air and thermal bonding, is
prohibited .
→ 2X00IN ISOLATION FROM SUPPLY PRIOR TO PERFORMING MAINTENANCE TASKS ON

HYBRID VEHICLES
Information

Fig 1: Removing Service Disconnector Cover On High-Voltage Battery
Fig 2: Removing Service Connector

Fig 3: Removing Service Disconnector From High-Voltage Battery

Fig 5: Removing High-Voltage Lines From High Volage Battery
The test log Verifying absence of electric charge and Restarting high-voltage system
FRONT COVER (ENGINE COMPARTMENT) .

Fig 6: Identifying Crash Panel For Power Electronics With Fastening Nut And Screws
Fig 8: Opening Clip For High-Voltage Line
Fig 9: Plugging High-Voltage Line For Air-Conditioning Compressor At Power Electronics
the absence of electric charge at the power electronics.
log.
PPN "Verifying absence of electric charge" and place it in the vehicle documents folder.

INFORMATION > STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM
Information
The contact surfaces of the equipotential bonding lines must be checked prior to installation.
Information
1. If the plug contacts are deformed or damaged, stop working on the system and contact
Technical Support .
2. If the plug connections are deformed or damaged, stop working on the system and
Support .
3. 5.3. Secure the crash panel with the fastening nut -5- . → Tightening torque: 9 Nm
(6.5 ftlb.)
Fig 3: Identifying Crash Panel For Power Electronics Fastening Nut And Screws
FRONT COVER (ENGINE COMPARTMENT)
Information
1. If the plug contacts are deformed or damaged, stop working on the system and contact
Technical Support .
2. If the plug connections are deformed or damaged, stop working on the system and
Support .
7. At the high-voltage battery, plug in the high-voltage lines -1- until the connectors engage
securely.
1. 8.1. Plug in the pilot line connector until it engages securely.

Fig 5: Plugging Pilot Line Connector

Fig 6: Installing Service Connector


Fig 8: Fitting Service Connector Cover
the Cayenne Hybrid.
WM 2X00IN INSULATION FAULT FINDING (CAYENNE S E-HYBRID) > TOOLS
Hybrid test adapter Workshop WE 1378

set equipment
Insulation tester Workshop WE 1379

equipment
High-voltage test Workshop WE 1585

adapter HVA 280 equipment
High-voltage test Workshop WE 1586
adapter HVR 40 equipment
WM 2X00IN INSULATION FAULT FINDING (CAYENNE S E-HYBRID) > INFORMATION

ON INSULATION FAULT FINDING
The measurements must be performed using the insulation tester Insulation tester WE 1379 .
A measuring voltage of 500 V must be selected.
To obtain the required measuring resistance, the measuring voltage must be present on the
insulation tester for at least 1 second .
The tolerance range is +/- 10% .
Two measurements must always be performed for each measuring point. Positive terminal on
shielding and negative terminal on shielding.
A measurement is only regarded as being within the tolerance range if both measured values are
within the tolerance range.
The direction of measurement of the insulation tester does not affect the test result.
The measured values must be documented in the "Insulation fault finding test log". The test log is
stored under Standard forms in the PIWIS information system.
WM 2X00IN INSULATION FAULT FINDING (CAYENNE S E-HYBRID) > INFORMATION

ON INSULATION FAULT FINDING > OVERVIEW OF FAULT FINDING PROCEDURE
(FAULT SEARCH TREE)
Fault search tree
WM 2X00IN INSULATION FAULT FINDING (CAYENNE S E-HYBRID) > PRELIMINARY

WORK
POWER SUPPLY/STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM
3. Perform function test on test adapter. → 2X00IN FUNCTION TEST ON TEST ADAPTER
WM 2X00IN INSULATION FAULT FINDING (CAYENNE S E-HYBRID) > TAKING

MEASUREMENTS > PERFORMING MEASUREMENT 1
Preliminary work for measurement 1:
2. Release high-voltage connector HVR 40 from the high-voltage battery and disconnect it.
Measurement 1.1:
Fig 1: Overview Of Luggage Compartment Cover (Measurement 1.1)
3. Connect high-voltage test adapter High-voltage test adapter HVR 40 WE 1586 to

high-voltage connector for the high-voltage charger -1- . Leave the second connection on the
test adapter open.
Fig 2: Identifying High-Voltage Test Adapter Connector
4. Perform measurement 1.1.
1. 4.1. Setpoint value: > 550 MOhm
Measurement 1.2:
Fig 3: Overview Of Luggage Compartment Cover (Measurement 1.2)
5. Connect high-voltage test adapter High-voltage test adapter HVR 40 WE 1586 to the
high-voltage battery -1- . Leave the second connection on the test adapter open.
1. 6.1. Setpoint value: > 2.4 MOhm
7. Evaluate the test results .
1. 7.1. If the specified measured values from measurement 1.1 are not within the
tolerance range and the specified measured values from measurement 1.2 are within
the tolerance range, continue with measurement 2 .
3. 7.3. The measured values from both measurements are not within the tolerance
range.
1. 7.3.1. Repeat the measurements.
2. 7.3.2. Check measuring equipment and repeat the measurements.
3. 7.3.3. Follow both paths for measurement 1.1 and measurement 1.2.
4. 7.3.4. Contact Technical Support.
4. 7.4. The measured values from both measurements are within the tolerance range.
1. 7.4.1. Insulation fault in high-voltage battery.
2. 7.4.2. Check the VAL again to determine whether an insulation fault is

present. If an insulation fault is indicated, carry out classification of the HV
battery and contact Technical Support.

MEASUREMENTS > PERFORMING MEASUREMENTS 2
1. Remove side trim panel for rear luggage compartment at the left. → 700319 REMOVING AND
INSTALLING SIDE TRIM PANEL FOR REAR LUGGAGE COMPARTMENT
2. Release high-voltage connector for rear PTC from the high-voltage charger and disconnect it.
3. Release high-voltage connector for front PTC from the high-voltage charger and disconnect it.
Fig 1: Overview Of High-Voltage Connections On High-Voltage Charger
1. -1- = HV connection for rear PTC
2. -2- = HV connection for front PTC
3. -3- = HV connection for HV battery
4. -4- = HV connection for charging socket (3-phase)
Measurement 2.1:
Fig 2: Overview Of Side Trim Panel For Rear Luggage Compartment (Measurement 2.1)

test adapter open.
Measurement 2.2:
6. Connect high-voltage test adapter High-voltage test adapter HVA 280 WE 1585 to
high-voltage connector for rear PTC -1- . Leave the second connection on the test adapter
open.

Fig 6: Overview Of Side Trim Panel For Rear Luggage Compartment (Measurement
2.3)
Measurement 2.3:
high-voltage connector for front PTC -1- . Leave the second connection on the test adapter
open.
tolerance range and the specified measured values from measurement 2.2 and 2.3
are within the tolerance range, continue with measurement 3 .
4. 10.4. The measured values from two or all measurements are not within the
tolerance range.

3. 10.4.3. Follow both paths for measurement 2.1, 2.2 and measurement 2.3.
5. 10.5. The measured values from two or all measurements are within the tolerance
range.

MEASUREMENTS > PERFORMING MEASUREMENTS 3
1. Release high-voltage connector from high-voltage battery to high-voltage charger and

disconnect it
Fig 1: Overview Of High-Voltage Connections On High-Voltage Charger
1. -1- = HV connection for rear PTC
2. -2- = HV connection for front PTC
3. -3- = HV connection for HV battery
4. -4- = HV connection for charging socket (3-phase)
Measurement 3.1:

test adapter open.
Measurement 3.2:
high-voltage charger for rear PTC -1- . Leave the second connection on the test adapter open.
Fig 5: Identifying High-Voltage Test Adapter
the tolerance range:
1. 6.1.1. Insulation fault in high-voltage line from high-voltage charger to

2. 6.1.2. Replace high-voltage line from high-voltage charger to high-voltage

battery following consultation with Technical Support. → 279319
REMOVING AND INSTALLING HIGH-VOLTAGE LINE BETWEEN
HIGH-VOLTAGE CHARGER AND HIGH-VOLTAGE BATTERY
1. 6.2.1. Insulation fault in high-voltage charger.

2. 6.2.2. Replace high-voltage charger following consultation with Technical
Support. → Installing High-Voltage Charger
range.

1. Release and disconnect high-voltage connector on rear PTC.
Measurement 4.1:
Fig 1: Performing Measurement Overview
high-voltage connector for high-voltage line for rear PTC -1- . Leave the second connection on
the test adapter open.
Measurement 4.2:
4. Connect high-voltage test adapter High-voltage test adapter HVA 280 WE 1585 to the rear
PTC -1- . Leave the second connection on the test adapter open.
1. 6.1.1. Insulation fault in high-voltage line from high-voltage charger to rear

PTC.
2. 6.1.2. Replace high-voltage line from high-voltage charger to rear PTC

following consultation with Technical Support. → 279319 REMOVING AND
INSTALLING HIGH-VOLTAGE LINE FROM HIGH-VOLTAGE CHARGER
TO ELECTRIC HEATER FOR HIGH-VOLTAGE BATTERY (REAR PTC)
1. 6.2.1. Insulation fault in rear PTC.

2. 6.2.2. Replace rear PTC following consultation with Technical Support. →
Installing Electric High-Voltage Battery Heater
range.

1. Remove front wheel housing liner trim panel at the left. → 505619 REMOVING AND
2. Release and disconnect high-voltage connector on front PTC.
Measurement 5.1:
Fig 1: Overview Of Front Wheel Housing Liner Trim Panel - Left (Measurement 5.1)

high-voltage connector for high-voltage line for front PTC -1- . Leave the second connection
on the test adapter open.
Measurement 5.2:
Fig 3: Overview Of Front Wheel Housing Liner Trim Panel - Left (Measurement 5.2)
5. Connect high-voltage test adapter High-voltage test adapter HVA 280 WE 1585 to the front
PTC -1- . Leave the second connection on the test adapter open.
Fig 4: Identifying High-Voltage Test Adapter HVA 280 WE 1585 Second Connection
1. 7.1.1. Insulation fault in high-voltage line from high-voltage charger to front

PTC.
2. 7.1.2. Replace high-voltage line from high-voltage charger to front PTC

following consultation with Technical Support. → Installing High-Voltage
Line From Battery To Power Electronics
1. 7.2.1. Insulation fault in front PTC.

2. 7.2.2. Replace front PTC following consultation with Technical Support. →
Installing Electric Passenger Compartment Heater
range.

Fig 1: Overview Of High-Voltage Connections For Power Electronics
-1- = cable shoe on high-voltage line from PE to HV battery
-2- = 2 = HV connection from PE to air-conditioning compressor
-3- = 3-phase wiring to electric machine

1. Unscrew both high-voltage connectors for high-voltage line to power electronics from the
high-voltage battery and disconnect them. → 270819 REMOVING AND INSTALLING
2. Unscrew media shield from the power electronics unit. → 279119 REMOVING AND
3. Release high-voltage connector from high-voltage air-conditioning compressor and disconnect

it. → 279119 REMOVING AND INSTALLING POWER ELECTRONICS FOR HIGH-VOLTAGE
SYSTEM
Measurement 6.1:
Fig 2: Overview Of Media Shield From Power Electronics Unit (Measurement 6.1)
high-voltage connector for high-voltage line for high-voltage air-conditioning compressor -1- .
Leave the second connection on the test adapter open.
Measurement 6.2:
Fig 4: Overview Of Media Shield From Power Electronics Unit (Measurement 6.2)
6. Connect high-voltage test adapter High-voltage test adapter HVA 280 WE 1585 to the power
electronics unit (high-voltage connection for air-conditioning compressor) -1- . Leave the
second connection on the test adapter open.
1. 7.1. Setpoint value: 2.9 MOhm
are within the tolerance range:
1. 8.1.1. Insulation fault in high-voltage battery.
2. 8.1.2. Replace high-voltage battery following consultation with Technical

Support. → 270855 REPLACING HIGH-VOLTAGE BATTERY
4. 8.4. The measured values from two or all measurements are not within the
tolerance range.
3. 8.4.3. Follow both paths for measurement 6.2 and measurement 6.3.
5. 8.5. The measured values from two or all measurements are within the tolerance
range.


1. Disconnect high-voltage line from high-voltage air-conditioning compressor. → 279319
REMOVING AND INSTALLING HIGH-VOLTAGE LINE FROM POWER ELECTRONICS TO
2. Remove front wheel housing liner trim panel at the left. → 505619 REMOVING AND
3. Remove front underbody panelling. → 108019 REMOVING AND INSTALLING ENGINE

GUARD
Measurement 7.1:
Fig 2: Overview Front Wheel Housing Liner Trim Panel (Measurement 7.1)
high-voltage connector for high-voltage line for high-voltage air-conditioning compressor.
Leave the second connection on the test adapter open.
Measurement 7.2:
6. Connect high-voltage test adapter VAS 6558/1-3 from Hybrid test adapter set WE 1378 to
the high-voltage air-conditioning compressor.
Fig 5: Identifying High-Voltage Test Adapter VAS 6558/1-3 Connector
1. 8.1.1. Insulation fault in high-voltage line from power electronics to

air-conditioning compressor.
2. 8.1.2. Replace high-voltage line from power electronics to air-conditioning

compressor following consultation with Technical Support. → 279319
REMOVING AND INSTALLING HIGH-VOLTAGE LINE FROM POWER
ELECTRONICS TO AIR-CONDITIONING COMPRESSOR
1. 8.2.1. Insulation fault in high-voltage air-conditioning compressor.

2. 8.2.2. Replace high-voltage air-conditioning compressor following
consultation with Technical Support. → Installing Electric Air-Conditioning
Compressor
range.


1. Unscrew and remove both cable shoes for high-voltage line to the high-voltage battery from
the power electronics unit. → 279119 REMOVING AND INSTALLING POWER
ELECTRONICS FOR HIGH-VOLTAGE SYSTEM
Measurement 8.1:
2. Hold both measuring tips of the insulation tester WE 1379 at each terminal shoe -1- and at
the insulation -2- on both high-voltage lines from the power electronics to the high-voltage
battery.
Fig 3: Measuring Insulation Resistance At Cable Shoes
1. 3.1. Setpoint value of both lines: > 550 MOhm
Measurement 8.2:
electronics unit (high-voltage connection for air-conditioning compressor). Leave the second
connection on the test adapter open.
1. 6.1.1. Insulation fault in high-voltage line from power electronics to

2. 6.1.2. Replace high-voltage line from power electronics to high-voltage

battery following consultation with Technical Support. → Installing
High-Voltage Line From Battery To Power Electronics
range.

1. Unscrew and remove 3-phase high-voltage line from power electronics unit. → 279119
REMOVING AND INSTALLING POWER ELECTRONICS FOR HIGH-VOLTAGE SYSTEM
Measurement 9.1:
Fig 2: Overview Of Power Electronics Unit
electronics unit. Leave the second connection on the test adapter open.
Fig 3: Connecting High-Voltage Test Adapter HVA 280 WE 1585 To Power Electronics Unit
Measurement 9.2:
Fig 4: Overview Of Power Electronics Unit (Measurement 9.2)
4. Hold both measuring tips of the insulation tester WE 1379 at one of the three terminal shoes
-1- and at the insulation -2- on the 3-phase high-voltage line.
1. 6.1.1. Insulation fault in power electronics.
2. 6.1.2. Replace power electronics following consultation with Technical

Support. → Installing Fuse For Power Electronics Unit
range.


1. Remove engine and electric machine. → 100127 REMOVING ENGINE FROM

TRANSMISSION AND MOUNTING ENGINE ON TRANSMISSION
2. Disconnect 3-phase wiring from electric machine. → 279319 REMOVING AND INSTALLING
Measurement 10.1:
Fig 1: Overview Of Power Electronics To Electric Motor (Measurement 10.1)
3. Use insulation tester Insulation tester WE 1379 to test the insulation resistance at the
contacts of the electric machine (measurement 10.1).
1. 3.1. Setpoint value: >550 MOhm
Measurement 10.2:
Fig 2: Overview Of Power Electronics To Electric Motor (Measurement 10.2)
4. Hold both measuring tips of the insulation tester WE 1379 at all three terminal shoes -1- and
at the insulation -2- on the 3-phase high-voltage line.
tolerance range and the specified measured values from measurement 10.2 are
within the tolerance range:
1. 6.1.1. Insulation fault in electric machine.
2. 6.1.2. Replace electric machine following consultation with Technical

Support. → 279019 REMOVING AND INSTALLING ELECTRIC MOTOR
WITH DECOUPLER (HYBRID MODULE)
tolerance range and the specified measured values from measurement 10.1 are
within the tolerance range:
1. 6.2.1. Insulation fault in 3-phase wiring from power electronics to electric

machine.
2. 6.2.2. Replace 3-phase wiring from power electronics to electric machine
following consultation with Technical Support. → Installing High-Voltage
Line From Power Electronics To Electric Motor
range.

SUPPLY/STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM (DIAGNOSTICS)
Locking device VW tool T40262

(CAYENNE S E-HYBRID) > GENERAL WARNING NOTES
technician (HVT).
Information
The procedure shown in the Workshop flow chart must be followed at all times. The Workshop flow
chart document is stored under Standard forms in the PPN.
Information
Information
Before starting to work on the high-voltage system, a high-voltage technician must isolate the
high-voltage system from the power supply.

Information
reactivation .

sign .
Information

(CAYENNE S E-HYBRID) > ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM
POWER SUPPLY (DIAGNOSTICS)
Information
Having successfully verified that the system is isolated from the power supply, attach green HV warning
signs to the vehicle.
Information
The test logs Verifying absence of electric charge (e-hybrid) and Restarting high-voltage system
(e-hybrid) can be found under Standard forms in the PPN.
Information
If absence of electric charge could not be verified automatically or if the function could not be run (see
display in PIWIS Tester II 9818 ), the voltage must be measured manually. See 'ISOLATING
HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER SUPPLY (MANUAL) '.
1. PIWIS Tester II 9818 must be connected to the vehicle before starting the System Tester.
3. Select Additional menu [F7].
4. Select High-voltage system in the Additional menu and press [F12].
5. Select the Isolate from power supply function and press [F12] to continue.
6. As soon as the relevant instruction appears on the Porsche System Tester, switch off ignition
(term. 15).
7. Follow the instructions on the Tester and read the information displayed.
8. When you are prompted to disconnect the 12 V service disconnector, open and secure the
connector as described below.
1. 8.1. Open luggage compartment lid and then open and remove the cover on the
luggage compartment trim at the right of the luggage compartment.
2. 8.2. Release service disconnector -1- , press the locking hook back slightly and
open the service disconnector.
Fig 2: Disconnecting Service Disconnector
3. 8.3. Lock the service disconnector with a padlock Locking device T40262 and store
the key in a safe place until the system is restarted.
9. Continue to follow the instructions on the Tester and read the information displayed.
10. Document the results in the test log Verifying absence of electric charge in accordance with
the display on the Porsche System Tester:
1. 10.1. Voltage values of the high-voltage components
2. 10.2. Symbols displayed in the instrument cluster and on the Porsche System Tester
3. 10.3. Code displayed on the Tester
11. Once you have isolated the system from the power supply, place the signed test log Verifying
absence of electric charge in the vehicle documents folder and attach green high-voltage
warning signs to the vehicle.
Information
If absence of electric charge could not be verified automatically or if the function could not be
run (see display in PIWIS Tester II 9818 ), the voltage must be measured manually. See
'ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER SUPPLY (MANUAL) '.

(CAYENNE S E-HYBRID) > STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM
Information
The test logs Verifying absence of electric charge (e-hybrid) and Restarting high-voltage system
(e-hybrid) can be found under Standard forms in the PPN.
Information
Always check the connections for the high-voltage lines and the connector holders before plugging in the
high-voltage lines.
If the plug contacts are deformed or damaged, stop working on the system and contact Technical
Support .
If the plug connections are deformed or damaged, stop working on the system and contact
Technical Support .
If the lines are deformed or damaged, stop working on the system and contact Technical Support
.
Information
1. Attach red HV warning sign to the vehicle
Always observe specified tightening torques.
3. Open and remove the padlock Locking device T40262 .
4. Release the service disconnector using a small screwdriver -a- , press the hook down slightly
and push it in -b- . Push service disconnector together -B- .
Fig 1: Closing Service Disconnector
5. Close the cover on the luggage compartment trim at the right of the luggage compartment.
6. Park the locked vehicle and wait 10 minutes .
high-voltage system, correct them according to the fault-finding strategy and then erase the
fault memory.
8. Create the test log Restarting high-voltage system (e-hybrid) and place it in the vehicle
documents folder.

SUPPLY/STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM (MANUAL) (CAYENNE S
E-HYBRID) > TOOLS
High-voltage Workshop WE 1585

test adapter equipment
HVA 280
high-voltage Workshop WE 1586
test adapter equipment
HVR 40
Locking device VW tool T40262

E-HYBRID) > GENERAL WARNING NOTES
technician (HVT).
Information
The procedure shown in the Workshop flow chart must be followed at all times. The Workshop flow
chart document is stored under Standard forms in the PPN.
Information
Information
Before starting to work on the high-voltage system, a high-voltage technician must isolate the
high-voltage system from the power supply.

Information
reactivation .

sign .
Information


E-HYBRID) > ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER
SUPPLY (MANUAL)
Information
Isolation from power supply is only verified manually if isolation from power supply cannot be verified
automatically (see display in PIWIS Tester II 9818 ).
Information
Work for which the high-voltage system has to be isolated from the power supply:
All work on a hybrid vehicle must only be carried out by persons who are at least qualified as an
Eip (Electrically instructed person) .
When carrying out any work on a hybrid vehicle, the hybrid-specific components in the
activity/work area must be visually inspected .
Anything anomalous or unclear must be reported to the HVT (high-voltage technician) or HVE
(high-voltage expert) .
Working close to high-voltage components and high-voltage lines using cutting, deforming and
sharp-edged tools or heat sources, such as welding, soldering, hot air and thermal bonding, is
prohibited .
Information
The dummy connection on the high-voltage charger can be used as an alternative measuring point for
Information
Having successfully verified that the system is isolated from the power supply, attach green HV warning
signs to the vehicle.
→ 2X00IN ISOLATION FROM SUPPLY PRIOR TO PERFORMING MAINTENANCE TASKS ON

HYBRID VEHICLES

3. Switch off ignition (term. 15).
4. Open luggage compartment lid and then open and remove the cover on the luggage
compartment trim at the right of the luggage compartment.
5. Release service disconnector, press release hook back slightly and open service disconnector.
Fig 2: Disconnecting Service Disconnector
6. Lock the service disconnector with a padlock Locking device T40262 and store the key in a
safe place until the system is restarted.
Information
When checking the system using high-voltage test adapter HVR 40 WE 1586 , make sure
not to damage the pins in the socket of the test adapter.
7. Perform function test on the high-voltage test adapter High-voltage test adapter HVA 280 WE
1585 or High-voltage test adapter HVR 40 WE 1586 in accordance with the test log for
verifying isolation from the power supply.→ 2X00IN FUNCTION TEST ON TEST ADAPTER
8. Use high-voltage test adapter HVR 40 WE 1586 and the voltage tester to measure the
voltage at the high-voltage battery.
1. 8.1. Release and disconnect high-voltage connector for high-voltage line to the
high-voltage charger at the high-voltage battery.
2. 8.2. High-voltage test adapter HVR 40 WE 1586 must be connected between the
high-voltage battery and high-voltage line to the high-voltage charger.

Fig 4: Measuring Voltage At High-Voltage Battery
9. High-voltage test adapter HVA 280 WE 1585 or high-voltage test adapter HVR 40 WE
1586 can now be disconnected.
10. Create test log Verifying absence of electric charge (e-hybrid) and place it in the vehicle
documents folder.
11. Attach green HV warning sign to the vehicle.
Information
The test logs Verifying absence of electric charge (e-hybrid) and Restarting high-voltage
system (e-hybrid) can be found under Standard forms in the PPN.
Information
If the system could not be isolated from the power supply, do not continue working on the
system and contact Technical Support.

E-HYBRID) > STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM
Information
Always check the connections for the high-voltage lines and the connector holders before plugging in the
high-voltage lines.
If the plug contacts are deformed or damaged, stop working on the system and contact Technical
Support .
If the plug connections are deformed or damaged, stop working on the system and contact
Technical Support .
If the lines are deformed or damaged, stop working on the system and contact Technical Support
.
Information
1. Attach red HV warning sign to the vehicle.
Always observe specified tightening torques.
3. At the high-voltage battery, connect HV line -1- and lock it.
Fig 1: Connecting HV Line To HV Charger
4. Open and remove the padlock Locking device T40262 .
5. Release the service disconnector using a small screwdriver -a- , press the hook down slightly
and push it in -b- . Push service disconnector together -B- .
Fig 2: Closing Service Disconnector
6. Close the cover on the luggage compartment trim at the right of the luggage compartment.
8. Create the test log Restarting high-voltage system (e-hybrid) and place it in the vehicle
documents folder.
Information
The test logs Verifying absence of electric charge (e-hybrid) and Restarting high-voltage
system (e-hybrid) can be found under Standard forms in the PPN.
WM 2X00IN ISOLATION FROM SUPPLY PRIOR TO PERFORMING MAINTENANCE

TASKS ON E-HYBRID VEHICLES (CAYENNE S E-HYBRID) > TOOLS
Insulated tool set Workshop WE 1593

equipment

TASKS ON E-HYBRID VEHICLES (CAYENNE S E-HYBRID) > ISOLATION FROM
SUPPLY PRIOR TO PERFORMING MAINTENANCE TASKS ON E-HYBRID VEHICLES
→ Always use insulated tools Insulated tool set WE 1593 when working on the high-voltage battery.

SYSTEM
Information
Specific qualifications are required for carrying out the maintenance tasks listed here.
The minimum qualification of the person performing the task is shown in the table.
The table also shows whether or not the vehicle must be isolated from the power supply in order to
perform the task.
Only HVTs are permitted to isolate the high-voltage system from the power supply .
The eip is permitted to perform defined tasks according to instructions and under the supervision of
the HVT .
Work on high-voltage system components must only be performed following isolation of the
high-voltage system from the power supply by the HVT .
All work on high-voltage vehicles must only be performed by persons who are at least qualified as
an eip .
When performing each task on a high-voltage vehicle, the high-voltage components in the
task/work area must be inspected visually .
Anything anomalous or unclear must be reported to the HVT or the high voltage expert (HVE) .
All work specified here refers to the removal and installation or replacement of the individual
components .
For regular maintenance work, the high-voltage system does not need to be isolated from the
power supply .
Information
Definition of isolating HV system from power supply:

Isolate system from power supply
Ensure that system cannot be switched back on again
Verify safe isolation from power supply
Information
Definition of minimum qualification:
Eip = Electrically instructed person
The eip may perform general work and maintenance tasks on a high-voltage vehicle as well as
mechanical work on the de-energized high-voltage system on instruction from the HVT .
HVT = High Voltage Technician
The high voltage technician's qualifications authorize him to do the same as an eip. The HVT is
additionally authorized to perform certified measurements to verify isolation of the high-voltage
system from the power supply. The HVT is authorized to do the following work on the isolated
high-voltage system .
Isolate system from power supply
Verify and document safe isolation from power supply
Delegate work on the isolated high-voltage system to the eip
Start the vehicle and complete the relevant documentation
HVE = High Voltage Expert
The HVE has additional knowledge to that of the HVT and is solely authorized to isolate the
high-voltage system in the vehicle from the power supply, in the event that the HVT is not able to
do this using the conventional tools and measurements .
If the authorization of the HVT to perform work on the high-voltage system is terminated, the HVE
must continue the work .
The task of the HVE is exclusively to deactivate the high-voltage system if this cannot be
performed using the conventional equipment or methods of the HVT .
→ 2X00IN GENERAL WARNING NOTES FOR WORKING ON THE HIGH-VOLTAGE VEHICLE

ELECTRICAL SYSTEM
→ 2X00IN ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER SUPPLY/STARTING


SUPPLY PRIOR TO PERFORMING MAINTENANCE TASKS ON E-HYBRID VEHICLES >
WORKING ON THE HIGH-VOLTAGE SYSTEM
When working on the following components: Minimum qualification:
Isolate high-voltage system from power supply HVT
Get the HVT to isolate the high-voltage system

When working on the following from the power supply before starting work? Minimum
components qualification:
Yes No
Electric machine with decoupler X (1)
Power electronics X HVT
12 V service disconnector X HVT
Removing and installing HV

X HVT
battery
Removing and installing control

X HVT
unit for HV battery
Cooling line inside HV battery X HVT
Cooling line outside of HV battery X Eip
Fuse for HV battery X HVT
Removing and installing E-box X HVT

(1)
High-voltage lines X
Charging socket X (1)
(1)
High-voltage charger X
Electric passenger compartment (1)

X
heater
(1)
Evaporator, HV valve block X
Electric HV battery heater X (1)
Front-axle carrier reinforcement X Eip
Electric air-conditioning (1)

X
compressor
Pressure regulator for decoupler X Eip

(1)
Decoupler (separating clutch) X
Pressure line for decoupler X Eip
Brake fluid for decoupler X Eip
Equipotential bonding lines X HVT
Work on the coolant system of the

X Eip
high-voltage components
Measurement at insulation
X HVT
resistors
Measurement at pilot line X HVT
Control unit for acoustic simulator X Eip
Acoustic simulator X Eip
(1) Eip1 A HVT must connect and disconnect the HV lines on the affected components.

CONVENTIONAL WORK CLOSE TO HIGH-VOLTAGE COMPONENTS
Get the HVT to isolate the

high-voltage system from the
power supply before starting Minimum
When working on the following components
work? qualification
Yes No
Removing and installing design cover X Eip
Spark plugs X Eip
Left catalytic converter X Eip
Right catalytic converter X Eip
Exhaust system X Eip
Cardan shaft X Eip
Removing and installing engine with transmission X (1)
(1)
Removing and installing engine X
Removing and installing transmission X (1)
Additional pressure pump for transmission oil (12 V) X Eip
Fuel tank X Eip
Front unit carrier X Eip
Rear axle housing X Eip
Underbody panelling X Eip
Welding work (covering high-voltage components and

X Eip
then carrying out visual inspection)
Body repair work (using straightening bench) X Eip
Body repair work (assembly work and dent removal) X Eip

Working close to high-voltage components and
high-voltage lines using cutting, deforming and
X Eip
sharp-edged tools or heat sources, such as welding,
soldering, hot air and thermal bonding
Removing and installing left headlight X Eip
Removing and installing right headlight X Eip
Removing and installing headlight bulbs X Eip

GENERAL WORK
Get the HVT to isolate the

high-voltage system from the
power supply before starting Minimum
When working on the following components:
work? qualification:
Yes No
Removing and installing 12 V battery X Eip
Removing and installing general control units and

X Eip
electric components (12 V)
Draining and filling fluids (coolant and oils) X Eip
Removing refrigerant by suction, evacuating and filling X Eip
A/C lines directly on the air-conditioning compressor X Eip
A/C lines in peripheral vehicle equipment (work that is

not carried out directly on the air-conditioning
X Eip
compressor, without opening the refrigerant circuit, e.g.
loosening and securing refrigerant lines).
Air conditioning performance test (for checking the

X Eip
pressure transmitter, using air conditioning service unit)
Work in the engine area for which the lines at the (1)
X
power electronics must be disconnected.
Work for which the engine must be raised (e.g.

X Eip
removing and installing engine mount).
Hydraulic pump for steering (12 V) X Eip
Electric vacuum pump (12 V) X Eip
Emissions inspection X Eip


TASKS ON HYBRID VEHICLES (CAYENNE S HYBRID) > TOOLS

6558/1

6558/8

TASKS ON HYBRID VEHICLES (CAYENNE S HYBRID) > ISOLATION FROM SUPPLY
PRIOR TO PERFORMING MAINTENANCE TASKS ON HYBRID VEHICLES
Information
Specific qualifications are required for carrying out the maintenance tasks listed here.
The qualification of the person performing the task is shown in the table.
The table also shows whether or not the vehicle must be isolated from the power supply in order to
perform the task.
Only HVTs are permitted to isolate the high-voltage system from the power supply .
The Eip is permitted to perform defined items of work according to instructions and under the
supervision of the HVT .
Work on high-voltage components must only be performed following isolation of the high-voltage
system from the power supply by the HVT .
All work on high-voltage vehicles must only be performed by persons who are at least qualified as
Eips .
When performing each task on a high-voltage vehicle, the high-voltage components in the
task/work area must be inspected visually .
Anything anomalous or unclear must be reported to the HVT or the high-voltage expert (HVE) .
All work specified here refers to the removal and installation or replacement of the individual
components .
For regular maintenance work, the high-voltage system does not need to be isolated from the
power supply .
Information
Definition of isolating the HV system from the power supply applies to isolating the system from
the power supply at the high-voltage battery (rear) and power electronics (front)
Isolate from power supply
Verify safe isolation from power supply
Information
Definition of minimum qualification:
Eip = Electrically instructed person
The Eip may perform general work and maintenance tasks on a high-voltage vehicle as well as
mechanical work on the isolated high-voltage system on instruction from the HVT .
HVT = High-voltage technician
The high-voltage technician's qualifications authorise him to do the same as an Eip. The HVT is
additionally authorized to perform certified measurements to verify isolation of the high-voltage
system from the power supply. The HVT is authorized to do the following work on the isolated
high-voltage system .
Isolate from power supply
Verify and document safe isolation from power supply
Delegate work on the isolated high-voltage system to the Eip
Start the vehicle and complete the relevant documentation
HVE = High-voltage expert

The HVE has additional knowledge to that of the HVT and is solely authorized to isolate the
high-voltage system in the vehicle from the power supply, in the event that the HVT is not able to
do this using the conventional tools and measurements .
If the authorization of the HVT to perform work on the high-voltage system is terminated, the HVE
must continue the work .
The task of the HVE is exclusively to isolate the high-voltage system from the power supply, if this
cannot be performed using the conventional equipment or methods of the HVT .

SYSTEM
→ 2X00IN ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER SUPPLY/STARTING


PRIOR TO PERFORMING MAINTENANCE TASKS ON HYBRID VEHICLES > WORK ON
THE HIGH-VOLTAGE SYSTEM
When working on the following components: Minimum qualification:
Isolate the high-voltage system from the power HVT

supply
Is the high-voltage system isolated from the

power supply by the HVT before starting
When working on the following Minimum
work?
components qualification:
Yes No
Electric machine with decoupler (2) Eip

(2)
Power electronics Eip
Service disconnector X HVT
Rear pilot line connector X HVT
Front pilot line connector X HVT
High-voltage line from power

(2)
electronics to air-conditioning Eip
compressor
High-voltage line from power (2)

Eip
electronics to electric machine
High-voltage line from hybrid battery (2) Eip

to power electronics
Removing and installing high-voltage (1)

Eip
battery
Charging high-voltage battery X HVT

(1)
High-voltage battery control unit HVT
Fan on high-voltage battery (1) Eip
Air extraction duct on high-voltage (1) Eip

battery
Air supply for the high-voltage battery

X Eip
fans
(2)
Electric air-conditioner compressor Eip
Pressure regulator for decoupler X Eip

(2)
Decoupler Eip
Pressure line for decoupler X Eip
Brake fluid for decoupler X Eip
Equipotential bonding lines X Eip
Work on the coolant system of the

X Eip
high-voltage components
Measurement at insulation resistors (2) HVT
(1) X1 Use measuring box Hybrid test adapter VAS 6558/1 WE 1378 to take measurements at the
high-voltage battery and measuring box Hybrid test adapter VAS 6558/8 WE 1446 to take
measurements on the high-voltage lines with power electronics.
(2)
X2 Use measuring box Hybrid test adapter VAS 6558/1 WE 1378 to take measurements at the
high-voltage battery and then at the front at the power electronics.

PRIOR TO PERFORMING MAINTENANCE TASKS ON HYBRID VEHICLES >
CONVENTIONAL WORK IN THE VICINITY OF HIGH-VOLTAGE COMPONENTS
Is the high-voltage system

isolated from the power supply
by the HVT before starting Minimum
When working on the following components
work? qualification
Yes No
Removing and installing design cover X Eip
Spark plugs X Eip

(1)
Left catalytic converter Eip
Right catalytic converter X Eip
Exhaust system X Eip
Cardan shaft X Eip

(2)
Removing and installing engine with transmission Eip
Removing and installing engine (2) Eip

(2)
Removing and installing transmission Eip
Auxiliary hydraulic pump for transmission oil (12 V) X Eip
Transfer gear X Eip
Fuel tank X Eip
Front unit carrier X Eip
Rear axle housing X Eip
Underbody panelling X Eip
Welding work (covering high-voltage components and

X Eip
then carrying out visual inspection)
(2)
Body repair work (using straightening bench) Eip
Body repair work (assembly work and dent removal) X Eip
Working close to high-voltage components and

high-voltage lines using cutting, deforming and (1) Eip
sharp-edged tools or heat sources, such as welding,
soldering, hot air and thermal bonding
Removing and installing left and right headlights X Eip
Removing and installing headlight bulbs X Eip
(1)
(2)

PRIOR TO PERFORMING MAINTENANCE TASKS ON HYBRID VEHICLES > GENERAL
WORK
Is the high-voltage system

isolated from the power
supply by the HVT before Minimum
When working on the following components:
starting work? qualification:
Yes No
Removing and installing 12 volt battery X Eip
Removing and installing general control units and

X Eip
electric battery (12 V)
Draining and filling fluids (coolant and oils) X Eip
Removing refrigerant by suction, evacuating and filling (1) Eip

(2)
Refrigerant line directly on air-conditioning compressor Eip
Air conditioning performance test (for checking the

pressure transmitter, using air conditioning service X Eip
unit)
Refrigerant line in peripheral vehicle equipment (work

that is not directly on the air-conditioning compressor,
X Eip
without opening the refrigerant circuit, e.g. loosening
and securing refrigerant lines).
Work in the engine/chassis area for which the cover

X Eip
plate on the power electronics must be removed.
Work in the engine area for which the cover plate must
(2)
be removed and lines must be disconnected at the HVT
power electronics.
Work for which the engine is raised by up to approx. (1)

Eip
20 cm (e.g. engine mountings).
Hydraulic pump for steering (12 V) X Eip
Electric vacuum pump (12 V) X Eip
Emissions inspection X Eip
(1)
(2)
WM 2X00IN BATTERY TRICKLE CHARGING (EXCEPT CAYENNE, CAYENNE GTS,

CAYENNE (3.0), CAYENNE TIP (3.0)) > INFORMATION > BATTERY TRICKLE
CHARGING
Information
When working or carrying out tests on the vehicle or when the vehicle is in the workshop, a battery
charger with a rated current of at least 40 A must be connected .
As soon as the vehicle is unlocked, e.g. the vehicle is in the workshop or salesroom, it must be
trickle charged with a battery charging device .

1. Open protective cover on the positive terminal for jump-lead starting -+- (-arrow- ).
Fig 1: Opening Protective Cover On Positive Terminal For Jump-Lead Starting
2. First, connect the positive cable from the charger to the positive terminal -+- .
3. Then connect the negative cable from the charger to the ground point for jump-lead starting - .
4. Read operating instructions for the charger.

5. Switch off all loads.
6. Switch on the charger.
WM 2X00IN BATTERY TRICKLE CHARGING (EXCEPT CAYENNE, CAYENNE GTS,

CAYENNE (3.0), CAYENNE TIP (3.0)) > INFORMATION > CONNECTING THE BATTERY
FOR TRICKLE CHARGING
A suitable battery charger must be connected to the vehicle electrical system when performing
the following tasks. All unnecessary electrical loads must be switched off .
When working on the vehicle for more than 15 minutes
When running a diagnosis using the Porsche System Tester
When adjusting the headlights
When working on or with the Infotainment system
If the doors, bonnet and rear lid are open for a long period of time or if these components are actuated
frequently
WM 2X00IN RULES RELATING TO CLEANLINESS AND INSTRUCTIONS FOR

WORKING ON THE FUEL SYSTEM (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE
INFORMATION > RULES RELATING TO CLEANLINESS AND INSTRUCTIONS FOR
WORKING ON THE FUEL SYSTEM
WARNING: Highly inflammable or explosive materials
Danger of fire or explosion
→ Avoid contact with hot parts or sources of ignition.
→ Use suction to remove ignitable vapors.
→ Attach warning sign in a clearly visible position.

necessary.
WARNING: Hot fuel and hot fuel lines.
Danger of scalding
→ Allow the fuel to cool down before opening line connections.
→ Wear protective gloves.
→ Wear protective goggles.
The work area and tools must be cleaned before working on the injection system.
Thoroughly clean connection points and adjacent areas before loosening them using engine or
brake cleaner and dry the cleaned area thoroughly.
During disassembly work, close off all open connections immediately using suitable clean
protection caps.
Do not remove the protection caps from any components until immediately before installation.
Pack components to be used again in new, sealable plastic bags.
Check the injection units and installation positions before installation by performing a visual
inspection for damage and soiling. Check that the injection unit stem is clean. If necessary, clean
the stem using a clean cloth, making sure not to damage it (no sharp tools!).
If the high-pressure lines will not be replaced, always mark the high-pressure lines during removal.
The high-pressure lines must only be re-fitted on the same cylinder.
Make sure not to damage the injection unit when removing the old sealing ring.
Check all new O-rings for signs of damage before fitting them. Coat O-rings with assembly oil or
engine oil before fitting them.
Align high-pressure lines without tension. Tighten all connections hand-tight at first and then
tighten to the specified torque.
High-pressure lines must never be re-bent.
A tool can only be used to loosen and tighten lines on the entire high-pressure system. All other
assembly and disassembly processes must be carried out by hand and without tools.
Press fuel return hoses onto the injection units from above using your hand until they lock on each
injection unit with an audible click (do not press in the release pin while doing this). Then press the
release pin down. Check that the fuel return hoses are seated securely by pulling them upwards
with your hand and check for leaks.
Individual common rail components cannot be disassembled. All the components must be replaced
in the event of a fault.
No assembly work must be carried out on the common rail system when the engine is running.
The common rail system must not be bled by loosening high-pressure components after starting
the engine.
Fit all tie-wraps, which you removed or cut during removal, back at the same position during
installation.
When the fuel system is open: Never use compressed air if at all possible. Do not move the vehicle
if possible.
Also make sure that no diesel gets onto the coolant hoses. The hoses must be cleaned
immediately if necessary. Always replace worn hoses.
To avoid letting the high-pressure pump run dry and to start the engine quickly after replacing
parts, the following points must always be observed:
CAUTION: Danger of irreparable damage to the high-pressure pump if it runs dry
To avoid letting the fuel high-pressure pump run dry and to start the engine quickly after replacing
If parts/components of the fuel system between the fuel tank and fuel high-pressure pump are
removed or replaced, the basic setting must be performed in order to bleed the fuel system.
Perform initial fuel fill procedure after installing the high-pressure pump.

E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > DISCONNECTING THE BATTERY
Battery can explode
Information
Information
The battery is located under the driver's seat.
1. Detach and fold over carpet in front of the driver's seat. → 704119 REMOVING AND
INSTALLING CARPET
2. Screw off ground strap at the ground point in front of the driver's seat:
3. Risk of short circuit! Screw off the ground strap -2- at the ground point -1- under the driver's
seat in front of the battery box.
Fig 1: Identifying Ground Point
4. Route or isolate the ground strap -2- so that all contact with a ground carrier (e.g. body,
battery terminal) is avoided.

E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > DISCONNECTING THE BATTERY >
CONNECTING THE BATTERY
1. Connect the battery
1. 1.1. Connect the ground strap -2- to the ground point -1- on the body in front of the
driver's seat and secure with the fastening nut.
Fig 1: Identifying Ground Point
2. Re-lay the carpet.
Effect of disconnection or total discharge of battery on electrical systems in the vehicle and the
precautions to be taken
Information
Control unit memories
Values and faults stored in the control units can be deleted if the battery is disconnected or completely
discharged.
If possible, all fault memories should be checked and, if necessary, printed out before the battery is
disconnected .
Information
Supply voltage fault entry
The entry "supply voltage" may be stored in various control units if the battery has been completely
discharged.
Delete the "supply voltage" entry from the control units in question .
Information
Ready status
In some countries (presently the U.S.A. and Canada), after disconnecting the battery, it is necessary to
reach the Ready status by a test drive and/or by using the Porsche System Tester DME control module
menu). If in doubt about this, contact the relevant importer.
Information
2470 DME control module
With all DME systems, the engine must run for several minutes before the engine control module can
relearn the idle speed and mixture adaptation values!
After disconnection of the power supply, the idle speed might change or fluctuate briefly until the throttle
valve adjusting unit has been readapted.
The mixture adaptation is also lost.
After the battery is connected:
With the DME, it is necessary to carry out a learning and adaptation routine as described below:
Switch ignition on for 30 seconds without starting the engine .
Do not actuate accelerator pedal .
This completes the adaptation of the throttle valve adjusting unit.
Information
Tyre pressure monitoring system
When the battery is disconnected and connected, the tire pressure is first displayed as "- - - ".
Once the battery has been disconnected and work is complete, the vehicle must be driven for a
short distance .
The actual pressures will then be displayed again.
Information
4560 Steering angle sensor
The steering angle sensor must be re-initialised when the battery is disconnected and connected.
Turn wheels to straight-ahead position .
Switch ignition off and then on again twice .
Start engine .
From the straight-ahead position, turn steering wheel approx. 20° to the right, past the
straight-ahead position .
Drive the vehicle straight ahead for at least one second at a speed above 4 km/h (2.5 mph) .
The steering angle sensor segment is recognized again in this process.
Once the sensor has been successfully initialized, the fault code that is stored in the fault memory is
documented using the fault deletion counter.
The fault memory erases itself automatically.
The PSM indicator light in the instrument cluster goes out.
Information
6014 Motor for sunroof
The limit positions of the sunroof are deleted from the control unit when the battery is disconnected and
connected.
Switch on ignition .
Press the sunroof button for several seconds in direction of travel .
After approx. 10 seconds, the sunroof performs an automatic standardization process and resets
all positions .
Keep the button pressed during the standardization process .
Afterwards, the sunroof is standardized correctly.
Information
6452 Power windows
The limit positions of the power windows are deleted from the control unit when the battery is
Perform the following procedure for all power windows:
Pull rocker switch and fully close window once .
Pull rocker switch once more .
The upper end position of the window is stored.
Press rocker switch and fully open window once .
Press rocker switch once more .
The lower end position of the window is stored.
Information
4815 Electrical steering column adjustment (ELVS)
The electrical steering column adjustment end positions (ELVS) are deleted when the battery is
The following buttons must be pressed in sequence in order to reinitializes electrical steering column
adjustment.
Press the extend button three times (extend towards the driver) .
Press the retract button once .

Press the extend button once (towards the driver) .
Press the up button once .
Press the down button once .
Once the buttons have been pressed correctly, the steering column automatically moves all axles and
stops at the center position (only works when the vehicle is stationary).
1. Carry out a test drive after connecting the battery.

E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > DISCONNECTING THE BATTERY >
TEST DRIVE AFTER CONNECTING BATTERY
Information
Depending on the vehicle equipment fitted, all these work steps are carried out during the test drive.
Read out the fault memories of all control units after the test drive.
If there is a fault present, check to see if the fault was caused by an undervoltage .
If faults were caused by an undervoltage (or CAN timeout error), erase the fault memory, perform
another test drive and read out the fault memory .
If faults were not caused by an undervoltage, correct the faults in accordance with GFF (Guided
Fault Finding) .
1. Check function of electric components.
WM 2X00IN IMPORTANT INFORMATION ON ADAPTING THE DME CONTROL UNIT

E-HYBRID, CAYENNE TURBO, CAYENNE S HYBRID, CAYENNE (3.0)) >
INFORMATION
Information
1. Adaptation values are deleted or stored in EEPROM when ignition is switched off after control
unit run-on has ended.
(Run-on period: 1 minute when engine is cold; up to 45 minutes when engine is hot)
Information
2. The following adaptations will be deleted automatically when you erase the fault memory (see
information under 1)):
1. Mixture adaptation
2. Lambda adaptation
3. Camshaft adaptation
4. Knock adaptation
5. Map-controlled thermostat adaptation

E-HYBRID, CAYENNE TURBO, CAYENNE S HYBRID, CAYENNE (3.0)) > DELETING
ADAPTATION VALUES > ALL ADAPTATIONS
Necessary after:
Replacing engine.
How?
1. PIWIS Tester:
1. 1.1. Meet preconditions:
1. 1.1.1. Engine off
2. 1.1.2. Ignition on
3. 1.1.3. Engine cold
2. 1.2. Select menu:
1. 1.2.1. DME
2. 1.2.2. Programming
3. 1.2.3. Automatic programming
3. 1.3. Start function by pressing [F8].
Information
The RBM data is also deleted here.

ADAPTATION VALUES > FUEL HIGH-PRESSURE ADAPTATION
Necessary after:
Replacing high-pressure pump
All work that must be carried out as a result of high-pressure faults, e.g. electric fuel pump, control
unit for electric fuel pump, etc.

ADAPTATION VALUES > OIL PUMP ADAPTATION
Necessary after:
Replacing oil pump
Replacing oil pressure control valve

ADAPTATION VALUES > MIXTURE ADAPTATION AND LAMBDA ADAPTATION
Necessary after:
Replacing high-pressure injectors
Correcting faults during load detection, mixture control, emissions measurement

ADAPTATION VALUES > INTAKE MANIFOLD PRESSURE SENSOR ADAPTATION
Necessary after:
Replacing intake manifold pressure sensor
Replacing boost pressure sensor (Turbo only)

ADAPTATION VALUES > BOOST PRESSURE CONTROL ADAPTATION (TURBO
ONLY)
Necessary after:
Replacing turbocharger
Correcting faults in boost pressure control system
How?
1. PIWIS Tester:
1. 1.1.1. Engine off
2. 1.1.2. Ignition on
3. 1.1.3. Engine cold

1. 1.2.1. DME
2. 1.2.2. Maintenance/repairs
3. 1.2.3. Delete adaptation values
3. 1.3. Press [F12] to continue.
1. 1.3.1. Information on deleting adaptation values.
4. 1.4. Press [F8] to confirm.
1. 1.4.1. Submenu of adaptation ranges.
5. 1.5. Select adaptation range and press [F12] to continue.
Information
1. Adaptation values are deleted or stored in EEPROM when ignition is

switched off after control unit run-on has ended.
6. 1.6. Switch off ignition.
7. 1.7. Adapt throttle valve (see below).

E-HYBRID, CAYENNE TURBO, CAYENNE S HYBRID, CAYENNE (3.0)) > WRITING
ADAPTATION VALUES (FOLLOWING DELETION) > SENSOR WHEEL ADAPTATION
Necessary after:
Necessary before:
Misfire diagnostics
How?
1. Drive with engine overrun:
1. 1.1.1. Engine at operating temperature.
2. 1.2. Accelerate to 3, 000 rpm (U /Min ) three times in quick succession in 2nd gear and
allow vehicle to roll with gear engaged (engine overrun).
Information

OVERWRITING ADAPTATION VALUES (WITHOUT DELETION) > THROTTLE VALVE
Necessary after:
Replacing throttle valve
Information
Consequences of Tester adaptation if conditions for automatic adaptation are not met (violated boundary
conditions):
For a fault entry in the load detection range (P0068 + P1069... P1077), the limits are extended in
order to prevent incorrect detections .
This extension is cancelled if an adaptation is performed when the conditions for automatic
adaptation are met, or after 15 warm-up cycles at the latest .
(Warm-up cycle = coolant temperature increases by more than 23 °C after start-up and reaches at
least 73 °C)
Following manual throttle valve adaptation when ambient conditions are not met, throttle valve
adaptation is carried out again automatically as soon as the ambient conditions are met .
There is NO 30-second waiting time here, but a slightly delayed engine start is possible once .
The ambient conditions for automatic adaptation are as follows:
Engine off and ignition on for > 30 seconds
Accelerator pedal not pressed
Vehicle is stationary
Power supply for throttle valve adjusting unit is OK
Coolant temperature 5 °C... 100 °C
Intake air temperature 5 °C... 40 °C
How?
1. Ignition on > 30 seconds if preconditions are met.

or
PIWIS Tester:
1. 1.1.1. Engine off.
2. 1.1.2. Ignition on.
1. 1.2.1. DME
3. 1.2.3. Adaptations
4. 1.2.4. Throttle valve adaptation
1. 1.3.1. Information.
4. 1.4. Press [F12] for detail view.
Information


OVERWRITING ADAPTATION VALUES (WITHOUT DELETION) > KICKDOWN
ACCELERATOR PEDAL MODULE (CAYENNE TIPTRONIC ONLY)
Necessary after:
Replacing accelerator pedal module
How?
1. PIWIS Tester:
1. 1.1.1. Engine off.

2. 1.1.2. Ignition on.
1. 1.2.1. DME
3. 1.2.3. Adaptations
4. 1.2.4. Kickdown adaptation
4. 1.4. Press accelerator pedal fully and release it again after 30 seconds.
Information


E-HYBRID, CAYENNE TURBO, CAYENNE S HYBRID, CAYENNE (3.0)) > TORQUE
LOSS > ONLY NECESSARY FOR VEHICLES WITH PDK
Necessary after:
Re-programming PDK control unit
Necessary before:
Re-calibrating PDK
Information
The accelerator pedal must always be pressed after approx. 1.5 minutes since each adaptation step is
limited to 5 Nm.
How?
1. Engine idling:
1. 1.1.1. Engine at operating temperature.
2. 1.2. Engine idling for 3 minutes without activating loads, press accelerator pedal
once after approx. 1.5 minutes during this time.
3. 1.3. Engine idling for 3 minutes with air conditioning switched on, press accelerator
pedal once after approx. 1.5 minutes during this time.
4. 1.4. Engine idling for 3 minutes with air conditioning switched on and transmission
range engaged, press accelerator pedal once after approx. 1.5 minutes during this
time.
Information


Service Manual: 90 - INSTRUMENTS -- 92A CAYENNE
WM 900319 REMOVING AND INSTALLING DASHBOARD INSET (CAYENNE,
1. Dashboard inset, top
2. Dashboard inset, center
3. Dashboard inset, bottom

PRELIMINARY WORK FOR DASHBOARD INSET AT THE TOP
1. Remove instrument cluster. → 902519 REMOVING AND INSTALLING INSTRUMENT

CLUSTER

PRELIMINARY WORK FOR DASHBOARD INSET AT THE BOTTOM
1. Remove dashboard molding on driver's side. → 705819 REMOVING AND INSTALLING
DASHBOARD MOLDING ON DRIVER'S SIDE
2. Remove dashboard inset at the center.
3. Remove steering column casing. → 481319 REMOVING AND INSTALLING STEERING

COLUMN CASING

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING DASHBOARD INSET >
REMOVING DASHBOARD INSET AT THE TOP

Fig 1: Identifying Dashboard Screws

REMOVING DASHBOARD INSET AT THE CENTRE
Information
1. Unclip center dashboard inset from the locks -1- from right to left.

REMOVING DASHBOARD INSET AT THE BOTTOM
Information
1. Unclip locks -1- from the dashboard inset at the bottom.
2. Unclip locks -2- from right to left.

3. Release and disconnect electric plug connection on ignition starter switch light -A- .
Fig 2: Removing Connector From Ignition Starter Switch
4. Release electric plug connection on temperature sensor -a- and disconnect it -A- .
Fig 3: Removing Temperature Sensor Connector

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING DASHBOARD INSET >
INSTALLING DASHBOARD INSET AT THE TOP
1. Tighten fastening screws.


INSTALLING DASHBOARD INSET AT THE CENTRE
1. Clip dashboard inset into the locks -1- from right to left.

INSTALLING DASHBOARD INSET AT THE BOTTOM
1. The dashboard inset at the bottom is installed in reverse order to removal.

SUBSEQUENT WORK FOR DASHBOARD INSET AT THE TOP
1. Install instrument cluster. → 902519 REMOVING AND INSTALLING INSTRUMENT

CLUSTER

SUBSEQUENT WORK FOR DASHBOARD INSET AT THE BOTTOM
1. Install steering column casing. → 481319 REMOVING AND INSTALLING STEERING

COLUMN CASING
2. Install dashboard inset at the center.
3. Install dashboard molding on driver's side. → 705819 REMOVING AND INSTALLING

MOLDING FOR DASHBOARD ON DRIVER'S SIDE
WM 902119 REMOVING AND INSTALLING COMPASS (CAYENNE, CAYENNE GTS,


value 1 2
Stopwatch or compass to cover Internal Torx screw, Tightening 3 Nm (2

for center loudspeaker M5 x 20 torque ftlb.)

1. Remove loudspeaker trim panel at the center. → 709019 REMOVING AND INSTALLING

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING COMPASS
NOTE: Voltage peaks
Fig 1: Identifying Compass Installation Position
1. Unscrew fastening screws -1- and remove compass from the trim panel.
Fig 2: Identifying Compass Screws
2. Disconnect electric plug connection from compass.

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING COMPASS
1. The compass is installed in reverse order to removal.
2. Tighten screws. Tightening torque 3 Nm (2 ftlb.)

1. Install loudspeaker trim panel at the center. → 709019 REMOVING AND INSTALLING
WM 902519 REMOVING AND INSTALLING INSTRUMENT CLUSTER (CAYENNE,


Instrument cluster mounting Tightening torque 1.5 Nm (1 ftlb.)

1. If the instrument cluster has to be replaced, the values/data must be read out before removal
using PIWIS Tester II 9818 . → 902555 REPLACING INSTRUMENT CLUSTER .
2. Remove dashboard inset at the center and bottom. → 900319 REMOVING AND INSTALLING
DASHBOARD INSET

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING INSTRUMENT CLUSTER
Fig 1: Identifying Instrument Cluster Installation Position

Fig 2: Identifying Instrument Cluster Screws

3. Release clip -1- on electric plug connection -a- and bend it over -A- , then disconnect
connector -B- .
Fig 4: Removing Instrument Cluster Connector

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING INSTRUMENT
CLUSTER
1. The instrument cluster is installed in reverse order to removal.
2. Tighten fastening screws -1- . Tightening torque 1.5 Nm (1 ftlb.)

Fig 1: Identifying Instrument Cluster Screws

1. Install dashboard inset at the center and bottom. → Installing Dashboard Inset
2. If the instrument cluster was replaced, the values/data that were read out must be written back
into the instrument cluster again using PIWIS Tester II 9818 . → 902555 REPLACING
INSTRUMENT CLUSTER .
WM 902555 REPLACING INSTRUMENT CLUSTER (CAYENNE, CAYENNE GTS,




CAYENNE S DIESEL, CAYENNE (3.0)) > READING AND WRITING VALUES
NOTE: Voltage drop
battery.
Information
Tester releases.
Information
If the instrument cluster is replaced, the fuel-level sensors must be calibrated using PIWIS Tester II
9818 .
To calibrate the fuel-level sensors, the fuel tank must be drained completely .
ignition.
3. Select the required control unit Instrument cluster in the overview .
9. Document the total mileage.
INSTRUMENT CLUSTER .
11. Switch on ignition and select Instrument cluster control unit.
12. Select the menu Maintenance/repairs , Control unit replacement .
13. Select Write data and press [F12] to continue.
16. Select the Set total mileage function and press [F12] to continue.
17. Select total mileage and enter the correct current mileage (value from the "old" instrument
cluster). Then press "Enter" to confirm your entry and press [F8] to write data.
18. Follow the instructions on the Tester and press [F8] to start the process.
19. Select the Calibrate fuel-level sensor function and press [F12] to continue.
20. Follow the instructions on the Tester and press [F12] to continue. The fuel tank must be
completely empty. → 200317 DRAINING AND FILLING FUEL
21. Calibrate the fuel-level sensors in accordance with the instructions on the Tester.
23. Return to the control unit overview .
24. Check the function of the instrument cluster and fuel level gauge during the test drive.
WM 903519 REMOVING AND INSTALLING GATEWAY CONTROL UNIT (CAYENNE,

Screw securing ST 4.2 x 16 Tightening 1.5 Nm (1

control unit to
gateway/PDC
holder
Screw securing M6 Tightening 6 Nm (4.5

holder to module
carrier

1. Read out values and coding using PIWIS Tester II 9818 before installing a new control unit. →
903555 REPLACING GATEWAY CONTROL UNIT .
2. Remove trim panel under dashboard at the left. → 701919 REMOVING AND INSTALLING
3. Loosen fuse box at the front left.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING GATEWAY CONTROL
UNIT
Information

Fig 1: Identifying Gateway Control Unit Installation Position
NOTE: Voltage peaks

Fig 2: Removing Control Unit Holder
2. Remove holder with control units -arrow A- and set them down in the footwell.
3. Release electric plug connection -a- and disconnect it from the control unit.
Fig 3: Disconnecting Connector For Gateway Control Unit
4. Unscrew fastening screws -2- on the back of the gateway control unit.
Fig 4: Removing Gateway Control Unit
5. Remove control unit.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING GATEWAY CONTROL
UNIT
Information
1. Position gateway control unit on the holder.
2. Tighten fastening screws -2- . Tightening torque 1.5 Nm (1 ftlb.)

Fig 1: Installing Control Unit On Holder
3. Plug in and lock electric plug connection -a- .

Fig 2: Locating Gateway Control Unit Connector
4. Position holder on dashboard support -arrow A- and tighten fastening screws -1- .
Fig 3: Fitting Control Unit Holder

1. Secure fuse box at the front left.
2. Install trim panel under dashboard at the left. → 701919 REMOVING AND INSTALLING TRIM
PANEL UNDER DASHBOARD
3. If the control unit was replaced, the new control unit must be taught to suit the vehicle using
PIWIS Tester II 9818 . → 903555 REPLACING GATEWAY CONTROL UNIT .
WM 903555 REPLACING GATEWAY CONTROL UNIT (CAYENNE, CAYENNE GTS,




CAYENNE S DIESEL, CAYENNE (3.0)) > CODING CONTROL UNIT
NOTE: Voltage drop
battery.
Information
Tester releases.
Information
by the vehicle.
GATEWAY CONTROL UNIT .
ignition.
3. Select the vehicle type under Diagnostics .
4. Select the required control unit Gateway in the overview and press [F12] to continue.
5. Extended identifications must now be selected.
6. Check the VIN and correct it if necessary.
7. Press [F7] to call up the Additional menu.
8. Maintenance of vehicle data must now be selected.
9. Check vehicle data based on information in the PIWIS information system and correct it if
necessary.
11. Automatic coding must be selected. Then start coding by pressing [F12].
continue.
15. Select the Online teaching function menu on the Start page.
16. Select Component protection and press [F12].
17. Select the required vehicle and press [F12].
18. Gateway component protection must be selected. Then press [F12].
19. Proceed in accordance with the instructions on the Tester.
20. Once gateway component protection has been taught successfully, switch back to the
Diagnostics function and select the required vehicle . Then press [F12].
transmitters).
WM 905019 REMOVING AND INSTALLING HORN (CAYENNE, CAYENNE GTS,
Horn to M10 Tightening 20 Nm (15

longitudinal torque ftlb.)
member


CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING HORN
Information
Fig 1: Identifying Horns Installation Position

NOTE: Voltage peaks
1. Unclip and remove charge air line -1- from the charge-air cooler -arrow- .
Fig 2: Removing Charge Air Line
2. Release electric plug connection -2- and disconnect it from the horn -arrow A- .
Fig 3: Removing Horn
3. Unclip electric wire harness from the holder -6- .
4. Unscrew fastening screw -3- and remove horn -5- with holder -6- .
5. Unscrew fastening screw -4- and remove horn -5- from the holder -6- .

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING HORN
Information
Make sure that the plug connections and lines are not touching the horns or the brackets.
1. Position horn -5- in such a way that the cut-out encloses the raised part -arrow- of the holder
-6- .
Fig 1: Positioning Horn
2. Tighten fastening screw -4- .
3. Install holder -6- with horn -5- .
4. Tighten fastening screw -3- . Tightening torque 20 Nm (15 ftlb.)
5. Connect electric plug connection -2- until it engages securely -arrow B- .
6. Clip in electric wire harness at the holder -6- .

Fig 2: Installing Horn
7. Install charge air line -1- on the charge-air cooler and clip it in -arrow- .
Fig 3: Installing Charge Air Line

WM 905819 REMOVING AND INSTALLING PLUG SOCKET (CAYENNE, CAYENNE

CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION > INFORMATION ON
INSTALLATION POSITIONS
Fig 1: Identifying Plug Sockets Installation Positions
A. Plug socket under glove compartment
B. Plug socket in front center console
C. Plug socket in rear center console
D. Plug socket in luggage compartment, left

WORK FOR PLUG SOCKET UNDER GLOVE COMPARTMENT
1. Remove cover under dashboard. → 702219 REMOVING AND INSTALLING COVER UNDER
DASHBOARD

WORK FOR PLUG SOCKET IN REAR CENTRE CONSOLE
1. Remove rear center console. → 681719 REMOVING AND INSTALLING CENTRE CONSOLE

WORK FOR PLUG SOCKET IN LUGGAGE COMPARTMENT
1. Detach side trim panel for luggage compartment close to the rear lid. → 700319 REMOVING
AND INSTALLING SIDE TRIM PANEL FOR REAR LUGGAGE COMPARTMENT

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING PLUG SOCKET > REMOVING
PLUG SOCKET UNDER GLOVE COMPARTMENT

Fig 1: Disconnecting Plug Connection On Plug Socket
2. Open the cover of the plug socket and press the plug socket -1- through in an outward
direction -A- .
Fig 2: Removing Plug Socket
3. Release the cover -2- (-B- ) and press it outwards -C- .

Fig 3: Removing Cover On Plug Socket

PLUG SOCKET IN FRONT CENTRE CONSOLE
1. Remove rubber mat -1- from storage bin -2- .

Fig 1: Identifying Centre Console Storage Bin Rubber Mat
2. Unscrew two fastening screws -3- .

Fig 2: Removing Storage Bin Screws
3. Lift up storage bin -2- (-A- ).

Fig 3: Lifting Storage Bin

5. Open the cover of the plug socket and press the plug socket -1- through in an outward
direction -A- .

Fig 6: Removing Plug Socket Cover

PLUG SOCKET IN REAR CENTRE CONSOLE

2. Press the plug socket -1- outwards -A- .


Fig 3: Removing Plug Socket Cover

PLUG SOCKET IN LUGGAGE COMPARTMENT
1. Release and disconnect electric plug connection.

Fig 1: Disconnecting Luggage Compartment Plug Socket Plug Connection
2. Unscrew plastic nut behind the trim panel.

Fig 2: Identifying Luggage Compartment Plug Socket Plastic Nut
3. Open the cover of the plug socket -3- (-A- ) and press the plug socket -4- out -B- .
Fig 3: Removing Plug Socket In Luggage Compartment

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING PLUG SOCKET > PLUG
SOCKET UNDER GLOVE COMPARTMENT
The plug socket under the glove compartment is installed in reverse order to removal.

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING PLUG SOCKET > INSTALLING
PLUG SOCKET IN FRONT CENTRE CONSOLE
The plug socket in the front center console is installed in reverse order to removal.

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING PLUG SOCKET > PLUG
SOCKET IN REAR CENTRE CONSOLE
The plug socket in the rear center console is installed in reverse order to removal.

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING PLUG SOCKET > INSTALLING
PLUG SOCKET IN LUGGAGE COMPARTMENT
The plug socket in the luggage compartment is installed in reverse order to removal.

WORK FOR PLUG SOCKET UNDER GLOVE COMPARTMENT
1. Install cover under dashboard. → 702219 REMOVING AND INSTALLING COVER UNDER
DASHBOARD

WORK FOR PLUG SOCKET IN REAR CENTRE CONSOLE
1. Install rear center console. → Installing Centre Console

WORK FOR PLUG SOCKET IN LUGGAGE COMPARTMENT
1. Secure side trim panel for luggage compartment close to the rear lid. → Installing Side Trim
Panel For Rear Luggage Compartment
WM 906219 REMOVING AND INSTALLING CIGARETTE LIGHTER (CAYENNE,

PRELIMINARY WORK FOR FRONT CIGARETTE LIGHTER
1. Remove cupholder. → 683019 REMOVING AND INSTALLING CUPHOLDER

PRELIMINARY WORK FOR REAR CIGARETTE LIGHTER
1. Remove rear center console. → 681719 REMOVING AND INSTALLING CENTRE CONSOLE

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING CIGARETTE LIGHTER >
REMOVING FRONT CIGARETTE LIGHTER
1. Pull cupholder -1- out of the center console -2- .

Fig 1: Disconnecting Plug Connection For Cigarette Lighter
2. Remove cupholder from the center console.
3. Release plug connection for the cigarette lighter -3- (-a- ) and disconnect it -arrow- .
4. Remove cupholder.
5. Press plug socket -1- for cigarette lighter through in an outward direction -A- .
Fig 2: Removing Plug Socket For Cigarette Lighter

Fig 3: Removing Cigarette Lighter Cover

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING CIGARETTE LIGHTER >
REMOVING REAR CIGARETTE LIGHTER

Fig 1: Disconnecting Cigarette Lighter Plug Socket Plug Connection
2. Press plug socket -1- for cigarette lighter through in an outward direction -A- .

Fig 3: Removing Cigarette Lighter Cover

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING CIGARETTE LIGHTER
1. The front cigarette lighter is installed in reverse order to removal.
2. The rear cigarette lighter is installed in reverse order to removal.

SUBSEQUENT WORK FOR FRONT CIGARETTE LIGHTER
1. Install cupholder. → Installing Cupholder

SUBSEQUENT WORK FOR REAR CIGARETTE LIGHTER
1. Install rear center console. → Installing Centre Console
WM 906419 REMOVING AND INSTALLING CONTROL UNIT FOR AUXILIARY ALARM

WORK
1. Check that Vehicle Servicing mode was activated by the customer.
2. Remove luggage compartment trim panel (luggage compartment cover). → 700619

REMOVING AND INSTALLING TRIM PANEL FOR LUGGAGE COMPARTMENT (LUGGAGE
COMPARTMENT COVER) AT THE LOCK SUPPORT

CONTROL UNIT FOR AUXILIARY ALARM SYSTEM
Fig 1: Identifying Control Unit For Auxiliary Alarm System Installation Position

1. Unscrew nuts -1- .
Fig 2: Removing Control Unit For Auxiliary Alarm System
2. Remove control unit for auxiliary alarm system -2- from its holder.
3. Release electric plug connection -a- , fold the securing clip over -A- and disconnect plug
connection -B- .
1. 3.1. To release, check locking lugs.

4. Release plug connections from antennas -a- and disconnect them -arrow- .
5. Remove control unit for auxiliary alarm system from the vehicle.

CONTROL UNIT FOR AUXILIARY ALARM SYSTEM
1. Plug in antenna plug connections for GSM -1- (red), GPS -2- (blue) and driver card -3- (grey)
-A- until they engage securely -B- .
Fig 1: Installing Antenna Plug Connections
2. Plug in electric plug connection -A- and fold locking clip over -B- .
Fig 2: Installing Auxiliary Alarm System Electric Plug Connection
3. Attach tie-wrap.
4. Position control unit for auxiliary alarm system -2- on the holder.
5. Tighten nuts -1- .

Fig 3: Installing Control Unit For Auxiliary Alarm System

WORK
1. Install luggage compartment trim panel (luggage compartment cover). → 700619 REMOVING
AND INSTALLING TRIM PANEL FOR LUGGAGE COMPARTMENT (LUGGAGE
COMPARTMENT COVER) AT THE LOCK SUPPORT
WM 906425 ACTIVATING PCC/PVTS (CAYENNE, CAYENNE GTS, CAYENNE TURBO S,




CAYENNE (3.0)) > ACTIVATING PCC/PVTS
NOTE: Voltage drop
battery.
Information
Tester releases.
Information
PCC/PVTS should be activated just before vehicle handover as the customer has access to the vehicle
and the term of the PCC/PVTS contract begins following activation.
1. Get installation code from the customer.
Information
If the installation code is not available, PCC/PVTS activation must be carried out during vehicle
handover.
2. PIWIS Tester must be connected to the vehicle before starting the Tester.
5. Start the diagnostic application.
7. Press [F7] Vehicle functions .
8. Start the Tester sequence Activate PCC/PVTS and continue by pressing [F12].
9. Read and follow the steps shown on the PIWIS Tester.
10. Log activation.
13. Perform a function test if possible.

Service Manual: 9X - ELECTRICAL SYSTEM - GENERAL -- 92A CAYENNE
WM 9X00IN BASIC INSTRUCTIONS AND PROCEDURE FOR CONTROL UNIT
PROGRAMMING USING THE PIWIS TESTER (CAYENNE, CAYENNE GTS & CAYENNE
TURBO S) > TOOLS
Battery Charger Workshop

WE 1353
HFL 65 Equipment

TURBO S) > BASIC INFORMATION AND INSTRUCTIONS FOR CONTROL UNIT
PROGRAMMING > BASIC INFORMATION ON CONTROL UNIT PROGRAMMING
Information
There are basically two different ways of carrying out control unit programming:
Using the "Programming" menu for the relevant control unit (e.g. for the DME and PDK control
units) .
or
Using the "Campaign" function in the Additional menu on the PIWIS Tester by entering a specific
programming code .
The type of control unit programming to be used is described in the relevant Technical Information.
TURBO S) > BASIC INFORMATION AND INSTRUCTIONS FOR CONTROL UNIT
PROGRAMMING > BASIC INSTRUCTIONS FOR CONTROL UNIT PROGRAMMING
NOTE: Fault entry in the fault memory and control unit programming aborted due to
undervoltage.
Increased current draw during diagnosis or control unit programming can cause a drop
in voltage, which can result in one or more fault entries and the abnormal termination of
the programming process.
→ Before commencing work, connect a suitable battery charger with a current rating of at least 40 A to
the jump-start terminals in the engine compartment.
NOTE: Control unit programming will be aborted if the WLAN connection is unstable.
An unstable WLAN connection can interrupt communication between PIWIS Tester II

and the vehicle communication module (VCI). As a result, control unit programming may
be aborted.
→ During control unit programming, always connect PIWIS Tester II to the vehicle communication
module (VCI) via the USB cable.
NOTE: Control unit programming will be aborted if the vehicle key is not recognized
If the vehicle key is not recognized in vehicles with Porsche Entry & Drive, programming
cannot be started or will be interrupted.
→ Switch on the ignition using the original vehicle key. To do this, replace the control panel in the ignition
lock with the original vehicle key if necessary.

TURBO S) > GENERAL PRELIMINARY WORK
1. Disconnect electric plug connection for the fan blower -1- (-a- ) to prevent the fan blower from
coming on during control unit programming.
Having the fan on and the associated increased current draw can cause a drop in voltage,
which can result in abnormal termination of control unit programming.
Fig 1: Identifying Electric Plug Connection Of Fan Blower
2. Connect a battery charger with a current rating of at least 40 A (e.g. Battery Charger HFL 65
WE 1353 ) to the jump-start terminals in the engine compartment and switch it on.
3. Switch on the ignition using the original driver's key . On vehicles with "Porsche Entry &
Drive", do this by replacing the control panel in the ignition lock with the original driver's key if
necessary.
4. PIWIS Tester II 9818 must be connected to the vehicle communication module (VCI) via the
USB cable . Then, connect the communication module to the vehicle and switch on the PIWIS
Tester.

TURBO S) > BASIC PROCEDURE FOR CONTROL UNIT PROGRAMMING USING THE
PIWIS TESTER > INFORMATION ON THE PROCEDURE FOR CONTROL UNIT
PROGRAMMING
Information
There are basically two different ways of carrying out control unit programming using the PIWIS Tester:
Using the "Programming" menu for the relevant control unit (e.g. for the DME and PDK control
units) → Control unit programming using the "Programming" menu .
or
Using the "Campaign" function in the Additional menu on the PIWIS Tester by entering a specific
programming code → Control unit programming using the "Campaign" function in the Additional
menu on the PIWIS Tester .
The type of control unit programming to be used is described in the relevant Technical Information.

PIWIS TESTER > CONTROL UNIT PROGRAMMING USING THE "PROGRAMMING"
MENU
1. On the PIWIS Tester start screen, call up the → 'Diagnostics' menu and select the relevant
vehicle type.
2. Select the control unit to be programmed in the control unit selection screen (→ "Overview"
menu) and press [>>] to confirm your selection → see Fig 1.
Fig 1: Identifying Control Unit Selection Screen Display

3. When the question "Create Vehicle Analysis Log (VAL)?" appears, either press [F12] to create
a VAL or press [F11] if you do not want to create a VAL.
4. Press [>>] to acknowledge the message that may appear informing you that campaigns for the
vehicle are stored in the PIWIS information system.
5. Once the control unit to be programmed has been found, select the → 'Programming' menu.
6. Select the → 'Automatic Programming' function and press [>>] to confirm your selection and
start the guided programming sequence → see Fig 2.
Fig 2: Identifying Automatic Programming Screen Display
7. Read and follow the Information And Instructions On The PIWIS Tester during the guided
programming sequence. Then press [>>] to continue.
During the programming sequence, the control unit is re-programmed and then re-coded
automatically if necessary.
Do Not Interrupt Programming And Coding .
Once control unit programming - and coding if necessary - is complete, you will be prompted to
switch the ignition off and then back on again after a specified waiting time.
Information
Once programming is completed successfully, the work described under → "General

subsequent work" must always be carried out.
If other specific subsequent work is required, this is described in the relevant Workshop
Manual or in the relevant Technical Information.
Information
1. If an error message is displayed during programming (e.g. "Campaign does not exist",
"No suitable programming rules found" or "Vehicle data could not be read", etc.), please
read and follow the appropriate instructions provided under → Troubleshooting .
2. If programming is interrupted (e.g. due to a voltage drop or if communication is aborted,

etc.) or if programming could not be carried out successfully (error message
"Programming unsuccessful"), programming must be repeated .
3. If coding is not carried out successfully during the guided programming sequence, the
control unit must be re-coded again separately once the guided programming sequence
is complete. To do this, select the relevant control unit in the control unit selection screen
("Overview" menu) and press [>>] to confirm your selection. Once the control unit has
been found, select the "Codings/adaptations " menu and re-code the control unit using
the 'Automatic coding' function .

PIWIS TESTER > CONTROL UNIT PROGRAMMING USING THE "CAMPAIGN"
FUNCTION IN THE ADDITIONAL MENU ON THE PIWIS TESTER
1. On the PIWIS Tester start screen, call up the → 'Diagnostics' menu and select the relevant
vehicle type.
2. In the control unit selection screen ("Overview" menu), press [F7] to call up the → 'Additional
menu' (→ see Fig 1).
3. When the question "Create Vehicle Analysis Log (VAL)?" appears, either press [>>] to create a
VAL or press [F11] if you do not want to create a VAL.
4. Press [>>] to acknowledge the message that may appear informing you that campaigns for the
vehicle are stored in the PIWIS information system.
5. Select the → 'Campaign' function and press [>>] to confirm your selection → see Fig 2.
You are then prompted to enter a programming code.

Fig 2: Identifying Additional Menu (Campaign)Screen Display
6. To enter the programming code, click in the relevant text box so that the cursor starts to flash
→ see Fig 3.
Fig 3: Identifying Programming Code Input Field Screen Display
7. Enter the Programming Code specified in the relevant description (Technical Information,
Workshop Manual) and press [Enter] to confirm your entry.
The text box turns blue.
8. Press [>>] to start the guided programming sequence.
Read and follow the Information And Instructions On The PIWIS Tester during the guided
programming sequence. Then press [>>] to continue.
During the programming sequence, the control unit is re-programmed and then re-coded
automatically if necessary.
Do Not Interrupt Programming And Coding .
Once control unit programming - and coding if necessary - is complete, you will be prompted to
switch the ignition off and then back on again after a specified waiting time.
Information
Once programming is completed successfully, the work described under → "General

Subsequent Work" must always be carried out.
If other specific subsequent work is required, this is described in the relevant Workshop
Manual or in the relevant Technical Information.
Information
1. If an error message is displayed during programming (e.g. "Campaign does not exist",
"No suitable programming rules found" or "Vehicle data could not be read", etc.), please
read and follow the appropriate instructions provided under → Troubleshooting .
2. If programming is interrupted (e.g. due to a voltage drop or if communication is aborted,

etc.) or if programming could not be carried out successfully (error message
"Programming unsuccessful"), programming must be repeated by entering the
programming code again (Additional menu > Campaign >> Enter campaign number). It
is not possible to program the control units manually .
3. If coding is not carried out successfully during the guided programming sequence, the
control unit must be re-coded again separately once the guided programming sequence
is complete. To do this, select the relevant control unit in the control unit selection screen
("Overview" menu) and press >> to confirm your selection. Once the control unit has
been found, select the "Codings/adaptations " menu and re-code the control unit using
the 'Automatic coding' function .

TURBO S) > GENERAL SUBSEQUENT WORK
1. Plug in electric plug connection for the fan blower.
2. Read out and erase all fault memories.
1. 2.1. In the control unit selection screen (→ 'Overview' menu), press [F7] to call up
the → 'Additional Menu' (→ see Fig 1).

2. 2.2.
Select the function → 'Read All Fault Memories And Erase If Required' and press
[>>] to confirm → see Fig 2.
The fault memories of the control units are read out.
Fig 2: Identifying Erasing Fault Memories Screen Display
3. 2.3. Once you have read out the fault memories, delete the fault memory entries by
pressing [F8].
4. 2.4. Press [>>] ("Yes") in response to the question as to whether you really want to
delete all fault memory entries.
The faults stored in the fault memories of the various control units are deleted.
Information
If there are still fault memory entries in individual control units, start the engine briefly and then
switch it off again. Wait for approx. 10 seconds before switching the ignition on again and
re-establish the connection between the PIWIS Tester and the vehicle. Then read out and
erase the fault memories of the affected control units again separately.
If the control units are found to have other faults, which cannot be erased and are Not Caused
By Control Unit Programming , these faults must be found and corrected.
4. Disconnect the PIWIS Tester from the vehicle.

5. Switch off and disconnect the battery charger.
6. On vehicles with Porsche Entry & Drive, replace the original driver's key in the ignition lock with
the control panel again.

TURBO S) > TROUBLESHOOTING
Information
This section describes possible Causes And Remedial Action for Error Messages that can occur
both during control unit programming using the 'Campaign' function and during control unit
programming using the 'Automatic Programming' function.
Error message after starting

Possible causes Remedial action
programming
Update PIWIS Tester software to

the software version specified in
PIWIS Tester software the Technical Information (or a
is not up-to-date higher software version). Then
enter the programming code again
and start programming.
Close the diagnostic application.

Specified campaign does not
Select the correct vehicle type and
exist Wrong vehicle type
restart the diagnostic application.
selected
Then enter the programming code
again and start programming.
Incorrect programming
Enter the programming code
code entered or
specified in the Technical
programming code not
Information correctly.
entered correctly
Campaign must not be

carried out on the Check vehicle assignment to the
vehicle or campaign campaign in PIWIS > Vehicle
was already carried Information .
No suitable programming rules
out.
found. Cause: Part Number Of
The Control Unit is not in the
programming rules.
Replacement control Check Porsche part number of the
unit with up-to-date relevant control unit in the →
software version was "Extended identification" menu.
installed
Information about the current Porsche
Software version of the
installed control unit is
already up-to-date
part numbers and software versions of
the affected control unit can be found in
Software version of the the relevant Workshop Manual or in the
control unit is a version relevant Technical Information.
that is not intended for
carrying out the
campaign.
Campaign must not be Check vehicle assignment to the

carried out on the campaign in PIWIS > 'Vehicle
vehicle. Information' menu.
No suitable programming rules
found. Cause: Current Vehicle
Equipment is not shown in the
Check vehicle order and correct it
programming rules. Please
if necessary (PIWIS Tester >
check vehicle order and change
Additional menu >> Maintenance
it if necessary. Vehicle order is wrong.
of vehicle data). Then enter the
programming code again and start
programming.
Switch on ignition and close and

Ignition not switched restart the diagnostic application.
Vehicle data could not be read
on Then enter the programming code
again and start programming.
WM 9X00IN MEASUREMENT OF CLOSED-CIRCUIT CURRENT (CAYENNE, CAYENNE

TURBO, CAYENNE GTS & CAYENNE TURBO S) > TOOLS
Closed-circuit current should be measured using the digital multimeter with a long integration time (to
filter out voltage peaks).
Fig 1: Identifying Digital Multimeter

TURBO, CAYENNE GTS & CAYENNE TURBO S) > PREPARATORY WORK ON THE
VEHICLE
Information
Before measuring the closed-circuit current, determine the vehicle equipment (I-numbers) and
establish the expected closed-circuit current with the aid of the attached table.
The closed-circuit current must only be measured on a cold vehicle (engine & brakes).
1. Close all doors and lids on the vehicle.
2. Read out the fault memory and delete the displayed faults if necessary.
3. Disconnect the battery.

TURBO, CAYENNE GTS & CAYENNE TURBO S) > CONNECTING THE MEASURING
DEVICE
1. Use alligator clips to connect the measuring device to the battery ground and body ground.
2. Remove ground strap from the body and secure against contact with the body. The entire
vehicle current now flows through the ammeter.

TURBO, CAYENNE GTS & CAYENNE TURBO S) > MEASUREMENT
Read off the measured values after the waiting period specified in the table.
1. Switch on ignition for 10 seconds.
3. Open the driver's door and close the rotary latch with a screwdriver while the door is open.
4. Lock the vehicle using the central-locking remote control and switch off passenger
compartment monitoring (press the button on the remote control twice in one second).
5. Wait 35 minutes before reading off the closed-circuit current.
Information
1. If the value of the closed-circuit current is higher than the value determined in the table,
the cause must be established systematically.
2. Recommended troubleshooting procedure: With the measuring device connected,

remove the fuses of terminal 30 and the relays successively. Observe the values
displayed on the measuring device when removing the fuses and relays in order to detect
a reduction in current.
3. The measured values can vary by approx. 20%.
4. The values listed in the table depend on the condition of the battery, the room
temperature, the engine temperature and therefore should only be regarded as
guidelines.
Reading Off The Measuring Range:
Read off the measuring range only after at least 35 minutes have passed since locking the
vehicle.
From to mA
35 min. Until battery is empty max. 30
Control unit Equipment Closed-circuit current in mA
Trailer 0.4
Alarm horn 0.86
Battery sensor Standard 0.25

Front BCM, front-end electronics Standard 3.05
Rear BCM, rear-end electronics Standard 7.63
Telephone handset 0
CDR 31 0.125
Roof console Standard 2.78
DME Standard 0
Steering column adjustment 0.05
ELV, electronic steering column lock Standard 0.035
Gateway Standard 0.335
Generator Standard 0.215
Main fuse box Standard 0.04
Front A/C control panel Standard 0.07
Rear A/C control panel 0.07
Instrument cluster Standard 0.19
Fuel pump control unit Standard 0.22
Steering column module Standard 0.03
Light switch Standard 0
Engine fan Standard 0.01
PASM 0.07
Parking brake Standard 0.03
PCM 0.15
PDCC 0.005
PDK 0.06
Powerlift tailgate 0.08
PSM Standard 0.03
Transverse lock 0.115
TPM (Tyre Pressure Monitoring) 0.02
Rain sensor 0.015
Sunroof 0.045
Seat, FL 0.16
Seat, FR 0.16
Auxiliary heater 0.03
Stopwatch 0.03
Auxiliary heater telestart 1.53
Door, RL 0.09
Door, RR 0.085
Door, FL 0.12
Door, FR 0.11
Amplifier 0.01
Burmester amplifier 0.015
Wiper Standard 0.01
Ignition lock Standard 0.07
Start-Stop Standard 0.01
Maximum Closed-Circuit Current 30 mA
Calculated closed-circuit current 19.45 mA
6. Connect battery and read out fault memory. Erase any faults if necessary. → Connecting The
Battery .

Closed-circuit current should be measured using the digital multimeter with a long integration time (to
filter out voltage peaks).
Fig 1: Identifying Digital Multimeter

TURBO, CAYENNE GTS & CAYENNE TURBO S) > PREPARATORY WORK ON THE
VEHICLE
Information
Before measuring the closed-circuit current, determine the vehicle equipment (I-numbers) and
establish the expected closed-circuit current with the aid of the attached table.
The closed-circuit current must only be measured on a cold vehicle (engine & brakes).
1. Close all doors and lids on the vehicle.
2. Read out the fault memory and delete the displayed faults if necessary.

TURBO, CAYENNE GTS & CAYENNE TURBO S) > CONNECTING THE MEASURING
DEVICE
1. Use alligator clips to connect the measuring device to the battery ground and body ground.
2. Remove ground strap from the body and secure against contact with the body. The entire
vehicle current now flows through the ammeter.

TURBO, CAYENNE GTS & CAYENNE TURBO S) > MEASUREMENT
Read off the measured values after the waiting period specified in the table.
1. Switch on ignition for 10 seconds.
3. Open the driver's door and close the rotary latch with a screwdriver while the door is open.
4. Lock the vehicle using the central-locking remote control and switch off passenger
compartment monitoring (press the button on the remote control twice in one second).
5. Wait 35 minutes before reading off the closed-circuit current.
Information
1. If the value of the closed-circuit current is higher than the value determined in the table,
the cause must be established systematically.
2. Recommended troubleshooting procedure: With the measuring device connected,

remove the fuses of terminal 30 and the relays successively. Observe the values
displayed on the measuring device when removing the fuses and relays in order to detect
a reduction in current.
3. The measured values can vary by approx. 20%.
4. The values listed in the table depend on the condition of the battery, the room
temperature, the engine temperature and therefore should only be regarded as
guidelines.
Reading Off The Measuring Range:
Read off the measuring range only after at least 35 minutes have passed since locking the
vehicle.
From to mA
35 min. Until battery is empty max. 30
Control unit Equipment Closed-circuit current in mA
Trailer 0.4
Alarm horn 0.86
Battery sensor Standard 0.25

Front BCM, front-end electronics Standard 3.05
Rear BCM, rear-end electronics Standard 7.63
Telephone handset 0
CDR 31 0.125
Roof console Standard 2.78
DME Standard 0
Steering column adjustment 0.05
ELV, electronic steering column lock Standard 0.035
Gateway Standard 0.335
Generator Standard 0.215
Main fuse box Standard 0.04
Front A/C control panel Standard 0.07
Rear A/C control panel 0.07
Instrument cluster Standard 0.19
Fuel pump control unit Standard 0.22
Steering column module Standard 0.03
Light switch Standard 0
Engine fan Standard 0.01
PASM 0.07
Parking brake Standard 0.03
PCM 0.15
PDCC 0.005
PDK 0.06
Powerlift tailgate 0.08
PSM Standard 0.03
Transverse lock 0.115
TPM (Tyre Pressure Monitoring) 0.02
Rain sensor 0.015
Sunroof 0.045
Seat, FL 0.16
Seat, FR 0.16
Auxiliary heater 0.03
Stopwatch 0.03
Auxiliary heater telestart 1.53
Door, RL 0.09
Door, RR 0.085
Door, FL 0.12
Door, FR 0.11
Amplifier 0.01
Burmester amplifier 0.015
Wiper Standard 0.01
Ignition lock Standard 0.07
Start-Stop Standard 0.01
Maximum closed-circuit current 30 mA
Calculated closed-circuit current 19.45 mA
6. Connect battery and read out fault memory. Erase any faults if necessary. → Connecting The
Battery
Service Manual: 10 - ENGINE - CRANKCASE, SUSPENSION -- 92A CAYENNE
WM 100119 REMOVING AND INSTALLING V6 HYBRID ENGINE (CAYENNE S E) >
TOOLS
hose clamp VW tool 3094
ball joint puller VW tool T10187

PRELIMINARY WORK
3. Disconnect the battery. → REMOVING BATTERY
4. Drain refrigerant from the air-conditioning system using suction. → 870317 ADDING
REFRIGERANT AND REMOVING BY SUCTION
5. Remove front wheels. → REMOVING WHEEL
6. Drain coolant for high-temperature and low-temperature cooling system. → DRAINING

COOLANT
TOOLS AND MATERIALS
The following tools are described .
1. Assembly mandrel => Height can be adjusted; used for mounting in the engine carrier;
equipped with a locking screw to prevent engine from tilting and for height adjustment. Item 2
in base carrier
2. Wheel hub holder => Secures the spring struts to prevent them from tilting. Inserted from
the side into the second cross member from the front
3. Assembly mandrel => Height can be adjusted; used for mounting in the front-axle carrier at
the front; equipped with a locking screw to prevent engine from tilting and for height
adjustment. Item 1 in base carrier
4. Support => Not used here.
5. Wishbone support => Used in conjunction with -5- to protect the wheel suspension and
spring struts from damage.
6. Assembly mandrel => For mounting on the front-axle carrier at the rear. Item 3 in base
carrier
7. Assembly mandrel => Guide for positioning the elevating platform into the body; first moves
into a bore in the body for centering roughly. Item 4 in base carrier
8. Assembly mandrel => For mounting on the transmission cross member. Item 5 on base
carrier
Fig 1: Identifying Engine Elevating Platform
1. Wheel hub holder => Secures the spring struts to prevent them from tilting.
2. Support => Prevents the engine from tilting backwards. Not generally used.
3. Lateral mounting mandrel for engine carrier => Height can be adjusted; used for mounting
in the engine carrier; equipped with a locking screw to prevent engine from tilting and for height
1. 3.1 - Support with height adjustment => Screwed into part 3.
2. 3.2 - Protection against tilting => Screwed into part 3.1. Prevents the engine from
tilting forward.
4. Front front-axle carrier mounting => Height can be adjusted; used for mounting in the
front-axle carrier at the front; equipped with a locking screw to prevent engine from tilting and
for height adjustment. Item 1 in base carrier
5. Rear front-axle carrier mounting => Item 3 in base carrier
6. Mounting in the body => Item 4 in base carrier
7. Mounting for transmission cross member => Item 5 in base carrier
Fig 2: Overview Of Engine Tools
Information
For the Cayenne S Diesel (V8), it may be necessary to convert the engine/transmission mounting WE
1206 !
Old version without supplementary set

Fig 3: Identifying Base Carrier
2, 5 and 8 - Not used for removing engine!
1. Screw in mounting mandrel for front-axle carrier at the front (instead of "2")
Information
1206 !
New version with supplementary set
1. Mounting mandrel for front front-axle carrier
2. Mounting mandrel for engine carrier
3. Mounting mandrel for rear front-axle carrier
4. Mounting mandrel for centering in the body.
5. Position of mounting mandrel on transmission cross member
1. Cayenne Diesel/Hybrid
2. Cayenne/S/GTS/Turbo/Turbo S
1. Cayenne S Diesel
7. Bracket for wheel carrier

8. Mounting for lower wishbone
9. Supplementary set
arrows - Nuts and screws
1. Convert engine/transmission mounting.
1. 1.1. Unscrew nuts -arrows - .
2. 1.2. Remove nuts and screws.
3. 1.3. Remove old cross member and replace it with new cross member -9- .
4. 1.4. Screw in and tighten screws and nuts.

REMOVING V6 HYBRID ENGINE
Information
For installation, it is a good idea to mark the installation position of the front-axle carrier diagonally
at least two places on the body. To do this, place the marks vertically with respect to the floor of the
body using a felt-tip pen (e.g. mark along the front-axle carrier mount with the pen). This makes it
easier to correctly position the front-axle carrier on the body during re-installation .
Information
Because of the high loosening torques, the four fastening screws on the front-axle carrier and the
two screws on the engine transverse bar can now be loosened. Loosen the screws by a maximum
of one turn .
Information
When lowering the engine, make sure that cables, hoses or lines are not trapped accidentally
between the engine and body. To prevent this, a second person must make sure that the cables,
hoses and lines do not get caught .
Information
1. Remove air guide pipe by pulling off the hose -1- and loosening the hose clamps -arrows- .
Fig 1: Locating Air Guide Pipe
2. Disconnect all connectors -1... 4- for oxygen sensors.

Fig 2: Identifying Oxygen Sensor Connectors
3. Remove windscreen wiper arms. → REMOVING WIPER ARMS
4. Remove plenum panel cover.
5. Remove anti-theft protection from the engine control unit.
6. Pull engine wiring harness connector off the engine control unit.
7. Unscrew ground strap and disconnect connector. -arrows-

Fig 3: Locating Ground Strap And Connector
8. Place engine wire harness on the engine.
1. 8.1. Open cover of central electrical system.
2. 8.2. Disconnect all connectors whose wires go to the engine.
3. 8.3. Remove engine wire harness from the plenum panel and place it on the engine.
Fig 4: Identifying Central Electrical System Cover
WARNING: Hot fluid
1. Danger of scalding
→ Let the fluid cool down.
9. Pull off coolant hose -1- () and disconnect vent lines -arrows- .
Fig 5: Locating Coolant Hose And Vent Line
WARNING: Hot fluid
10. Pull off secondary-air line -1- and coolant hoses -arrows- .
Fig 6: Locating Secondary-Air And Coolant Hoses
WARNING: Hot fluid
11. Pull off coolant hoses -arrows- .

Fig 7: Locating Coolant Hoses
CAUTION: Escaping residual air
NOTE: Opened refrigerant system for repairs.
1. Risk of moisture getting into the refrigerant system.
2. Risk of contaminating the refrigerant circuit.
3. Risk of saturation and irreparable damage to desiccator.
4. Irreparable damage to the desiccator can damage the compressor and

evaporator.
→ After opening the refrigerant circuit, close off the lines/connections immediately using
suitable stoppers.
→ The desiccator must be replaced if the air humidity is high and if the refrigerant circuit is left
open for a long time.
12. Disconnect refrigerant line for air conditioning. Close off open lines using suitable stoppers.
Fig 8: Locating Engine Refrigerant Line
13. Remove crash panel on power and control electronics for electric drive. → REMOVING FUSE
FOR POWER ELECTRONICS UNIT
WARNING: Hot fluid
14. Open the locks on the two rapid-action couplings -arrows- and pull off the coolant lines.
Fig 9: Opening Coolant Lines
15. Release and pull off the high-voltage line for the electric air-conditioning compressor -1- .
Fig 10: Pulling Air-Conditioning Compressor High-Voltage Line
16. Release and unplug the pilot connector -1- at the power electronics. Release and pull off the
high-voltage lines -2, 3, 4- one after the other. Unclip high-voltage lines and place them on the
engine.
Fig 11: Removing Pilot Connector And High-Voltage Lines For Electric Motor

evaporator.
suitable stoppers.
17. Unplug connector on the air-conditioner compressor -arrow- . Unscrew screw -1- and remove
refrigerant line from the air-conditioner compressor.
Fig 12: Identifying Air-Conditioning Compressor Connector
WARNING: Emerging fuel
1. Danger of fire or explosion
→ Do not work on the fuel system when the engine is hot.
→ Keep clear of naked flames and ignition sources.
18. Disconnect the fuel supply line -arrow- .

Fig 13: Locating Fuel Supply Line
19. Disconnect connector -arrow- at the steering gear.

Fig 14: Locating Steering Gear Connector
20. Remove heat shield -1- for universal joint.

Fig 15: Locating Heat Shield On Universal Joint
21. Remove universal joint -1- from the steering gear and push it upwards. Pull off hoses -2- on
the coolant pipes.
Fig 16: Identifying Universal Joint And Hoses
22. Unscrew ground strap on drive motor -arrow- .

Fig 17: Locating Drive Motor Ground Strap
23. Unscrew clamp -1- . Pull out securing clasp -arrow- and remove bleeder for clutch actuation.
Close off open lines.
Fig 18: Locating Clutch Actuation Bleeder
24. Release front right wheel housing liner, disconnect connector for auxiliary hydraulic pump
control unit and expose wire harness.
Fig 19: Locating Auxiliary Hydraulic Pump Control Unit Connector
25. Unscrew ground strap -A- on the right longitudinal member.

Fig 20: Identifying Ground Strap On Longitudinal Member
26. Unscrew screw -A- and pull connections off the transmission oil cooler. Collect emerging oil.
Fig 21: Identifying Transmission Oil Cooler Connections
27. Clamp power-steering hose using hose clamp 3094 . Disconnect power steering lines
-arrows- . Collect emerging oil.
Fig 22: Locating Power-Steering Lines
WARNING: Hot fluid
28. Disconnect coolant hoses -arrows- and remove upper coolant hose -1- from the brackets.
29. Press off trailing arm.
1. 29.1. Unscrew nut for upper trailing arm by several turns and press off the joint using
ball joint puller T10187 .
2. 29.2. Completely unscrew nut and disconnect trailing arm.

Fig 24: Pressing Trailing Arm
30. Disconnect connectors -arrow- from the front speed sensors at the left and right.
Fig 25: Locating Speed Sensor Connectors
31. Disconnect connector -arrow- for wear indicator.

Fig 26: Locating Wear Indicator Connector
32. Unscrew screws -arrows- for line bracket.

Fig 27: Locating Line Bracket Screws
33. Unscrew screw -arrow- on connecting link at the bottom.
Screw off nut -A- on double wishbone. Leave the screw in the bore hole.
Fig 28: Locating Connecting Link And Double Wishbone Screw
34. Unscrew screws -A- on the brake calliper, remove brake calliper and secure in the wheel
housing with a tension strap.
Repeat these steps for the wheel suspension on the opposite side of vehicle.
Fig 29: Identifying Brake Caliper Screws
35. Disconnect connector -arrows- at the transmission.

Fig 30: Locating Transmission Connector
36. Remove exhaust system.
1. 36.1. Release clamping sleeves -1- and -2- between the front and center silencers.
1. Risk of squashing or crushing
2. 36.2. Support the exhaust system between the center silencer and rear silencer with
engine and gearbox jack. Unscrew exhaust system mountings and lower the exhaust
system.
Fig 31: Identifying Exhaust System Clamping Sleeves
37. Remove rear cardan shaft. → REMOVING REAR CARDAN SHAFT
38. Disconnect shift mechanism at the ball joint and unscrew from transmission.
Fig 32: Locating Shift Mechanism
39. Mark the installation position of the front-axle carrier diagonally at least two places on the body
using a felt-tip pen. This makes it easier to correctly position the front-axle carrier on the body
during re-installation. → Marking installation position of front-axle carrier
Fig 33: Marking Front-Axle Carrier Installation Position
40. Set up the lifting platform according to instructions
→ Removing V6 Hybrid Engine . Then position it under the engine and raise it. When you do
this, ensure that the positioning guides of the lifting platform are inserted into the body. →
Lifting platform under engine
Fig 34: Identifying Engine Platform
41. The -arrows- show the mounting points for the mounting frame in the front-axle carrier (view
from below here).
Fig 35: Locating Front-Axle Carrier Mounting Points
42. Position lifting platform in the front-axle carrier in the mounting points provided -(arrows)- , -4
into the body- .
Fig 36: Lifting Engine Platform
43. Secure the wheel bearing housing. To do this, turn the rubber discs upwards until they are set
under the steering knuckle. Then tighten the retaining brackets on the wheel hub and lifting
platform. -arrow-
Fig 37: Locating Wheel Bearing Housing Bolt
44. Remove screws -A- for the right and left spring struts.
Fig 38: Locating Connecting Link And Double Wishbone Screw
45. Mark the final position of the lifting platform -1- on the workshop floor using a suitable tool, e.g.
adhesive tape -A- .
Fig 39: Position Engine Lifting Platform
46. Loosen the transmission cross member. To do this, loosen the four fastening screws -A- .
Fig 40: Identifying Transmission Cross Member Screws
47. Secure the engine/transmission unit. Then secure the mounting mandrels on the engine
transverse bar with the locking screws.
48. Loosen the four fastening screws on the front-axle carrier and the two fastening screws on the
engine transverse bar. -arrows-
Fig 41: Locating Front-Axle Carrier And Fastening Screws
49. Get a second mechanic to help .
1st mechanic: Lower the lifting platform slowly by approx. 20 to 30 cm.
2nd mechanic: Observe the lowering process and check that the components, hoses and lines
have sufficient clearance.
NOTE: Lowering power unit
1. Risk of damage to connections
→ Disconnect all connections to the body.

Slowly lower the power unit while constantly checking clearance.

INSTALLING V6 HYBRID ENGINE
NOTE: Assembly work in engine compartment
Risk of damage to lines
→ Route all the various lines (e.g. for fuel, hydraulics, coolant and refrigerant, brake fluid, etc.) and
electric lines in such a way that the original line routing is restored.
Information
The tightening specifications for the basic engine are stored centrally (→ 1001IN TIGHTENING
TORQUES, TIGHTENING SEQUENCES, ASSEMBLY OVERVIEWS ).
Tightening torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission
or body) or for peripheral engine equipment can be found in the corresponding documents.
Information
Due to currently correct tightening specifications, the screw specifications can be found in the
corresponding repair descriptions for the assemblies chassis, transmission, electrics, etc .
Information
1. Tightening torques:
1. 1.1. Engine: → 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES,

ASSEMBLY OVERVIEWS
2. 1.2. Transmission: → 3X00IN TIGHTENING TORQUE, TIGHTENING SEQUENCE

AND ASSEMBLY OVERVIEW
3. 1.3. Chassis: → 4X00IN TIGHTENING TORQUES FOR FRONT AXLE
4. 1.4. Brakes: → 4X00IN TIGHTENING TORQUES FOR BRAKE MECHANISM
5. 1.5. Steering: → 4X00IN TIGHTENING TORQUES FOR STEERING
2. Move ring gear and pinion shaft under the vehicle using the elevating platform.
3. Reconnect all electric connections, lines, hoses and plug connections that were disconnected
during removal.
4. For hybrid vehicles, it is particularly important that the contact surfaces of the equipotential
bonding lines (ground connection for hybrid module) are clean and free of grease.
5. Install plenum panel cover.
6. Install wiper arms at the left and right. → INSTALLING WIPER ARMS
7. Connect air conditioning lines.
8. Fill in power-steering oil. → 4890IN TEST AND ASSEMBLY WORK ON POWER STEERING
9. Check engine-oil level. → 170101 CHECKING ENGINE-OIL LEVEL

SUBSEQUENT WORK
1. Connect the battery. → INSTALLING BATTERY
2. Fill in refrigerant for the air conditioning system again. → 870317 ADDING REFRIGERANT
AND REMOVING BY SUCTION
3. Install front wheels. → INSTALLING WHEEL
4. Fill in coolant for high-temperature and low-temperature cooling system. → FILLING THE
COOLING SYSTEM (INCLUDES BLEEDING)
7. Bleed the clutch system. → 300107 BLEEDING THE CLUTCH SYSTEM
8. Erase the fault memory. → WM 0335IN DIAGNOSTIC MAINTENANCE: RESETTING

DIAGNOSTIC SYSTEM AND SERVICE INTERVAL (CAYENNE, CAYENNE S, CAYENNE S
E-HYBRID, CAYENNE TURBO, CAYENNE (3.0), CAYENNE GTS & CAYENNE TURBO S)
9. After erasing the fault memory of the power electronics control unit, the phase angle and
temperature model of the electric motor must be calibrated. Certain temperature ranges of the
power electronics and electric motor must be observed in order to perform complete
calibration.
1. 9.1. The phase angle and temperature model are calibrated by actuating the brake
and terminal 50 for approx. 2 seconds without starting the vehicle. No other
conditions must be met for calibrating the phase angle.
2. 9.2. Defined temperatures on the electric motor (< 60 °C) and a temperature
difference between the electric motor and power electronics (< 20°C) must be
observed in order to calibrate the temperature model. If these temperatures are not
observed, the phase angle can be calibrated and the vehicle can be started but the
temperature model will not be calibrated.
3. 9.3. If the temperature conditions are met after stopping the vehicle in the case of a
vehicle that has not been calibrated fully, the temperature model will be calibrated
automatically the next time the vehicle is started (actuate the brake and terminal 50,
start the vehicle). The first start attempt is perceived as a hung start or false start.
The vehicle can then be started after a terminal change (ignition off/on).
10. Observe applicable safety measures when carrying out a test drive.
WM 100119 REMOVING AND INSTALLING ENGINE (CAYENNE GTS, CAYENNE

TURBO) > TOOLS
disassembly Commercially Nr.21

tool available tool
ball joint VW tool T10187

puller

TURBO) > PRELIMINARY WORK > PRELIMINARY WORK FOR REMOVING AND
INSTALLING ENGINE
1. Read out the DME fault memory. → 0101IN DIAGNOSTIC SYSTEM: READING OUT FAULT
MEMORY AND ACTIVATING SYSTEMS
2. For vehicles with air suspension:
Move air suspension into service position. → 4301IN BLEEDING AND FILLING LEVELLING
SYSTEM
3. Remove engine guard with transverse strut. → Removing Engine Guard 108019 REMOVING
AND INSTALLING ENGINE GUARD
4. On vehicles with 19-inch brake system: Remove the air guide at the anti-roll bar. → 407719
REMOVING AND INSTALLING FRONT STABILIZER (PDCC)

BATTERY
6. Remove front wheels. → REMOVING WHEEL
7. Remove the front wheel housing liners. → REMOVING FRONT WHEEL HOUSING LINER
8. Move bonnet into service position. → REMOVING FRONT PNEUMATIC SPRING
9. Remove right cross panel. → REMOVING CROSS PANEL
10. Remove engine compartment trim panels. → REMOVING FRONT TRIM PANEL (ENGINE
COMPARTMENT)
11. Loosen the torque support. → Removing Torque Support
12. Remove design cover on throttle valve. → Removing Engine Cover (Design Cover)
13. Drain coolant. → DRAINING COOLANT
14. Evacuate the air conditioning system. → DRAINING AND FILLING REFRIGERANT

TURBO) > TOOLS AND MATERIALS
equipped with a locking screw to prevent engine from tipping and for height adjustment. Item 2
in base carrier
2. Wheel hub holder => Secures the spring struts to prevent them from tipping. Inserted from
the front; equipped with a locking screw to prevent engine from tipping and for height
carrier
7. Assembly mandrel => Guide for positioning the lifting platform into the body; first moves into
a bore in the body for centering roughly. Item 4 in base carrier
carrier
Fig 1: Identifying Engine Lifting Platform
1. Wheel hub holder => Secures the spring struts to prevent them from tipping.
2. Support => Prevents the engine from tipping backwards. Not generally used.
in the engine carrier; equipped with a locking screw to prevent engine from tipping and for
height adjustment. Item 2 in base carrier
2. 3.2 - Protection against tipping => Screwed into Part 3.1. Prevents the engine
from tipping forward.
front-axle carrier at the front; equipped with a locking screw to prevent engine from tipping and

Fig 2: Overview Of Tool
2, 5 und 8 - Not used for removing engine!
Fig 3: Identifying Base Carrier With Mounting Mandrels

TURBO) > REMOVING ENGINE
necessary.
NOTE: Aggressive fluids
Risk of damage to components and surfaces
→ Do not spill fluids.
→ In the event of contact, wash the component or surface with water.
→ Replace components that are already damaged.
Information
For installation, it is a good idea to mark the installation position of the front-axle carrier diagonally
at least two places on the body. To do this, place the marks vertically with respect to the floor of the
body using a felt-tip pen (e.g. mark along the front-axle carrier mount with the pen). This makes it
easier to correctly position the front-axle carrier on the body during re-installation .
Information
Because of the high loosening torques, the four fastening screws on the front-axle carrier and the
two screws on the engine transverse bar can now be loosened. Loosen the screws by a maximum
of one turn .
Information
When lowering the engine, make sure that cables, hoses or lines are not trapped accidentally
between the engine and body. To prevent this, a second person must make sure that the cables,
hoses and lines do not get caught .
Information
1. Release electric plug connection -1- - M - on the DME control unit -2- (-a- ) and pull it off -A-
.
Fig 1: Removing DME Control Unit Plug Connection
2. Loosen fastening nut -1- for ground point at the body and remove ground cable -2- to the
DME control unit.
Cut the tie-wrap if necessary.
3. Remove the tie-wrap -3- if necessary.

Fig 2: Identifying Body Ground Point
4. Open the cover of the front relay box in the plenum panel. → 970955 REPLACING SUB-PART
OF WIRE HARNESS IN ENGINE COMPARTMENT AT THE FRONT LEFT
5. Release and unplug the three electric plug connections -1- on the engine wire harness.
Fig 3: Identifying Engine Plug Connections
6. Unclip the engine wire harness -1- in the plenum panel from the retaining clips -2- and
remove it.
Fig 4: Identifying Plenum Panel Engine Wire Harness
7. Disconnect B+ transfer point at the left of the engine compartment.

Fig 5: Removing B Positive Transfer Point
8. Release electric plug connections -1- at the left cross panel -a, b and pull them off -A, B- .
Fig 6: Removing Left Cross Panel Plug Connections
9. Release electric plug connections -1- at the right cross panel -a, b- and pull them off -A, B- .
Fig 7: Removing Right Cross Panel Plug Connections
10. Lay the engine wire harness on the engine and secure it.
11. Remove intake pipe. → REMOVING COWL FOR THROTTLE HOUSING (Y-PIPE)
12. Drain the hydraulic fluid reservoir -1- and the PDCC reservoir -2- , if necessary, using a
suitable tool.
Then remove the hoses -3, 4- at the tanks and close them off using suitable stoppers. →
REMOVING RESERVOIR , → 430955 REPLACING RESERVOIR (PDCC)
Fig 8: Identifying Hydraulic Reservoir Hoses
13. Loosen the fuel line -1- at the plenum panel.
14. Release the clamp -2- on the tank ventilation line.
15. Pull the vacuum hose -3- off the lower part -4- of the line.
Fig 9: Identifying Plenum Panel Lines
16. Disconnect the coolant line -1- from the coolant reservoir -2- at the bleeder valve.
17. Loosen the clamp -3- on the coolant hose -4- at the coolant reservoir -2- .
Pull off the coolant hose.

Fig 10: Identifying Coolant Reservoir Lines
18. Loosen clamps -1- on the coolant hoses -2- at the top of the engine.
Pull off coolant hoses -2- .

Fig 11: Identifying Engine Coolant Hoses
19. Loosen the clamp -1- on the vacuum line -2- at the vacuum pump -3- and pull off the vacuum
line.
Fig 12: Identifying Vacuum Pump Line
20. Raise the vehicle.
21. Unscrew fastening screws -1, 2- for holders -3, 4- for brake hydraulic lines.
22. Loosen holders from the wheel bearing housing -5- .

Fig 13: Identifying Hydraulic Lines Holders
23. Release electric plug connections -1- for the speed sensor on the wheel bearing housing -a-
and pull them off -A- .
Fig 14: Locating Wheel Bearing Housing Plug Connections
24. Remove the brake calliper and suspend it at a suitable position in the wheel arch →
Suspending brake calliper (do not open brake hydraulics!).
Also protect the brake calliper (e.g. with a cloth or suitable rubber mat) to prevent damage to
the paintwork.
Fig 15: Identifying Brake Caliper
25. Remove fastening screws -1- for the connecting links -2- at the bottom of the anti-roll bar -3-
.
Fig 16: Identifying Anti-Roll Bar Connecting Link
26. Press out the ball joint between the wheel carrier and upper wishbone using ball joint puller
T10187 .
27. Unscrew the fastening screw -2- for the spring strut -3- and at the same time, raise the axle
support -1- as far as required using a suitable jack -4- so that the fastening screw can be
unscrewed easily.
Fig 17: Removing Spring Strut Mounting
28. Disconnect the ground point on the right longitudinal member. -arrow-
Fig 18: Locating Right Longitudinal Member Ground Point
29. Loosen the fastening screw -1- on the holder -2- for ATF lines -3- at the thermostat -4- .
Fig 19: Identifying Thermostat To Transmission ATF Lines
30. Place a suitable container underneath to catch emerging ATF .
1. Pull ATF lines out of the thermostat.
2. Close off the ATF lines and bores on the thermostat using suitable stoppers.
31. Loosen fastening screws -1- on the heat shield -2- at the steering gear.
Remove heat shield -2- .

Fig 20: Identifying Steering Gear Heat Shield
32. Loosen the clamping screw -1- on the steering column -2- at the steering gear -3- .
Slide the steering column -2- upwards -arrow- and pull it down off the steering gear -3- (-A-
).
Fig 21: Loosening Steering Column
33. Pull clamps -1- off the coolant lines -2- for the heating water heat exchanger in the engine
compartment at the rear left on the wheel housing.
Fig 22: Identifying Front Left Wheel Housing Coolant Lines
34. Pull off coolant hoses -2- .
35. Loosen the fastening screw -1- for the refrigerant line -2- at the front left longitudinal member
-3- and pull out the line.
Fig 23: Identifying Front Left Refrigerant Line
36. Remove the line -1- from the air-conditioning compressor to the condenser -2- .
1. 36.1. To do this, unscrew the fastening screw -3- for the line -1- at the condenser
-2- .
2. 36.2. Close off lines and connection pieces.

Fig 24: Identifying Air-Conditioning Compressor To Condenser Line
37. Loosen the clamp -1- on the hydraulic line -2- in the front left wheel housing and pull the hose
off the hydraulic line.
Close off the line and connection piece using suitable stoppers.
Fig 25: Identifying Front Left Hydraulic Line
38. Loosen the cardan shaft at the transfer gear using a mounting lever and tie it up. →
REMOVING FRONT CARDAN SHAFT
39. Release electric plug connections -1, 2- at the right of the transfer gear -a, b- and pull them
off -A, B- .
Fig 26: Removing Transfer Gear Plug Connections
40. Release electric plug connections -1, 2- at the bottom of the transfer gear -a, b- and pull them
off -A, B- .
41. Mark gearshift position - N - -1- on automatic transmission -2- with a suitable pen -A- .
Fig 28: Identifying Gearshift Position Marking
42. Remove shift cable -3- on automatic transmission -4- .
→ REMOVING SELECTOR LEVER CABLE
1. 42.1. Unclip the cable -3- at the front of the ball joint -1- using disassembly tool
Nr.21 .
2. 42.2. Unscrew fastening screws -2- on the shift cable -3- .

Fig 29: Removing Shift Cable
43. Loosen fastening nuts -8- on the exhaust clamp (clamping sleeve) -3- between the catalytic
converter and exhaust system. Slide exhaust clamps onto the exhaust system. The exhaust
clamps must not be re-used. → REMOVING EXHAUST SYSTEM
Fig 30: Identifying Exhaust Clamps
44. Mark the installation position of the front-axle carrier diagonally at least two places on the body
using a felt-tip pen. This makes it easier to correctly position the front-axle carrier on the body
during reinstallation. → Marking installation position of front-axle carrier
Fig 31: Marking Front-Axle Carrier Position
45. Set up the lifting platform according to instructions
→ 100119 REMOVING AND INSTALLING ENGINE Then position it under the engine and
raise it. When you do this, ensure that the positioning guides of the lifting platform are inserted
into the body. → Lifting platform under engine
Fig 32: Identifying Engine Lifting Platform
46. The -arrows- show the mounting points for the mounting frame in the front-axle carrier (view
from below here).
Fig 33: Locating Front-Axle Carrier Mounting Points
47. Position lifting platform in the front-axle carrier in the mounting points provided -(arrows)- , -4
into the body- .
Fig 34: Lifting Platform
48. Secure the wheel bearing housing. To do this, turn the rubber discs upwards until they are set
under the steering knuckle. Then tighten the retaining brackets on the wheel hub and lifting
platform. -arrow-
Fig 35: Locating Wheel Bearing Housing
49. Mark the final position of the lifting platform -1- on the workshop floor using a suitable tool, e.g.
adhesive tape -A- .
50. Loosen the transmission cross member. To do this, loosen the four fastening screws -A- .
Fig 37: Identifying Transmission Cross Member Fastening Screws
51. Secure the engine/transmission unit. Then secure the mounting mandrels on the engine
transverse bar with the locking screws.
52. Loosen the four fastening screws on the front-axle carrier and the two fastening screws on the
engine transverse bar. -arrows-
Fig 38: Locating Front-Axle Carrier And Fastening Screws
53. Get a second mechanic to help .
1st mechanic: Lower the lifting platform slowly by approx. 20 to 30 cm.
2nd mechanic: Observe the lowering process and check that the components, hoses and lines
have sufficient clearance.

TURBO) > INSTALLING ENGINE
Information
Information
Due to currently correct tightening specifications, the screw specifications can be found in the
corresponding repair descriptions for the assemblies chassis, transmission, electrics, etc .
Information
1. Raise the body to a comfortable working height with the platform lift.
2. Slide the lifting platform -1- with the engine/transmission assembly to the marked positions
-A- on the workshop floor.
3. Raise the engine/transmission unit into the body using the lifting platform → Guiding
engine/transmission unit into the body with the lifting platform . Make sure there is sufficient
clearance. The freely-suspended lines (e.g. PDCC) must be routed in such a way that they do
not go back into the installation position (the lines must not be trapped). The insertion guides
-4- on the lifting platform must fit into the holes in the body. When doing so, use the markings
used for removal as a positioning guide.
Fig 2: Lifting Engine Platform

Fig 3: Installing Engine/Transmission Unit Into Body
4. Tighten the fastening screws -arrows- on the front-axle carrier.
→ 4X00IN TIGHTENING TORQUES FOR FRONT AXLE

Fig 4: Locating Front-Axle Carrier And Engine Carrier Screw
5. Fit fastening screws -A- for transmission cross member.

Fig 5: Identifying Transmission Cross Member Fastening Screws
6. Loosen the lateral supports on the wheel hubs. → Wheel hub support
7. Fit the brake calliper. → REMOVING FRONT BRAKE CALLIPER

Fig 6: Locating Wheel Hub Support
8. Lower the lifting platform slowly and remove it.
9. Plug in electric plug connections -1, 2- at the bottom of the transfer gear -A, B- and lock them
-a, b-
10. Plug in electric plug connections -1, 2- at the right of the transfer gear -A, B- and lock them
-a, b- .
Fig 8: Installing Transfer Gear Plug Connections
11. Push new exhaust clamps (clamping sleeves) -3- onto the exhaust pipes. The threaded joint
must be pointing downwards.
Tighten fastening screws. → INSTALLING EXHAUST SYSTEM

Fig 9: Locating Exhaust Clamps
12. Fit shift cable -3- on automatic transmission -4- .
→ INSTALLING SELECTOR LEVER CABLE
1. 12.1. Clip in shift cable -3- at the ball joint -1- .
2. 12.2. Fit the fastening screws -2- .

Fig 10: Identifying Automatic Transmission Shift Cable
13. Fit rear cardan shaft on the transfer gear. → INSTALLING REAR CARDAN SHAFT
14. Slide hose onto the hydraulic line -2- in the front left wheel housing and position the clamp -1-
.
Fig 11: Identifying Front Left Hydraulic Line
15. Fit the coolant line -1- from the air-conditioning compressor to the condenser -2- . →
INSTALLING AIR-CONDITIONING COMPRESSOR/CONDENSER LINE
Use a new sealing ring .
Make sure that the guide pin at the connection point fits into the mounting for the refrigerant
line.
1. 15.1. Fit the coolant line -1- on the condenser -2- and screw in the fastening screw
-3- .
Fig 12: Identifying Air-Conditioning Compressor To Condenser Line
16. Position front part of refrigerant line -2- from the compressor to the evaporator at the
longitudinal member -3- at the left. → INSTALLING CONDENSER/EVAPORATOR LINE AT
THE FRONT
Use a new sealing ring .
line.
Screw in fastening screw -1- .

Fig 13: Identifying Front Left Refrigerant Line
17. Attach hoses -2- to the coolant lines in the engine compartment at the rear left and position
the clamps -1- .
Fig 14: Identifying Front Left Wheel Housing Coolant Lines
18. Fit the steering column -2- on the steering gear -3- .
→ INSTALLING STEERING COLUMN (CENTRE)
1. 18.1. Fit the steering column -2- from above -arrow- onto the steering gear -3- (-A-
).
Fig 15: Installing Steering Column
2. 18.2. Fit clamping screw. → 4X00IN TIGHTENING TORQUES FOR STEERING
Always use a new clamping screw .
19. Position the heat shield -2- on the steering gear and fit the fastening screws -1- .
Fig 16: Identifying Steering Gear Heat Shield
20. Fit ATF lines at the thermostat. → INSTALLING LINES FOR ATF COOLING
1. 20.1. Insert ATF lines -3- into the thermostat -4- .
2. 20.2. Position holder -2- for ATF lines -3- to the ATF thermostat -4- .
Ensure that the lines are seated correctly.
3. 20.3. Fit the fastening screw -1- .

Fig 17: Identifying Thermostat To Transmission ATF Lines
21. Fit the ground point on the right longitudinal member.

Fig 18: Locating Right Longitudinal Member Ground Point
22. Fit the wheel bearing housing on the ball joint of the upper trailing arm. → INSTALLING
UPPER TRAILING ARM (STEEL SPRINGS)
23. Raise the axle support -1- as far as required using a suitable jack -4- until the fastening screw
-2- slides easily through the spring strut -3- and axle support.
Fig 19: Locating Spring Strut Threaded Joint
24. Fit the fastening screw -2- for the spring strut -3- and trailing arm -2- . → 4X00IN
TIGHTENING TORQUES FOR FRONT AXLE
25. Plug in electric plug connection -1- for the speed sensor on the wheel bearing housing -A-
and lock it -a- .
Fig 20: Locating Speed Sensor Electric Plug Connection
26. Position and fit the brake calliper on the brake disc at the wheel bearing housing. →
INSTALLING FRONT BRAKE CALLIPER
27. Fit the holders -1, 2- for the hydraulic lines on the wheel bearing housing -3- .
Fig 21: Identifying Hydraulic Lines Mounting
28. Fit the connecting link -2- on the anti-roll bar -3- and screw in the fastening screw -1- .
Fig 22: Identifying Anti-Roll Bar Connecting Link
29. Lower the vehicle.
30. Attach vacuum line -2- to the vacuum pump -3- and lock the connection -1- .
Fig 23: Identifying Vacuum Pump Line
31. Attach coolant hoses -2- at the top of the engine and fit the clamps -1- .
Fig 24: Identifying Engine Coolant Hoses
32. Fit the intake pipe. → INSTALLING COWL FOR THROTTLE HOUSING (Y-PIPE)
33. Slide the coolant line -4- at the bottom onto the coolant reservoir -2- and lock the clamp -3- .
34. Attach the coolant hose -1- to the bleeder valve and lock the clamp.
Fig 25: Identifying Coolant Reservoir Lines
35. Plug in electric plug connections -1- at the right cross panel -A, B and lock them -a, b- .
Fig 26: Attaching Right Cross Panel Plug Connections
36. Plug in electric plug connections -1- at the left cross panel -A, B and lock them -a, b- .
Fig 27: Attaching Left Cross Panel Plug Connections
37. Route the engine wire harness -1- in the plenum panel and clip it into the retaining clips -2- .
Fig 28: Identifying Plenum Panel Engine Wire Harness
38. Fit B+ transfer point on the left in the engine compartment. → B+ transfer point
Fig 29: Attaching B Positive Transfer Point
39. Plug in and lock the three electric plug connections -1- for the engine wire harness in the relay
box.
Fig 30: Identifying Relay Box Plug Connections
40. Close the relay box. → SECURING MAIN WIRE HARNESS IN ENGINE COMPARTMENT AT
THE LEFT
41. Fit the fuel line -1- at the plenum panel.
42. Attach tank vent lines and lock the clamp -2- .
43. Attach vacuum hose -3- to the lower part -4- of the vacuum line.
Fig 31: Identifying Plenum Panel Lines
44. Fit the ground strap -2- in the plenum panel at the body and screw on the fastening nut -1- .
Secure the ground strap to the engine wire harness with tie-wraps -3- if necessary.
Fig 32: Identifying Body Ground Point
45. Plug in electric plug connection -1- on the engine control unit -2- (-A- ) and lock it -a- .
Fig 33: Locating Engine Control Unit Plug Connection
46. Fit hydraulic lines -3, 4- at the hydraulic fluid reservoir -1- and at the PDCC reservoir -2- if
necessary.
Fig 34: Identifying Hydraulic Reservoir Hoses

TURBO) > SUBSEQUENT WORK > SUBSEQUENT WORK FOR REMOVING AND
INSTALLING ENGINE
1. On vehicles with 19-inch brake system: Fit the air guide at the anti-roll bar. → INSTALLING
ANTI-ROLL BAR
2. Fit front wheel housing liners. → INSTALLING FRONT WHEEL HOUSING LINER
3. Fit wheels. → INSTALLING WHEEL
4. Install right cross panel. → INSTALLING CROSS PANEL
5. Fit torque support. → Installing Torque Support
6. Fit design cover on the throttle valve. → Installing Engine Cover (Design Cover) 108319
REMOVING AND INSTALLING ENGINE COVER
8. Fill the air conditioning system. → DRAINING AND FILLING REFRIGERANT

9. Check engine-oil level. → 170117 CHANGING ENGINE OIL AND OIL FILTER
10. Bleed the cooling system. → FILLING THE COOLING SYSTEM (INCLUDES BLEEDING)
11. Bleed the power steering. → 4890IN TEST AND ASSEMBLY WORK ON POWER STEERING
12. Bleed the PDCC system if necessary. → WM 430307 BLEEDING PORSCHE DYNAMIC
CHASSIS CONTROL (PDCC)
13. Check ATF level and top up if necessary. → 370235 CHECKING AND TOPPING UP ATF
14. Move bonnet out of service position.
15. Fit engine compartment trim panels. → INSTALLING FRONT TRIM PANEL (ENGINE
COMPARTMENT)
16. Perform suspension alignment. → 449503 SUSPENSION ALIGNMENT, COMPLETE
17. The high-pressure adaptation must be reset when replacing the engine.
18. Read out DME fault memory and compare with the log you printed prior to removal.
WM 100127 REMOVING ENGINE FROM TRANSMISSION AND MOUNTING ENGINE ON

TRANSMISSION (CAYENNE GTS, CAYENNE TURBO) > TOOLS
locating pin Special tool 95950
insert Special tool 96870

bit insert Special tool 96880
socket-wrench Special tool 97140

insert

TRANSMISSION (CAYENNE GTS, CAYENNE TURBO) > PRELIMINARY WORK >
PRELIMINARY WORK FOR REMOVING ENGINE FROM TRANSMISSION AND
MOUNTING ENGINE ON TRANSMISSION
1. Engine removed. Engine/transmission unit is on the lifting platform. → Removing

Engine 100119 REMOVING AND INSTALLING ENGINE
2. Detach the design cover from the engine. → Removing Engine Cover (Design Cover) 108319
REMOVING AND INSTALLING ENGINE COVER (DESIGN COVER)

TRANSMISSION (CAYENNE GTS, CAYENNE TURBO) > REMOVING ENGINE FROM
TRANSMISSION
Information
When removing the engine, ensure that the torque converter in the automatic transmission does
not slip out of the transmission .
Keep the torque converter pressed in position using a screwdriver when removing the engine .
Information
Information
Fig 1: Identifying Engine/Transmission Assembly
1. Detach holder -1- for ATF lines at the front of the engine.
Fig 2: Identifying Engine ATF Lines Holder - Front
2. Detach holder -1- for ATF lines at the rear of the engine.
Fig 3: Identifying Engine ATF Lines Holder - Rear
3. Loosen clamps -1- for the coolant hoses -2- on the left of the transmission.
Pull off coolant hoses.

Fig 4: Identifying Coolant Hoses
4. Unscrew fastening screws -1- for coolant line holder -2- , bend holder to one side.
Fig 5: Identifying Coolant Lines Holder
5. Unclip the wire harness -1- for the oxygen sensors on the left cylinder head cover out of the
holder -2- .
Fig 6: Identifying Left Oxygen Sensor Wire Harness
6. Unclip wire harness -1- from oxygen sensors on the right from the holders -2- .
Fig 7: Identifying Right Oxygen Sensor Wire Harness
7. Spray the fastening screws on the primary catalytic converter with penetrating oil and leave to
take effect.
Loosen the fastening screws -1- on the catalytic converter.

Fig 8: Identifying Primary Catalytic Converters
8. Loosen the fastening screws -1- for the holders -2- of the left and right primary catalytic
converters -3- .
Fig 9: Identifying Primary Catalytic Converter Holder
9. Loosen the fastening screws -1- on the left and right for the rear holders -2- of the catalytic
converters on the transmission.
Fig 10: Identifying Catalytic Converters Holder
10. Remove the catalytic converters and set them aside.
11. Remove the front cardan shaft. → REMOVING FRONT CARDAN SHAFT
12. Release the electric plug connection -1- of the crankshaft pulse sender at the bottom of the
transmission -a- and pull it off -A- .
Loosen the tie-wrap at the coolant line holder on the left if necessary.
Fig 11: Removing Crankshaft Pulse Sender Plug Connection
13. Unclip the hose -1- for the transmission vent from the holder -2- .
Fig 12: Identifying Transmission Vent Hose
14. Loosen the clamp -1- for the coolant hose -2- to the ATF heat exchanger on the right and pull
off the hose from the connection piece.
Fig 13: Identifying Right Coolant Line
15. Pull off vacuum hose -1- for the vacuum supply at the T-piece -2- .
Unclip the vacuum line -3- from the holder -4- .

Fig 14: Identifying Vacuum Supply Line
16. Remove plug -1- used to seal the converter assembly opening.
Fig 15: Removing Converter Assembly Seal Plug
17. Remove converter screws. To do this, read and follow the next steps. → REMOVING
TORQUE CONVERTER
18. Turn crankshaft clockwise using special tool socket-wrench insert 97140 .
19. Insert special tool locating pin 95950 into the front bore on the converter bell housing
-arrow- and hold upwards with slight pressure until it engages when the crankshaft is turned.
Fig 16: Locating Converter Screws
20. Position special tool bit insert 96880 on the converter screw through the opening in the
engine block and connect bit snap-on head and special tool insert 96870 one after the other.
Fig 17: Opening Converter Screws
21. Remove special tool locating pins 95950 before loosening the converter screws.
22. Unscrew converter screw and twist out.
23. Complete the steps described above for the other five screws.
24. Secure engine to the lifting tackle and to the workshop crane
→ Securing engine to workshop crane .

Fig 18: Securing Engine Using Workshop Crane
25. Secure the transmission with a wooden block to prevent it from tipping over.
Fig 19: Locating Wooden Block
26. Lift the engine/transmission unit until the four screws on the two engine mounts can be
removed.
→ Removing Engine Mounting 103519 REMOVING AND INSTALLING ENGINE MOUNT
27. Slowly lower the engine/transmission unit onto the wooden block. The engine is still
suspended securely on the workshop crane.
28. Loosen the fastening screws -1- for the transmission to the engine.
Fig 20: Identifying Engine Transmission Screws
29. Remove engine from transmission. Press the torque converter off the drive plate with a
screwdriver if necessary.
30. Remove the engine from the transmission at the lifting crane.
Fig 21: Identifying Engine Transmission Lifting Platform

TRANSMISSION (CAYENNE GTS, CAYENNE TURBO) > SUBSEQUENT WORK >
SUBSEQUENT WORK FOR REMOVING ENGINE FROM TRANSMISSION AND
1. Fit the design cover on the engine. → Installing Engine Cover (Design Cover)
2. Install engine. → Installing Engine
WM 100137 DISASSEMBLING AND ASSEMBLING ENGINE (CAYENNE S, CAYENNE

TURBO, CAYENNE GTS, CAYENNE TURBO S) > DISASSEMBLING AND
ASSEMBLING ENGINE
For instructions, see:
1. Disassemble the engine. → 1001Z1 DISASSEMBLING ENGINE
2. Assemble the engine. → 1001Z2 ASSEMBLING ENGINE
WM 100137 DISASSEMBLING AND ASSEMBLING V6 DFI ENGINE (CAYENNE TIP

"PLATINUM EDITION", CAYENNE TIP, CAYENNE MAN) > TOOLS
camshaft bar VW tool T10068A
Fit assembly VW tool T10215

fixture
funnel VW tool T10333

"PLATINUM EDITION", CAYENNE TIP, CAYENNE MAN) > TECHNICAL VALUES
Cheese head bolt M6 x 30 Tightening torque 8 Nm (6 ftlb.)
Components Temperature 17°C

Internal serration M10 x 78 Initial tightening 30 Nm (22
screw on crankshaft (always replace) ftlb.)
bearing cover
Internal serration Torque angle 180°

screw on crankshaft
bearing cover
Countersunk screw M6 x 13 (always Initial tightening 10 Nm (7.5

on drive plate for replace) ftlb.)
inductive pickup
Countersunk screw Torque angle 90°

on drive plate for
inductive pickup
Connecting rod M9 x 1 x 50 Initial tightening 30 Nm (22

bolts (always replace) ftlb.)
Connecting rod Torque angle 90°

bolts
Hexagon-head bolt M6 x 16 Tightening torque 10 Nm (7.5

on vibration ftlb.)
balancer joint flange
Hexagon-head bolt Tightening torque 8 Nm (6 ftlb.)

on lower
timing-case cover
Hexagon-head bolt M18 x 1.5 x 40 Initial tightening 100 Nm (74

on crankshaft (always replace) ftlb.)
vibration balancer
Hexagon-head bolt Torque angle 180°

on crankshaft
vibration balancer
Hexagon-head bolts M8 x 20 Tightening torque 8 Nm (6 ftlb.)

on oil pump
Cylinder-head M9 x 1.25 x 141 Initial tightening 15 Nm (11

screws (internal (7 ea., center) ftlb.)
serration) and M9 x 1.25 x
111 (13 ea.,
outer), always
replace
Cylinder-head Tightening torque 30 Nm (22

screws (internal ftlb.)
serration)
Cylinder-head Torque angle 180°

screws (internal
serration)
Hexagon nut on M7 Initial tightening 5 Nm (3.5
camshaft bearing ftlb.)
cover
Hexagon nut on Torque angle 45°

camshaft bearing
cover
Cheese head bolt M6 x 30 Tightening torque 8 Nm (6 ftlb.)
Oval-head screw on M6 x 25 Tightening torque 8 Nm (6 ftlb.)

timing chain
housing
Hexagon-head bolts M8 x 20 Tightening torque 8 Nm (6 ftlb.)

on oil pump
Chain tensioner M22 x 1.5 x 18.7 Tightening torque 50 Nm (37

ftlb.)
Bearing pin on M8 x 11.5 Tightening torque 10 Nm (7.5

guide rail for drive ftlb.)
chain
Hexagon-head bolt M10 x 40 Initial tightening 60 Nm (44

on drive wheel for (always replace) ftlb.)
timing chain
Hexagon-head bolt Torque angle 90°

on drive wheel for
timing chain
Bolt for guide rail Tightening torque 10 Nm (7.5

ftlb.)
Fastening screw on Tightening torque 20 Nm (15

guide rail ftlb.)
Hexagon-head bolt M8 x 45 Tightening torque 23 Nm (17

on guide rail ftlb.)
Hexagon-head bolts M12 x 1.5 x 85 Initial tightening 60 Nm (44

on camshaft (always replace) ftlb.)
controllers
Hexagon-head bolts Torque angle 90°

on camshaft
controllers
Hexagon-head bolt M6 x 16 (20 ea.); Tightening torque 10 Nm (7.5

on lower M6 x 58 (2 ea.) ftlb.)
timing-case cover

vacuum pump

vacuum pump
Hexagon-head bolts M6 x 20 Tightening torque 12 Nm (9
on oil pan ftlb.)
Fastening screw on With guide Tightening torque 10 Nm (7.5

cylinder head cover sleeve ftlb.)
Oil cooler cover Tightening torque 25 Nm (19

ftlb.)
Oil pressure switch Tightening torque 20 Nm (15

ftlb.)
Lower part of oil Tightening torque 25 Nm (19

filter ftlb.)
Oil drain plug Tightening torque 10 Nm (7.5

ftlb.)
Hexagon-head bolt M6 x 65 Tightening torque 23 Nm (17

on oil/water heat ftlb.)
exchanger
Fuel line to fuel Tightening torque 22 Nm (16

distributor pipe ftlb.)
Fuel line at plenum Tightening torque 35 Nm (26

panel ftlb.)
Cheese head bolts M8 x 55 (always Initial tightening 30 Nm (22

on fuel distributor replace) ftlb.)
pipe
Cheese head bolts Torque angle 90°

on fuel distributor
pipe
Oval-head screw on M6 x 18 (always Tightening torque 8 Nm (6 ftlb.)

coolant pump replace)
Hexagon nut on M8 (always Tightening torque 25 Nm (19

exhaust manifold replace) ftlb.)
Fit bolt on unit M8 x 28 Tightening torque 23 Nm (17

carrier ftlb.)
Cheese head bolt M8 x 40 Tightening torque 23 Nm (17

on unit carrier ftlb.)
Cheese head bolts M8 x 30 Tightening torque 25 Nm (19

on belt tensioner ftlb.)

Information
Dispose of fluid in accordance with legal requirements .
1. Remove engine → Removing Engine .

2. Remove engine from transmission → Removing Engine From Transmission 100127
REMOVING ENGINE FROM TRANSMISSION AND MOUNTING ENGINE ON
TRANSMISSION .
3. Secure engine on mounting bracket → WM 1001IN SUPPORTING ENGINE ON MOUNTING

BRACKET .
4. Remove engine retaining eyebolts at front and rear → Securing Engine To Workshop Crane
(Includes Fitting Transport Eyebolt) .

"PLATINUM EDITION", CAYENNE TIP, CAYENNE MAN) > DISASSEMBLING V6 DFI
ENGINE
1. Remove engine wire harness → REMOVING WIRE HARNESS FOR ENGINE .
2. Remove bar ignition modules → REMOVING BAR IGNITION MODULES .
3. Remove intake-air distributor → REMOVING INTAKE-AIR DISTRIBUTOR .
4. Remove drive belt → REMOVING DRIVE BELT .
5. Remove belt tensioner → 137319 REMOVING AND INSTALLING BELT TENSIONER ON DFI
ENGINES .
arrows - Belt tensioner

Fig 1: Locating Belt Tensioner
6. Remove unit carrier
1. Belt tensioner
2. Cheese head bolt on belt tensioner
3. Unit carrier
4. Fit bolt for unit carrier
5. Cheese head bolt for unit carrier
6. Dowel sleeve for unit carrier
7. Deflection roller with fastening screw
8. Drive belt (poly-rib belt)
9. Generator
10. Coolant pump pulley
11. Drive wheel for air-conditioning compressor

12. Power-steering pump pulley
13. Crankshaft vibration damper

Fig 2: Identifying Unit Carrier Components
7. Remove generator → REMOVING GENERATOR .
8. Remove coolant pump → REMOVING COOLANT PUMP .
1. 8.1. Remove coolant pump pulley if necessary.

arrows - Oval-head screws for pulley (coolant pump)
Fig 3: Locating Coolant Pump
9. Remove all coolant hoses and additional coolant pump with holder.
2. 9.2. Pull off cable plugs and remove coolant hoses -3, 4 and 5- .
3. 9.3. Remove additional coolant pump with sheetmetal holder -1- .
1. Sheetmetal holder
2. Fastening screws for coolant pump holder
3. Coolant hose
4. Coolant hose
5. Coolant hose
Fig 4: Identifying Coolant Pump Components
10. Remove oil/water heat exchanger and engine support arm → REMOVING ENGINE OIL
COOLER .
11. Remove exhaust manifold if necessary → REMOVING EXHAUST MANIFOLD .
arrows - Exhaust manifold fastening nuts

Fig 5: Locating Exhaust Manifold Nuts
12. Remove fuel distributor pipe (fuel rail) → REMOVING FUEL DISTRIBUTOR PIPE (FUEL
RAIL) .
1. Fuel line (low-pressure)
2. Cheese head bolts for fuel distributor pipe
3. Fuel injectors
Fig 6: Identifying Fuel Distributor Pipe
13. Remove coolant regulator → REMOVING COOLANT REGULATOR .
1. 13.1. Loosen spring band clamp -2- .
2. 13.2. Pull thermostat housing -1- completely out of the cylinder block.
1. Thermostat housing
2. Spring band clamp
3. Coolant hose
Fig 7: Identifying Thermostat Housing, Coolant Hose And Spring Band Clamp
14. Remove cylinder head cover → REMOVING CYLINDER HEAD COVER .
15. Remove flywheel/drive plate.
1. 15.1. Remove dual-mass flywheel on vehicles with manual transmission →

REMOVING DRIVE PLATE .
2. 15.2. Remove drive plate on vehicles with automatic transmission → REMOVING

DRIVE PLATE FOR TORQUE CONVERTER .
16. Remove oil pan → REMOVING OIL PAN .
17. Remove timing-case cover at the top and bottom → REMOVING TIMING-CASE COVER .
18. Set crankshaft for cylinder 1 to compression TDC → 150502 CHECKING THE TIMING .
Information
Removal of chain tensioner
1. Press the bottom chain tensioner together during removal because otherwise it will push
out due to spring tensioning. Secure chain tensioner with a tie-wrap in tensioned state .
19. Remove chain tensioner → REMOVING CHAIN TENSIONER .
20. Remove timing chains → REMOVING TIMING CHAINS .

1. 20.1. Remove camshaft controllers → REMOVING CAMSHAFT CONTROLLER .
21. Remove camshafts → REMOVING CAMSHAFTS .
1. 21.1. Remove timing chain housing
2. 21.2. Remove intake camshaft. Loosen the hexagon nuts on the bearing covers
alternately and crosswise. Note the sequence in which the bearing covers are
removed.
1. 21.2.1. Remove bearing covers 1 and 13.
3. 21.2.3. Remove bearing cover 7.
3. 21.3. Remove outlet camshaft. Loosen the hexagon nuts on the bearing covers
alternately and crosswise. Note the sequence in which the bearing covers are
removed.
3. 21.3.3. Remove bearing cover 8.
1. Intake camshaft
2. Camshaft bearing cover
3. Outlet camshaft
4. Hexagon nut on camshaft bearing cover
5. Sealing rings (40 x 1.5)
6. Timing chain housing
7. Oval-head screw on timing chain housing
8. Outlet camshaft controller (marking 32 A)
9. Intake camshaft controller (marking 24 E)
10. Hexagon-head bolts on camshaft controllers
11. Cylinder head height (min. height a=139.9 mm)
12. Drive gear wheel for high-pressure pump
13. Bearing shaft
14. Valves
15. Dowel sleeve

16. Cylinder head
17. Pump tappet
18. Support element
19. Valve stem seal
20. Timing chain
21. Safety clip
22. Rocker arm
23. Valve spring
24. Valve-spring plate
25. Valve collets

Fig 8: Overview Of Cylinder Head (V6 DFI Engine)
1. Cheese head bolt → Tightening torque: 8 Nm (6 ftlb.)

Fig 9: Removing Timing Chain Housing
22. Remove hydraulic tappets → REMOVING HYDRAULIC TAPPETS .
23. Remove cylinder head → REMOVING CYLINDER HEAD .
1. 23.1. Remove and dispose of cylinder head gasket.
24. Remove oil pump → REMOVING OIL PUMP .
Information
Removal of connecting-rod bearing cap :
1. Connecting-rod bearing caps must be marked and numbered during removal. Retaining
lugs of bearing shells are pressed together. The cast lugs of connecting-rod bearings and
connecting-rod big end are identical!
25. Remove pistons → REMOVING PISTONS .
26. Remove vibration balancer. → REMOVING VIBRATION DAMPER

Fig 10: Removing Vibration Balancer
27. Remove joint flange behind the vibration balancer.
1. 27.1. Unscrew hexagon-head bolts -3- .
2. 27.2. Carefully lever off the joint flange -2- with a screwdriver.
1. Cylinder block
2. Vibration balancer joint flange
3. Hexagon-head bolt on vibration balancer joint flange
4. Straight pin
5. Lower timing-case cover
6. Fastening screw on lower timing-case cover

Fig 11: Identifying Crankshaft Joint Flange And Bolts
Information
Removal of crankshaft
Before removing the crankshaft, have a suitable tray ready so that the pulse-generating wheel
is not damaged as a result of excessive contact.
The engine is secured on the engine support to facilitate assembly work.
When replacing bearing shells, only use bearing shells with the same color coding.
28. Remove crankshaft. → REMOVING CRANKSHAFT

1. 28.1. Prepare a clean surface for laying down the crankshaft. Make sure not to
damage the drive plate for the inductive pickup (speed sender) when laying down the
crankshaft.
2. 28.2. Remove crankshaft bearing covers -1- and lay them down arranged according
to cylinder.
3. 28.3. Dispose of thrust washers -4- and crankshaft bearing shells -3- .
4. 28.4. Remove the crankshaft and lay it down on the prepared surface.
5. 28.5. Remove oil spray nozzles -8- if necessary.
1. Crankshaft bearing covers
2. Internal serration screws on crankshaft bearing covers
3. Crankshaft bearing shells must always be replaced
4. Thrust washer for bearing cover 5 must always be replaced
5. Crankshaft
6. Drive plate for inductive pickup (speed sender)
7. Fastening screw on drive plate for inductive pickup (speed sender)
8. Oil spray nozzle

Fig 12: Identifying Crank Drive (V6 DFI Engine)

"PLATINUM EDITION", CAYENNE TIP, CAYENNE MAN) > ASSEMBLING V6 DFI
ENGINE
Information
If cold or excessively low-tempered components are sealed to each other by applying sealant, leaks can
occur because of condensed water forming or components distorting. Components must be uniformly at
least → Temperature: 17°C .
Information
Detailed instructions for installing pistons must be observed at all times .
The cast lugs, the twist lock (locking lugs) -1- and the flat side of the piston crown -2- are on the
same side .
Fig 1: Locating Pistons And Connecting Rods
1. Install crankshaft → INSTALLING CRANKSHAFT .
Information
1. Bearing covers for the crankshaft are numbered 1 to 7 and the numbers can be read on
the side facing the exhaust .
2. Bearing no. 5 is a guide or thrust bearing with two thrust washers at the side .
3. The twist locks or retaining lugs are on the same side .
4. Bearing screws must be replaced .
5. Bearing shells must be replaced. Use only identical color markings
1. 1.1. Oil bearing shells with engine oil and place them on the crankshaft/crankcase.
Make sure that the twist lock → Twist lock is inserted cleanly in the crankcase.
2. 1.2. Always replace bearing shells. Observe relevant classification.
3. 1.3. Fit thrust bearing no. 5 with thrust washers -4- (insert using grease, lubricating
groove facing outwards) and then fit the remaining bearing covers.
4. 1.4. Tap crankshaft bearing covers on securely as far as they will go using a rubber
hammer so that the tightening torque will be accurate.
5. 1.5. Internal serration screws on the crankshaft bearing covers -2- must always be
replaced and screwed in by hand.
6. 1.6. Then gradually tighten the bearing covers from the inside out to the specified
torque -2- .
7. 1.7. As a test, turn the crankshaft several times to check that it turns smoothly.
8. 1.8. If the drive plate -6- for the inductive pickup (speed sender) was removed from
the crankshaft, the drive plate must be replaced .
1. 1.8.1. Tighten the countersunk screws -7- on the drive plate to the
specified tightening torque.
1. Crankshaft bearing covers
2. Internal serration screw on crankshaft bearing cover → Initial tightening: 30 Nm (22

ftlb.) → Torque angle: 180°
3. Bearing shell
4. Thrust washer for bearing cover 5
5. Crankshaft
6. Drive plate for inductive pickup
7. Countersunk screw on drive plate for inductive pickup → Initial tightening: 10 Nm

(7.5 ftlb.) → Torque angle: 90°
8. Oil spray nozzle


Fig 3: Twisting Drive Plate Lock
2. Install pistons → INSTALLING PISTONS .
1. 2.1. Pull dowel sleeve -arrow- out of the bore hole so that special tool funnel
T10333 can be positioned flat on the cylinder block.
2. 2.2. Oil the piston well and insert it into the funnel.
3. 2.3. Align all pistons so that the deep valve recesses -1 and 2- are facing the middle
of the cylinder block and the arrows -3- on the pistons are facing the vibration
damper.
4. 2.4. Position the piston funnel on the cylinder block and align it so that the high edge
-arrow- is facing the middle of the cylinder block.
5. 2.5. Slide piston fully into the cylinder bore.
1. 2.5.1. Turn the crankshaft back and forth if necessary.
6. 2.6. Insert dowel sleeves back into the bore hole -arrow- .
7. 2.7. Oil connecting-rod bearing shells -5- .
Information
1. Always replace the connecting-rod bearing shells and oil them before inserting
them into the bearing covers .
2. 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 .
Fig 4: Identifying Connecting-Rod Bearing Cast Lugs
3. 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. 2.8. Assign connecting rod bearing caps correctly and screw in the connecting rod
bolts -7- by hand. When doing so, make sure that the locking lugs on the bearing
shells are aligned.
9. 2.9. Carefully tap the connecting rod bearing caps -6 - with a plastic hammer until
they are seated correctly so that the tightening torque will be accurate.
10. 2.10. Tighten all connecting rod bearing screws -7- to the specified tightening torque.
11. 2.11. Turn the crankshaft several times to check that it turns smoothly.
12. 2.12. Align the crankshaft so that the gap -arrow- on the drive plate for the inductive
pickup is facing downwards (rough TDC presetting).
1. Piston rings (move gap by 120°)

2. Piston
3. Circlip
4. Connecting rod
5. Connecting rod bearings must always be replaced . Observe relevant

classification.
6. Connecting rod bearing cap
7. Connecting rod bolts → Initial tightening: 30 Nm (22 ftlb.) → Torque

angle: 90°
8. Cylinder block
9. Piston pin
Fig 5: Overview Of Piston/Connecting Rod
arrow - Dowel pin

Fig 6: Locating Cylinder Block Dowel Sleeve
1. Valve recesses on cylinders 1, 3 and 5
3. Arrow pointing towards vibration balancer

Fig 7: Identifying Pistons Installation Direction (V6 DFI Engine)

Fig 8: Locating Cylinder Block Piston Funnel
arrow - Setting of gap on drive plate for inductive pickup (speed sender)
Fig 9: Locating Inductive Pickup Drive Plate
3. Fit joint flange for vibration balancer → 137419 REMOVING AND INSTALLING SEALING
RING FOR VIBRATION BALANCER .
1. 3.1. Apply 2-mm thick bead of sealant -arrows- .
2. 3.2. Fit assembly fixture T10215 (guide sleeve) -1- on the crank pin -3- to prevent
damage to the vibration balancer joint flange.
3. 3.3. Slide the joint flange -2- over the guide sleeve -1- until it is touching the cylinder
block.
4. 3.4. Tighten hexagon-head bolts -3- on joint flange -2- to the specified torque.
1. Cylinder block
3. Hexagon-head bolt on vibration balancer joint flange → Tightening

4. Straight pin, M8 x 18
6. Hexagon-head bolt on lower timing-case cover → Tightening torque: 8

Nm (6 ftlb.)
Fig 10: Identifying Crankshaft Joint Flange, Guide Sleeve And Head Bolts

Fig 11: Applying Sealant To Joint Flange
1. Assembly fixture (guide sleeve)
3. Crankshaft flange
Fig 12: Identifying Crankshaft And Vibration Balancer Joint Flange
4. Fit vibration balancer for crankshaft. → INSTALLING VIBRATION DAMPER
1. 4.1. Tighten hexagon-head bolt on crankshaft vibration balancer → Initial

tightening: 100 Nm (74 ftlb.) → Torque angle: 180° .
Fig 13: Tightening Crankshaft Vibration Balancer Bolt
5. Position engine to the compression TDC of cylinder 1.
arrow - Crankshaft/vibration balancer marking

Fig 14: Locating Pulley And Housing Cover TDC Marking
6. Install oil pump. → INSTALLING
arrows - Hexagon-head bolt on oil pump → Tightening torque: 8 Nm (6 ftlb.)

Fig 15: Locating Oil Pump Bolts
7. Install cylinder head. → INSTALLING CYLINDER HEAD
1. 7.1. Thoroughly clean all sealing faces before assembly.
2. 7.2. Cylinder head gasket must always be replaced .
3. 7.3. Always observe tightening sequence (1-20) for cylinder-head screws -1-20- and
1. 7.3.1. Tighten cylinder-head screws to an initial tightening torque of 15 Nm

(11 ftlb.).
2. 7.3.2. Tighten cylinder-head screws to 30 Nm (22 ftlb.).
3. 7.3.3. Then tighten all cylinder-head screws a second time to 30 Nm (22

ftlb.).
4. 7.3.4. And finally, tighten the cylinder-head screws to a torque angle of

180°.
Fig 16: Identifying Engine Cylinder Sequence
1-6 - Pistons of cylinders 1-6
1-20 - Tightening sequence for cylinder-head screws → Initial tightening:

15 Nm (11 ftlb.) → Tightening torque: 30 Nm (22 ftlb.) → Torque angle:
180°
8. Install hydraulic tappets. → INSTALLING HYDRAULIC TAPPETS
9. Install the camshafts.
1. 9.1. Insert the camshafts into the cylinder head in such a way that the camshaft bar
T10068A fits into the slots on the intake and outlet camshafts at the same time. →
INSTALLING CAMSHAFTS .
1, 3, 5, 7, 9, 11, 13 Bearing covers on intake camshaft
2, 4, 6, 8, 10, 12, 14 Bearing covers on outlet camshaft
2. 9.2. Install intake camshaft. Note the sequence in which the bearing covers are
installed.
1. 9.2.1. First fit bearing covers 5 and 9 and tighten the hexagon nuts
alternately and crosswise.
2. 9.2.2. Repeat the process for bearing covers 1 and 13.
3. 9.2.3. Repeat the process for bearing cover 5.
3. 9.3. Install outlet camshaft. Note the sequence in which the bearing covers are
installed. Use the same torque and torque angle as for the intake camshaft.
1. 9.3.1. First fit bearing covers 6 and 10 and tighten the hexagon nuts
alternately and crosswise.
3. 9.3.3. Repeat the process for bearing cover 8.
4. 9.4. Install timing chain housing.
1. Intake camshaft
2. Camshaft bearing cover
3. Outlet camshaft
4. Hexagon nut on camshaft bearing cover → Initial tightening: 5 Nm (3.5

ftlb.) → Torque angle: 45°
7. Oval-head screw on timing chain housing
10. Hexagon-head bolts on camshaft controllers
11. Cylinder head height (min. height a=139.9 mm)
13. Bearing shaft
14. Valves
15. Dowel sleeve
16. Cylinder head
17. Pump tappet
18. Support element
19. Valve stem seal
20. Timing chain
21. Safety clip
22. Rocker arm
23. Valve spring
25. Valve collets

arrow - Hexagon for countering the camshaft

Fig 18: Locating Camshaft Installation Position
1. Cheese head bolt → Tightening torque: 8 Nm (6 ftlb.)

Fig 19: Installing Timing Chain Housing
10. Fit timing chains. → INSTALLING TIMING CHAINS
1. 10.1. Install chain tensioner. → INSTALLING CHAIN TENSIONER
2. 10.2. Install camshaft controllers. → INSTALLING CAMSHAFT CONTROLLER
2. Oval-head screw on timing chain housing → Tightening torque: 8 Nm (6

ftlb.)
3. Timing chain
5. Sealing ring
6. Oil pump
7. Fastening screw on oil pump → Tightening torque: 8 Nm (6 ftlb.)
8. Tensioning rail
9. Chain tensioner on timing chain → Tightening torque: 50 Nm (37 ftlb.)
10. Sealing ring (A22 x 27), always replace

11. Bearing pin on guide rail → Tightening torque: 10 Nm (7.5 ftlb.)
12. Sprocket
13. Drive wheel for timing chain
14. Hexagon-head bolt → Initial tightening: 60 Nm (44 ftlb.) → Torque

angle: 90°
15. Chain tensioner for drive chain
16. Drive gear wheel for drive chain
17. Drive chain
18. Guide rail for drive chain
19. Bolt for guide rail → Tightening torque: 10 Nm (7.5 ftlb.)
20. Fastening screw on guide rail → Tightening torque: 20 Nm (15 ftlb.)
21. Hexagon-head bolt on guide rail → Tightening torque: 23 Nm (17 ftlb.)
22. Hexagon-head bolts on camshaft controllers → Initial tightening: 60 Nm

(44 ftlb.) → Torque angle: 90°
23. Guide rail for timing chain
26. Valve for outlet camshaft controller
27. Valve for intake camshaft controller
28. Guide rail

Fig 20: Overview Of Timing Chains
11. Check the timing. → 150502 CHECKING THE TIMING ON V6 DFI ENGINES
12. Fit upper and lower timing-case cover. → INSTALLING TIMING-CASE COVER
1. 12.1. Fit lower timing-case cover.
2. 12.2. Fit upper timing-case cover.
1. Cylinder block
3. Hexagon-head bolt on vibration balancer joint flange
4. Straight pin, M8 x 18
6. Hexagon-head bolt on lower timing-case cover → Tightening torque: 10

Nm (7.5 ftlb.)
Fig 21: Identifying Crankshaft Joint Flange, Cylinder Block, Pin And Bolt
1. 1 - Drive shaft
2. 2 - Upper timing-case cover
3. 3 - Oval-head screw → Tightening torque: 8 Nm (6 ftlb.)
4. 4 - Oval-head screw on vacuum pump → Tightening torque: 8 Nm (6

ftlb.)
5. 6 - Seal
6. 7 - Sealing ring
Information
Installation of oil pan
Check the best-before date on the sealing compound.
The oil pan must be installed within 5 minutes of applying the silicone sealant.
The bead of sealant that is applied must not be thicker than the specified thickness because
otherwise excess sealant can get into the oil pan and can block the strainer in the oil pump
intake pipe.
Allow the sealant to dry for at least 30 minutes after installing the oil pan. Only then can engine
oil be filled in.
13. Install oil pan. → INSTALLING OIL PAN
1-25 - Hexagon-head bolts on oil pan → Tightening torque: 12 Nm (9 ftlb.)
Fig 23: Timing Chain Housing Cover Bolts Tightening Sequence
14. Install cylinder head cover. → INSTALLING CYLINDER HEAD COVER
1. Cylinder head cover
2. Cylinder-head gasket
3. Fastening screw on cylinder head cover → Tightening torque: 10 Nm (7.5 ftlb.)
4. Cover
Fig 24: Identifying Valve Cover Seal, Cylinder Head Cover And Gasket
15. Install flywheel/drive plate.
1. 15.1. Install dual-mass flywheel on vehicles with manual transmission.
2. 15.2. Remove drive plate on vehicles with automatic transmission. → REMOVING

DRIVE PLATE
16. Install oil/water heat exchanger. → INSTALLING ENGINE OIL COOLER
1. Oil-filter housing
2. Seal must always be replaced
3. Sealing rings must always be replaced
4. Oil cooler
5. Oil cooler cover → Tightening torque: 25 Nm (19 ftlb.)
6. Oil pressure switch → Tightening torque: 20 Nm (15 ftlb.)
7. Oil filter
8. Lower part of oil filter → Tightening torque: 25 Nm (19 ftlb.)
9. Oil drain plug → Tightening torque: 10 Nm (7.5 ftlb.)

10. Hexagon-head bolt on oil/water heat exchanger → Tightening torque: 23 Nm (17
ftlb.)
Fig 25: Identifying Oil-Filter Housing
17. Install coolant regulator. → INSTALLING
1. 17.1. Fit thermostat housing -1- completely into the cylinder block.
2. 17.2. Slide coolant hose -3- onto the thermostat housing.
3. 17.3. Fasten spring band clamp -2- .
3. Coolant hose
Fig 26: Identifying Coolant Regulator, Thermostat Housing And Coolant Hose
18. Install fuel distributor pipe and fuel injectors. → INSTALLING FUEL DISTRIBUTOR PIPE
(FUEL RAIL)
1. Fuel low-pressure line → Tightening torque: 22 Nm (16 ftlb.) → Tightening

torque: 35 Nm (26 ftlb.)
2. Cheese head bolts on fuel distributor pipe → Initial tightening: 30 Nm (22 ftlb.) →
Torque angle: 90°
3. Fuel injectors
Fig 27: Identifying Cylinders Fuel Distributor Pipe
19. Install coolant pump.→ INSTALLING COOLANT PUMP
arrows - Oval-head screw (coolant pump) → Tightening torque: 8 Nm (6 ftlb.)

Fig 28: Locating Coolant Pump Screws
20. Install exhaust manifold.
→ INSTALLING EXHAUST MANIFOLD
arrows - Hexagon nut on exhaust manifold → Tightening torque: 25 Nm (19 ftlb.)

Fig 29: Locating Exhaust Manifold Nut
21. Install intake-air distributor. → INSTALLING INTAKE-AIR DISTRIBUTOR
22. Install guide tube for oil dipstick. Sealing ring must always be replaced . → INSTALLING
GUIDE FOR OIL DIPSTICK
23. Install unit carrier.
1. Belt tensioner
2. Cheese head bolt on belt tensioner
3. Unit carrier
4. Fit bolt on unit carrier → Tightening torque: 23 Nm (17 ftlb.)
5. Cheese head bolt on unit carrier → Tightening torque: 23 Nm (17 ftlb.)
6. Dowel sleeve for unit carrier
7. Deflection roller with fastening screw
8. Drive belt (poly-rib belt)
9. Generator
10. Coolant pump pulley
11. Drive wheel for air-conditioning compressor
13. Crankshaft vibration damper

Fig 30: Identifying Generator, Coolant Pump Pulley And Crankshaft Vibration Damper
24. Install the generator. → INSTALLING GENERATOR

25. Install hydraulic pump (power-steering pump). → 48981900 REMOVING AND INSTALLING
HYDRAULIC PUMP (CAYENNE V6)
26. Install belt tensioner. → INSTALLING BELT TENSIONER
arrows - Cheese head bolts on belt tensioner → Tightening torque: 25 Nm (19 ftlb.)
Fig 31: Locating Belt Tensioner Bolt
27. Fit and tension the drive belt.
→ INSTALLING DRIVE BELT
1. Crankshaft vibration balancer
2. Coolant pump
3. Drive belt tensioning roller
4. Air-conditioning compressor
5. Power-steering pump/tandem pump
6. Generator
7. Deflection roller
Fig 32: Drive Belt Routing Diagram
28. Install bar ignition modules. → INSTALLING BAR IGNITION MODULES
1. Connectors for bar ignition modules
2. Retaining clips
3. Engine wire harness

Fig 33: Identifying Ignition Coils And Spark Plugs
29. Fit engine wire harness. → REMOVING WIRE HARNESS FOR ENGINE
1. 29.1. Clip in engine wire harness at the rear engine housing using the retaining clips
-arrows- .
2. 29.2. Connect engine wire harness to the oil/water heat exchanger.
arrows - Retaining clips

Fig 34: Locating Engine Wire Harness (Rear)

Fig 35: Locating Engine Wire Harness (Front Left)

1. Remove engine from the mounting bracket. → WM 1001IN SUPPORTING ENGINE ON

MOUNTING BRACKET
2. Mount the transmission. → 100127 REMOVING ENGINE FROM TRANSMISSION AND

3. Install the engine. → Installing V6 Hybrid Engine
4. Perform a test drive and check for leaks and correct function.
1. 4.1. Clean the engine and carry out a thorough check for leaks after the test drive.
WM 1001IN LIFTING THE ENGINE WITH A WORKSHOP CRANE (EXCEPT CAYENNE,

CAYENNE GTS, CAYENNE TURBO S, CAYENNE S HYBRID, CAYENNE S E, CAYENNE

suspending VW tool 3033
device
engine VW tool 3269

support
Transport Special tool 9700/2

eyebolt

Transport M8 Tightening 23 Nm (17

eyebolt torque ftlb.)
Special tool - Tightening 45 Nm (33

engine support torque ftlb.)

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > SECURING ENGINE TO WORKSHOP
CRANE (INCLUDES FITTING TRANSPORT EYEBOLT)
CAUTION: Heavy components
Risk of squashing
→ Get someone to help if necessary.
Information
Always remove the rear transport eyebolt when installing the engine before handing the vehicle over to
the customer or before carrying out a test drive. Otherwise, the fitted eyebolt can cut through the fuel line
at the plenum panel in the event of a frontal crash.
Fig 1: Identifying Transport Eyebolt Position
1. Pull the design cover of the throttle valve straight up and off, if it is not already removed.
2. Transport eyebolt 9700/2 must be secured between the DFI high-pressure pump and the
vacuum pump on the engine.
1. 2.1. Unclip rear wire harness. -Clip-

Fig 2: Identifying DFI High-Pressure Pump Wire Harness
2. 2.2. Remove screw on sheetmetal holder and take off sheetmetal holder. -2-
1. -1- - High-pressure pump
2. -2- - Sheetmetal holder for wire harness
3. -3- - Vacuum pump

Fig 3: Removing Sheetmetal Holder Screw
3. 2.3. Move transport eyebolt into installation position and secure at this position →
Securing transport eyebolt . Secure transport eyebolt using the screw for the
sheetmetal holder -1- and an additional M8 screw -2- underneath. The lower
screw-in thread is a blind hole, so choose an appropriate screw length or use a
washer if the screw you are using is too long. → Tightening torque: 23 Nm (17
ftlb.)
1. -1- - Screw for sheetmetal holder
2. -2- - Additional M8 screw

Fig 4: Identifying Transport Eyebolt
3. Engage one hook of the suspending device 3033 in the rear transport eyebolt 9700/2 on
the engine -A- Position 2 - rear of engine . Engage the other hook of the suspending device
at the front of the engine -B- Position 9 - front of engine . Raise the workshop crane slightly
and tension the spindles slightly. → Engine removed with suspending device
Fig 5: Identifying Suspending Device

Fig 6: Removing Engine Using Suspending Device
4. Carefully lift the engine and balance it or separate the engine from the transmission,
depending on what you want to do.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > FITTING ENGINE SUPPORT
Information
The engine needs to be suspended on an assembly support for certain repair work .
1. Remove right engine support arm. To do this, loosen the four fastening screws → Fastening
screws
Fig 1: Locating Engine Support Arm Screws
2. Fit the engine support engine support 3269 . Make sure the mounting shaft is positioned
centrally in the longitudinal direction of the engine. Fit the fastening screws. → Tightening
Fig 2: Locating Engine Support Screws
3. Lift the engine with the workshop crane and secure it on the assembly support. To do this,
guide the engine support straight into the assembly support WE 1171 or a similar support,
without tilting it.
WM 1001IN ENGINE NUMBER MARKING (CAYENNE, CAYENNE S HYBRID, CAYENNE

S E, CAYENNE TURBO) > ENGINE NUMBER MARKING - CAYENNE
The engine number ("Engine code" and "Serial number") can be found next to the vibration damper
-arrow- on the cylinder block.
Fig 1: Locating Engine Number Marking - Cayenne
WM 1001IN INFORMATION ON MAGNESIUM COMPONENTS AND ALUMINUM

SCREWS (CAYENNE TIP, CAYENNE MAN, CAYENNE S, CAYENNE TURBO, CAYENNE
GTS, CAYENNE S HYBRID, CAYENNE TURBO S, CAYENNE DIESEL, CAYENNE S
DIESEL, CAYENNE TIP (3.0)) > TOOLS

Electronic Special tool 9768
torque wrench

DIESEL, CAYENNE TIP (3.0)) > TECHNICAL VALUES
Aluminum AL9 Initial 4 Nm (3 ftlb.)

screw, M6 tightening
Aluminum AL9 Final tightening 90°

screw, M6
Aluminum AL9 Initial 10 Nm (7.5

screw, M8 tightening ftlb.)

screw, M8
Aluminum AL9 Initial 20 Nm (15

screw, M10 tightening ftlb.)

screw, M10

DIESEL, CAYENNE TIP (3.0)) > INFORMATION ON WORKING WITH ALUMINUM
SCREWS > INFORMATION ON ALUMINUM SCREWS
Information
Aluminum screws and steel screws have different properties!
Most aluminum screws are identified on Porsche V-engines by an internal Torx screw with internal
pin (→ Aluminum screw on V-engines). Aluminum screws can be identified differently on
transmissions, on the chassis and on engines from other manufacturers. The design-related
distinguishing features can be omitted if necessary .
One differentiating feature is that aluminum screws are lighter than steel screws of the same size
(e.g. screws used in bar ignition modules) .
Aluminum screws are different from steel screws in that they are not magnetic . If in doubt, check
the screws using a magnet .
The aluminum screws used at present have the additional marking RIBE (manufacturer) and
AL9 (strength) on the screw head. → Aluminum screw on V-engines
Screws with an internal pin can be loosened and tightened using commercially available bit inserts
with a hole (safety bits) .
Fig 1: Identifying V-Engines Aluminum Screw
Aluminum screws must be used only once . Replace the screws whenever they have been
loosened .
Aluminum screws must always be tightened in two steps ( torque and torque angle ) or require a
special yield-point wrench Electronic torque wrench 9768 . The specified tightening torques and
torque angles must always be observed. The extent to which a screw is tightened can be limited
using a yield-point wrench .
There is no need to tighten by clicking once as this may cause irreparable damage to the screw .
Sealants that can come into contact with aluminum screws in threaded bores must be approved
for use with aluminum screws by Porsche => if this is not observed, there will be increased friction
in the screw thread and the aluminum screw will break .
Aluminum screws must not be fitted using tightening parameters for steel screws => the
aluminum screw will break .
Screw threads must be perfectly clean . Sealant residue or chips increase the friction coefficient
=> the aluminum screw will break. Blow out thread holes .
ALUMINUM SCREWS TIGHTENING SPECIFICATION
Thread Strength Tightening procedure
M6 AL9 → Initial tightening: 4 Nm (3

ftlb.) and → Final tightening:
90° or yield-point wrench.
M8 AL9 → Initial tightening: 10 Nm (7.5



DIESEL, CAYENNE TIP (3.0)) > INFORMATION ON WORKING WITH MAGNESIUM
COMPONENTS
The following components are made of magnesium:
1. Both valve covers (cylinder head covers) are made of magnesium
2. Timing-case cover is made of magnesium
3. Oil guide housing is made of magnesium ; aluminum oil pan.

Fig 1: Identifying Engine Block Magnesium Components
WARNING: Magnesium chips
Danger of fire
→ Do not collect magnesium grinding dust, magnesium chips or abraded material in open containers.
Use containers that can be sealed tightly.
→ A small amount of chips produced when re-cutting threads, for example, is not important.
→ If larger amounts of magnesium chips and dust are produced, these must not be stored dry.
→ The dust and chips must be removed by suction during extensive grinding work.
→ Avoid making sparks when working with magnesium.
→ Extinguish magnesium fires using fire extinguishers for metal fires rather than water.
Information
Magnesium is corrosive in the event of contact with steel, copper or aluminum with a high copper
content .
Damaged magnesium threads must be repaired using aluminum threaded bushes without copper
content that have been approved by Porsche. M6 x 12 Helicoil inserts (999.504.084.01) are
currently approved .
Magnesium components must only come into contact with screws (aluminum screws, coated
screws), lubricants and sealing compounds that have been approved by Porsche ( risk of
corrosion ) .
Heat-resistant copper paste cannot be used ( risk of corrosion ) .
Magnesium components must not come into contact with steel parts (panels, clamps, etc.) ( risk of
corrosion ). → Possible corrosion on valve cover if steel plate clips are used inadvertently
Fig 2: Identifying Valve Cover Corrosion Marking
Only use type-specific accessories and spare parts approved by Porsche . Do not use previously
used parts or parts from the "tool kit" .
Always keep threaded joints and contact surfaces of magnesium components dry . Blow-dry
threaded bores immediately if threaded joints are opened .
WM 1001IN SUPPORTING ENGINE ON MOUNTING BRACKET (CAYENNE S E) >

TOOLS

workshop Workshop WE 1188
hoist VAS equipment
6100
Mobile Workshop WE 1323

Assembly equipment
Station
bracket for V6 Workshop WE 1337

TDI engine equipment
VAS 6095/1-4
Lifting tackle VW tool 2024 A

TECHNICAL VALUES
Engine with Tightening 40 Nm (30

bracket on torque ftlb.)
assembly
support

PRELIMINARY WORK
1. Remove electric drive motor from the engine. → Removing Engine From Transmission 100127
TRANSMISSION
2. Remove electric air-conditioning compressor from the engine. → REMOVING ELECTRIC


PRELIMINARY WORK > SUPPORTING ENGINE ON MOUNTING BRACKET
1. Lifting tackle 2024 A must be engaged on the engine suspension eyelet and on the
workshop hoist VAS 6100 WE 1188 as shown.
Fig 1: Lifting Engine Block
2. Take up some of the weight of the engine with the workshop hoist, but do not raise the engine.
3. Unscrew nuts -arrow- for engine mountings at the left and right.
Fig 2: Locating Engine Mountings Nuts
4. Lift engine off engine carrier.
5. Unscrew screws -arrows- and remove engine support on the left.

Fig 3: Locating Left Engine Support Screws
6. Unscrew screws and remove engine support on the right.

Fig 4: Locating Right Engine Support Screws
7. Secure engine with bracket -VAS 6095/1-5- on the bracket for V6 TDI engine VAS 6095/1-4
WE 1337 Mobile Assembly Station WE 1323 as shown. → Tightening torque: 40 Nm (30
ftlb.)
Fig 5: Securing Engine With Bracket
WM 1001IN LIFTING THE ENGINE WITH A WORKSHOP CRANE (CAYENNE S,

CAYENNE TURBO, CAYENNE GTS, CAYENNE TURBO S) > TOOLS

Suspending VW tool 3033
device

CAYENNE TURBO, CAYENNE GTS, CAYENNE TURBO S) > INFORMATION > LIFTING
THE ENGINE WITH A WORKSHOP CRANE
When does the engine have to be raised? =>
Replacement engine is in the transport frame.
Engine is secured to the mounting bracket.
Engine is removed and placed on a pallet.
Engine/transmission unit is removed and placed on the lifting platform.

CAYENNE TURBO, CAYENNE GTS, CAYENNE TURBO S) > TOOLS AND MATERIALS
> TOOLS
Fig 1: Identifying Suspending Device
-A- Suspending device Only this tool is tested and approved by

3033 Porsche. It guarantees only vertical
traction of the transport eyebolt with no
side or transverse forces .
-B- This tool is not used on

the 4.8-litre engine. The
M48/01 and M48/51
have eyelets provided
on the engine, like the
V6 .

CAYENNE TURBO, CAYENNE GTS, CAYENNE TURBO S) > SECURING ENGINE TO
ENGINE CRANE
Risk of squashing

Information
When removing the new engine from the transport frame, it may be necessary to safeguard the
engine against lateral movement
When removing the new engine from the transport frame, it may be necessary to raise the
transport frame at the side (flat jack or similar). → Workshop crane and transport frame using a
second worker und against scratching by covering it with a blanket .
Fig 1: Identifying Workshop Crane And Transport Frame
Information
1. Pull the design cover of the throttle valve straight up and off, if it is not already removed.
2. Engage one hook of the suspending device 3033 in the rear transport eyebolt on the engine.
Engage the other hook of the suspending device at the front of the engine. Raise the workshop
crane slightly and tension the spindles slightly. The suspending device must be adjusted
evenly. → Workshop crane on the V8 engine
Fig 2: Lifting Engine Using Workshop Crane
3. Carefully lift the engine and balance it or separate the engine from the transmission,
depending on what you want to do.
WM 1001IN SECURING V8 ENGINE ON ASSEMBLY SUPPORT (CAYENNE S,


mounting Special tool 9590
elements
engine Special tool 9676/1

support

CAYENNE TURBO, CAYENNE GTS, CAYENNE TURBO S) > PRELIMINARY WORK >
SECURING 4.8 L DFI V8 ENGINE ON ASSEMBLY SUPPORT
1. Lift the engine with a workshop crane. → 1001IN LIFTING THE ENGINE WITH A
WORKSHOP CRANE

CAYENNE TURBO, CAYENNE GTS, CAYENNE TURBO S) > SECURING V8 ENGINE
ON ASSEMBLY SUPPORT
Risk of squashing

Information
The engine needs to be suspended on an assembly support for certain repair work .
Information
A modified engine support is used on the Cayenne E2 because of the Start Stop starter .
The turbo engine, including flywheel, weighs about 250 kg. To avoid overloading the engine
support, make sure that there are no additional loads (e.g. heavy components stored in the vehicle
or a person sitting in the vehicle) .
Information
1. Secure engine support 9676/1 to the engine. To do this, use the four screws mounting
elements 9590 and tighten them. → Engine support
Fig 1: Securing Engine Support
2. Move engine in front of the engine support (assembly support) using the workshop crane and
guide it in with the help of a second worker. Raise engine so that the engine can be eased in
horizontally. → Engine crane and engine on assembly support
Fig 2: Moving Engine Crane And Engine Assembly Support
3. Secure engine on assembly support. → 1001IN SECURING ENGINE ON ASSEMBLY

SUPPORT
Fig 3: Securing Engine On Assembly Support
WM 1001IN SUPPORTING THE ENGINE ON THE BODY (CAYENNE GTS, CAYENNE

TURBO S, CAYENNE S HYBRID, CAYENNE S E, CAYENNE TURBO, CAYENNE (3.0)) >
TOOLS
Support VW tool 10-222 A

bracket
bonnet stay Special tool 9704
Pipe VW tool T40091/1
Joiner VW tool T40091/3

support VW tool T40091/50-51
Support VW tool T40091/52-53
Support VW tool T40093/3P
adjustable VW tool T40093/51

foot

PRELIMINARY WORK > PRELIMINARY WORK FOR SUPPORTING ENGINE ON THE
BODY
1. Move bonnet into service position using bonnet stay 9704 . → REMOVING FRONT
PNEUMATIC SPRING
2. Remove engine compartment trim panel. → REMOVING FRONT TRIM PANEL (ENGINE
COMPARTMENT)
3. Remove torque support. → Removing Torque Support
4. Remove engine cover (design cover). → Removing Engine Cover (Design Cover)
5. Loosen PDCC reservoir and set it aside (do not open hydraulic lines). → 430955 REPLACING
RESERVOIR (PDCC)
6. Remove right air-cleaner box. → REMOVING AIR CLEANER HOUSING

TOOLS AND MATERIALS > TOOLS
1. Support bracket 10-222 A
2. Pipe T40091/1
3. Support T40091/52-53 in combination with head of support T40091/50-51
4. Support T40093/3P with adjustable foot T40093/51
5. Joiner T40091/3
6. Lifting tackle 3033

Fig 1: Identifying Engine Supporting Tools

SUPPORTING THE ENGINE ON THE BODY
Information
Never use defective lifting equipment (bent or damaged tools must not be used or repaired. Always
replace these tools). Check tools for signs of damage before use .
Information
The engine must be supported on the body for some repair work on the front axle and engine
bearings .
Information
When assembling the suspending device, make sure that adjacent components are not scratched
or damaged .
Fig 1: Identifying Engine Support Assembly
1. Assemble the head of the support T40091/50-51 with the support T40091/52-53 .
2. Support T40091/52-53 (-1- ) must then be fitted on the top fastening points of the spring
struts.
1. 2.1. The mountings -2- must be seated exactly on the fastening nuts -3- .
2. 2.2. Ensure that the supports are seated correctly on the spring-strut threaded joints.
Fig 2: Installing Engine Support
3. Attach the front support in the engine compartment.
1. 3.1. Adjustable foot T40093/51 must now be connected to the support T40093/3P
.
2. 3.2. Fit the front support -1- on the longitudinal member seam at the right.
Fig 3: Identifying Front Support
4. Support the engine on the body.
1. 4.1. Joiner T40091/3 (-5- ) can now be pushed onto the support bracket 10-222
A (-1- ).
2. 4.2. Connect the front support -4- to the support bracket 10-222 A and support on
the left spring strut mount -3- .
3. 4.3. Fit the pipe T40091/1 (-4- ) into the joiner T40091/3 and the support on the
right spring strut mount -3- .
5. Secure the lifting tackle 3033 (-6- ) to the support bracket 10-222 A .
6. Engage the two fastening eyelets -2- on the lifting tackle 3033 at the fastening eyelets -1-
on the engine.
1. 6.1. Adjust the suspension at the spindles and set it as horizontal as possible.
2. 6.2. Tension the engine slightly and make sure that the force is distributed uniformly
over both spindles.
3. 6.3. Do not load the spindles at the side and position them until they are as vertical
as possible. Assemble as shown in the illustrations.
4. 6.4. Make sure that the suspension is not pressing back against the plenum panel.
Fig 4: Identifying Engine Tool

SUBSEQUENT WORK > SUBSEQUENT WORK FOR SUPPORTING THE ENGINE ON
THE BODY
1. Fit right air-cleaner box.
2. Fit torque support. → Installing Torque Support
3. Fit PDCC reservoir. → 430955 REPLACING RESERVOIR (PDCC)
4. Fit engine cover (design cover). → Installing Engine Cover (Design Cover)
5. Fit engine compartment trim panel. → INSTALLING FRONT TRIM PANEL (ENGINE
COMPARTMENT)
6. Bonnet stay 9704 can now be removed. Then, fit the gas-filled shock absorber at the bonnet.
→ INSTALLING FRONT PNEUMATIC SPRING
WM 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES, ASSEMBLY

OVERVIEWS (CAYENNE S E) > TECHNICAL VALUES
Location Description Type Basic Tolerance Tolerance

value 1 2
Initial 4 Nm (3
Aluminum screw, M6 AL9
tightening ftlb.)
Final
Aluminum screw, M6 AL9 90°
tightening
Initial 10 Nm
tightening (7.5 ftlb.)
Final
tightening
Initial 20 Nm
tightening (15 ftlb.)
Final
tightening
Fastening screws for engine Initial 120 Nm

Replace
carrier tightening (89 ftlb.)
Fastening screws for engine Final

+180°
carrier tightening
Fastening screw securing

Tightening 60 Nm
engine mounting to engine
torque (44 ftlb.)
carrier

Tightening 40 Nm
right engine support to
torque (30 ftlb.)
engine

Initial 50 Nm
right engine support to
engine

Final
right engine support to +90°
tightening
engine
Fastening nut securing

Tightening 75 Nm
engine support to engine
torque (56 ftlb.)
mounting
Fastening screw securing Tightening 40 Nm

left engine support to engine torque (30 ftlb.)

left engine support to engine torque (15 ftlb.)

Tightening 60 Nm
engine mounting to engine
torque (44 ftlb.)
carrier

electric drive motor to engine torque (48 ftlb.)
Fastening screw securing Initial 20 Nm

Replace
electric drive motor to engine tightening (15 ftlb.)
Fastening screws securing Final

+90°
electric drive motor to engine tightening



Initial 30 Nm
electric drive motor and Replace
transmission

Final
electric drive motor to 90°
tightening
transmission
Oil thread and contact Initial 50 Nm

Connecting rod bolts
surface tightening (37 ftlb.)
Oil thread and contact Final

Connecting rod bolts +90°
surface tightening
Fastening screw for oil spray Tightening 9 Nm

jet torque (6.5 ftlb.)
Fastening screw for joint Tighten in diagonally Tightening 9 Nm

flange on pulley side opposite sequence torque (6.5 ftlb.)
14 Nm
Screw plug for TDC marking Tightening
(10.5
on crankshaft torque
ftlb.)
Deflection roller for Tightening 42 Nm

poly-V-belt torque (31 ftlb.)
Vibration damper to Initial 20 Nm

Replace
crankcase tightening (15 ftlb.)
Vibration damper to Final

90°
crankcase tightening
Tensioner for poly-V-belt to Tightening 40 Nm

crankcase torque (30 ftlb.)
Fastening screw for vibration Initial 20 Nm

Replace
damper tightening (15 ftlb.)
Fastening screw for vibration Final

+90°
damper tightening
Fastening screw for joint Tighten in diagonally Tightening 9 Nm

flange on pulley side opposite sequence and in torque (6.5 ftlb.)
steps

Tightening 20 Nm
poly-V-belt pulley for coolant
torque (15 ftlb.)
pump to coolant pump
Fastening screw for coolant Tightening 9 Nm

pump torque (6.5 ftlb.)
Fastening screw on
Tightening 40 Nm
tensioning element for
torque (30 ftlb.)
poly-V-belt pulley
Fastening screw for vibration Initial 20 Nm

Replace
damper tightening (15 ftlb.)
Fastening screw for vibration Final

+90°
damper tightening

generator to engine torque (15 ftlb.)

Tightening 40 Nm
deflection roller for
torque (30 ftlb.)
poly-V-belt
Fastening screw for joint Tightening 9 Nm

flange on pulley side torque (6.5 ftlb.)

Tightening 20 Nm
torque (15 ftlb.)

Fastening screw on Tightening 40 Nm

tensioner for poly-V-belt torque (30 ftlb.)
Fastening nut securing cable Tightening 20 Nm

shoe to generator torque (15 ftlb.)
Fastening screw for drive Initial 60 Nm

Replace
plate tightening (44 ftlb.)
Fastening screw for drive Final

+90°
plate tightening
Fastening screw for drive Initial 60 Nm

Replace
plate tightening (44 ftlb.)
Fastening screw for drive Final

+90°
plate tightening

Tightening 60 Nm
balance weight on
torque (44 ftlb.)
transmission side
Fastening screw for end Tightening 13 Nm
plate torque (9.5 ftlb.)

Tightening 60 Nm
balance weight on pulley
torque (44 ftlb.)
side
Tightening 9 Nm
Fastening nut
torque (6.5 ftlb.)
Fastening screw for Initial 80 Nm

Replace
camshaft controller tightening (59 ftlb.)
Fastening screw for Final

+90°
camshaft controller tightening

Replace
camshaft sprocket tightening (59 ftlb.)

+90°
camshaft sprocket tightening
Fastening screw for chain Tightening 9 Nm

tensioner torque (6.5 ftlb.)

Initial 8 Nm (6
bearing plate for drive
tightening ftlb.)
sprocket

Final
bearing plate for drive +45°
tightening
sprocket
Fastening screw for bearing Initial 5 Nm

Replace
pin tightening (3.5 ftlb.)
+60 Nm
Fastening screw for bearing Final
(+44
pin tightening
ftlb.)

Replace
camshaft sprocket tightening (59 ftlb.)

+90°
camshaft sprocket tightening

Replace
camshaft controller tightening (59 ftlb.)

+90°
camshaft controller tightening

Replace
pin tightening (22 ftlb.)

+90°
pin tightening
Fastening screw for guide Initial 10 Nm

Replace
rail tightening (7.5 ftlb.)
Fastening screw for guide Final

+90°
rail tightening

Replace
pin tightening (3.5 ftlb.)
+60 Nm
(+44
pin tightening
ftlb.)

Replace

+90°
rail tightening

Replace

+90°
rail tightening

Initial 8 Nm (6
bearing plate for drive
tightening ftlb.)
sprocket

Final
bearing plate for drive +45°
tightening
sprocket

Replace
pin tightening (22 ftlb.)

+90°
pin tightening


Replace

+90°
rail tightening

Replace
drive sprocket for oil pump tightening (22 ftlb.)
Fastening screw securing Final

+90°
drive sprocket for oil pump tightening

Replace
sprocket for balance shaft tightening (11 ftlb.)
Fastening screw securing Final
+90°
sprocket for balance shaft tightening
Fastening screw for chain Initial 10 Nm

Replace
tensioner tightening (7.5 ftlb.)
Fastening screw for chain Final

+45°
tensioner tightening
Fastening screw on hall Tightening 9 Nm

sender torque (6.5 ftlb.)
Fastening screw for cylinder Initial 40 Nm

Replace
head tightening (30 ftlb.)
Fastening screw on cylinder Tightening

+90°
head torque
Fastening screw on cylinder Final

+90°
head tightening
Fastening screw on cylinder Tightening 9 Nm

head cover torque (6.5 ftlb.)

connector strip torque (3.5 ftlb.)
Fastening screw for Tightening 5 Nm

Replace
camshaft control torque (3.5 ftlb.)
Fastening screws securing Replace aluminum screws Tightening 9 Nm

chain box to cylinder head with steel screws torque (6.5 ftlb.)
Fastening screw for cylinder Tightening 9 Nm

head torque (6.5 ftlb.)
Fastening screw for cylinder Tightening 9 Nm

head torque (6.5 ftlb.)
Fastening screw securing Initial 8 Nm (6

Replace
guide frame for camshafts tightening ftlb.)

+90°
frame for camshafts tightening
Fastening nut for oil level Tightening 9 Nm

and oil temperature sensor torque (6.5 ftlb.)
Fastening screw for baffle Tightening 9 Nm

Tightening 9 Nm
Fastening screw Fit with securing liquid
torque (6.5 ftlb.)
Fastening screw for engine Initial 3 Nm (2

Replace
oil cooler tightening ftlb.)
Fastening screw for engine Final

+90°
oil cooler tightening
Fastening screw for engine Tightening 9 Nm
oil cooler (bottom) torque (6.5 ftlb.)

mounting saddle torque (6.5 ftlb.)
Initial 30 Nm
Fastening screw for sprocket Replace
Final
Fastening screw for sprocket +90°
tightening
Tightening 20 Nm
Fastening screw for oil pump
torque (15 ftlb.)
Tightening 30 Nm
Oil drain plug
torque (22 ftlb.)
Fastening screw on oil-filter Tightening

13 Nm
housing torque
Tightening
Oil pressure switch 20 Nm
torque
Fastening nut on oil-filter Tightening 13 Nm

On double screw
housing torque (9.5 ftlb.)
Fastening screw on oil-filter Tightening 9 Nm

housing torque (6.5 ftlb.)
Tightening
Lid on oil-filter housing 35 Nm
torque
Double screw securing Tightening

16 Nm
oil-filter housing torque
Oil pressure switch for Tightening

20 Nm
reduced oil pressure torque
Tightening 20 Nm
Oil non-return valve
torque (15 ftlb.)
Fastening screw on cover Tightening 9 Nm

with oil separator torque (6.5 ftlb.)
Fastening screw on cover Tightening 9 Nm

with oil separator torque (6.5 ftlb.)
Fastening screw for positive Tightening 3 Nm (2

crankcase ventilation pipes torque ftlb.)
Tightening 20 Nm
Oil non-return valve
torque (15 ftlb.)
Fastening screw for front left Tightening 9 Nm

coolant pipes torque (6.5 ftlb.)


Tightening 22 Nm
holder for front left coolant
torque (16 ftlb.)
pipes to engine
Fastening screw for front Tightening 9 Nm

coolant pipe torque (6.5 ftlb.)


Tightening 9 Nm
lower coolant pipe to
torque (6.5 ftlb.)
compressor

Tightening 9 Nm
lower coolant pipe to
torque (6.5 ftlb.)
compressor

Tightening 9 Nm
upper coolant pipe to
torque (6.5 ftlb.)
compressor

Tightening 9 Nm
upper coolant pipe to
torque (6.5 ftlb.)
compressor
Fastening screw for upper Tightening 9 Nm



oil cooler pipes torque (6.5 ftlb.)

oil cooler pipes torque (6.5 ftlb.)

coolant pipe to transmission torque (6.5 ftlb.)





Tightening 20 Nm
torque (15 ftlb.)
Initial 8 Nm (6
Fastening screw for adapter
tightening ftlb.)
Torque
Fastening screw for adapter Torque angle 90°
angle


regulator torque (6.5 ftlb.)
Fastening screws for Tightening 25 Nm

radiator torque (19 ftlb.)
Fastening screw for top Tightening 5 Nm

radiator mounting torque (3.5 ftlb.)


Tightening 20 Nm
torque (15 ftlb.)
Initial 8 Nm (6
tightening ftlb.)
Torque
angle


regulator torque (6.5 ftlb.)
Fastening screw on engine Tightening 27 Nm

suspension eyelet torque (20 ftlb.)

insulation plate torque (3.5 ftlb.)
Fastening screw on throttle Tightening 10 Nm

valve control unit torque (7.5 ftlb.)

connection piece torque (7.5 ftlb.)
Tightening 9 Nm
Fastening screw on holder
torque (6.5 ftlb.)

regulating valve control unit torque (7.5 ftlb.)
Fastening screw for intake Tightening 10 Nm
Replace
air temperature sensor torque (7.5 ftlb.)
Fastening nut on Tightening 20 Nm

compressor torque (15 ftlb.)
Fastening screw for boost Tightening 10 Nm

Replace
pressure sensor torque (7.5 ftlb.)

Tightening 10 Nm
charge-air cooler to Self-locking
torque (7.5 ftlb.)
compressor housing

Tightening 10 Nm
charge-air cooler to Self-locking
torque (7.5 ftlb.)
compressor housing
Fastening screw for drive Tightening 25 Nm

Self-locking/replace
head torque (19 ftlb.)
Fastening screw on lower Tightening 9 Nm

part of air cleaner torque (6.5 ftlb.)

Tightening 2.5 Nm
potentiometer to intake
torque (2 ftlb.)
manifold flap
Tightening 22 Nm
Fuel pressure sensor Oil thread
torque (16 ftlb.)

high-pressure line holder torque (6.5 ftlb.)
Union nut for fuel Tightening 27 Nm

high-pressure lines torque (20 ftlb.)

Tightening
fuel high-pressure line to 9 Nm
torque
holder
Tightening 9 Nm
Fastening nut
torque (6.5 ftlb.)

Tightening 9 Nm
retaining bar for fuel
torque (6.5 ftlb.)
distributor
Tightening 2.5 Nm
Fastening screw
torque (2 ftlb.)
Tightening 40 Nm
Union nut for fuel distributor
torque (30 ftlb.)

Tightening 9 Nm
high-pressure pump to
torque (6.5 ftlb.)
housing
Tightening 27 Nm
Adapter
torque (20 ftlb.)
Tightening 27 Nm
Adapter
torque (20 ftlb.)
Union nut securing fuel

Tightening 25 Nm
high-pressure line to
torque (19 ftlb.)
high-pressure pump
Fuel pressure sensor for low Tightening 15 Nm

pressure torque (11 ftlb.)
Fastening nut for fuel supply Tightening 9 Nm

line holder torque (6.5 ftlb.)


high-pressure pump housing torque (6.5 ftlb.)
Fastening nut on protective Tightening 9 Nm

Tightening 55 Nm
Oxygen sensor
torque (41 ftlb.)
Tightening 55 Nm
Oxygen sensor
torque (41 ftlb.)
Fastening screws on Tightening 9 Nm

combination valve torque (6.5 ftlb.)
Fastening screws on Tightening 5 Nm

secondary air pipe torque (3.5 ftlb.)
Fastening nut on holder for Tightening 9 Nm

secondary air pump motor torque (6.5 ftlb.)
Fastening nut on exhaust Replace and grease with Tightening 25 Nm

manifold hot screw paste torque (19 ftlb.)
Fastening screw for heat Tightening 10 Nm

shield torque (7.5 ftlb.)
Fastening nut securing front

Replace and grease with Tightening 23 Nm
exhaust pipe to exhaust
hot screw paste torque (17 ftlb.)
manifold

Tightening 23 Nm
catalytic converter to front Replace
torque (17 ftlb.)
silencer

catalytic converter to
exhaust manifold
Fastening screw on support Tightening 23 Nm

for left catalytic converter torque (17 ftlb.)
catalytic converter to
exhaust manifold

Tightening 23 Nm
catalytic converter to front Replace
torque (17 ftlb.)
silencer

for right catalytic converter torque (17 ftlb.)

for right front silencer torque (17 ftlb.)

for left front silencer torque (17 ftlb.)
Fastening nut on clamping Tightening 35 Nm

sleeve torque (26 ftlb.)


Tightening 9 Nm
catalytic converter holder to
torque (6.5 ftlb.)
transmission, left

Tightening 23 Nm
torque (17 ftlb.)
transmission, left

Tightening 9 Nm
torque (6.5 ftlb.)
transmission, right

Tightening 23 Nm
torque (17 ftlb.)
transmission, right

suspension torque (17 ftlb.)




Tightening 30 Nm
Tailpipe
torque (22 ftlb.)
Tightening 30 Nm
Tailpipe
torque (22 ftlb.)
Tightening 10 Nm
adapter for starter to
torque (7.5 ftlb.)
transmission
Fastening screw (M10 x 95) Initial 15 Nm

for starter tightening (11 ftlb.)
Fastening screw (M10 x 95) Final

+105° +/-30°
for starter tightening
Fastening screw (M12 x 75) Initial 30 Nm

for starter tightening (22 ftlb.)
Fastening screw (M12 x 75) Final

+105° +/-30°
for starter tightening

generator torque (15 ftlb.)
Fastening nut securing Tightening 20 Nm

electric line to generator torque (15 ftlb.)

Fastening screw for knock Tightening 20 Nm

sensor torque (15 ftlb.)

camshaft control valve torque (3.5 ftlb.)
Tightening 30 Nm
Spark plug
torque (22 ftlb.)
Fastening screw for electric Tightening 5 Nm

wire harness torque (3.5 ftlb.)

speed sender torque (6.5 ftlb.)

sender 2 torque (6.5 ftlb.)

air-conditioning compressor torque (15 ftlb.)

refrigerant line torque (17 ftlb.)

OVERVIEWS (CAYENNE S E) > TECHNICAL VALUES > OVERVIEW
Information
The tightening steps in the tightening sequences relate to tightening screws uniformly, i.e. all
affected screws must first be tightened uniformly to the first torque value, then all screws are
tightened one stage further, and so on .
Replace all O-rings following removal!

The torques in the table below generally apply to screws that are not specifically listed =>
The bolt quality is indicated on the screw head at the top as a decimal number, e.g. "8.8" or
"12.9" .
Bolt quality 8.8 Bolt quality 10.9 Bolt quality 12.9
Thread [Nm (ftlb.)] Thread [Nm (ftlb.)] Thread [Nm (ftlb.)]
M4 3 (2) M4 4 (3) M4 5 (3.5)
M5 6 (4.5) M5 8 (6) M5 10 (7.5)
M6 10 (7.5) M6 13 (9.5) M6 16 (12)
M8 23 (17) M8 33 (24) M8 39 (29)
M10 45 (33) M10 65 (48) M10 80 (59)
M10 x 1.25 50 (37) M10 x 1.25 70 (52) M10 x 1.25 85 (63)
M12 80 (59) M12 115 (85) M12 135 (100)
M12 x 1.25 90 (67) M12 x 1.25 125 (93) M12 x 1.25 150 (111)
M12 x 1.5 85 (63) M12 x 1.5 120 (89) M12 x 1.5 145 (107)
M14 130 (96) M14 180 (133) M14 220 (163)
M16 200 (148) M16 280 (204) M16 335 (248)
ALUMINUM SCREWS TIGHTENING SPECIFICATION




OVERVIEWS (CAYENNE S E) > GROUP 10 - ENGINE - CRANKCASE, SUSPENSION >
ASSEMBLY OVERVIEW - ANCILLARY UNIT MOUNTS
Information
For more information, see P ORSCHE E LECTRONIC PAR T S CATALOGUE "PET"
1. Screws for engine carrier/replace → Initial tightening: 120 Nm (89 ftlb.) → Final tightening:
+180°
2. Engine mounting
3. Screw → Tightening torque: 60 Nm (44 ftlb.)
4. Screw, M10 x 35 → Tightening torque: 40 Nm (30 ftlb.)
4* - Screw, M10 x 45 → Initial tightening: 50 Nm (37 ftlb.) → Final tightening: +90°
5 - Nut → Tightening torque: 75 Nm (56 ftlb.)
6 - Right engine support
7 - Left engine support
8 - Screw → Tightening torque: 40 Nm (30 ftlb.)
11 - Engine mounting
12 - Engine carrier
-
Fig 1: Overview Of Ancillary Unit Mounts

TIGHTENING TORQUES FOR ELECTRIC DRIVE MOTOR ON ENGINE
1, 2, 3 - Screw, M12 x 70 → Tightening torque: 65 Nm (48 ftlb.)
4 - Screw, M10 x 85 with nut → Tightening torque: 45 Nm (33 ftlb.)
5, 6, 7, 8 - Screw, M10 x 60/replace → Initial tightening: 20 Nm (15 ftlb.) → Final tightening: +90°
9 - Screw, M12 x 70 → Tightening torque: 65 Nm (48 ftlb.)
10 - Screw, M12 x 60, multiple-tooth → Tightening torque: 65 Nm (48 ftlb.)
Fig 1: Identifying Electric Drive Motor Screws

TIGHTENING TORQUE FOR ELECTRIC DRIVE MOTOR ON TRANSMISSION
1... 10 - Screws/replace → Initial tightening: 30 Nm (22 ftlb.) → Final tightening: 90°
Fig 1: Electric Drive Motor To Transmission Bolts Tightening Sequence

TIGHTENING TORQUE FOR AUTOMATIC TRANSMISSION TO ENGINE
1. M10 x 60 Bi-hexagonal flange screw
5. M10 x 95 Bi-hexagonal flange screw/for securing starter
6. M12 x 75 Bi-hexagonal flange screw/for securing starter

10. M12 x 140 x 90 Bi-hexagonal flange screw
11. M12 x 140 x 90 Bi-hexagonal flange screw

Fig 1: Automatic Transmission To Engine Screw Tightening Sequence
CONVERTER SCREW TORQUE SPECIFICATION
Torque
Item
Initial tightening Final tightening Tolerance
1... 5 15 Nm (11 ftlb.) +105° +/- 30°
6... 11 30 Nm (22 ftlb.) +105° +/- 30°

OVERVIEWS (CAYENNE S E) > GROUP 13 - ENGINE - CRANK DRIVE, PISTONS >
ASSEMBLY OVERVIEW - PISTONS AND CONNECTING RODS
1. Screws/replace → Initial tightening: 50 Nm (37 ftlb.) → Final tightening: +90°
1. Oil thread and contactsurface
2. Use old screw to measure radial clearance, tighten to 50 Nm (37 ftlb.) but do not tighten
further.
2. Connecting-rod bearing cap

1. Mark forre-installation
2. Mark cylinder allocation with paint/colored marker
3. Bearing shells
1. Check that retaining lugs are seated securely
2. Mark used bearing shells for re-installation, but not on the running surface.
3. Oversize bearing shells are available for re-machined crankshaftcon-rod journals
4. Connecting-rod bearing lugs are aligned
4. Circlip/replace
5. Piston pin
1. Heat stiff pistons to approx.60°C
6. Pistons
1. Mark installation position and allocation to cylinder
7. Piston rings
1. Offset gap by 120°
2. Installation position: "TOP" marking or side with lettering towardspiston crown

Fig 1: Overview Of Pistons And Connecting Rods

CHECKING PISTON-RING END CLEARANCE
Push in the piston ring at a right angle to the cylinder wall from above until it is approx.15 mm away from
the edge of the cylinder.
Piston ring New [mm] Wear limit [mm]

1st compression ring 0.20... 0.30 0.80
2nd compression ring 0.50... 0.70 0.80
Oil scraper ring 0.25... 0.50 Not yet determined
Fig 1: Checking Piston-Ring End Clearance

CHECKING PISTON-RING VERTICAL CLEARANCE
Clean ring groove on piston before checking clearance.
Piston ring New [mm] Wear limit [mm]
1st compression ring 0.04... 0.08 0.20
2nd compression ring 0.03... 0.07 0.20
Oil scraper ring 0.02... 0.06 0.15

Fig 1: Checking Piston-Ring Vertical Clearance

OVERVIEWS (CAYENNE S E) > GROUP 13 - ENGINE - CRANK DRIVE, PISTONS > OIL
SPRAY JET FOR PISTON COOLING
-1- - Screw, fit with securing liquid → Tightening torque: 9 Nm (6.5 ftlb.)
-2- - Oil spray jet with spray jet valve (opening pressure: 2...2.4 bar overpressure)
Fig 1: Identifying Oil Spray Jet For Piston Cooling

ASSEMBLY OVERVIEW - CRANKSHAFT
1. Joint flange on pulley side/replace
2. Screw → Tightening torque: 9 Nm (6.5 ftlb.)
3. Crankshaft
4. Dowel sleeve/insert in guideframe
5. Seal/replace
6. Screw
1. For guide frame sealing faces on cylinder block
2. Different screw lengths and screw heads

7. Screw (long, large collar)/replace
1. For guide frame, inner row
8. Screw (short, small collar)/replace
1. For guide frame, outer row
9. Guide frame
10. Seal/replace
11. Thrust plate
1. Only on 3rd crankshaft bearing
2. Lubricating grooves facingoutwards
3. Check secure fitting in guideframe
12. Bearing shell
1. For guide frame without lubricating groove
2. Mark used bearing shells for re-installation, but not on the running surface
3. Replace bearing shells worn down to baselayer
4. Check installation position
5. Insert new bearing shells for guide frame with correct color markings.
13. Thrust plate
1. Only on 3rd crankshaft bearing
2. Lubricating grooves facingoutwards
3. Check secure fitting in cylinderblock
14. Bearing shell
1. For cylinder block with lubricating groove
2. Mark used bearing shells for re-installation, but not on the running surface
3. Replace bearing shells worn down to baselayer
4. Check installationposition
5. Insert new bearing shells for guide frame with correct color markings.
15. Cylinder block

Fig 1: Overview Of Crankshaft

SCREW PLUG FOR "TDC" MARKING ON CRANKSHAFT
The screw plug is located under the left engine support
Replace seal
TORQUE SPECIFICATION
Screw plug for Tightening 14 Nm (10.5

TDC marking torque ftlb.)
on crankshaft
Fig 1: Locating TDC Marker Screw Plug

APPLY SEALANT ON GUIDE FRAME, POSITION OF DOWEL SLEEVES
Clean sealing faces. Sealing faces must be free of oil and grease at top and bottom.
Apply beads of sealant -arrows- to clean sealing faces of the guide frame as shown.
Groove on the sealing face must be completely filled with sealant.
Beads of sealant must project 1.5...2.0 mm over the sealing face.
Fit gaskets -1- and -2- .

Check that dowel sleeves -3- ... -6- are inserted in the guide frame at the positions shown.
Fig 1: Locating Guide Frame Sealant Applying Area

INSTALL GUIDE FRAME
Replace screws1...16 for guideframe
Fit long screws in the inner row of the guide frame.
Tighten screws1...31 in three steps as follows:
Step Screws Tightening torque/torque angle
1. 1... 16 50 Nm (37 ftlb.)
2. 1... 16 Turn 90° further
3. 17... 31 20 Nm (15 ftlb.) +90°

Fig 1: Identifying Guide Frame

ALLOCATION OF CRANKSHAFT BEARING SHELLS FOR CYLINDER BLOCK
Bearing shells of the correct thickness are allocated to the cylinder block at the factory. Colored dots on
the side of the bearing shell are used to indicate bearing shell thickness.
The allocation of the bearing shells to the cylinder block is indicated on the guide frame by a letter next
to the relevant bearing item 1... 4.
Letter on guide frame Color of bearing
R= red
G= yellow
B= blue
S= black
Fig 1: Identifying Crankshaft Bearing Shells

ALLOCATION OF CRANKSHAFT BEARING SHELLS FOR GUIDE FRAME
Bearing shells of the correct thickness are allocated to the guide frame at the factory. Colored dots on
the side of the bearing shell are used to indicate bearing shell thickness.
The correct allocation of bearing shells to guide frame is indicated by a sequence of letters on the
transmission flange of the crankshaft. The first letter in the sequence stands for bearing "1", the second
letter for bearing "2", etc.
Letter on guide frame Color of bearing
R= red
G= yellow
B= blue
S= black
Fig 1: Identifying Guide Frame Crankshaft Bearing Shells

CRANKSHAFT DIMENSIONS
Crankshaft bearing journal diameter Connecting-rod bearing pin diameter

Grinding size
[mm] [mm]
Basic
65.00 -0.0220.042 56.00-0.022-0.042
dimension

ASSEMBLY OVERVIEW - POLY-V-BELT DRIVE FOR COMPRESSOR
1. Poly-V-belt for compressor
3. Washer
4. Cover
5. Compressor
6. Deflection roller for poly-V-belt
7. Vibration damper
8. Screw/replace → Initial tightening: 20 Nm (15 ftlb.) → Final tightening: 90°
9. Tensioning element for poly-V-belt

Fig 1: Overview Of Compressor V-Belt Drive

ASSEMBLY OVERVIEW - POLY-V-BELT DRIVE
1. Poly-V-belt
2. Screw/replace → Initial tightening: 20 Nm (15 ftlb.) → Final tightening: +90°
3. Poly-V-belt pulley for generator

4. Joint flange on pulley side
Not shown - Screw → Tightening torque: 9 Nm (6.5 ftlb.)
6. Poly-V-belt pulley for coolant pump
7. Coolant pump
9. Tensioning element for poly-V-belt
Not shown - Screw → Tightening torque: 40 Nm (30 ftlb.)

Fig 1: Overview Of Poly-V-Belt Drive

ASSEMBLY OVERVIEW - POLY-V-BELT DRIVE
1. Poly-V-belt/mark rolling direction
3. Generator
5. Cover for deflection roller
6. Deflection roller for poly-V-belt → Tightening torque: 40 Nm (30 ftlb.)
11. Coolant pump
12. Joint flange on pulley side/replace
13. Screw
14. Holder for vane type pump
15. Sliding bush
16. Screw
17. Vane type pump
18. Pulley for vane type pump
19. Screw
20. Tensioner for poly-V-belt → Tightening torque: 40 Nm (30 ftlb.)
21. Holder for air-conditioning compressor
22. Screw
24. Screw
25. Dowel sleeve
26. Cover for tensioner
27. Vibration damper

Not shown - Cable shoe on generator → Tightening torque: 20 Nm (15 ftlb.)

ASSEMBLY OVERVIEW - DRIVE PLATE
1. Drive plate

3. Dowel pin
4. Sensor wheel for engine speed sender
5. Needle-roller bearing
6. Shaft sealing ring/replace
7. Crankshaft
8. Rubber stopper
9. Engine speed sender

Fig 1: Overview Of Drive Plate

ASSEMBLY OVERVIEW - DRIVE PLATE
1. Drive plate
3. Sensor wheel, for engine speed

4. Shaft sealing ring, for crankshaft at transmission side/replace
5. Dowel pin
6. Crankshaft

ASSEMBLY OVERVIEW - BALANCE SHAFT
1. Balance shaft
3. Balance weight on transmission side
1. Can only be fitted at one position on the balanceshaft
4. End plate
6. Balance weight on pulley side

Fig 1: Overview Of Balance Shaft

OVERVIEWS (CAYENNE S E) > GROUP 15 - ENGINE - CYLINDER HEAD, VALVE
DRIVE > ASSEMBLY OVERVIEW - TIMING CHAIN COVERS
1. Screw
2. Shaft seal, for crankshaft at transmission side/replace
3. Screw
4. Dowel sleeve
5. Lower timing chain cover
6. Threaded pin
7. Cylinder-head gasket
8. Screw/replace
9. Holder, for wire harness
10. Holder, for wire harness
11. Screw/replace
12. Left timing chain cover
13. Seal/replace
14. Seal/replace
15. Right cylinder head gasket
16. Right timing chain cover
17. Nut → Tightening torque: 9 Nm (6.5 ftlb.)
18. Holder, for electric lines
19. Threaded pin
20. Holder, for heat shield
21. Screw/replace
22. Dowel sleeve
23. Screw/replace
24. Cover
26. Screw
27. Cover, for engine speed sender

Fig 1: Overview Of Timing Chain Covers

DRIVE > LEFT TIMING CHAIN COVER/TIGHTENING TORQUE AND TIGHTENING
SEQUENCE
Replace screws that are tightened to an additional torque angle.
Tighten the holders -arrows A, B- together with the left timing chain cover.
Tighten screws in 2 steps in the sequence shown:
1. 1... 8 5 Nm (3.5 ftlb.)
Fig 1: Locating Left Timing Chain Cover Holder

DRIVE > RIGHT TIMING CHAIN COVER/TIGHTENING TORQUE AND TIGHTENING
SEQUENCE
Tighten screws in 2 steps in the sequence shown:

1. 1... 8 5 Nm (3.5 ftlb.)
Fig 1: Locating Right Timing Chain Cover Holder

DRIVE > LOWER TIMING CHAIN COVER/TIGHTENING TORQUE AND TIGHTENING
SEQUENCE
Tighten screws in 8 steps as follows:
1. ArrowsReplace aluminum screws 9 Nm (6.5 ftlb.)

with steel screws
2. 1... 10 3 Nm (2 ftlb.) in diagonally

opposite sequence
3. 1, 2, 4, 5, 7 Turn 90° further
4. 8, 9, 10 8 Nm (6 ftlb.)
5. 8, 9, 10 Turn 90° further
6. 3 16 Nm (12 ftlb.)
7. 6 20 Nm (15 ftlb.)
8. 6 Turn 90° further

Fig 1: Locating Timing Chain Cover Screws

DRIVE > ASSEMBLY OVERVIEW - TIMING CHAINS > LEFT TIMING CHAIN

3. Camshaft sprocket, for outlet camshaft
4. Camshaft controller, for intake camshaft
1. "in-take" marking
5. Left timing chain
1. For re-installation, mark rolling direction with paint/colormarker
2. Remove from camshafts
7. Slide
8. Chain tensioner, for left timing chain
9. Bearing plate, for drive sprocket
11. Drive sprocket, for left timing chain
12. Bearing pin, for drive sprocket for left timing chain
13. Screws/replace → Initial tightening: 5 Nm (3.5 ftlb.) → Final tightening: +60 Nm (+44
ftlb.)
Fig 1: Identifying Left Timing Chain Components

DRIVE > ASSEMBLY OVERVIEW - TIMING CHAINS > RIGHT TIMING CHAIN
2. Camshaft sprocket, for outlet camshaft

4. Camshaft controller, for intake camshaft
Fig 1: Identifying Right Timing Chain Components
6. Bearing pin, for drive sprocket for right timing chain
1. Asymmetrical version
7. Drive sprocket, for right timing chain

8. Right timing chain
2. Remove fromcamshafts
9. Thrust washer, for drive sprocket for right timing chain
10. Chain tensioner, for right timing chain
11. Slide

DRIVE > ASSEMBLY OVERVIEW - TIMING CHAINS > ASSEMBLY OVERVIEW - DRIVE
CHAIN FOR TIMING DRIVE MECHANISM
1. Guide rail
2. Screw/replace → Initial tightening: 10 Nm (7.5 ftlb.) → Final tightening: +90°
3. Screws/replace → Initial tightening: 5 Nm (3.5 ftlb.) → Final tightening: +60 Nm (+44

ftlb.)
4. Bearing pin, for drive sprocket
5. Drive sprocket, for left timing chain
7. Drive chain, for timing drive mechanism
9. Guide rail
11. Bearing plate, for drive sprocket
12. Drive sprocket, for right timing chain
13. Thrust washer
16. Seal/replace
17. Chain tensioner
19. Crankshaft

Fig 1: Overview Of Drive Chain (Timing Drive Mechanism)

DRIVE > ASSEMBLY OVERVIEW - TIMING CHAINS > ASSEMBLY OVERVIEW - DRIVE
CHAIN FOR AUXILIARY DRIVES
1. Crankshaft
2. Drive chain, for auxiliary drives
3. Drive sprocket, for oil pump
1. Installation position: Side with lettering towards engine
5. Compression spring
7. Sprocket for balance shaft
8. Chain tensioner with guide rail

Fig 1: Overview Of Drive Chain (Auxiliary Drives)

DRIVE > ASSEMBLY OVERVIEW - TIMING CHAINS > ASSEMBLY OVERVIEW -
CYLINDER HEAD
1. Cylinder-head gasket/replace
2. Cylinder head
3. Screw
4. Vacuum pump
5. O-ring/replace
6. Hall sender
8. Screw/replace → Initial tightening: 40 Nm (30 ftlb.) → Tightening torque: +90° → Final

tightening: +90°
9. Ignition coil
11. Seal/replace if damaged or leaking
12. Cover
13. Screw/replace if seal is damaged → Tightening torque: 9 Nm (6.5 ftlb.)
15. Connector strip for ignition coils
16. Cylinder head cover seal/replace if seal is damaged
17. Solenoid valve for camshaft control on intake side
18. Screw/replace → Tightening torque: 5 Nm (3.5 ftlb.)
19. O-ring/replace
Fig 1: Overview Of Cylinder Head

DRIVE > ASSEMBLY OVERVIEW - TIMING CHAINS > THREADED JOINT SECURING
CHAIN BOX TO CYLINDER HEAD
arrows - Screws, steel → Tightening torque: 9 Nm (6.5 ftlb.)
Tighten screws after the cylinder head screws.

Fig 1: Locating Lower Timing Chain Cover Screws

DRIVE > ASSEMBLY OVERVIEW - TIMING CHAINS > CYLINDER HEAD COVER, LEFT
- TIGHTENING TORQUE AND TIGHTENING SEQUENCE
Tighten screws in the sequence -1... 12- to → Tightening torque: 9 Nm (6.5 ftlb.) until secure.
Fig 1: Left Cylinder Head Cover Screws Tightening Sequence

DRIVE > ASSEMBLY OVERVIEW - TIMING CHAINS > CYLINDER HEAD COVER,
RIGHT - TIGHTENING TORQUE AND TIGHTENING SEQUENCE
Tighten screws in the sequence -1... 12- to → Tightening torque: 9 Nm (6.5 ftlb.) until secure
Fig 1: Right Cylinder Head Cover Screws Tightening Sequence

DRIVE > ASSEMBLY OVERVIEW - TIMING CHAINS > CYLINDER HEAD TIGHTENING
TORQUE AND TIGHTENING SEQUENCE
Replace cylinder head screws.
Tighten screws in the specified sequence in four steps as follows:
1. Screw in as far as they will go by hand.
2. Tighten to 40 Nm (30 ftlb.) until secure
3. Turn 90°further
4. Turn 90°further
Fig 1: Cylinder Head Screws Tightening Sequence

DRIVE > ASSEMBLY OVERVIEW - TIMING CHAINS > ASSEMBLY OVERVIEW - VALVE
DRIVE
Information
Intake and outlet valves must not be reworked. They can only be ground.
1. Sealing plug
1. Install usingsealant
2. Cylinder head
3. Valve stem seal
4. Valve spring
5. Hydraulic compensating element
1. Clipped into rocker arm item 8 .

2. Oil running surfaces before installation.
3. Mark installation position for re-installation.
7. Valve collets
8. Rocker arm
1. Mark installation position forre-installation
2. Check roller bearing for ease of movement
3. Oil running surface beforeinstallation
4. To install, clip safety clip item 9 onto hydraulic compensating element item 5 .
9. Safety clip
1. Not available individually
2. Check that clip is seatedsecurely
10. Intake camshaft
11. Screw/replace
12. Guide frame, with integrated camshaft bearings
13. Plain compression ring
14. Not installed
15. Outlet camshaft
16. Oil strainer, not installed
17. Intake valve
1. Must not be machined; only grinding ispermitted
18. Outlet valve
1. Must not be machined; only grinding ispermitted
Fig 1: Overview Of Valve Drive

DRIVE > ASSEMBLY OVERVIEW - TIMING CHAINS > INSTALLATION POSITION OF
VALVE SPRINGS
Closely spaced spring coils -arrow- facing the cylinder head

Fig 1: Locating Valve Springs Installation Position

DRIVE > ASSEMBLY OVERVIEW - TIMING CHAINS > GUIDE FRAME FOR
CAMSHAFTS - TIGHTENING TORQUE AND TIGHTENING SEQUENCE
1. 1... 21 Screw in as far as they will go by

handThe guide frame must make
contact with the cylinder head
over the entire contact surface.
2. 1... 21 → Initial tightening: 8 Nm (6

ftlb.)
3. 1... 21 → Final tightening: +90°

VALVE SPECIFICATION
Dimension Intake valve Outlet valve
Diameter a [mm] 33.85 +/- 0.10 28.0 +/- 0.10
Diameter b [mm] 5.98 +/- 0.01 5.96 +/- 0.01
c [mm] 104.00 +/- 0.20 101.9 +/- 0.20
Angle α [°] 45 45
Fig 1: Identifying Valve Dimensions

OVERVIEWS (CAYENNE S E) > GROUP 17 - ENGINE - LUBRICATION > ASSEMBLY
OVERVIEW - OIL PAN, OIL PUMP, ENGINE OIL COOLER
2. Oil level and oil temperature sensor

3. Sealing ring/replace
4. Lower part of oil pan
5. Replace screw → Tightening torque: 9 Nm (6.5 ftlb.)
6. Baffle plate (bottom)
7. Screw/replace
8. Upper part of oil pan
9. Dowel sleeve
10. O-ring/replace
12. Baffle plate (top)
13. Seal/replace
14. Seal/replace
16. Engine oil cooler
18. Drive shaft for oil pump
20. Sleeve
21. Mounting saddle
23. Oil pump sprocket
25. O-ring/replace
26. Seal/replace
27. O-ring/replace
28. Oil pump
30. Screw/replace
32. Oil drain plug → Tightening torque: 30 Nm (22 ftlb.)

Fig 1: Overview Of Oil Pan, Oil Pump And Engine Oil Cooler
Lower part of oil pan - tightening torque and tightening sequence:
Tighten screws in two steps as follows:
Step 1: 5 Nm (3.5 ftlb.) in diagonally opposite sequence
Step 2: Turn 90° further in diagonally opposite sequence

Fig 2: Oil Pan Lower Part Screws Tightening Sequence
Upper part of oil pan - tightening torque and tightening sequence:
Step 1: 8 Nm (6 ftlb.) in diagonally opposite sequence

Fig 3: Oil Pan Upper Part Screws Tightening Sequence

OVERVIEW - OIL-FILTER HOUSING, OIL PRESSURE SWITCH
1. Screw → Tightening torque: 13 Nm

2. Oil pressure switch/switching pressure 2.5... 3.2 bar/including sealing ring → Tightening
torque: 20 Nm
3. Sealing ring/not available individually; replace oil pressure switch in the event of leaks!
4. Collar nut → Tightening torque: 13 Nm (9.5 ftlb.)
6. Sleeve
7. Rubber sleeve
1. With filter bypass valve
2. Withoil non-return valve, cannot bereplaced
9. O-ring/replace
10. Lid → Tightening torque: 35 Nm
12. Oil filter element
13. Double screw → Tightening torque: 16 Nm
14. Seal/replace
Fig 1: Overview Of Oil-Filter Housing And Oil Pressure Switch

OVERVIEWS (CAYENNE S E) > GROUP 17 - ENGINE - LUBRICATION > OIL
PRESSURE SWITCH FOR REDUCED OIL PRESSURE
Switching pressure 0.75...1.05 bar
Grey insulator
→ Tightening torque: 20 Nm
-1- Oil pressure switch for reduced oil pressure
-2- Electric plug connection
Fig 1: Identifying Oil Pressure Switch

OVERVIEW - OIL NON-RETURN VALVE, OIL SEPARATOR
1. O-ring/replace
2. Oil non-return valve, for oil supply for right cylinder head → Tightening torque: 20 Nm (15
ftlb.)
3. Seal/replace
4. Cover with oil separator
1. With connection for positive crankcase ventilation

6. O-ring/replace
7. Adapter, for positive crankcase ventilation
8. O-ring/replace
11. Pipes for positive crankcase ventilation
1. To cylinder head covers
12. O-ring/replace
13. Positive crankcase ventilation hose to air guide pipe
14. Hose clamp
15. Oil non-return valve, for oil supply for left cylinder head → Tightening torque: 20 Nm (15
ftlb.)
16. O-ring/replace
Fig 1: Overview Of Oil Non-Return Valve And Oil Separator

OVERVIEWS (CAYENNE S E) > GROUP 19 - ENGINE - COOLING SYSTEM -
INSTALLATION POSITIONS > INSTALLATION POSITIONS OF HIGH-TEMPERATURE
COOLING COMPONENTS
1. Coolant reservoir

3. Coolant temperature sensor
4. Coolant pump
5. Coolant temperature sensor at cooler output
6. Coolant regulator
Fig 1: Identifying High-Temperature Cooling Components Installation Positions

INSTALLATION POSITIONS > INSTALLATION POSITIONS OF HIGH-TEMPERATURE
COOLING COMPONENTS
3. Coolant pipes, to heat exchanger for heater

Fig 1: Identifying High-Temperature Cooling Components Installation Positions

INSTALLATION POSITIONS > INSTALLATION POSITIONS OF LOW-TEMPERATURE
COOLING COMPONENTS
2. Power electronics
3. Pump for charge-air cooling
4. Centre cooler for low-temperature cooling
5. Right cooler for low-temperature cooling

Fig 1: Identifying Low-Temperature Cooling Components Positions

INSTALLATION POSITIONS > INSTALLATION POSITIONS OF LOW-TEMPERATURE
COOLING COMPONENTS

Fig 1: Identifying Low-Temperature Cooling Components Installation Positions

INSTALLATION POSITIONS > INSTALLATION POSITIONS OF COOLING SYSTEM
COMPONENTS FOR ELECTRIC DRIVE MOTOR
1. Transmission oil preheater
2. To heat exchanger
3. Shut-off valve for transmission oil preheater
4. Coolant pump
5. Coolant reservoir for high-temperature cooling
6. Coolant run-on pump
7. Shut-off valve for drive motor cooling system
8. Drive motor for electric drive

Fig 1: Identifying Cooling System Components Positions

OVERVIEWS (CAYENNE S E) > GROUP 19 - ENGINE COOLING SYSTEM - ASSEMBLY
OVERVIEW > ASSEMBLY OVERVIEW - COOLING SYSTEM FOR
HIGH-TEMPERATURE COOLING
Replace O-rings and seals.
Pull plug-in couplings to make sure they areseated securely.

Tightening torques for M6 screws: 10 Nm (7.5 ftlb.)
Tightening torques for M8 screws: 20 Nm (15 ftlb.)
2. Adapter
3. Front coolant pipe
6. Upper coolant pipe
8. Radiator

Fig 1: Overview Of Cooling System For High-Temperature Cooling

OVERVIEW > ASSEMBLY OVERVIEW - COOLING SYSTEM FOR
HIGH-TEMPERATURE COOLING

5. Coolant pipes to heat exchanger for heater
8. Radiator

Fig 1: Overview Of Cooling System For High-Temperature Cooling

OVERVIEW > ASSEMBLY OVERVIEW - COOLING SYSTEM FOR LOW-TEMPERATURE
COOLING

2. Coolant pipes on charge air cooler
3. Bleeder valve
4. Power electronics

Fig 1: Overview Of Cooling System For Low-Temperature Cooling

OVERVIEW > ASSEMBLY OVERVIEW - COOLING SYSTEM FOR LOW-TEMPERATURE
COOLING
2. Bleeder valve
3. Coolant pipes on charge-air cooler
5. Left cooler for low-temperature cooling, for charge-air cooling
6. Right cooler for low-temperature cooling, for charge-air cooling

Fig 1: Overview Of Cooling System For Low-Temperature Cooling

OVERVIEW > ASSEMBLY OVERVIEW - COOLING SYSTEM FOR ELECTRIC DRIVE
MOTOR
2. Shut-off valve for transmission oil preheater
3. Transmission oil preheater
4. Shut-off valve for drive motor cooling
7. Adapter
Fig 1: Overview Of Cooling System For Electric Drive Motor

OVERVIEW > ASSEMBLY OVERVIEW - COOLANT PIPES

1. Upper coolant pipe on compressor
3. Coolant regulator with housing
6. Retaining clip
7. T-piece forpower and control electronics for electric drive
8. Return pipe for engine oil cooler
9. Supply pipe for engine oil cooler
10. Hose for charge-air cooling pump
12. Lower coolant pipe on compressor

Fig 1: Overview Of Coolant Pipes

OVERVIEW > ASSEMBLY OVERVIEW - COOLANT PIPES
2. Coolant pipes, front left

5. Holder
10. Seal/replace
11. O-ring/replace
14. Lower coolant pipe on compressor
16. Dowel sleeve
17. Seal/replace
19. Seal/replace
20. Upper coolant pipe on compressor
21. Dowel sleeve
23. Seal/replace
24. Seal/replace
25. O-ring/replace
28. Seal/replace
32. Engine oil cooler pipes
33. O-ring/replace
34. Retaining clip

OVERVIEW > COOLANT PIPES ON TRANSMISSION

3. Right coolant pipe on transmission
6. Rear left coolant pipes on transmission

Fig 1: Identifying Transmission Coolant Pipes

OVERVIEW > ASSEMBLY OVERVIEW - COOLANT PUMP, COOLANT REGULATOR,
ADAPTERS
4. Coolant pump with seal
5. Screw → Initial tightening: 8 Nm (6 ftlb.) → Torque angle: 90°
7. Washer
9. Adapter
10. Seal/replace
11. Seal/replace

Fig 1: Overview Of Coolant Pump, Coolant Regulator And Adapters

OVERVIEWS (CAYENNE S E) > GROUP 19 - ENGINE - COOLING - CONNECTION
DIAGRAM FOR COOLANT HOSES > CONNECTION DIAGRAM FOR
HIGH-TEMPERATURE COOLANT HOSES

3. Shut-off valve for drive motor cooling system
4. ATF preheater
5. Heat exchanger
6. Shut-off valve for ATF preheater
7. Engine
9. Radiator with ATF cooler and condenser

Fig 1: High-Temperature Coolant Hoses Connection Diagram

DIAGRAM FOR COOLANT HOSES > CONNECTION DIAGRAM FOR
LOW-TEMPERATURE COOLANT HOSES
2. Charge air cooler

3. Power and control electronics for electric drive

Fig 1: Low-Temperature Coolant Hoses Connection Diagram

DIAGRAM FOR COOLANT HOSES > CONNECTION DIAGRAM FOR COOLANT HOSES
Information
Blue = large cooling system
Red = small cooling system
Orange = cooling system for charge-air cooler
Brown = heating system
The arrows are pointing in direction of flow of coolant
1. Right cooler for charge-air cooling system
2. Bleeder screw
3. Radiator with integrated ATF cooler
6. Generator
7. Right charge-air cooler in compressor housing
8. Bleeder screw
10. Cap for coolant reservoir
11. to heat exchanger for heater
12. Cylinder head, bank 1 (right)
13. from heat exchanger for heater
14. Coolant pump
15. Cylinder head, bank 2 (left)
16. Bleeder screw
17. Left charge-air cooler in compressor housing
20. Not installed
21. Check valve
22. Bleeder screw
23. Left cooler for charge-air cooling system

24. Check valve
Fig 1: Coolant Hoses Connection Diagram

DIAGRAM FOR COOLANT HOSES > ASSEMBLY OVERVIEW - RADIATOR AND
RADIATOR FAN
1. Radiator module with condenser and ATF cooler
2. Fan frame
3. Radiator fan
4. Rubber mounting for radiator mounting
5. Bottom radiator mounting
6. Screws → Tightening torque: 25 Nm (19 ftlb.)
7. Top radiator mounting
8. Rubber mounting for radiator mounting
9. Screws → Tightening torque: 5 Nm (3.5 ftlb.)
10. Locking pins.

Fig 1: Overview Of Radiator And Radiator Fan

DIAGRAM FOR COOLANT HOSES > ASSEMBLY OVERVIEW - COOLANT PUMP,
COOLANT REGULATOR, ADAPTERS

5. Screw → Initial tightening: 8 Nm (6 ftlb.) → Torque angle: 90°
7. Washer
9. Adapter
10. Seal/replace
11. Seal/replace


OVERVIEWS (CAYENNE S E) > GROUP 21 - SUPERCHARGING > ASSEMBLY
OVERVIEW - COMPRESSOR
1. Engine suspension eyelet

3. Compressor
4. Insulation plate
6. Rubber sleeve
7. Intermediate flange
9. Throttle valve control unit
10. O-rings/replace
11. Connection piece
13. Change-over valve holder
17. Regulating valve control unit
18. Bleeder screw for left charge-air cooler
20. Intake air temperature sensor
21. O-rings/replace
22. Nut → Tightening torque: 20 Nm (15 ftlb.)
23. O-ring/replace
24. Threaded pin
26. Boost pressure sensor
27. Seals/replace
28. O-ring/replace
29. Positive crankcase ventilation adapter
30. O-ring/replace
Fig 1: Overview Of Compressor

OVERVIEW - CHARGE-AIR COOLER
1. Seal/replace
2. O-ring/replace
1. Coat the charge-air cooler with engine oil during installation

3. O-ring/replace
1. Coat the charge-air cooler with engine oil duringinstallation
4. Compressor housing
5. Seal/replace
6. Right charge-air cooler
8. Seal
2. Must not be separated from charge-aircooler
3. Coat with engine oil duringinstallation
10. Left charge-air cooler
11. Seal
3. Coat with engine oil during removal and installation

Fig 1: Overview Of Charge-Air Cooler

OVERVIEW - DRIVE HEAD
1. Screw/replace → Tightening torque: 25 Nm (19 ftlb.)
1. Before installation, always clean threaded bores with a thread cutter to remove any
residual particles
2. Drive head
3. Decoupling spring
Fig 1: Overview Of Drive Head

OVERVIEWS (CAYENNE S E) > GROUP 24 - FUEL SYSTEM, ELECTRONIC INJECTION
> ASSEMBLY OVERVIEW - AIR CLEANER
1. Water drain/clean
2. Air guide from lock support
4. Lower part of air cleaner/clean to remove salt residues, dirt and leaves
5. Air guide pipe/clean to remove salt residues, dirt and leaves
6. Air-cleaner element
7. Vent hose
8. Upper part of air cleaner/clean to remove salt residues, dirt and leaves
9. O-ring/replace
10. Hose for secondary air pump motor
11. Rubber sleeve

Fig 1: Overview Of Air Cleaner

> ASSEMBLY OVERVIEW - LOWER PART OF INTAKE MANIFOLD
1. Screw → Tightening torque: 2.5 Nm (2 ftlb.)
2. Potentiometer for intake manifold flap
3. Sealing ring/replace if damaged

4. Sleeve
5. Fuel pressure sensor → Tightening torque: 22 Nm (16 ftlb.)
6. Holder
8. High-pressure lines → Tightening torque: 27 Nm (20 ftlb.)
12. Screw → Tightening torque: 2.5 Nm (2 ftlb.)
13. Retaining bar for fuel distributor
14. Union nut → Tightening torque: 40 Nm (30 ftlb.)
15. Fuel distributor
16. Seal/replace
17. Lower part of intake manifold
18. Seal/replace
19. Support ring
20. O-ring/replace, coat with engine oil before installation
21. Spacer ring/replace if damaged
22. Fuel injector
23. Top sealing washer
24. Bottom sealing washer
25. Circlip
26. Combustion chamber sealing ring/replace
27. Sealing ring/replace if damaged
28. Actuating lever for vacuum actuator
29. Vacuum hose for intake manifold flap valve
30. Vacuum actuator for intake manifold flap control

Fig 1: Overview Of Intake Manifold Lower Part

> ASSEMBLY OVERVIEW - HIGH-PRESSURE PUMP
2. High-pressure pump with fuel metering valve/do not disassemble
3. Adapter → Tightening torque: 27 Nm (20 ftlb.)

4. Adapter → Tightening torque: 27 Nm (20 ftlb.)
5. Hose clamp
6. Fuel high-pressure line → Tightening torque: 25 Nm (19 ftlb.)
7. Fuel supply line
8. Fuel pressure sensor for low pressure → Tightening torque: 15 Nm (11 ftlb.)
10. Seal/replace
11. Housing
12. O-ring/replace
13. Hall sender
17. Protective plate
18. Roller tappet/coat with engine oil before installation
19. O-ring/replace, coat with engine oil before installation

Fig 1: Overview Of High-Pressure Pump

OVERVIEWS (CAYENNE S E) > GROUP 24 - OXYGEN SENSORS > ASSEMBLY
OVERVIEW - OXYGEN SENSORS
Position Oxygen sensor Heater Plug connection
-1- Oxygen sensor Heater for oxygen sensor 4-pin, black

downstream of catalytic 1 downstream of
converter catalytic converter
-2- Oxygen sensor Heater for oxygen sensor 6-pin, black
-3- Oxygen sensor Heater for oxygen sensor 4-pin, brown

downstream of catalytic 2 downstream of
converter catalytic converter
-4- Oxygen sensor 2 Heater for oxygen sensor 6-pin, brown

2
Fig 1: Identifying Oxygen Sensor Connector

OVERVIEWS (CAYENNE S E) > GROUP 24 - OXYGEN SENSORS > PLUG
CONNECTIONS FOR OXYGEN SENSORS (CYLINDER BANK 1)
-1- for oxygen sensor with heater for oxygen sensor
-2- for oxygen sensor downstream of catalytic converter with heater for oxygen sensor 1
downstream of catalytic converter.

OVERVIEWS (CAYENNE S E) > GROUP 24 - OXYGEN SENSORS > PLUG
CONNECTIONS FOR OXYGEN SENSORS (CYLINDER BANK 2)
-1- for oxygen sensor 2 with heater for oxygen sensor 2
-2- for oxygen sensor downstream of catalytic converter with heater for oxygen sensor 2

OVERVIEWS (CAYENNE S E) > GROUP 24 - OXYGEN SENSORS > INSTALLATION
POSITION FOR OXYGEN SENSORS > INSTALLATION POSITION OF OXYGEN
SENSORS ON CYLINDER BANK 1 (RIGHT)
-1- Oxygen sensor downstream of catalytic converter with heater for oxygen sensor 1
-2- Oxygen sensor with heater for oxygen sensor
Tightening torque: → Tightening torque: 55 Nm (41 ftlb.)

Fig 1: Identifying Oxygen Sensor Installation Position

OVERVIEWS (CAYENNE S E) > GROUP 24 - OXYGEN SENSORS > INSTALLATION
POSITION FOR OXYGEN SENSORS > INSTALLATION POSITION OF OXYGEN
SENSORS ON CYLINDER BANK 2 (LEFT)
-1- Oxygen sensor 2 with heater for oxygen sensor 2
-2- Oxygen sensor 2 downstream of catalytic converter with heater for oxygen sensor 2
downstream of catalytic converter
Tightening torque: → Tightening torque: 55 Nm (41 ftlb.)

Fig 1: Identifying Oxygen Sensor On Cylinder Bank 2 Installation Position

OVERVIEWS (CAYENNE S E) > GROUP 26 - EXHAUST SYSTEM > ASSEMBLY
OVERVIEW - AIR INJECTION SYSTEM
1. Vacuum hose from secondary-air injection valve 1
2. Right combination valve for secondary air
4. Sender 1 for secondary air pressure
5. O-ring/replace
7. Left combination valve for secondary air

9. Seal/replace
10. Hose for secondary air on pressure side
11. Rubber-metal mount
12. Motor for secondary air
13. Holder/riveted to body
15. O-rings/replace if damaged
16. Hose for secondary air on intake side
17. Secondary air pipe
18. Seal/replace
Fig 1: Overview Of Air Injection System

OVERVIEW - EXHAUST MANIFOLD
1. Nut/replace → Tightening torque: 25 Nm (19 ftlb.)
2. Heat shield holder
3. Exhaust manifold
4. Seal/replace
5. Heat shield
7. Oxygen sensor upstream of catalytic converter
8. Front exhaust pipe with catalytic converter and front silencer
10. Seal/replace
Fig 1: Overview Of Exhaust Manifold

OVERVIEWS (CAYENNE S E) > GROUP 26 - EXHAUST SYSTEM > LEFT EXHAUST
MANIFOLD - TIGHTENING TORQUE AND TIGHTENING SEQUENCE
Tighten nuts in the sequence -1...9- in 3 steps as follows:
1. Screw on nuts hand-tight .
2. Tighten to 15 Nm (11 ftlb.) initially.

3. Tighten to 25 Nm (19 ftlb.) .
Fig 1: Left Exhaust Manifold Nuts Tightening Sequence

OVERVIEWS (CAYENNE S E) > GROUP 26 - EXHAUST SYSTEM > RIGHT EXHAUST
MANIFOLD - TIGHTENING TORQUE AND TIGHTENING SEQUENCE
Tighten nuts in the sequence -1...9- in 3 steps as follows:
1. Screw on nuts hand-tight .
2. Tighten to 15 Nm (11 ftlb.) initially.
3. Tighten to 25 Nm (19 ftlb.) .

Fig 1: Right Exhaust Manifold Nuts Tightening Sequence

OVERVIEW - CATALYTIC CONVERTERS AND FRONT SILENCERS
1. Left front silencer
2. Seal/replace
4. Oxygen sensor 2 downstream of catalytic converter
5. Catalytic converter for cylinder bank 2 (left)
7. Seal/replace
8. Support for left catalytic converter

10. Support for right catalytic converter
12. Seal/replace
13. Oxygen sensor downstream of catalytic converter
14. Catalytic converter for cylinder bank 1 (right)
16. Seal/replace
17. Right front silencer
20. Support for right front silencer
21. Support for left front silencer
24. Right clamping sleeve
25. Left clamping sleeve

Fig 1: Overview Of Catalytic Converters And Front Silencers

OVERVIEW - HOLDERS FOR CATALYTIC CONVERTERS > INDIVIDUAL
COMPONENTS OF THE RIGHT HOLDER
2. Holder, left
Fig 1: Identifying Left Catalytic Converter Holder

OVERVIEW - HOLDERS FOR CATALYTIC CONVERTERS > INDIVIDUAL
COMPONENTS OF THE LEFT HOLDER
2. Holder

Fig 1: Identifying Right Catalytic Converter Holder

OVERVIEW - CENTRE AND REAR SILENCERS
2. Suspension/replace if damaged
7. Front clamping sleeve

9. Front clamping sleeve
10. Centre silencer
13. Left tailpipe → Tightening torque: 30 Nm (22 ftlb.)
14. Rear silencer
15. Right tailpipe → Tightening torque: 30 Nm (22 ftlb.)

Fig 1: Overview Of Centre And Rear Silencers
Installation position of front clamping sleeves:
Threaded joints are facingoutwards

Fig 2: Identifying Front Clamp Installation Position

OVERVIEWS (CAYENNE S E) > GROUP 27 - STARTER, POWER SUPPLY >
ASSEMBLY OVERVIEW - STARTER
1. Starter
2. Adapter for starter
4. Dowel sleeve
Fig 1: Overview Of Starter Sleeves
Not shown - Screw, M10 x 95 → Initial tightening: 15 Nm (11 ftlb.) → Final tightening: +105°+/-30°
Not shown - Screw, M12 x 75 → Initial tightening: 30 Nm (22 ftlb.) → Final tightening: +105°+/-30°

OVERVIEWS (CAYENNE S E) > GROUP 27 - STARTER, POWER SUPPLY >
ASSEMBLY OVERVIEW - GENERATOR
1. Generator

Not shown - Nut → Tightening torque: 20 Nm (15 ftlb.)

OVERVIEWS (CAYENNE S E) > GROUP 28 - IGNITION SYSTEM > ASSEMBLY
OVERVIEW - IGNITION SYSTEM
2. Hall sender
3. O-ring/replace
4. Knock sensor
6. Camshaft control valve 1
8. O-ring/replace
9. Spark plug → Tightening torque: 30 Nm (22 ftlb.)
10. Ignition coil
12. Electric wire harness
13. Camshaft control valve 2
16. O-ring/replace
17. Hall sender

Fig 1: Overview Of Ignition System

OVERVIEWS (CAYENNE S E) > GROUP 87 - AIR-CONDITIONING COMPRESSOR >
ASSEMBLY OVERVIEW - AIR-CONDITIONING COMPRESSOR
3. Dowel sleeve
4. Refrigerant line (low-pressure)
5. Refrigerant line (high-pressure)
8. Poly-V-belt
Fig 1: Overview Of Air-Conditioning Compressor

OVERVIEWS FOR ENGINE (CAYENNE S, CAYENNE TURBO, CAYENNE GTS,
CAYENNE TURBO S) > TECHNICAL VALUES
Aluminum screw, M6 AL9 Initial 4 Nm (3 ftlb.)

tightening
Aluminum screw, M6 AL9 Final 90°

tightening
Aluminum screw, M8 AL9 Initial 10 Nm (7.5

tightening ftlb.)

tightening
Aluminum screw, M10 AL9 Initial 20 Nm (15

tightening ftlb.)

tightening
Screw plug for upper M22 Tightening 30 Nm (22

part of crankcase torque ftlb.)
Screw plug for upper M22 Torque angle 60°

part of crankcase
Splash valves to M6 Tightening 10 Nm (7.5

upper part of torque ftlb.)
crankcase
Thrust-bearing screws M11 (10 ea.); Initial 30 Nm (22

securing lower part of tighten screws tightening ftlb.)
crankcase to upper within 5 minutes;
part of crankcase observe
tightening
sequence.
Thrust-bearing screws M11 (10 ea.); Torque angle 90°

securing lower part of tighten screws
tightening
sequence.
Thrust-bearing screws M10 (10 ea.); Initial 22 Nm (16

securing lower part of tighten screws tightening ftlb.)
tightening
sequence.
Thrust-bearing screws M10 (10 ea.); Torque angle 60°
securing lower part of tighten screws
tightening
sequence.
Lower part of M8 x 70; always Initial 10 Nm (7.5

crankcase to upper use new tightening ftlb.)
part of crankcase aluminum screws
(cross bolt
connection)
Lower part of M8 x 70; always Final 90°

crankcase to upper use new tightening
part of crankcase aluminum screws
(cross bolt
connection)
Lower part of M8 x 35 (2 ea.) Tightening 23 Nm (17

crankcase to upper torque ftlb.)
part of crankcase
Lower part of M8 x 50 (2 ea.) Tightening 23 Nm (17

crankcase to upper torque ftlb.)
part of crankcase
Bracket for auxiliary M10 x 45 (9 ea.), Tightening 65 Nm (48

units/engine mounting countersunk torque ftlb.)
to lower part of screw
crankcase
Hydraulic mount to M10 x 65 (2 ea.) Tightening 60 Nm (44

engine carrier torque ftlb.)
Hydraulic mount to M12 nut Tightening 75 Nm (56

bracket for auxiliary torque ftlb.)
units
Right engine carrier to M10 x 45 (6 ea.), Tightening 65 Nm (48

crankcase countersunk torque ftlb.)
screw
Hydraulic mount to M10 x 65 (2 ea.) Tightening 60 Nm (44

engine carrier torque ftlb.)
Hydraulic mount to M12 nut Tightening 75 Nm (56

units
Oil mist separator to Screw elements, Tightening 10 Nm (7.5

valve cover M6 torque ftlb.)
Holder to timing-case M6; always use Initial 4 Nm (3 ftlb.)

cover new aluminum tightening
screws
Holder to timing-case M6 Final 90°
cover tightening
Lid and vent line to M6 x 12 (1 ea.) Tightening 10 Nm (7.5

lower part of torque ftlb.)
crankcase
Design cover to bar Tightening 4.4 Nm (3.5

ignition module torque ftlb.)
Deflection roller with M10 x 90 (1 ea.) Tightening 32 Nm (24

timing-case cover to torque ftlb.)
upper part of
crankcase
Tensioner to lever M8 x 33 (1 ea.) Tightening 32 Nm (24

torque ftlb.)
Tensioning roller to M10 x 28 (1 ea.) Tightening 32 Nm (24

tensioning lever torque ftlb.)
Complete lever to M8 x 96 Tightening 32 Nm (24

timing-case cover and torque ftlb.)
cylinder head
Belt tensioner and M8 x 96 Tightening 32 Nm (24

bracket
Deflection roller with M10 x 90 (1 ea.) Tightening 32 Nm (24

cylinder head
Connecting rod cap to M9 x 56 (16 ea.) Tightening 8 Nm (6 ftlb.)

connecting rod Step 1 Tightening torque
sequence as
synchronous as
possible; use
new bolts
Connecting rod cap to M9 x 56 (16 ea.) Tightening 20 Nm (15

connecting rod Step 2 Tightening torque ftlb.)
sequence as
synchronous as
possible; use
new bolts
Connecting rod cap to M9 x 56 (16 ea.) Tightening 40 Nm (30

connecting rod Step 3 Tightening torque ftlb.)
sequence as
synchronous as
possible; use
new bolts
Connecting rod cap to M9 x 56 (16 ea.) Torque angle 90°

connecting rod Step 4 Tightening
sequence as
synchronous as
possible; use
new bolts
Pulley to coolant M8 x 16 (3 ea.) Tightening 23 Nm (17

pump torque ftlb.)
Vibration damper to M18 x 1.5 x 72 (1 Tightening 20 Nm (15

crankshaft ea.) Step 1 torque ftlb.)
Counter screw
torque at damper

Counter screw
torque at damper

Counter screw
torque at damper
Vibration damper to M18 x 1.5 x 72 (1 Torque angle 180°

crankshaft ea.) Step 4
Counter screw
torque at damper
Pulley to power- M8 x 16 (3 ea.) Tightening 23 Nm (17

steering/tandem pump torque ftlb.)
Additional screws M8 x 40 (1 ea.) Tightening 23 Nm (17

securing cylinder torque ftlb.)
head (cylinders 1 - 4)
to crankcase
Screw plug for M14 x 1 (2 ea.) Tightening 2 Nm (1.5

variable valve-lift torque ftlb.)
control oil duct on
cylinder head
Spark plugs in M14 x 1.25 Refit Tightening 25 Nm (19

cylinder head used spark plugs torque ftlb.)
Spark plugs in M14 x 1.25 Initial Tightening 30 Nm (22

cylinder head tightening of new torque ftlb.)
spark plugs
Oil duct screw plug in M8 x 1 (4 ea.) Tightening 5 Nm (3.5

cylinder head torque ftlb.)
Spark plugs in M14 x 1.25 Refit Tightening 25 Nm (19

cylinder head used spark plugs torque ftlb.)
Spark plugs in M14 x 1.25 Initial Tightening 30 Nm (22

cylinder head tightening of new torque ftlb.)
spark plugs
Screw plug for M14 x 1 (2 ea.) Tightening 2 Nm (1.5
control oil duct on
cylinder head
Cylinder head to M11 x 1.5 x 140 Tightening 30 Nm (22

upper part of (20 ea.) Step 1; torque ftlb.)
crankcase 1st turn
Cylinder head to Step 1; 2nd turn Tightening 50 Nm (37

crankcase
Cylinder head to Step 2; loosen Torque angle 720°

upper part of (approx. 2 turns)
crankcase
Cylinder head to Step 3; 1st turn Tightening 30 Nm (22

crankcase
Cylinder head to Step 3; 2nd turn Tightening 30 Nm (22

crankcase
Cylinder head to Step 3; 3rd turn Torque angle 110°

upper part of
crankcase
Screw plug M8 Tightening 5 Nm (3.5

torque ftlb.)
Oil duct screw plug on M14 Tightening 15 Nm (11

Screw plug for M12 Tightening 15 Nm (11

secondary air duct torque ftlb.)
Screw plug for M10 Tightening 8 Nm (6 ftlb.)

cylinder head torque
Screw plug for M10 Tightening 8 Nm (6 ftlb.)

cylinder head torque
Screw plug for M12 Tightening 15 Nm (11

secondary air duct torque ftlb.)
Oil duct screw plug on M14 Tightening 15 Nm (11

Hall sender (phase M6 x 20 (2 ea.); Initial 4 Nm (3 ftlb.)

sensor) to valve cover always use new tightening
1-4/5-8 aluminum screws
Hall sender (phase M6 x 20 (2 ea.); Final 90°

Hall sender (phase M6 x 20 (2 ea.); Initial 4 Nm (3 ftlb.)
Hall sender (phase M6 x 20 (2 ea.); Final 90°

Bar ignition module to M6 x 20 (4 ea.); Initial 4 Nm (3 ftlb.)

valve cover always use new tightening
aluminum screws
Bar ignition module to M6 x 20 (4 ea.); Final 90°

aluminum screws
Valve cover to cylinder M6 x 30; always Initial 4 Nm (3 ftlb.)

head use new tightening
aluminum screws
Valve cover to cylinder M6 x 30; always Final 90°

aluminum screws
Transport eyebolt and M8 x 35 (2 ea.) Tightening 23 Nm (17

valve cover to cylinder torque ftlb.)
head
Valve cover to cylinder M8 x 35 on Initial 10 Nm (7.5

head torque support (3 tightening ftlb.)
ea.); always use
new aluminum
screws
Valve cover to cylinder M8 x 35 on Final 90°

head torque support (3 tightening
ea.); always use
new aluminum
screws
Transport eyebolt and M8 x 35 (2 ea.) Tightening 23 Nm (17

valve cover to cylinder torque ftlb.)
head
Valve cover to cylinder M6 x 30; always Initial 4 Nm (3 ftlb.)

aluminum screws
Valve cover to cylinder M6 x 30; always Final 90°

aluminum screws
Bar ignition module to M6 x 20 (4 ea.); Initial 4 Nm (3 ftlb.)

aluminum screws
Bar ignition module to M6 x 20 (4 ea.); Final 90°
aluminum screws
Hydraulic valve for M5 x 12 Tightening 6 Nm (4.5

control to cylinder
head
Camshaft housing to M6 x 35 Tightening 13 Nm (9.5

Mounting saddle for M6 x 70 Tightening 13 Nm (9.5

cylinders 1-4 and torque ftlb.)
intake and outlet
camshaft housing to
cylinder head
Hydraulic valve for M5 x 12 Tightening 6 Nm (4.5

control to cylinder
head
Mounting saddle for M6 x 70 Tightening 13 Nm (9.5

cylinders 5-8 and torque ftlb.)
intake and outlet
camshaft housing to
cylinder head
Camshaft housing to M6 x 35 Tightening 13 Nm (9.5

Camshaft controller to M12; new screw Tightening 10 Nm (7.5

intake camshaft must be used, torque ftlb.)
Step 1 (counter
screw torque at
hexagon)
Camshaft controller to Step 2 (counter Tightening 30 Nm (22

intake camshaft screw torque at torque ftlb.)
hexagon)
Camshaft controller to Step 3 (counter Torque angle 100°

intake camshaft screw torque at
hexagon)
Camshaft controller to Loosening step 1 Torque angle 90°

intake camshaft
Camshaft controller to Loosening step 2 Torque angle 360°

intake camshaft
Camshaft controller to Step 1 (counter Tightening 30 Nm (22

intake camshaft screw torque at torque ftlb.)
hexagon)
Camshaft controller to Step 2 (counter Torque angle 135°
intake camshaft screw torque at
hexagon)
Hydraulic valve for M5 x 12 (4 ea.) Tightening 6 Nm (4.5

camshaft control to torque ftlb.)
camshaft mounting
saddle
Camshaft sprocket to M12; screw must Tightening 10 Nm (7.5

outlet camshaft be replaced; Step torque ftlb.)
1 (counter screw
torque at
sprocket)
Camshaft sprocket to Step 2 (counter Tightening 50 Nm (37

outlet camshaft screw torque at torque ftlb.)
sprocket)
Camshaft sprocket to Step 3 (counter Torque angle 90°

outlet camshaft screw torque at
sprocket)
Deflector rail to M8 x 35 (4 ea.) Tightening 32 Nm (24

crankcase and torque ftlb.)
cylinder head
Timing-chain M10 Tightening 35 Nm (26

tensioning rail to lower torque ftlb.)
part of crankcase
Guide rail to lower M8 (2 ea.) Tightening 20 Nm (15

part of crankcase and torque ftlb.)
cylinder head
Chain tensioner to M22 x 1.5 (1 ea.) Tightening 60 Nm (44

timing-case cover torque ftlb.)
Timing-case cover to M6 x 30; always Initial 4 Nm (3 ftlb.)

crankcase and use new tightening
cylinder head aluminum
screws; 23 ea.
Timing-case cover to M6 x 30; always Final 90°

crankcase and use new tightening
cylinder head aluminum
screws; 23 ea.
Inner timing-case M6 x 55; always Initial 4 Nm (3 ftlb.)

cover to upper part of use new tightening
crankcase and aluminum
cylinder head screws; 4 ea.
Inner timing-case M6 x 55; always Final 90°

cover to upper part of use new tightening
crankcase and aluminum
cylinder head screws; 4 ea.
Outer timing-case M6 x 55; always Initial 4 Nm (3 ftlb.)
cover to cylinder head use new tightening
aluminum
screws; 1 ea.
Outer timing-case M6 x 55; always Final 90°

cover to cylinder head use new tightening
aluminum
screws; 1 ea.
Timing-case cover M8 x 55; always Initial 10 Nm (7.5

(location of chain use new tightening ftlb.)
tensioner) to upper aluminum
part of crankcase and screws; 2 ea.
cylinder head
Timing-case cover M8 x 55; always Final 90°

(location of chain use new tightening
tensioner) to upper aluminum
part of crankcase and screws; 2 ea.
cylinder head
Sealing flange to M6 x 20 (2 ea.); Initial 4 Nm (3 ftlb.)

timing-case cover always use new tightening
aluminum screws
Sealing flange to M6 x 20 (2 ea.); Final 90°

aluminum screws
Sealing flange to M6 x 55 (2 ea.); Initial 4 Nm (3 ftlb.)

upper part of always use new tightening
crankcase aluminum screws
Sealing flange to M6 x 55 (2 ea.); Final 90°

upper part of always use new tightening
Chain tensioner to M22 x 1.5 (1 ea.) Tightening 60 Nm (44

timing-case cover torque ftlb.)
Oil-filter cover to oil Special wrench Tightening 25 Nm (19

guide housing a/f 94/36 (1 ea.) torque ftlb.)
Oil/water heat M6 x 20 (6 ea.) Tightening 10 Nm (7.5

exchanger to oil guide torque ftlb.)
housing
Joint flange to oil M6 x 20 (2 ea.) Tightening 10 Nm (7.5

guide housing torque ftlb.)
Oil guide housing to M6 x 30; always Initial 4 Nm (3 ftlb.)

lower part of use new tightening
Oil guide housing to M6 x 30; always Final 90°

lower part of use new tightening
Oil level sensor to oil Tightening 10 Nm (7.5

Timing-case cover to M6 x 30; always Initial 4 Nm (3 ftlb.)

oil guide housing use new tightening
aluminum screws
Timing-case cover to M6 x 30; always Final 90°

oil guide housing use new tightening
aluminum screws
Oil pressure sensor M6 Tightening 10 Nm (7.5

with adapter to lower torque ftlb.)
part of crankcase
Test connection to oil M10 x 1 (1 ea.) Tightening 15 Nm (11

pressure sensor torque ftlb.)
adapter
Oil pressure pipe to oil M6 x 16 (3 ea.) Tightening 12 Nm (9

pump and oil guide torque ftlb.)
housing
Oil regulating line to M6 x 16 (2 ea.) Tightening 12 Nm (9

oil pump and oil guide torque ftlb.)
housing
Turbocharger M6 x 16 (2 ea.) Tightening 12 Nm (9

extraction line to oil torque ftlb.)
pump
Pressure-stage intake M6 x 20 (2 ea.) Tightening 12 Nm (9

pipe to oil pump torque ftlb.)
Oil pressure pipe to oil M6 x 16 (3 ea.) Tightening 12 Nm (9

pump and oil guide torque ftlb.)
housing
Oil regulating line to M6 x 16 (2 ea.) Tightening 12 Nm (9

oil pump and oil guide torque ftlb.)
housing
Pressure-stage intake M6 x 20 (2 ea.) Tightening 12 Nm (9

pipe to oil pump torque ftlb.)
Oil drain plug to oil M18 x 1 (1 ea.) Tightening 50 Nm (37

pan torque ftlb.)
Oil pan to oil guide M6 x 20 Tightening 10 Nm (7.5

housing torque ftlb.)
Oil guide (oil plate) to M6 x 20 (6 ea.) Tightening 10 Nm (7.5

crankcase
Oil pump drive M8 x 22 (1 ea.); Initial 20 Nm (15
sprocket to oil pump Step 1; replace tightening ftlb.)
screw following
removal
Oil pump drive M8 x 22 (1 ea.); Torque angle 90°

sprocket to oil pump Step 2; replace
screw following
removal
Solenoid valve to oil M36 x 1.5 (1 ea.) Tightening 40 Nm (30

pump torque ftlb.)
2-stage oil pump to M6 x 45 (3 ea.) Tightening 13 Nm (9.5

crankcase
Sprocket cover to oil M6 x 16 (3 ea.) Tightening 10 Nm (7.5

pump (2-part) torque ftlb.)
Oil pump drive M8 x 22 (1 ea.); Initial 20 Nm (15

sprocket to oil pump Step 1; replace tightening ftlb.)
screw following
removal
Oil pump drive M8 x 22 (1 ea.); Torque angle 90°

sprocket to oil pump Step 2; replace
screw following
removal
Solenoid valve to oil M36 x 1.5 (1 ea.) Tightening 40 Nm (30

pump torque ftlb.)
2-stage oil pump to M6 x 45 (3 ea.) Tightening 13 Nm (9.5

crankcase
Sprocket cover to oil M6 x 16 (3 ea.) Tightening 10 Nm (7.5

pump (2-part) torque ftlb.)
Coolant pump to M6 x 25 (5 ea.) Tightening 12 Nm (9

upper part of Observe torque ftlb.)
sequence
Heating coolant pipe M6 x 16 (2 ea.) Tightening 12 Nm (9

to collection pipe torque ftlb.)
Screw plug for M14 x 1.5 (3 ea.) Tightening 30 Nm (22

collection pipe (2 ea.) torque ftlb.)
Coolant collection M6 x 25 (8 ea.) Tightening 12 Nm (9

pipe to upper part of torque ftlb.)
crankcase
Thermostat housing to M6 x 25 (3 ea.) Tightening 12 Nm (9

upper part of Observe torque ftlb.)
sequence
Connection piece to M6 Tightening 10 Nm (7.5

generator torque ftlb.)
Coolant return line to M6 x 20 (1 ea.) Tightening 10 Nm (7.5

thermostat housing torque ftlb.)
Holder for coolant M6; always use Initial 4 Nm (3 ftlb.)

hose to timing-case new aluminum tightening
cover screws
Holder for coolant M6; always use Final 90°

cover screws

Coolant return line to M6 x 20 (1 ea.) Tightening 10 Nm (7.5

thermostat housing torque ftlb.)
Holder for coolant M6; always use Initial 4 Nm (3 ftlb.)

cover screws
Holder for coolant M6; always use Final 90°

cover screws
Coolant line to M6 Tightening 10 Nm (7.5

collection pipe torque ftlb.)

Coolant line to M6 Tightening 10 Nm (7.5

collection pipe torque ftlb.)

Vent line to cylinder M6 x 16 (2 ea.) Tightening 10 Nm (7.5

head torque ftlb.)
Screw-type clamps for Tightening 5.5 Nm (4

pressure and intake torque ftlb.)
pipes
Supply/return M6 x 16 (2 ea.) Tightening 10 Nm (7.5

connection piece to torque ftlb.)
generator
Right coolant supply M6 (1 ea.) Tightening 8.5 Nm (6

line to right torque ftlb.)
turbocharger coolant
line
Coolant supply line to M12 x 1.25 (2 Tightening 30 Nm (22
turbocharger ea.) torque ftlb.)
Coolant return line to M12 x 1.25 (2 Tightening 30 Nm (22

Coolant return line M6 (1 ea.) Tightening 8.5 Nm (6

torque ftlb.)
Coolant supply line to M12 x 1.25 (2 Tightening 30 Nm (22

Coolant return line to M12 x 1.25 (2 Tightening 30 Nm (22

Coolant supply pipe to M16 x 1.5 (1 ea.) Tightening 35 Nm (26

left turbocharger torque ftlb.)
Vent line to M16 x 1.5 (2 ea.) Tightening 35 Nm (26

turbocharger oil torque ftlb.)
extraction line
Holding clamp on vent M6 x 12 (2 ea.) Tightening 10 Nm (7.5

line to collection pipe torque ftlb.)
Holding clamp on vent M6 (2 ea.) Tightening 6.5 Nm (5

Turbocharger oil feed M16 x 1.5 (2 ea.) Tightening 40 Nm (30

line to connection torque ftlb.)
piece
Turbocharger oil feed M14 x 1.5 (2 ea.) Tightening 35 Nm (26

line to cylinder head torque ftlb.)
Check valve M12 x 1.5 (2 ea.) Tightening 45 Nm (33

turbocharger
Turbocharger oil M6 x 12 (2 ea.) Tightening 10 Nm (7.5

extraction line to oil torque ftlb.)
guide housing
Oil extraction line to M6 x 16 (4 ea.) Tightening 10 Nm (7.5

turbocharger torque ftlb.)
Holding clamp on vent M6 (2 ea.) Tightening 6.5 Nm (5

Holding clamp on vent M6 x 12 (2 ea.) Tightening 10 Nm (7.5

Turbocharger oil feed M6 x 12 (1 ea.) Tightening 10 Nm (7.5

line holder to lower torque ftlb.)
part of crankcase
Holding clamp for oil M6 x 12 (1 ea.) Tightening 10 Nm (7.5

feed line to holder torque ftlb.)
Oil extraction line to M6 x 16 (4 ea.) Tightening 10 Nm (7.5
turbocharger torque ftlb.)
Check valve M12 x 1.5 (2 ea.) Tightening 45 Nm (33

turbocharger
Holder to timing-case M6; always use Initial 4 Nm (3 ftlb.)

screws
Holder to timing-case M6; always use Final 90°

screws
Holder for M6 Tightening 10 Nm (7.5

change-over valve torque ftlb.)
rubber element to
crankcase
Stopper to fuel gallery M12 x 1.5 (1 ea.) Tightening 25 Nm (19

(high-pressure rail) (3 turns: tighten, torque ftlb.)
loosen, tighten)
High-pressure sensor M10 x 1 Tightening 20 Nm (15

to fuel gallery (high- torque ftlb.)
pressure rail)
Spacer sleeve with M8 x 30 (4 ea.) Tightening 23 Nm (17

holder for injector torque ftlb.)
(high-pressure fuel
injector) to cylinder
head
Fuel gallery (high- M6 x 16 (3 ea.) Tightening 10 Nm (7.5

pressure rail) to torque ftlb.)
crankcase
Fuel gallery (high- M6 x 25 (1 ea.) Tightening 10 Nm (7.5

pressure rail) and torque ftlb.)
thermostat housing to
crankcase
Fuel line (high- M12 x 1.5 (8 ea.) Tightening 25 Nm (19

pressure line) to (3 turns: tighten, torque ftlb.)
injector (high-pressure loosen, tighten)
fuel injector)
High-pressure line M12 x 1.5 (2 ea.); Tightening 25 Nm (19

between (3 turns: tighten, torque ftlb.)
high-pressure pump loosen, tighten)
and fuel gallery (high-
pressure rail)
Low-pressure line to M14 x 1.5 (1 ea.); Tightening 25 Nm (19

high-pressure pump (3 turns: tighten, torque ftlb.)
loosen, tighten)
Fuel line holder to M8 x 24 (1 ea.) Tightening 23 Nm (17
High-pressure pump Screw socket, M6 Tightening 10 Nm (7.5

to cylinder head x 25 (2 ea.) torque ftlb.)
Protective plate to M6 x 20 (3 ea.) Tightening 10 Nm (7.5

screw socket torque ftlb.)
High-pressure pump M6 x 25 (1 ea.) Tightening 10 Nm (7.5

to cylinder head torque ftlb.)
Temperature sensor M12 x 1.5 (1 ea.) Tightening 20 Nm (15

to fuel low-pressure torque ftlb.)
line
High-pressure line M12 x 1.5 (2 ea.); Tightening 25 Nm (19

between (3 turns: tighten, torque ftlb.)
high-pressure pump loosen, tighten)
and fuel gallery (high-
pressure rail)
Low-pressure line to M14 x 1.5 (1 ea.); Tightening 25 Nm (19

high-pressure pump (3 turns: tighten, torque ftlb.)
loosen, tighten)
Fuel line holder to M8 x 24 (1 ea.) Tightening 23 Nm (17

High-pressure pump Screw socket, M6 Tightening 10 Nm (7.5

to cylinder head x 25 (2 ea.) torque ftlb.)
Protective plate to M6 x 12 (3 ea.) Tightening 10 Nm (7.5

screw socket torque ftlb.)
High-pressure pump M6 x 25 (1 ea.) Tightening 10 Nm (7.5

Temperature sensor M12 x 1.5 (1 ea.) Tightening 20 Nm (15

to fuel low-pressure torque ftlb.)
line
Decoupling element M7, align module; Tightening 15 Nm (11

on intake system observe torque ftlb.)
tightening
sequence
Heat socket to intake 5 x 16 Tightening 4 Nm (3 ftlb.)

system torque
Pressure sensor to 5 x 16 Tightening 4 Nm (3 ftlb.)

intake system torque
Electronic accelerator 6 x 50 Tightening 7 Nm (5 ftlb.)

to intake system torque
Actuator cover to M5 Tightening 4 Nm (3 ftlb.)

variable intake torque
manifold (adjusting
unit to intake
manifold)
Decoupling element M7, align module; Tightening 15 Nm (11

on intake system observe torque ftlb.)
tightening
sequence
Heat socket to intake 5 x 16 Tightening 4 Nm (3 ftlb.)

system torque
Pressure sensor to 5 x 16 Tightening 4 Nm (3 ftlb.)

intake system torque
Electronic accelerator 6 x 50 Tightening 7 Nm (5 ftlb.)

to intake system torque
Turbocharger to M8 x 75 (6 ea.) Initial 23 Nm (17

exhaust manifold tightening ftlb.)
Turbocharger to M8 x 75 (6 ea.) Final 30 Nm (22

Exhaust manifold to M8 (24 ea.); Tightening 33 Nm (24

cylinder head, turbo observe torque ftlb.) (check
engine tightening nuts by
sequence clicking once)

cylinder head, turbo observe torque ftlb.) (check
engine tightening nuts by
sequence clicking once)
Turbocharger to M8 x 75 (6 ea.) Initial 23 Nm (17

Turbocharger to M8 x 75 (6 ea.) Final 30 Nm (22


cylinder head, observe correct torque ftlb.) (check
naturally aspirated tightening nuts by
engine sequence clicking once)
Oxygen sensor on M18 x 1.5 (2 ea.) Tightening 45 Nm (33 +/-5 Nm (+/-

primary catalytic torque ftlb.) 3.5 ftlb.)
converter to exhaust
manifold

cylinder head, observe correct torque ftlb.) (check
naturally aspirated tightening nuts by
engine sequence clicking once)
Oxygen sensor on M18 x 1.5 (2 ea.) Tightening 45 Nm (33 +/-5 Nm (+/-

primary catalytic torque ftlb.) 3.5 ftlb.)
converter to exhaust
manifold
Temperature sensor M14 Tightening 30 Nm (22

Wire harness M6 Tightening 12 Nm (9

torque ftlb.)
Wire harness to valve M6 x 20 (2 ea.); Initial 4 Nm (3 ftlb.)

cover and eyelet always use new tightening
aluminum screws
Wire harness to valve M6 x 20 (2 ea.); Final 90°

cover and eyelet always use new tightening
aluminum screws
Wire harness for M6 Tightening 12 Nm (9

ground point on torque ftlb.)
cylinder head
Wire harness to M6 x 20 (2 ea.); Initial 4 Nm (3 ftlb.)

aluminum screws
Wire harness to M6 x 20 (2 ea.); Final 90°

aluminum screws
B+ line to starter M8 (1 ea.) Tightening 18 Nm (13

torque ftlb.)
Terminal 50 line to M6 (1 ea.) Tightening 6.5 Nm (5

starter torque ftlb.)
B+ line to generator M8 (1 ea.) Tightening 23 Nm (17

torque ftlb.)
Generator to lower M8 x 95 (2 ea.) Tightening 23 Nm (17

part of crankcase and torque ftlb.)
upper part of
crankcase
Generator to upper M8 x 35 (1 ea.) Tightening 23 Nm (17

part of crankcase torque ftlb.)
Starter to upper part M10 x 45 (2 ea.) Tightening 45 Nm (33

of crankcase torque ftlb.)
Knock sensor to M8 x 35 (4 ea.) Tightening 23 Nm (17

crankcase
Vacuum pump to M6 x 25 (3 ea.) Tightening 10 Nm (7.5

Tandem pump to M8 x 20 (1 ea.) Tightening 23 Nm (17

units
Power-steering pump M8 x 20 (1 ea.) Tightening 23 Nm (17
to bracket for auxiliary torque ftlb.)
units
Power-steering pump M8 x 35 (3 ea.) Tightening 23 Nm (17

to adapter bracket torque ftlb.)
Tandem M8 x 35 (3 ea.) Tightening 23 Nm (17

pump/adapter bracket torque ftlb.)
to bracket for auxiliary
units
Support bracket to M8; always use Initial 10 Nm (7.5

generator new aluminum tightening ftlb.)
screws
Support bracket to M8; always use Final 90°

generator new aluminum tightening
screws
Pulley to coolant M8 x 16 (3 ea.) Tightening 23 Nm (17

pump torque ftlb.)

Counter screw
torque at damper

Counter screw
torque at damper

Counter screw
torque at damper
Vibration damper to M18 x 1.5 x 72 (1 Torque angle 180°

crankshaft ea.) Step 4
Counter screw
torque at damper
Pulley to power- M8 x 16 (3 ea.) Tightening 23 Nm (17

steering/tandem pump torque ftlb.)
Air conditioning M10 x 100 x 90 Tightening 46 Nm (34

compressor to bracket (1 ea.) torque ftlb.)
for auxiliary units
Air conditioning M8 x 100 x 41 (2 Tightening 23 Nm (17

compressor to bracket ea.) torque ftlb.)
for auxiliary units

CAYENNE TURBO S) > TECHNICAL VALUES > GENERAL OVERVIEW
Information
The tightening steps in the tightening sequences relate to tightening screws uniformly, i.e. all
affected screws must first be tightened uniformly to the first torque value, then all screws are
tightened one stage further, and so on .
Replace all O-rings following removal!
The torques in the table below generally apply to screws that are not specifically listed =>
The bolt quality is indicated on the screw head at the top as a decimal number, e.g. "8.8" or
"12.9" .
Bolt quality 8.8 Bolt quality 10.9 Bolt quality 12.9
Thread [Nm (ftlb.)] Thread [Nm (ftlb.)] Thread [Nm (ftlb.)]
M4 3 (2) M4 4 (3) M4 5 (3.5)
M5 6 (4.5) M5 8 (6) M5 10 (7.5)
M6 10 (7.5) M6 13 (9.5) M6 16 (12)
M8 23 (17) M8 33 (24) M8 39 (29)
M10 45 (33) M10 65 (48) M10 80 (59)
M10 x 1.25 50 (37) M10 x 1.25 70 (52) M10 x 1.25 85 (63)
M12 80 (59) M12 115 (85) M12 135 (100)
M12 x 1.25 90 (67) M12 x 1.25 125 (93) M12 x 1.25 150 (111)
M12 x 1.5 85 (63) M12 x 1.5 120 (89) M12 x 1.5 145 (107)
M14 130 (96) M14 180 (133) M14 220 (163)
M16 200 (148) M16 280 (207) M16 335 (248)




CAYENNE TURBO S) > TECHNICAL VALUES > GROUP 10, CRANKCASE
1. Upper part of crankcase
2. Lid
3. Sealing ring
4. Screw plug for upper part of crankcase → Tightening torque: 30 Nm (22 ftlb.) and →
Torque angle: 60°
5. Dowel sleeve
6. Oil spray jet
7. Screw, M6 x 16 → Tightening torque: 10 Nm (7.5 ftlb.)
A. Direction of travel
Fig 1: Crankcase Screw Tightening Sequence
1. Lower part of crankcase
2. Straight pin, 6 x 18
3. Sealing ring
4. Sealant application - Doboseal 224N (999.915.573.43, status 09/08)
5. Thrust-bearing screw M11; tighten screws within 5 minutes; observe tightening sequence. →
Initial tightening: 30 Nm (22 ftlb.) → Torque angle: 90°
6. Thrust-bearing screw M10; tighten screws within 5 minutes; observe tightening sequence. →
Initial tightening: 22 Nm (16 ftlb.) → Torque angle: 60°
7. Aluminum screw , M8 x 70; (cross bolt connection); always use new aluminum screws; →
Initial tightening: 10 Nm (7.5 ftlb.) and → Final tightening: 90°
10. Dowel sleeve
Fig 2: Crankcase Lower Part Screws Tightening Sequence (V8 2WD)
1. Wipe off sealant residue after fitting
Fig 3: Applying Sealant On Engine Block Gasket
1 to 20 - Tightening sequence for M11 and M10 screws => Observe different torques!
Fig 4: Thrust-Bearing Screws Tightening Sequence

Fig 5: Crankcase Lower Part To Upper Part Screws Tightening Sequence
1. Bracket for auxiliary units/engine mounting
3. Hydraulic mount, left
4. Engine carrier
6. Dowel sleeve
7. Nut, M12 x 1.5 → Tightening torque: 75 Nm (56 ftlb.)

Fig 6: Identifying Auxiliary Units And Engine Mounting Right Bracket
1. Engine carrier, cylinders 1 to 4
3. Hydraulic mount, right
4. Engine carrier
6. Nut, M12 x 1.5 → Tightening torque: 75 Nm (56 ftlb.)
7. Bores for screws, M10 x 45
A. Installation view of engine carrier on crankcase

Fig 7: Identifying Auxiliary Units And Engine Mounting Left Bracket
1. Engine ventilation/oil mist separator
2. Molded seal
3. Molded seal
4. Screw elements, M6 → Tightening torque: 10 Nm (7.5 ftlb.)

Fig 8: Identifying Oil Mist Separator Components

1. Engine ventilation line
2. Line for oil mist separator to intake-air distributor
3. Tank ventilation
4. Aluminum holder
5. Aluminum screw (holder); see FigureTiming-case cover

Fig 9: Identifying Engine Ventilation Line, Tank Ventilation And Aluminum Holder
2. Full-throttle ventilation check valve with lines secured; one-way coupling for turbocharger
intake manifold
3. Tank ventilation
4. Aluminum holder
6. Belt tensioner
7. Holder
8. Fastening screw; see FigureBelt drive

Fig 10: Identifying Turbo Engines Ventilation
1. Ventilation pipe with sealing ring (holder to timing-case cover) → Initial tightening: 4 Nm (3
ftlb.) and → Final tightening: 90°
A. Installation view of ventilation pipe

Fig 11: Identifying Positive Crankcase Ventilation Components - Turbo Engine

1. Design cover for cylinder bank 1 to 4
3. Screw; design cover to bar ignition module → Tightening torque: 4.4 Nm (3.5 ftlb.)
4. Mounting points (rubber ball elements)

Fig 12: Identifying Engine Cover

CAYENNE TURBO S) > TECHNICAL VALUES > GROUP 13, CRANKSHAFT BELT
DRIVE
Information
Twist lock for bearing shells always on the same side.
1. Crankshaft
3. Spring, 5 x 6.5
4. Thrust washer (grooves facing out)
5. Main bearing shell, upper
6. Main bearing shell, lower
7. Shaft sealing ring => Do not touch sealing ring lip! Clean crankshaft flange and oil lightly
8. View of crankshaft flange

9. Crankshaft bearing classification (four types) Y Yellow; B Blue, R Red; N Green =>
(example: YYYYYBBBB; 5 main shaft bearings with yellow marking, 4 double (8) connecting
rod bearings with blue marking) => For numbering, see A
A. Direction of travel (main bearing 1 is the first in direction of travel against output)
Fig 1: Identifying Crankshaft Components
1. Deflection roller → Tightening torque: 32 Nm (24 ftlb.)
2. Hydraulic belt tensioner; tensioner to lever → Tightening torque: 32 Nm (24 ftlb.) ;

tensioning roller to tensioning lever → Tightening torque: 32 Nm (24 ftlb.)
3. Screw, M8 x 96; complete lever to timing-case cover and cylinder head → Tightening torque:
32 Nm (24 ftlb.) ; belt tensioner and timing-case cover to bracket → Tightening torque: 32
Nm (24 ftlb.)
4. Deflection roller → Tightening torque: 32 Nm (24 ftlb.)
5. Dual poly V-belt

Fig 2: Identifying Drive Belt Components
1. Piston-ring set; oil with engine oil; TOP marking facing upwards; oil scraper ring down; ring
gaps offset by 120°
2. Piston; different on naturally aspirated and turbo engines; combustion chamber recess facing
center of engine; left and right different; direction of travel arrow in direction of travel
3. Piston-pin circlip (positioned at 6 o'clock or 11 o'clock)
4. Piston pin; oil
5. Connecting rod
6. Connecting rod bolt; replace as it must be tightened in the plastic range; oil bolt → Tightening
torque: 8 Nm (6 ftlb.) → Tightening torque: 20 Nm (15 ftlb.) → Tightening torque: 40 Nm
(30 ftlb.) → Torque angle: 90°
7. Connecting rod bearing shells; oil with engine oil

Fig 3: Identifying Piston And Connecting Rod Components
A. View A (identification area for connecting-rod number; fit connecting rod with identification area
facing exhaust side; markings on rod and cap must be on the same side)
B. View B (fit bearing shells flush and press in by hand)
C. View C (fit bearing shells flush and press in by hand)

Fig 4: Locating Connecting-Rod Assembly

1. Marking for dimension group (just one permitted per engine, in this case x)
2. Porsche short numeric code without main or middle number
3. Short numeric code (supplier)
4. Marking area for weight group (just one permitted per engine, + or -)
5. Cylinder bank identification (V6 1-3 and 4-6) (V8 1-4 and 5-8)
6. Barcode 128 (short numeric code without main group or weight group)
7. Arrow marking in direction of travel
8. Identification for dimension group
10. Inspection stamp (supplier)

Fig 5: Identifying Piston Classification - Naturally Aspirated Engine
2. Porsche short numeric code without main or middle number
3. Short numeric code (supplier)
4. Cylinder bank identification (V8 1-4 and 5-8)
6. Barcode 128 (short numeric code without main group or weight group)

8. Marking for dimension group (just one permitted per engine, in this case x)
10. Inspection stamp (supplier)

Fig 6: Identifying Piston Classification - Turbo Engine
1. Radial shaft seal (use protection cap for radial shaft seal for fitting; only fit when crankcase is
screwed on)
2. Crankcase
3. Crankshaft
4. Radial shaft seal (sectional view)
Fig 7: Identifying Radial Shaft Seal
1. Water pump pulley
3. Vibration damper
4. Screw, M18 x 1.5 x 72; use new screw; → Tightening torque: 20 Nm (15 ftlb.) → Tightening
torque: 50 Nm (37 ftlb.) → Tightening torque: 100 Nm (74 ftlb.) → Torque angle: 180°
5. Pulley on power-steering pump
7. Tandem pump pulley

Fig 8: Identifying Crankshaft Pulleys

CAYENNE TURBO S) > TECHNICAL VALUES > GROUP 15, CYLINDER HEAD, VALVE
DRIVE
Information
The eyelets must not be inadvertently secured using aluminum screws! => Aluminum screws
would break and the suspended engine would fall down!
1. Intake valve
2. Valve-seat ring (intake)
3. Valve guide
4. Lower valve-spring plate (intake)
5. Valve stem seal
6. Set of valve springs (intake)
7. Upper valve-spring plate (intake)
8. Valve collet
9. Upper valve-spring plate (outlet)
10. Valve spring (one outlet valve spring)
11. Lower valve-spring plate (outlet)

12. Outlet valve
13. Valve-seat ring (outlet)

Fig 1: Identifying Cylinder Head Valves - Naturally Aspirated Engines
1. Intake valve
2. Valve-seat ring (intake)
3. Valve guide
4. Lower valve-spring plate (intake)
5. Valve stem seal
6. Set of valve springs (intake)
7. Upper valve-spring plate (intake)
8. Valve collet
9. Upper valve-spring plate (outlet)
10. Valve spring (two outlet valve springs for turbo engines)
11. Lower valve-spring plate (outlet)
12. Valve-seat ring (outlet)
13. Outlet valve

Fig 2: Identifying Cylinder Head Valves - Turbo Engines
1. Cylinder head 1 to 4
2. Cylinder head gasket 1 to 4
3. Screw, M8 → Tightening torque: 23 Nm (17 ftlb.)
4. Cover
5. Stopper
6. Stopper
7. Restrictor for valve-lift control → Tightening torque: 2 Nm (1.5 ftlb.)
8. Cylinder-head screws => For tightening specifications, see TIGHTENING SEQUENCE FOR
CYLINDER HEAD
9. Spark plug; when reinstalled → Tightening torque: 25 Nm (19 ftlb.) ; if fitting new spark
plugs → Tightening torque: 30 Nm (22 ftlb.)
Fig 3: Identifying Cylinder Head
2. Screw plug → Tightening torque: 5 Nm (3.5 ftlb.)
3. Spark plug; when reinstalled → Tightening torque: 25 Nm (19 ftlb.) ; if fitting new spark
plugs → Tightening torque: 30 Nm (22 ftlb.)
5. Stopper
6. Restrictor for valve-lift control → Tightening torque: 2 Nm (1.5 ftlb.)
7. Stopper
8. Cover
9. Cylinder-head screws => For tightening specifications, see TIGHTENING SEQUENCE FOR
CYLINDER HEAD
1 to 10 - 1st initial tightening → Tightening torque: 30 Nm (22 ftlb.) ; 2nd initial tightening →
Tightening torque: 50 Nm (37 ftlb.) ; loosen by 2 turns → Torque angle: 720° ; 1st turn →
Tightening torque: 30 Nm (22 ftlb.) ; 2nd turn → Tightening torque: 30 Nm (22 ftlb.) ; 3rd turn and
final tightening (torque angle) → Torque angle: 110°

1. Screw plug → Tightening torque: 5 Nm (3.5 ftlb.)
2. Threaded bolt => fit with medium-strength securing liquid. Visible length 17 mm (naturally
aspirated engine) and 26 mm (turbo engine) (when screwed into cylinder head)
3. Screw plug (instead of turbocharger oil line on naturally aspirated engine) → Tightening
4. Sealing ring
5. Sealing ring
6. Screw plug for secondary air duct → Tightening torque: 15 Nm (11 ftlb.)
7. Sealing ring
8. Screw plug → Tightening torque: 8 Nm (6 ftlb.)
9. Stopper
10. Oil bearing surfaces on camshafts with engine oil
Fig 6: Identifying Cylinders Catches
1. Stopper
2. Screw plug → Tightening torque: 8 Nm (6 ftlb.)
3. Sealing ring
4. Screw plug for secondary air duct → Tightening torque: 15 Nm (11 ftlb.)
5. Sealing ring
6. Sealing ring
7. Screw plug (instead of turbocharger oil line on naturally aspirated engine) → Tightening
8. Threaded bolt => fit with medium-strength securing liquid. Visible length 17 mm (naturally
aspirated engine) and 26 mm (turbo engine) (when screwed into cylinder head)
9. Oil bearing surfaces on camshafts with engine oil

Fig 7: Identifying Cylinders Catches
1. Valve cover for cylinders 1 to 4 (align over bar ignition modules)
2. Oil cap
3. Aluminum screw , M6 x 20; hall sender (phase sensor); always use new aluminum screws →
Initial tightening: 4 Nm (3 ftlb.) and → Final tightening: 90°
4. Hall sender
5. Sealing ring
6. Valve cover seal
7. Valve cover seal, inner
8. Seal for hydraulic valve for camshaft control

Fig 8: Identifying Valve Cover Seals (Cylinders 1 To 4)
1. Valve cover for cylinders 5 to 8 (align over bar ignition modules)
2. Hall sender
3. Aluminum screw , M6 x 20; hall sender (phase sensor); always use new aluminum screws →
Initial tightening: 4 Nm (3 ftlb.) and → Final tightening: 90°
4. Sealing ring
5. Valve cover seal
6. Valve cover seal, inner
7. Seal for hydraulic valve for camshaft control

Fig 9: Identifying Valve Cover Seals (Cylinders 5 To 8)
Fig 10: Cylinders Valve Cover Screw Tightening Sequence (1 To 4)

Fig 11: Cylinders Valve Cover Screw Tightening Sequence (1 To 4)
Fig 12: Identifying Bar Ignition Modules And Valve Cover Screws (Cylinders 1 To 4)
1. Valve cover for cylinder bank 1 to 4 (align over bar ignition modules)
2. Bar ignition module
3. Aluminum screw , M6 x 20; bar ignition module; always use new aluminum screws; → Initial
tightening: 4 Nm (3 ftlb.) and → Final tightening: 90°
4. Aluminum screw , M6 x 30; always use new aluminum screws; → Initial tightening: 4 Nm
(3 ftlb.) and → Final tightening: 90°
5. Cap
6. Steel screw to eyelet → Tightening torque: 23 Nm (17 ftlb.)
7. Eyelet
8. Aluminum screw , M8 x 35 (on torque support); always use new aluminum screws; → Initial
tightening: 10 Nm (7.5 ftlb.) and → Final tightening: 90° Steel screw to eyelet.
Fig 13: Identifying Bar Ignition Modules And Valve Cover Screws (Cylinder Bank 5 To 8)
1. Valve cover for cylinder bank 5 to 8 (align over bar ignition modules)
2. Eyelet
3. Steel screw to eyelet → Tightening torque: 23 Nm (17 ftlb.)
5. Bar ignition module
6. Aluminum screw , M6 x 20; bar ignition module; always use new aluminum screws; → Initial
tightening: 4 Nm (3 ftlb.) and → Final tightening: 90°
7. Sheetmetal holder
8. Cap
1. Camshaft (outlet)
2. Camshaft (intake)
3. Hydraulic valve for variable valve-lift control
5. Switching tappet (oil with engine oil)
6. Flat-base tappet (oil with engine oil)
7. Stopper
8. Mounting saddle 1 to 4
9. Stopper
10. Bearing locations (oil with engine oil)
Fig 14: Identifying Camshafts (Cylinder Bank 1 To 4)
2. Housing
3. Dowel sleeve
4. Housing (intake)
5. Housing (outlet)
7. Bearing surfaces (oil with engine oil)
Fig 15: Identifying Camshaft Mount (Cylinder Bank 1 To 4)
2. Flat-base tappet (oil with engine oil)
7. Stopper
8. Mounting saddle, cylinders 5 to 8
9. Stopper
Fig 16: Identifying Camshafts (Cylinders 5 To 8)
1. Dowel sleeves
2. Housing (intake)
4. Housing
6. Housing (outlet)
Fig 17: Identifying Camshaft Mount (Cylinders 5 To 8)
Fig 18: Identifying Camshaft Housing And Screws
1. Screw, M12 Tighten fully after setting timing .; new screw must be used; Initial tightening,
Step 1 → Tightening torque: 10 Nm (7.5 ftlb.) ; Initial tightening, Step 2 → Tightening
torque: 30 Nm (22 ftlb.) ; Initial tightening, Step 3 (torque angle) → Torque angle: 100° ;
Loosening process, Step 1 → Torque angle: 90° ; Loosening process, Step 2 → Torque
angle: 360° ; Final tightening, Step 1 → Tightening torque: 30 Nm (22 ftlb.) ; Final
tightening, Step 2 (torque angle) → Torque angle: 135°
2. Camshaft controller with integrated hexagon for countering
3. Hydraulic valve for camshaft control
A. Cylinders 1 to 4
B. Cylinders 5 to 8
Fig 19: V8 Turbo Engine Identification
1. Outlet camshaft identification (green)
2. Intake camshaft identification (blue)
3. Intake camshaft identification (blue)
A. Cylinders 1 to 4
B. Cylinders 5 to 8
Fig 20: V8 Naturally Aspirated Engine Camshaft Identification
2. Intake camshaft identification (white)

Fig 21: Camshaft Housing Identification
All markings can be read from the exhaust side/main diagram applies symmetrically for
both cylinder heads
1. Matching number for cylinder head/intake camshaft housing, cylinder 1 (E1)
5. Matching number for cylinder head/outlet camshaft housing, cylinder 1 (A1)
arrow - Direction of travel
1. Double-chain camshaft drive
2. Camshaft sprocket with integrated hexagon for countering
3. Screw, M12 Tighten fully after setting timing .; screw must be replaced; 1st turn →
Tightening torque: 10 Nm (7.5 ftlb.) ; 2nd turn → Tightening torque: 50 Nm (37 ftlb.) ;
final tightening (torque angle) → Torque angle: 90°
4. Deflector rail
6. Camshaft-to-camshaft guide pad
Fig 22: Identifying Timing Chain And Sprockets
1. Crankshaft sprocket
2. Friction plates/diamond washers; reusable
3. Oil pump drive chain
4. Drive in spring wedge with a plastic hammer
5. Oil pump
Fig 23: Identifying Oil Pump Chain Drive
1. Threaded peg → Tightening torque: 35 Nm (26 ftlb.)
2. Threaded peg → Tightening torque: 20 Nm (15 ftlb.)
3. Guide rail
4. Tensioning rail
5. Chain tensioner with sealing ring; always use new sealing ring → Tightening torque: 60 Nm
(44 ftlb.)
6. Pin (for locking the oil-pump tensioning rail)
Fig 24: Identifying Timing Chain And Chain Guide
1. Timing-case cover
2. Timing-case cover seal, outer right (fill openings with sealant, see 6)
3. Timing-case cover seal, inner
4. Timing-case cover seal, rib
5. Timing-case cover seal, outer left (fill openings with sealant, see 6)
6. Sealant application on timing chain housing; Loctite 5900 (000.043.204.35 status 10/08)
Fig 25: Identifying Timing-Case Cover Seals
1. When timing-case cover is fitted, apply sealant to joint before fitting valve covers
2. When timing-case cover is fitted, apply sealant to joint before fitting valve covers
Fig 26: Identifying Engine Sealant Applying Area
1. When timing-case cover is fitted, apply sealant to joint before fitting valve covers 20 mm -
Length of sealant applied to joint
Fig 27: Identifying Valve Cover Sealant Applying Area
A. Aluminum screw , M6 x 30; timing-case cover to crankcase and cylinder head; always use
new aluminum screws; → Initial tightening: 4 Nm (3 ftlb.) and → Final tightening: 90°
B. Aluminum screw M6 x 55; inner timing-case cover to upper part of crankcase and cylinder
head; always use new aluminum screws; → Initial tightening: 4 Nm (3 ftlb.) and → Final
tightening: 90° ; Outer timing-case cover to cylinder head → Initial tightening: 4 Nm (3
C. Aluminum screw , M8 x 55; timing-case cover (location of chain tensioner) to upper part of
crankcase and cylinder head; always use new aluminum screws; → Initial tightening: 10 Nm
(7.5 ftlb.) and → Final tightening: 90°
D. The timing-case cover must be level with the lower part of the crankcase (use steel rule or dial
gauge)
Fig 28: Timing-Case Cover Screws Tightening Sequence
1. Joint flange (oil sealing lip with engine oil); align with sleeve or vibration balancer
4. Sealing ring; always replace
5. Chain tensioner → Tightening torque: 60 Nm (44 ftlb.)

Fig 29: Identifying Chain Tensioner

CAYENNE TURBO S) > TECHNICAL VALUES > GROUP 17, LUBRICATION
1. Oil guide housing
2. Oil-filter cover → Tightening torque: 25 Nm (19 ftlb.)
3. Oil filter
4. Oil-filter sealing ring
5. Oil duct adapter (cannot be replaced)
6. Heat exchanger seal
7. Oil-water heat exchanger
8. Screw, M6 x 20; self-tapping screws ex-works; metric screws can also be used → Tightening
Fig 1: Identifying Oil/Water Heat Exchanger Components
1. Sealant application (geometry, 1-mm bead of sealant)
Fig 2: Applying Sealant To Oil Guide Housing

2. Sealing flange
3. Sealing ring
4. Oil guide housing to lower part of crankcase Aluminum screw ; always use new aluminum
screws → Initial tightening: 4 Nm (3 ftlb.) and → Final tightening: 90°
5. Oil level sensor
6. Oil level sensor to oil guide housing (steel screw) → Tightening torque: 10 Nm (7.5 ftlb.) ;
Fig 3: Identifying Oil Guide Housing With Accessories
7. Timing-case cover to oil guide housing Aluminum screw ; always use new aluminum screws
→ Initial tightening: 4 Nm (3 ftlb.) and → Final tightening: 90°
1. Oil-pressure sensor adapter
2. Sealing ring
3. Oil-pressure sender with temperature sensor
5. Stopper → Tightening torque: 15 Nm (11 ftlb.)
6. Sealing ring
Fig 4: Identifying Oil Pressure Sensor Adapter And Sealing Ring
1. Oil extraction line for turbocharger, cylinders 1 to 4
3. Intake manifold on oil pump
4. O-ring
5. Oil pressure pipe
6. O-ring
7. O-ring, 22 x 3
8. Oil control line
9. O-ring
10. O-ring
11. Screw, M6 x 16; oil pressure pipe to oil pump and oil guide housing → Tightening torque: 12
Nm (9 ftlb.) ; oil regulating line to oil pump and oil guide housing → Tightening torque: 12
Nm (9 ftlb.) ; turbocharger extraction line to oil pump → Tightening torque: 12 Nm (9 ftlb.)
Fig 5: Identifying Oil Lines, O-Ring And Oil Pressure Pipe - Turbo Engine
A. For arrangement of oil lines.
B. Direction of travel
1. Oil pump intake manifold
2. O-ring
4. O-ring
5. O-ring
6. Oil regulating line
7. O-ring
8. O-ring
9. Screw, M6 x 16; oil pressure pipe to oil pump and oil guide housing → Tightening torque: 12
Nm (9 ftlb.) ; oil regulating line to oil pump and oil guide housing → Tightening torque: 12
Nm (9 ftlb.)

Fig 6: Identifying Oil Lines, O-Ring And Oil Pressure Pipe - Naturally Aspirated Engine
1. Mount for oil extraction line for turbocharger, cylinders 1 to 4
2. Mount for oil extraction line for turbocharger, cylinders 5 to 8
3. Mount for oil separator vent line, cylinders 5 to 8
4. Mount for oil pump intake manifold
6 - Mount for oil pressure pipe
9 - Mount for oil regulating line
Fig 7: Identifying Oil Lines, Turbo Engine Intake Manifold
1. Mount for oil pump intake manifold
2. Mount for oil separator vent line, cylinders 5 to 8
3. Mount for oil pressure pipe
4. Mount for oil regulating line

Fig 8: Identifying Oil Lines, Naturally Aspirated Engine Intake Manifold

1. Oil pan with reusable seal inserted
2. Sealing ring
3. Oil drain plug, M18 x 1.5 → Tightening torque: 50 Nm (37 ftlb.)
Fig 9: Identifying Oil Pan Screws
1. Oil guide (oil plate)
2. Oil return seal
4. Bulkhead seal
5. Joining socket
6. O-ring
7. Assembly depth until locking lug engages
Fig 10: Identifying Oil Guide And Seal (Oil Plate)
1. Oil pump with extraction stage
2. Screw, M8 x 22; replace; 1st turn → Initial tightening: 20 Nm (15 ftlb.) ; final tightening
(torque angle) → Torque angle: 90°
4. Cap screw, M36 x 1.5 x 12 → Tightening torque: 40 Nm (30 ftlb.)
5. Solenoid valve
6. O-ring (grease before fitting)
7. Dowel sleeve
9. Sprocket cover
11. Drive chain
12. Connection for intake manifold joining socket
Fig 11: Identifying Oil Pump, O-Ring And Screws
1. Oil pump
2. Screw, M8 x 22; replace; 1st turn → Initial tightening: 20 Nm (15 ftlb.) ; final tightening
(torque angle) → Torque angle: 90°
4. Cap screw, M36 x 1.5 x 12 → Tightening torque: 40 Nm (30 ftlb.)
5. Solenoid valve
7. Dowel sleeve
9. Sprocket cover
11. Drive chain

Fig 12: Identifying Oil Pump On Naturally Aspirated Engine

CAYENNE TURBO S) > TECHNICAL VALUES > GROUP 19, COOLING
1. Coolant pump
2. Seal; fitted in pump
3. Screw, M6 x 25 => For details of tightening sequence, see below → Tightening torque: 12
Nm (9 ftlb.)
Fig 1: Identifying Coolant Pump Seal
Fig 2: Coolant Pump Screw Tightening Sequence
1. Heating coolant pipe

3. Sealing ring
4. Screw plug, M16 x 1.5 → Tightening torque: 30 Nm (22 ftlb.)
6. Coolant guide tube (collection pipe)
7. Sheetmetal seal
8. Stopper
Fig 3: Identifying Coolant Pipe, Screw, Sealing Ring And Guide
3. Screw, M6 x 25; screwed to fuel high-pressure distributor pipe => see relevant section
4. Seal for thermostat housing; replace
5. Thermostat insert; including electric heating element

Fig 4: Identifying Thermostat Housing And Coolant Regulator
Fig 5: Thermostat Housing Screws Tightening Sequence
1. Connection piece on generator
2. Screw for connection piece → Tightening torque: 10 Nm (7.5 ftlb.)

4. Coolant return line
5. Coolant return hose assembly
6. Holder
7. Screw, M6 Aluminum screw ; always use new aluminum screws → Initial tightening: 4 Nm
8. Clip
Fig 6: Identifying Coolant Return Line - Turbo Engine
6. Holder
7. Screw, M6 Aluminum screw ; always use new aluminum screws → Initial tightening: 4 Nm
8. Clip
Fig 7: Identifying Coolant Return Line - Naturally Aspirated Engine
1. Screw, M6; coolant line to collection pipe → Tightening torque: 10 Nm (7.5 ftlb.)
2. Coolant pipe
5. Coolant supply hose for oil/coolant heat exchanger
6. Coolant supply hose to generator

Fig 8: Identifying Coolant Supply Line - Turbo Engine
1. Screw, M6; coolant line to collection pipe → Tightening torque: 10 Nm (7.5 ftlb.)
2. Coolant pipe

Fig 9: Identifying Coolant Supply Line - Naturally Aspirated Engine
1. Vent line

Fig 10: Identifying Ventilation Line And Screws

CAYENNE TURBO S) > TECHNICAL VALUES > GROUP 21, TURBOCHARGING
Information
Tighten screw-type clamps for securing pressure and intake pipes and pressure and suction hoses to
charge-air cooler and turbocharger to → Tightening torque: 5.5 Nm (4 ftlb.) .
1. Coolant return line for turbocharger, cylinders 1 to 4
2. Coolant supply line for turbocharger, cylinders 1 to 4
3. Coolant supply hose for turbocharger, cylinders 1 to 4
5. Clip
6. Hexagon nut, M6 → Tightening torque: 8.5 Nm (6 ftlb.)
7. Banjo bolt, M12 x 1.25; coolant supply line to turbocharger → Tightening torque: 30 Nm (22
ftlb.) ; coolant return line to turbocharger → Tightening torque: 30 Nm (22 ftlb.)
8. Connection for coolant supply hose for turbocharger, cylinders 1 to 4
9. Connection for coolant return hose for turbocharger, cylinders 1 to 4
Fig 1: Identifying Coolant Return Line For Turbocharger
1. Coolant supply line for turbocharger, cylinders 5 to 8
2. Hexagon nut, M6 → Tightening torque: 8.5 Nm (6 ftlb.)
3. Clip
4. Coolant return line for turbocharger, cylinders 5 to 8
5. Banjo bolt, M12 x 1.25; coolant supply line to turbocharger → Tightening torque: 30 Nm (22
ftlb.) ; coolant return line to turbocharger → Tightening torque: 30 Nm (22 ftlb.)
6. Collection pipe connection → Tightening torque: 35 Nm (26 ftlb.)
7. Connection for coolant supply hose for turbocharger, cylinders 5 to 8
8. Turbocharger, cylinders 5 to 8
Fig 2: Identifying Coolant Return Line For Turbocharger
1. Turbocharger vent line for cylinders 1 to 4; vent line to turbocharger oil extraction line →
Tightening torque: 35 Nm (26 ftlb.) ; holding clamp on vent line to collection pipe, M6 screw
→ Tightening torque: 10 Nm (7.5 ftlb.) ; holding clamp on vent line to collection pipe, M6 nut
→ Tightening torque: 6.5 Nm (5 ftlb.)
2. Turbocharger oil feed line for cylinders 1 to 4; turbocharger oil feed line to connection piece →
Tightening torque: 40 Nm (30 ftlb.) ; turbocharger oil feed line to cylinder head →
Tightening torque: 35 Nm (26 ftlb.)
3. Connection piece → Tightening torque: 45 Nm (33 ftlb.)
4. Sealing ring
5. Oil extraction line
8. Seal for turbocharger, cylinders 1 to 4

Fig 3: Identifying Turbocharger Vent Line For Cylinders (1-4)
1. Oil feed line for turbocharger, cylinders 5 to 8
2. Nut, M6 → Tightening torque: 6.5 Nm (5 ftlb.)
3. Holding clamp
4. Vent line on turbocharger for cylinders 5 to 8 → Tightening torque: 10 Nm (7.5 ftlb.)
5. Holding clamp
6. Screw, M6 x 12; turbocharger oil feed line holder to lower part of crankcase → Tightening
torque: 10 Nm (7.5 ftlb.) ; holding clamp for oil feed line to holder → Tightening torque: 10
Nm (7.5 ftlb.)
10. Sealing ring
11. Connection piece → Tightening torque: 45 Nm (33 ftlb.)
12. Clip
13. Holder for oil feed line

Fig 4: Identifying Turbocharger Vent Line For Cylinders (5-8)
4 - Turbocharger bracket (no longer used)
6 - Stud
Fig 5: Identifying Turbocharger (Cylinders 1 To 4)

2. Turbocharger bracket (no longer used)
6 - Stud
Fig 6: Identifying Turbocharger (Cylinders 5 To 8)
1. Pressure line, boost pressure line
2. Hose clamp
3. Cycle valve
4. Combination holder
5. Holder to timing-case cover → Initial tightening: 4 Nm (3 ftlb.) and → Final tightening: 90°
6. Control line
7. Control line
8. Hose holder
Fig 7: Identifying Boost Pressure, Wastegate And Hose Clamp
1. Pressure line
2. Vacuum line
3. Hose clamp
5. Holder
6. Rubber element
7. Electric change-over valve
8. Control line
A. View A; connection of pressure line to intake-air distributor

Fig 8: Identifying Boost Pressure And Wastegate 2

CAYENNE TURBO S) > TECHNICAL VALUES > GROUP 24, FUEL SYSTEM
1. Fuel distributor pipe (fuel gallery)
2. Stopper; in 3 turns (tighten, loosen, tighten) → Tightening torque: 25 Nm (19 ftlb.)
3. High-pressure sensor → Tightening torque: 20 Nm (15 ftlb.)

Fig 1: Identifying Fuel Distributor Pipe
1. Holder
3. Injector (high-pressure fuel injector)

Fig 2: Identifying Injectors (High-Pressure Fuel Injectors)

3. High-pressure line connection
4. Connection to injector (high-pressure fuel injector); in 3 turns (tighten, loosen, tighten) →

Fig 3: Identifying Fuel Distributor Pipe Mount
1. High-pressure pump
2. High-pressure line; (3 turns: tighten, loosen, tighten) → Tightening torque: 25 Nm (19 ftlb.)
3. Low-pressure line; (3 turns: tighten, loosen, tighten) → Tightening torque: 25 Nm (19 ftlb.)
4. Screw socket, M8 → Tightening torque: 23 Nm (17 ftlb.)
5. Screw socket, M6 → Tightening torque: 10 Nm (7.5 ftlb.)
6. Protective plate
A. Required line distance (5 to 8 mm) between high-pressure line and low-pressure line
Fig 4: Identifying High-Pressure Pump On Turbo Engine, 6-Piston Pump
Temperature sensor; not shown, to low-pressure line → Tightening torque: 20 Nm (15 ftlb.)
1. High-pressure pump
2. High-pressure line; (3 turns: tighten, loosen, tighten) → Tightening torque: 25 Nm (19 ftlb.)
3. Low-pressure line; (3 turns: tighten, loosen, tighten) → Tightening torque: 25 Nm (19 ftlb.)
4. Screw socket, M8 → Tightening torque: 23 Nm (17 ftlb.)
5. Screw socket, M6 → Tightening torque: 10 Nm (7.5 ftlb.)
6. Protective plate
A. Required line distance (5 to 8 mm) between high-pressure line and low-pressure line
Fig 5: Identifying High-Pressure Pump On Naturally Aspirated Engine, 3-Piston Pump
Temperature sensor; not shown, to low-pressure line → Tightening torque: 20 Nm (15 ftlb.)
Fig 6: Intake Module Screws Tightening Sequence
1. Intake module
2. Decoupling module (fastening part); observe tightening sequence → Tightening torque: 15
Nm (11 ftlb.)
3. Screw, 5 x 16 → Tightening torque: 4 Nm (3 ftlb.) and → Tightening torque: 4 Nm (3 ftlb.)
4. Pressure sensor
5. Intake module seal; check that seal is aligned and fitted correctly!
6. Heat socket
7. Screw, 6 x 50 → Tightening torque: 7 Nm (5 ftlb.)
8. Electronic accelerator
9. Seal
10. Ball socket
Fig 7: Identifying Intake Module Components - Naturally Aspirated Engine
1. Pipe
2. Connecting piece
3. Variable intake manifold adjuster/adjusting unit
4. Lip seal
5. Connecting element
6. Vacuum unit with cover (actuator)

8. Driver
9. Connecting rod
10. Vacuum line
Fig 8: Identifying Variable Intake Manifold Components - Naturally Aspirated Engine
1. Intake module
2. Decoupling module (fastening part); observe tightening sequence → Tightening torque: 15

Nm (11 ftlb.)
3. Screw, 5 x 16 → Tightening torque: 4 Nm (3 ftlb.) and → Tightening torque: 4 Nm (3 ftlb.)
4. Pressure sensor
5. Intake module seal; check that seal is aligned and fitted correctly!
6. Heat socket
7. Screw, 6 x 50 → Tightening torque: 7 Nm (5 ftlb.)
9. Seal
10. Ball socket

Fig 9: Identifying Intake Air Module Components - Turbo Engine

CAYENNE TURBO S) > TECHNICAL VALUES > GROUP 26, EXHAUST SYSTEM
1. Exhaust manifold
2. Exhaust manifold seal
3. Exhaust turbocharger seal
4. Screw, M8 x 75 → Initial tightening: 23 Nm (17 ftlb.) → Final tightening: 30 Nm (22 ftlb.)
5. Hexagon nut, M8; (check nuts by clicking once); observe tightening sequence → Tightening
torque: 33 Nm (24 ftlb.) (check nuts by clicking once)
A. Marking on seal visible from outside

Fig 1: Exhaust Manifold Screws Tightening Sequence - Naturally Aspirated Engine
Fig 2: Exhaust Manifold Screws Tightening Sequence - Turbo Engine

Fig 3: Locating Exhaust Manifold Seal - Turbo Engine, Cylinders 1 To 4
1. Exhaust manifold
2. Hexagon nut, M8; (check nuts by clicking once); observe tightening sequence → Tightening
torque: 33 Nm (24 ftlb.) (check nuts by clicking once)
3. Screw, M8 x 75 → Initial tightening: 23 Nm (17 ftlb.) → Final tightening: 30 Nm (22 ftlb.)
4. Exhaust turbocharger seal

Fig 4: Locating Exhaust Manifold Seal - Turbo Engine, Cylinders 5 To 8
1. Exhaust manifold
3. Hexagon nut, M8; (check nuts by clicking once); observe correct tightening sequence →
Tightening torque: 33 Nm (24 ftlb.) (check nuts by clicking once)
4. Oxygen sensor → Tightening torque: 45 Nm (33 ftlb.)+/-5 Nm (+/-3.5 ftlb.)

Fig 5: Locating Exhaust Manifold Seal - Naturally Aspirated Engine, Cylinders 1 To 4
1. Exhaust manifold
2. Seal
3. Hexagon nut, M8; (check nuts by clicking once); observe correct tightening sequence →
Tightening torque: 33 Nm (24 ftlb.) (check nuts by clicking once)
4. Oxygen sensor → Tightening torque: 45 Nm (33 ftlb.)+/-5 Nm (+/-3.5 ftlb.)

Fig 6: Locating Exhaust Manifold Seal - Naturally Aspirated Engine, Cylinders 5 To 8

CAYENNE TURBO S) > TECHNICAL VALUES > GROUP 27/97, ENGINE ELECTRICS
1. Temperature sensor for engine compartment (installation position of cylinder 8)
2. Rubber sleeve
3. Temperature sensor (installation position of cylinder 4) → Tightening torque: 30 Nm (22

ftlb.)
Fig 1: Identifying Engine Temperature Sensor
2. Aluminum screw, M6 (wire harness to valve cover and eyelet) → Initial tightening: 4 Nm (3
Fig 2: Identifying Engine Wire Harness Screws (Inner V And Valve Cover)

2. Aluminum screw, M6 (wire harness to timing-case cover) → Initial tightening: 4 Nm (3 ftlb.)
and → Final tightening: 90°
Fig 3: Identifying Engine Wire Harness For Timing Case (Valve Cover And Sides)
1. Bar ignition module, cylinder 1
5. Injector, cylinder 5

17. Camshaft controller
18. Camshaft controller
21. Engine ground
22. Engine ground
23. Engine ground
24. Engine ground
25. Speed sensor
26. Hall sender (phase sensor)
28. Knock sensor
29. Knock sensor
30. Knock sensor
31. Knock sensor
32. Tank vent
33. Generator
34. Crankcase heating
35. Flow control valve
36. Oil pressure regulating valve
37. Water temperature sensor
39. Oil level sensor
40. Oil-pressure sender with oil temperature sensor
41. Electronic accelerator (throttle adjuster)
42. High-pressure sensor
43. Starter, terminal 50

46. Generator, B+
47. Transfer point on vehicle, B+
48. Intake manifold switch-over valve
49. Vehicle/engine connection point
51. DME (DFI) control unit
52. Secondary-air pump
53. Pressure sensor load detection
54. Engine compartment temperature sensor
55. Map-controlled thermostat (electrically heated coolant regulator)

Fig 4: Identifying Bar Ignition Module - Naturally Aspirated Engine

17. Camshaft adjuster
18. Camshaft adjuster
21. Engine ground
22. Engine ground
23. Engine ground
24. Engine ground
25. Speed sensor
28. Knock sensor
29. Knock sensor
30. Knock sensor
31. Knock sensor
32. Tank vent
33. Generator
34. Crankcase heating

35. Flow control valve
36. Oil pressure regulating valve
37. Water temperature sensor
39. Oil level sensor
40. Oil-pressure sender with oil temperature sensor
41. Electronic accelerator (throttle adjuster)
42. High-pressure sensor
46. Generator, B+
47. Transfer point on vehicle, B+
48. Intake manifold switch-over valve
51. DME (DFI) control unit
52. Secondary-air pump
53. Ambient air valve
54. Pressure sensor load detection
55. Engine compartment temperature sensor
56. Boost pressure valve
58. Map-controlled thermostat (electrically heated coolant regulator)

Fig 5: Identifying Bar Ignition Module - Turbo Engines
1. Nut, M8 → Tightening torque: 18 Nm (13 ftlb.)
2. Nut, M6 → Tightening torque: 6.5 Nm (5 ftlb.)
3. Cover; optionally installed ex-works, if cover is not fitted, the battery must be secured with a
clamp
Fig 6: Identifying Wire Harness For Starter
1. Cap nut, M8 → Tightening torque: 23 Nm (17 ftlb.)

Fig 7: Identifying Generator Wire Harness
1. Generator

A. View
Fig 8: Installing Generator
1. Starter; Start Stop starter is larger

Group 28
1. Knock sensor
Fig 10: Identifying Knock Sensors Screws
Group 47
1. Vacuum pump
3. Sealing ring
4. Sealing ring
Fig 11: Identifying Vacuum Pump Sealing Ring And Screws
Group 48
1. Air conditioning compressor
2. Screw, M10 x 100
3. Screw, M8 x 10
4. Holder
5. Screw, M8 x 20; tandem pump to bracket for auxiliary units → Tightening torque: 23 Nm (17
ftlb.) ; power-steering pump to bracket for auxiliary units → Tightening torque: 23 Nm (17
ftlb.)
6. Tandem pump
7. Screw, M8 x 35; power-steering pump to adapter bracket → Tightening torque: 23 Nm (17

ftlb.) ; tandem pump/adapter bracket to bracket for auxiliary units → Tightening torque: 23
Nm (17 ftlb.)
8. Power-steering pump
9. Aluminum screw , M8; always use new aluminum screws → Initial tightening: 10 Nm (7.5
10. Support bracket is made of magnesium
11. Dowel sleeve

Fig 12: Identifying Auxiliary Units
3. Vibration damper
4. Screw, M18 x 1.5 x 72; use new screw; → Tightening torque: 20 Nm (15 ftlb.) → Tightening
torque: 50 Nm (37 ftlb.) → Tightening torque: 100 Nm (74 ftlb.) → Torque angle: 180°
5. Pulley on power-steering pump

Fig 13: Identifying Water Pump Pulley And Screws
Group 87
1. Air conditioning compressor
4. Holder
5. Screw, M8 x 20
6. Tandem pump
7. Screw, M8 x 35
8. Power-steering pump
9. Screw, M8 x 35
10. Support bracket is made of magnesium
11. Dowel sleeve

Fig 14: Identifying Auxiliary Units Screws
WM 1001IN TOOLS AND WORKSHOP EQUIPMENT FOR ENGINE (CAYENNE TIP,

CAYENNE MAN, CAYENNE S, CAYENNE TURBO, CAYENNE GTS, CAYENNE S
HYBRID, CAYENNE TURBO S, CAYENNE DIESEL, CAYENNE S DIESEL) > TOOLS
AND MATERIALS
equipped with a locking screw to prevent engine from tilting and for height adjustment. Item 2
in base carrier
2. Wheel hub holder => Secures the spring struts to prevent them from tilting. Inserted from
the front; equipped with a locking screw to prevent engine from tilting and for height
carrier
7. Assembly mandrel => Guide for positioning the elevating platform into the body; first moves
into a bore in the body for centering roughly. Item 4 in base carrier
carrier
Fig 1: Identifying Engine Tools And Workshop Equipment
1. Wheel hub holder => Secures the spring struts to prevent them from tilting.
2. Support => Prevents the engine from tilting backwards. Not generally used.
in the engine carrier; equipped with a locking screw to prevent engine from tilting and for height
adjustment.
Item 2 in base carrier
2. 3.2 - Protection against tilting => Screwed into part 3.1. Prevents the engine from
tilting forward.
front-axle carrier at the front; equipped with a locking screw to prevent engine from tilting and

Fig 2: Identifying Engine Tools
Information
1206 !

AND MATERIALS > OLD VERSION WITHOUT SUPPLEMENTARY SET
2, 5 and 8 - Not used for removing engine!
Information
1206 !

AND MATERIALS > NEW VERSION WITH SUPPLEMENTARY SET
1. Mounting mandrel for front front-axle carrier
2. Mounting mandrel for engine carrier
3. Mounting mandrel for rear front-axle carrier
4. Mounting mandrel for centering in the body.
1. Cayenne Diesel/Hybrid
2. Cayenne/S/GTS/Turbo/Turbo S
1. Cayenne S Diesel
7. Bracket for wheel carrier

8. Mounting for lower wishbone
9. Supplementary set
arrows - Nuts and screws
1. Convert engine/transmission mounting.
1. 1.1. Unscrew nuts - arrows - .
2. 1.2. Remove nuts and screws.
3. 1.3. Remove old cross member and replace it with new cross member -9- .
4. 1.4. Screw in and tighten screws and nuts.
WM 1001Z1 DISASSEMBLING ENGINE (CAYENNE S, CAYENNE TURBO, CAYENNE

GTS, CAYENNE TURBO S) > TOOLS

holding bridge Special tool 9677/1
brace Special tool 9679/1

GTS, CAYENNE TURBO S) > PRELIMINARY WORK
1. Remove the engine. → Removing Engine 100119 REMOVING AND INSTALLING ENGINE
2. Remove engine from transmission. → Removing Engine From Transmission 100127

TRANSMISSION

SUPPORT
4. Drain engine oil. For details, see → 170117 CHANGING ENGINE OIL AND OIL FILTER

GTS, CAYENNE TURBO S) > DISASSEMBLING ENGINE
NOTE: Interchanged or dirty bucket tappets
Scoring on cylinder head
→ Since the bucket tappets have been run in the fitting bores, do not interchange them.
→ Absolute cleanliness is essential.
Information
Have a collection pan and some cloths ready before starting work on the engine block. Close off open
hoses immediately after opening them using suitable stoppers. Residual fluid can leak out.
Information
For many components, it is only necessary to partially disassemble the engine. The extent of
disassembly depends on the damage and scope of repairs to be carried out.
When replacing the cylinder head gasket, many components, such as the vacuum pump, injectors and
exhaust manifolds, remain on the cylinder head. In this case, the cylinder head can be lifted from the
crankcase with all components intact.
1. Remove drive belt. → 137819 REMOVING AND INSTALLING DRIVE BELT
2. Remove power-steering pump and air conditioning compressor if necessary.
3. Remove spark plugs. → 287020 REMOVING AND FITTING SPARK PLUGS
4. Remove tank vent line -3- and engine ventilation lines -1 and 2- .
2. Oil mist separator line to intake-air distributor
3. Tank ventilation
4. Aluminum holder
5. Aluminum screw (holder); see Fig 35Timing-case cover

Fig 1: Identifying Engine Ventilation Line - Naturally Aspirated Engines
5. Remove oil mist separator. → 105519 REMOVING AND INSTALLING OIL MIST SEPARATOR
6. Remove intake-air distributor. → 244619 REMOVING AND INSTALLING INTAKE-AIR

DISTRIBUTOR
7. Remove fuel distribution pipe. → 243019 REMOVING AND INSTALLING FUEL
DISTRIBUTION PIPE
8. Remove high-pressure pump at cylinder 8. → 246319 REMOVING AND INSTALLING

HIGH-PRESSURE PUMP
9. Remove vacuum pump at cylinder 4. To do this, loosen the three screws. → Vacuum pump
10. Detach and remove the coolant hose assembly -5- . Remove coolant pipe -4- .
2. Connection piece screw
3. Screw, M6 x 20
6. Holder
7. M6 screw
8. Clip
11. Remove water pump. → 195019 REMOVING AND INSTALLING COOLANT PUMP
Fig 4: Identifying Coolant Pump Screws
12. Remove vent line.
2. 12.2. Unclip vent line -2- from the cable duct and remove it -arrow- .
Fig 5: Removing Vent Line
13. Remove heat protection panels on both sides.

Fig 6: Locating Heat Protection Panels - V8 Naturally Aspirated Engine
14. Remove the generator. Expose the peripheral equipment and unscrew the generator.
1. 14.1. Remove support bracket (crash support) -10- from the generator (two screws)
-9- .
Fig 7: Identifying Engine Auxiliary Units Components
2. 14.2. Remove fastening screws on the generator -2 and 3- .

Fig 8: Identifying Generator Screws
3. 14.3. Carefully remove generator and disconnect B+ cable. To do this, remove nut on
the rear of the generator.
15. Remove high-pressure line -2- from the cylinder head. To do this, remove union nut -4- .
Fig 9: Identifying High-Pressure Pump Components - Naturally Aspirated Engine
16. Disconnect the cable plug at the coolant regulator (thermostat insert) using pointed-nose
pliers. Remove engine wire harness. For details, see → 975219 REMOVING AND
INSTALLING WIRE HARNESS FOR ENGINE
1. 16.1. Unscrew fastening screws.
2. 16.2. Lift engine wire harness up and out -arrow-

Fig 10: Loosening Engine Wire Harness
17. Disconnect coolant pipe -1- at the collection pipe -6- . To do this, remove the screws -2- .
Fig 11: Identifying Coolant Guide Screws
1. 2 - M6 screw
2. 3 - Sealing ring
3. 4 - Screw plug, M16 x 1.5
4. 5 - M6 screw
5. 6 - Coolant guide tube (collection pipe)
6. 7 - Metal seal
7. 8 - Stopper
18. Remove thermostat housing.
1. 18.1. Pull out thermostat insert (coolant regulator) -5- . Pull out thermostat insert
(coolant regulator) using a solid electric cable. For a detailed description of how to
remove the thermostat insert, see → 195819 REMOVING AND INSTALLING
COOLANT REGULATOR .
2. 18.2. Detach thermostat housing and remove with the coolant pipe fitted.
2. Screw, M6 x 25
3. Screw, M6 x 25; screwed to fuel high-pressure distribution pipe.

Fig 12: Identifying Thermostat Housing And Coolant Regulator Screws
19. Remove metal pipe for coolant supply -2- . Remove coolant hoses and metal pipe -5 and 6- .
1. M6 screw; securing coolant line to collection pipe
2. Coolant pipe

20. Remove starter -1- . To do this, remove the screws -2- .

21. Remove exhaust manifold on both sides. To do this, expose cable for oxygen sensor (lambda
sensor).
Fig 15: Locating Exhaust Manifold Seal-Naturally Aspirated Engine (Cylinders 1 To 4)
22. Remove engine carrier with engine mountings on both sides. Then remove the brackets for the
auxiliary units. → Left bracket for auxiliary units and engine mounting → Right bracket for
auxiliary units and engine mounting

Fig 17: Removing Auxiliary Units And Engine Mounting Right Bracket
23. Remove belt tensioner and deflection rollers. To do this, carefully lever off the covers on the
rollers and unscrew the components. -1, 2, 3, 4-
Fig 18: Identifying Engine Drive Belt
24. Unscrew oil pressure sensor -3- with adapter -1- from the crankcase. To do this, remove the
screws -4- .
Fig 19: Identifying Oil Pressure Sensor, Adapter And Screws
25. Remove both cylinder head covers (valve covers). → Bar ignition modules and valve covers,
cylinder row 1 to 4 → Bar ignition modules and valve covers, cylinder bank 5 to 8
Fig 20: Identifying Bar Ignition Modules And Valve Covers

Fig 21: Identifying Bar Ignition Modules And Valve Covers
Information
Support the engine at the oil pan or engine carrier using suitable lifting equipment and a wide
wooden block.
26. Loosen screw on vibration balancer by two turns -4 and 3- . To do this, hold a brace brace
9679/1 at the vibration balancer with the help of a second worker. Support the brace on the
floor if necessary. A very high torque is required to loosen the screw (more than 800 Nm/592
ftlb.). A long 3/4-inch tool is the best tool to use for this. The engine should be supported to
prevent it from tipping over.
Fig 22: Supporting Engine

Fig 23: Identifying Engine Pulleys
27. Turn the crankshaft at the vibration balancer so that the staking bore of the vibration balancer
is located approx. 45° degrees in front of the lower staking point on the timing-case cover. →
Staking bore 45 degrees before TDC
Fig 24: Removing Chain Tensioner
28. Remove chain tensioner for timing chain from the timing-case cover. -5-
Fig 25: Identifying Crankshaft Bore Position
29. Loosen camshaft controller and sprockets on the four camshafts by 2 turns. Always counter at
the hexagon on the components when doing this. → Sprocket → Camshaft controller
Fig 26: Loosening Camshaft Controller And Sprockets

Fig 27: Loosening Camshaft Controller
30. Rem↓ove vibration balancer.
31. Turn the engine around. The oil pan must be facing upwards.
32. Unscrew oil pan -1- . To do this, remove all the screws -4- . The inserted seal can be reused.
It only needs to be replaced if damaged (cracked, worn down, hardened, etc.) or if it is leaking.
Fig 28: Identifying Oil Pan Screws
33. Detach and remove joint flange on the oil pressure control valve -2- . Disconnect oil level
sensor and remove by turning -5- .
34. Remove all oil lines between the oil guide housing and oil pump. → Oil lines on naturally
aspirated engine → Oil lines, intake pipe on naturally aspirated engine
Fig 30: Identifying Oil Lines - Naturally Aspirated Engine
Fig 31: Identifying Oil Lines Intake Pipe - Naturally Aspirated Engine
35. Remove all screws between the oil guide housing and crankcase/timing-case cover -4- . Don't
forget the screws at the front -7- .
1. Screw, M6 x 20
2. Joint flange
3. Sealing ring
4. Oil guide housing to lower part of crankcase - aluminum screw
5. Oil level sensor
6. Oil level sensor to oil guide housing (steel screw)
7. Timing-case cover to oil guide housing - aluminum screw

36. The oil guide housing is sealed with glue. To make it easier to remove, carefully lever off the oil
guide housing between the outer flanges on the crankcase and the oil guide housing. →
Removing oil guide housing Loosen by tapping carefully with a plastic hammer if necessary.
Remove the entire oil guide housing. Remove old sealing ring for the crankcase.
Fig 33: Removing Oil Guide Housing
37. Remove joint flange on vibration balancer -1- at the timing-case cover. To do this, remove the
screws -2 and 3- .
Fig 34: Identifying Chain Tensioner Screws
38. Remove all M6 and M8 screws on the timing-case cover → Timing-case cover and lift off the
timing-case cover. Also remove all the metal seals -2, 3, 4, 5- .
Fig 35: Identifying Timing-Case Cover Screws
1. Timing-case cover
2. Timing-case cover seal, outer right (fill openings with sealant, see 6)
3. Timing-case cover seal, inner
4. Timing-case cover seal, rib
5. Timing-case cover seal, outer left (fill openings with sealant, see 6)
6. Applying sealant to timing chain housing; Loctite 5900 (000.043.204.35 status 10/09)
Fig 36: Identifying Timing-Case Cover Seals
39. Remove timing chain -1- (mark rolling direction for re-installation using a felt-tip pen) from all
the sprockets and place on a clean surface.
40. Remove tensioning rail -4- . Remove threaded peg -1- if necessary.
Fig 38: Identifying Tensioning Rail
41. Remove U-rail (guide rail) -4- . To do this, remove four M8 screws -5- .
Fig 39: Identifying Timing Chain And Sprockets Screws
42. Carefully slacken the lower tensioning rail for the oil pump chain. Press the tensioning rail back
with a small screwdriver until both staking holes between the tensioning rail and guide rail are
aligned. → Oil pump tensioning rail
Fig 40: Pressing Oil Pump Tensioning Rail
43. Stake tensioning rail for oil pump chain through the hole in the guide rail using a suitable drill
bit, drift punch or nail. This slackens the oil pump chain. → Staking tensioning rail for oil pump
chain
Fig 41: Installing Oil Pump Chain Tensioning Rail
44. Remove the guide rail -3- . The guide rail is locked with -6- .
Fig 42: Removing Guide Rail
45. If the sprockets and camshaft controllers are to be separated from the camshafts, now
unscrew the loosened camshaft controllers and sprockets.
1. Screw, M12 Tighten fully after setting timing .
3. Camshaft control hydraulic valve
4. Screw, M5 x 12
Fig 43: Identifying Camshaft Adjustment Screws And Camshaft Control Hydraulic Valve
46. Slowly and uniformly loosen and then unscrew all M6 screws -3 and 5- in the camshaft
housings -2, 4 and 6- . The bearing covers are marked E for intake camshaft and A for outlet
camshaft. The bearing covers are numbered consecutively by cylinder. The bearing covers are
seated very securely in the cylinder head because of a dowel sleeve -1- . Jiggle free using a
pliers if necessary. Place on a marked, clean surface.
Fig 44: Identifying Camshaft Mount Screws (Cylinders 5 To 8)

47. Remove camshafts -3 and 6- and place on a marked, clean surface.
Fig 45: Identifying Camshafts (Cylinders 5 To 8)
48. Remove valve lifters -1 and 2- and place on a marked, clean surface in such a way that they
cannot be mixed up.
Fig 46: Valve Lifters Information Diagram
49. Remove mounting saddle at the front -8- . This hides the cylinder head screws underneath.
50. Remove front M8 screw securing the cylinder head of cylinders 1 to 4 to the crankcase. -3-
51. Turn the engine so that the cylinder head you want to remove is pointing straight upwards.
52. The injectors can now be removed easily if necessary. For details, see → 244019 REMOVING
AND INSTALLING FUEL INJECTOR
53. Remove cylinder head screws in the opposite order to the tightening sequence shown →
Tightening sequence for cylinder head below . Remove cylinder head.

54. Remove cylinder head gasket.
55. Remove cylinder head for cylinders 5 to 8 in the same way.
56. Turn the engine around. The oil pump must be facing upwards.
57. Remove chain cover for oil pump -9- . To do this, remove the screws -10- .
Fig 49: Identifying Oil Pump Screws - Naturally Aspirated Engine
58. Remove drive pinion for oil pump. Screw is tightened beyond the elastic limit. Use a
screwdriver to counter at the oil pump through the bore in the drive pinion. → Countering oil
pump pinion
Fig 50: Turning Oil Pump Pinion
59. Remove oil pump pinion with chain and crankshaft pinion. → Oil pump chain
Fig 51: Removing Oil Pump Chain
60. Unscrew oil pump -1- . To do this, remove the screws -8- . Pull oil pump out at the point
where the pipe engages at the rear with the oil plate. When doing so, make sure that the
locking lug does not break off. Swivel oil pump up and out.
61. Unscrew oil plate/oil guide.

Fig 52: Identifying Engine Oil Guide (Oil Plate)
62. Remove lower part of crankcase. First unscrew the four M8 screws on the output side -8 and
9- .
Fig 53: Identifying Crankcase Lower Part
1. 62.1. Unscrew outer M8 cross bolt connection in the opposite order to the tightening
sequence. Always use new aluminum screws.
Fig 54: Crankcase Screws Tightening Sequence
2. 62.2. Unscrew M10 and M11 thrust-bearing screws in the opposite order to the
tightening sequence. Start with the outer M10 screws first.
3. 62.3. Lift off lower part of crankcase. Get a second person to help if necessary.
Remove old sealing ring for the upper part of the crankcase. Remove bearing shells
if necessary and mark them.
63. Secure the crankshaft at the center using a holding bridge holding bridge 9677/1 . Tighten
screws slightly. -1-
Fig 56: Identifying Crankshaft Screws
64. Loosen connecting rod bolts -6- and take off connecting rod caps -5- . Push piston in question
out of the crankcase using a wooden rod. Hold it in your other hand or get another person to
help. Fit connecting rod cap hand-tight to the connecting rod again using the old screws and
set down after marking according to the relevant cylinder. The connecting rod bolts must be
replaced with new ones during re-installation. The connecting rods are cracked and the
connecting rod code is facing the exhaust side. The combustion chamber recess on the piston
is facing the injector.
Fig 57: Identifying Piston And Connecting Rod
65. Remove all pistons in the same way.
66. (If you have not already done so) turn the engine so that the crankshaft is at the top.
1. Risk of squashing
67. After removing all the pistons, remove the crankshaft -1- (remove holding bridge) and place on
a clean surface.
68. Remove all bearing shells -5 and 6- and thrust washers -4- if necessary. Mark the bearing
shells and set them down.
69. Remove oil spray jets -6- . To do this, loosen the screws -7- .
Fig 58: Identifying Crankshaft
Fig 59: Identifying Crankcase Upper Part
70. Remove coolant guide -6- . Remove seals -7- .
1. 2 - M6 screw
2. 3 - Sealing ring
3. 4 - Screw plug, M16 x 1.5
4. 5 - M6 screw
5. 6 - Coolant guide tube (collection pipe)
6. 7 - Metal seal
7. 8 - Stopper
Fig 60: Identifying Coolant Guide Screws And Sealing Ring
WM 1001Z2 ASSEMBLING ENGINE (CAYENNE S, CAYENNE TURBO, CAYENNE GTS,

CAYENNE TURBO S) > TOOLS
mounting Special tool 9590

elements
engine Special tool 9676/1
support
holding bridge Special tool 9677/1
brace Special tool 9679/1
funnel Special tool 9784/1

cover for dust Special tool NR.165
protection
when fitting
the engine

CAYENNE TURBO S) > PRELIMINARY WORK
Check that the following assembly preconditions have been met:
Oil guide housing pre-fitted with oil filter and oil/water heat exchanger.
Examine the oil mist separator to check that seals and screw elements are pre-fitted.
Check cylinder head cover (valve cover) to ensure that surrounding seal, seals for spark plug
recesses, seal for hydraulic valve of camshaft control, hall sender for camshaft and oil filler cover
are fitted.
Intake-air distributor with seals, heat socket, screws and throttle housing inserted.
Generator with both fitted coolant connection pieces and sheetmetal cable holders.
Upper part of crankcase fitted on flywheel side with two water plugs. Screw plugs fitted.
The upper part of the crankcase together with the engine support engine support 9676/1 is
attached to the assembly support. Use the four screws mounting elements 9590 and tighten
them. → 1001IN SECURING ENGINE ON ASSEMBLY SUPPORT (MOUNTING BRACKET)

CAYENNE TURBO S) > ASSEMBLING ENGINE
CAUTION: Ingress of dirt
Danger of material damage due to blocked oil bores/oil ducts.
→ Absolute cleanliness is essential when working on the engine.
→ Lay removed engine parts on a clean base and make sure to cover them.
→ Use the cover for dust protection when fitting the engine NR.165 on the engine assembly
support.

Risk of squashing
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.
CAUTION: Emerging residual fluid can soil the engine!
Residual fluid (fuel, oil, Pentosin, coolant, etc.) will emerge even after a long time
when disassembling and assembling the engine .
→ Place a drip tray under the engine at the assembly support.
→ Have a sufficient number of cleaning cloths ready.
→ Close off engine openings with plugs.
Information
Information
The bearing shells are available in various classes. The classes are indicated by the color marking
on the outside. For every bearing (main and connecting rod bearings), the color marking must
match the corresponding letter on the flywheel flange of the crankshaft . -arrow- Each letter on the
flywheel flange of the crankshaft indicates the correct color classification of the bearing shell .
Fig 1: Locating Bearing Shell Color Marking
Information
The corresponding connecting-rod bearing shells must be selected according to the marking on
the crankshaft transmission flange (4-digit) and inserted into the connecting rod .
When removing the pistons with connecting rods, the pistons should be marked with a water-
resistant marker on both the piston and connecting rod according to cylinder and cylinder bank .
The removed pistons and connecting rods must be cleaned carefully so as not to remove the
markings .
The connecting rod code is installed to the exhaust side as standard. The direction of travel arrow
on the DFI piston is always on the same side as the connecting rod code -A- . The pistons are
assigned to the cylinder bank (1 to 4 and 5 to 8), i.e. because of the DFI combustion chamber
recess there are two different pistons for the left and right cylinder bank .
When installing the piston in the crankcase, the direction of travel arrow must point in the direction
of travel when installed. It is always on the same side as the connecting rod code. The combustion
chamber recess on the piston is always on the intake side. Note the assignment of the pistons to
the cylinder bank .
Naturally aspirated engines and turbo engines have different pistons .
Fig 2: Identifying Connecting Rod Code
The code on the connecting-rod big end and connecting rod cap must always be on the same side
and at the exhaust side . -A-
NOTE: Select the correct piston for the correct cylinder bank. Install with connecting
rod code on the exhaust side with the direction of travel arrow on the piston.
Fig 3: Identifying Connecting Rod Code
Information
Connecting rod bolts must always be replaced .
1. Place crankshaft bearing shells into the lower part of the crankcase.
1. 1.1. Select crankshaft bearing shell classification based on the inscription on the
crankshaft's flywheel flange -9- . Example: GGGGB GGGG mean 5 main shaft
bearings and 4 double connecting rod bearings (8 connecting rods in total). The
engraved letters are the abbreviations for the color code of the bearing shells (G for
yellow , B for blue , R for red , N for green ). Based on the example above,
yellow bearing shells are to be selected for the main shaft bearings 1 to 4 and a blue
bearing shell is to be selected for the fifth main shaft bearing. The connecting rod
bearing shells should all have a yellow marking in this case.
1. Crankshaft (stroke: 83 mm)
3. Spring wedge
4. Thrust washer
5. Main bearing shell, upper
6. Main bearing shell, lower
7. Shaft seal
8. View of crankshaft flange
9. Crankshaft bearing classification (four types) G Yellow; ↑B Blue, R Red;

N Green => (example: GGGGG-BBBB; 5 main shaft bearings with yellow
marking, 4 double (8) connecting rod bearings with blue marking) => For
numbering, see A
Fig 4: Identifying Crankshaft, Thrust Washer And Main Bearing Shell
2. 1.2. Place crankshaft bearing shells with lubricating groove and bore -2- into the
upper part of the crankcase -1- . Smooth crankshaft bearing shells -3- belong in the
lower part of the crankcase. Insert the thrust washers into the center with grooves
facing outwards (affix using multipurpose grease) or alternatively wait until after the
crankshaft has been inserted.
Fig 5: Identifying Bearing Shells

Fig 6: Inserting Bearing Shells

Fig 7: Identifying Thrust Washer
3. 1.3. Oil crankshaft bearing shells on the outside and inside with engine oil and insert
correctly into ↓the lower part of the crankcase according to the twist lock. Place lower
part of crankcase on a clean surface. The retaining lugs (twist lock) prevent it from
being installed incorrectly. As the thrust washers fall off without the crankshaft, do not
insert until after the crankshaft is fitted.
2. If you have not already done so, fit knock sensors on the upper part of the crankcase using
screws.
1. 2.1. Align the knock sensors between cylinder 1 and 2 and cylinder 5 and 6 parallel
to the cylinder head and the plug connection parallel to the starter. Fit knock sensors
hand-tight.
2. 2.2. Insert starter briefly and align concealed knock sensors so that there is no knock
sensor near the starter. Remove the starter. Fit plug connection for knock sensor
between cylinders 3 and 4 in the direction of the water pump so that it is turned
upwards and slightly towards the cylinder head. Fit plug connection for knock sensor
between cylinders 7 and 8 in the direction of the flywheel so that it is turned upwards
and slightly towards the cylinder head.
3. 2.3. Fit knock sensors correctly.
1. Knock sensor
2. Screw, M8 x 35
Fig 8: Identifying Knock Sensors Screws
4. 2.4. Insert two seals for the thermostat housing into the upper part of the crankcase
on both sides. -2-
Fig 9: Identifying Crankcase And Thermostat Housing Seals
3. Check coolant guide (collection pipe) to make sure that the sealing faces are clean and free of
burrs. Fit metal seals on left and right, screw in screws securely on metal seals by hand. Move
coolant guide at the upper part of the crankcase into installation position and fit it.
1. Coolant pipe
2. M6 screw
3. Sealing ring
4. Screw plug, M16 x 1.5
5. M6 screw
7. Metal seal
8. Stopper
Fig 10: Identifying Coolant Guide, Sealing Ring, Metal Seal And Screws
4. Fit oil spray jets -6- .

Fig 11: Identifying Crankcase Upper Part
Insert oil spray jets into the upper part of the crankcase and screw them on. To do this, grease
the sealing ring sparingly with Kluber Syntheso GLEP 1 and fit it. Check that oil spray jets are
pointing in the correct direction of spray toward the inside of the piston crown. The oil spray jet
must be aimed at the piston crown.
→ Spray direction → Spray direction from side
Fig 12: Identifying Oil Spray Jets

Fig 13: Identifying Oil Spray Jets (Side View)
5. Pre-fit spring wedge of crankshaft into the corresponding groove on the crankshaft using a
plastic hammer if necessary.
6. Pre-fit all pistons with connecting rods and piston rings, number by cylinder and place to one
side. For details, see → 131037 DISASSEMBLING AND ASSEMBLING PISTONS
1. Piston-ring set
2. Pistons
3. Circlip/piston-pin circlip
4. Piston pins
5. Connecting rods
6. Connecting rod bolt; replace as it must be tightened in the plastic area
7. Connecting-rod bearing shells

7. Check that all the seals are installed in the oil plate (oil return). → Oil return (oil plate)
Fig 15: Identifying Oil Return Line (Oil Plate)
8. If you have not already done so, drive dowel sleeves for the metal seals in the timing-case
cover using a copper or plastic hammer.
9. Insert new metal seals on the timing-case cover and press onto dowel sleeves.
10. Oil pump is pre-fitted with the oil pressure control valve.
11. Cylinder heads fitted with solenoid valves of the valve lift switchover, camshaft housings
loosely positioned and removed camshafts prepared. Alternatively, the camshaft housings,
which have been marked according to installation position, can be set down on a clean surface
together with the corresponding camshafts. Cam followers and injectors are fitted.
12. If you have not already done so, drive in dowel sleeves on auxiliary unit bracket for power-
steering pump or tandem pump using a copper or plastic hammer.
13. Move starter into installation position and screw down. → INSTALLING STARTER
14. Insert crankshaft and oil crankshaft bearing pin and connecting-rod bearing pin.
15. First position the timing chain pinion with the ring gear of the oil pump drive onto the crankshaft
stub (check that the two diamond washers at the front and rear on the ring gear are clipped in
-1- ). Then position the drive pinion of the oil pump chain -2- with respect to the crankcase.
Fig 16: Pressing Timing Chain Pinion On Crankshaft Stub

Fig 17: Identifying Timing Chain Pinion (Diamond Washers)
16. Fit crankshaft holding bridge holding bridge 9677/1 in the center of the crankshaft.
Fig 18: Identifying Crankshaft Secured Bolt
17. Turn upper part of crankcase and oil cylinder liners.
18. Pre-tension pistons using an assembly funnel funnel 9784/1 and press pistons into the
cylinder. For details, see → 131020 REMOVING AND INSTALLING PISTONS
19. Remove crankshaft holding bridge. Apply Doboseal 224N sealant (999.915.573.43, status
04/10) to the lower part of the crankcase as shown. Insert sealing ring -3- into the upper part
of the crankcase and position the lower part of the crankcase onto the upper part of the
crankcase. Insert all the fastening screws, fit to the prescribed tightening torque within 5
minutes and wipe off excess sealant.
1. Wipe off sealant residues after fitting
Fig 19: Applying Sealant
20. Tighten M11 and M10 bearing screws to the prescribed torques. → Tightening sequence for
thrust-bearing screws below
1 bis 20 - Tightening sequence for M11 and M10 screws => Observe different torques!
1. Lower part of crankcase
3. O-ring
5. Thrust-bearing screw M11; tighten screws within 5 minutes; observe tightening

sequence.
6. Thrust-bearing screw M10; tighten screws within 5 minutes; observe tightening

sequence.
7. Aluminum screw , M8 x 70; (cross bolt connection); always use new aluminum
screws
8. Screw, M8 x 35
9. Screw, M8 x 50
10. Dowel sleeve
Fig 21: Identifying Crankcase Lower Part
21. Fit cross bolt connection.

Fig 22: Crankcase Bolts Tightening Sequence
22. Fit M8 screws on the side -8 and 9- . Remove emerging sealant.
23. Punch in or imprint the engine number if necessary (when replacing engine). Use a 4-mm
number embossing tool and counter at the cast-metal part with a hammer.
24. Move oil plate with all the seals into installation position and secure to the lower part of the
crankcase.
Fig 23: Identifying Oil Guide Screws (Oil Plate)
25. Fit the oil pump → Oil pump on naturally aspirated engine below.
Fig 24: Identifying Oil Pump Components - Naturally Aspirated Engine
26. Position the oil pump sprocket with drive chain with respect to the crankshaft chain pinion →
Oil pump chain below. Counter the oil pump sprocket at the oil pump using a screwdriver and
fit a new screw.
Fig 25: Positioning Oil Pump Chain

Fig 26: Turning Oil Pump Pinion
27. Fit cover plate for oil pump drive (drive pinion cover) using three screws.
28. Turn engine and clean sealing faces. Blow out bores of cylinder head screws. Position both
cylinder head seals. Part number/marking facing upward. When doing so, make sure that
the cylinder head gasket is positioned on the dowel sleeves.
29. Unscrew front camshaft mounting saddles (lower parts) of the cylinder heads (if you have not
already done so), as the bores in the cylinder head screws are covered. -8-
3. Hydraulic valve for variable valve lift control
4. Screw, M5 x 12
6. Bucket tappet (oil with engine oil)
7. Stopper
8. Mounting saddle 1 to 4
9. Stopper
10. Bearing locations (oil with engine oil)
30. Position cylinder heads, insert cylinder head screws and fit them. Observe tightening sequence
and prescribed tightening torque.
3. M8 screw
4. Cap
5. Stopper
6. Stopper
7. Restrictor for valve lift adjustment
8. Cylinder-head screws => For tightening specifications, see TIGHTENING

SEQUENCE FOR CYLINDER HEAD
9. Spark plug
Fig 28: Identifying Cylinder Head (1 To 4)
31. Fit front M8 screw of cylinder head 1 to 4. -3-

32. Coat camshaft bearings with normal multipurpose grease or engine oil.
33. Insert bucket tappets into the cylinder head if necessary (bucket tappets for intake and outlet
side have different diameters). The bucket tappets have a twist lock that fits into a guide
groove in the cylinder head. Fit used bucket tappets at the same position.
34. Position vibration balancer with screw tightened by hand. Turn crankshaft to just before
cylinder 1 TDC (prevents the valves from sitting on the piston when directly at TDC). -2-
Fig 30: Identifying Crankshaft Position Angle
Information
A data matrix coding is shown on the staking dihedron of the camshafts. This is a square
black/white dotted marking used for electronic identification purposes during the production
process. This marking can be used as an aid when inserting the camshafts into the cylinder
head. All four camshafts press against the valves the least when the data matrix coding is
facing upwards during installation.
35. Insert camshafts so that the minimum amount of pressure is exerted on the valve springs and
coat bearing locations with normal multipurpose grease or engine oil. Position bearing covers
correctly and screw down. The housings are numbered and marked with E (intake) or A
(outlet). Fit camshaft bearing covers evenly and gradually, and slowly tighten to the specified
tightening torque. The camshafts must not be strained or tilted. Outlet camshafts and intake
camshafts (also bank-specific) cannot be used interchangeably because of the bearing
locations and length.
A. Cylinders 1 to 4
B. Cylinders 5 to 8
Fig 31: Camshaft Identification - V8 Naturally Aspirated Engine
1. All markings can be read from the exhaust side/main diagram applies
symmetrically for both cylinder heads
1. Matching number for cylinder head/intake camshaft bearing cover, cylinder 1 (E1)
5. Matching number for cylinder head/outlet camshaft bearing cover, cylinder 1 (A1)
Arrow - Direction of travel

Fig 32: Camshaft Bearing Cover Identification
1. Dowel sleeves
2. Bearing cover (intake)
3. Screw, M6 x 70
4. Bearing cover
5. Screw, M6 x 35
6. Bearing cover (outlet)
Fig 33: Identifying Camshaft Mount (Cylinders 5 To 8)
36. Move both hydraulic valves for camshaft control into installation position and fit them. -3 and
4-
3. Camshaft control hydraulic valve
4. Screw, M5 x 12
Fig 34: Identifying Camshaft Adjustment Screws
37. Fit threaded peg for tensioning and guide rails if necessary. -1 and 2-
1. Threaded peg
2. Threaded peg
3. Guide rail
4. Tensioning rail
5. Chain tensioner with sealing ring
6. Pin (for locking the oil-pump tensioning rail)
38. Fit guide rail with tensioning rail for oil pump chain and pull locking pin (tensioning rail will be
released).
39. Fit U-shaped deflection rail -4- .
1. Double-chain camshaft drive
2. Camshaft sprocket
4. Deflector rail
5. Screw, M8 x 35
6. Camshaft-to-camshaft guide pad
Fig 36: Identifying Timing Chain, Sprockets And Tensioning Rail
40. Fit tensioning rail and let it hang.
41. Fit both small guide rail pieces between the camshaft controller and sprocket (if removed).
42. Loosely fit camshaft controller and sprockets using screws.
43. Position timing chain and guide correctly over guide and tensioning rails.
44. Fit timing-case cover. Secure sheetmetal holder for tank vent to the upper screw on the
timing-case cover at the 1st cylinder. → INSTALLING TIMING-CASE COVER .
45. Replace and fit joint flange (sealing ring) between the vibration damper and timing-case cover.
→ 137419 REMOVING AND INSTALLING CRANKSHAFT SEALING RING FOR
PULLEY/VIBRATION BALANCER
46. Turn the engine around. Oil pump is upright.
47. Lay sealing ring in the lower part of the crankcase.
48. Apply sealant to the oil guide housing as specified. Sealant should be applied thinly and
evenly. Screw down within 5 minutes.
Fig 37: Identifying Oil Guide Housing Sealant Applying Area
49. Position oil guide housing and align against transmission or projection of lower part of the
crankcase. On the transmission side, the oil guide housing must not project further than the
crankcase. Make sure that the transmission can later be screwed evenly to the block. The oil
guide housing can be adjusted in the same way as the timing-case cover (using dial gauge,
etc.). For details, see → 175019 REMOVING AND INSTALLING OIL GUIDE HOUSING
50. Screw down oil guide housing. Tighten all screws uniformly in diagonally opposite sequence
-4- . Don't forget the screws between the oil guide housing and timing-case cover (five screws
behind front vibration balancer, bores are currently overhead). -7-
1. Screw, M6 x 20
2. Joint flange
3. Sealing ring
5. Oil level sensor

51. Place sealing ring on intake manifold and fit intake manifold. Tighten all oil pipes. Replace
sealing rings. → Oil lines on naturally aspirated engine → Oil lines, intake pipe on naturally
aspirated engine

Fig 40: Identifying Oil Lines, Intake Pipe - Naturally Aspirated Engine
52. Push joint flange of the oil pressure control valve through the side opening in the housing via
the oil pressure control valve and secure using two screws -2 and 3- .
1. Screw, M6 x 20
2. Joint flange
3. Sealing ring
5. Oil level sensor

53. Fit oil level sensor (turn carefully when inserting sensor). -5 and 6-
54. Fit oil pan with reusable seal and tighten evenly and in diagonally opposite sequence.
Fig 42: Identifying Oil Pan
55. Turn the engine around.
56. Position vibration balancer with screw tightened by hand.
57. Set the timing. Follow procedure exactly. → 150516 SETTING TIMING FOR CAMSHAFTS
WARNING: Risk of damage to the engine and danger of crushing if the engine
tips over
1. When removing and installing the vibration damper with the engine removed
(engine on assembly support), excessive use of force can cause the assembly
mounting to become kinked.
→ The engine must be supported at the oil pan or engine carrier using suitable lifting
equipment and a wide wooden block. This applies to all engines and assembly mountings.
58. Tighten vibration balancer -3 and 4- to the specified torque (use a brace brace 9679/1 ).
Make a mark between the screw and the vibration balancer using a water-resistant marker
(continuous line from screw to vibration balancer). Mark a second line on the vibration balancer
at 180° from the first marking. Tighten from first marking to the second marking (torque-angle
tightening). For details, see → 137619 REMOVING AND INSTALLING PULLEY (VIBRATION
BALANCER)
Fig 43: Supporting Engine
2. Screw, M8 x 16
3. Vibration damper
4. Screw, M18 x 1.5 x 72; use new screw

6. Screw, M8 x 16

Fig 44: Identifying Water Pump Pulley
59. Fit high-pressure pump at cylinder head for cylinders 5 to 8. For details, see → INSTALLING
HIGH-PRESSURE PUMP .
60. Move vacuum pump at cylinder head for cylinders 1 to 4 into installation position and fit it. →
INSTALLING VACUUM PUMP
1. Vacuum pump
2. Screw, M6 x 25
3. O-ring
4. O-ring
Fig 45: Identifying Vacuum Pump, O-Ring And Screws
61. Fit spark plugs if necessary. → 287020 REMOVING AND FITTING SPARK PLUGS
62. Fit both cylinder head covers (valve covers). Centre cylinder head cover over the bar ignition
modules. For details, see → INSTALLING CYLINDER HEAD COVER
63. Fit both eyelets.
64. Move thermostat housing between the two sides of the crankcase into installation position.
Tighten three screws (leave one loose for the fuel rail). Grease sealing ring on the small
coolant pipe sparingly with Kluber Syntheso GLEP 1 and press it into the thermostat housing
from the front. Fit from the rear with a screw. Alternatively, the thermostat housing can be
pre-fitted and installed complete with the rear coolant pipe.
2. Screw, M6 x 25
3. Screw, M6 x 25; screwed to fuel high-pressure distribution pipe

Fig 46: Identifying Thermostat Housing And Coolant Regulator Screws
65. Grease sealing rings on the thermostat housing with Kluberplus S06-100 assembly gel (diluted
50:50 with water) and press them as far as they will go into the thermostat housing. For details,
see → 195819 REMOVING AND INSTALLING COOLANT REGULATOR (THERMOSTAT
INSERT)
66. Grease both sealing rings on the coolant pipe sparingly with Kluber Syntheso GLEP 1 and
press them into the thermostat housing from the rear. Align with screw points on the coolant
collection pipe and then screw down!
1. Heater coolant pipe
2. M6 screw
3. Sealing ring
4. Screw plug, M16 x 1.5
5. M6 screw
7. Metal seal
8. Stopper
Fig 47: Identifying Heater Coolant Pipe, Coolant Guide And Screws
67. Fit the water pump. Fit pulley for water pump. For details, see → INSTALLING COOLANT
PUMP
68. Fit oil pressure sensor with adapter. Replace sealing rings.
1. Oil pressure sensor adapter
2. O-ring
4. Screw, M6 x 40
5. Stopper
6. Sealing ring
Fig 48: Identifying Oil Pressure Sensor And Adapter
69. Fit bracket for auxiliary units for power-steering pump or tandem pump (PDCC) and air
conditioning compressor -1- .
70. Fit bearing console on the right. -1-

Fig 50: Identifying Auxiliary Units And Engine Mounting Right Bracket
71. Fit and secure the engine mountings. When doing so, make sure to fit the mountings at the
correct installation position. → Installing Engine Mounting
72. Fit coolant pipe between coolant collection pipe and generator. Replace sealing rings.
2. Coolant pipe

Fig 51: Identifying Naturally Aspirated Engine Coolant Supply
73. Fit the generator and crash support. For details, see → INSTALLING GENERATOR
1. Generator
2. Screw, M8 x 95
3. Screw, M8 x 35
A. View
Fig 52: Identifying Generator Screws

74. Fit deflection rollers and belt tensioner and press on cover.
2. Hydraulic belt tensioner; tensioner at the lever, tensioning roller at the tensioning
lever
3. M8 screw; complete lever on timing-case cover and cylinder head; belt tensioner and
timing-case cover at the console
5. Dual poly-V-belt
Fig 53: Identifying Engine Drive Belt
75. Fit crankshaft sealing ring on flywheel side. See → INSTALLING CRANKSHAFT
76. Fit coolant hosing and secure clamps.
2. Coolant pipe

3. Screw, M6 x 20
6. Holder
7. M6 screw Aluminum screw ; always use new aluminum screws
8. Clip
77. Lay coolant vent line at both cylinder heads (grease sealing rings sparingly with Kluber
Syntheso GLEP 1). Pull off injector plug if necessary and fit coolant vent line into the clips at
the rear. Screw down coolant vent line with seals at both cylinder heads.
1. Vent line
2. Screw, M6 x 16
Fig 56: Identifying Ventilation Line Screws

78. Roughly position engine wire harness. Place cable duct onto coolant collection pipe and lay
both harnesses for the cylinder banks. At the timing-case cover lay them downwards to the
generator. Wire up air conditioning compressor, insert injectors, wire up bar ignition modules.
Screw down ground points. For details, see → 975219 REMOVING AND INSTALLING WIRE
HARNESS FOR ENGINE
79. Fit high-pressure line and low-pressure line → High-pressure pump on naturally aspirated
engine . To do this, fit union nut in the cylinder head. Clip in cable duct at the union nut.
Fig 57: Identifying High-Pressure Pump Components - Naturally Aspirated Engine
80. Fit high-pressure fuel distribution pipe. For details, see → INSTALLING FUEL DISTRIBUTOR
PIPE (FUEL RAIL)
81. Check the DFI high-pressure system for leaks. → 243001 CHECKING FUEL DISTRIBUTION
PIPE FOR LEAKS
82. Fit exhaust manifold. Fit seal correctly. Observe tightening sequence.
Fig 58: Locating Exhaust Manifold Seal - Naturally Aspirated Engine
83. Lay tank vent with plastic line at cylinder bank 1 to 4 and clip it in at the sheetmetal brackets.
-3-
3. Tank ventilation
4. Aluminum holder

Fig 59: Identifying Engine Ventilation Line - Naturally Aspirated Engines
84. Prepare and fit intake-air distributor. Ensure that the seals are seated correctly. Move intake-air
distributor into installation position. Check that the switch-over valve is seated and connected
properly. For details, see → 244619 REMOVING AND INSTALLING INTAKE-AIR
DISTRIBUTOR
85. Fit oil mist separator. For details, see → Installing Oil Separator 105519 REMOVING AND
INSTALLING OIL MIST SEPARATOR .
86. Fit power-steering pump. For details, see installation description → INSTALLATION
87. Fit air conditioning compressor. → INSTALLING AIR-CONDITIONING

COMPRESSOR/CONDENSER LINE
88. Fit pulley for power-steering pump or tandem pump.
2. Screw, M8 x 16
3. Vibration damper
4. M18 screw; always use a new screw
6. Screw, M8 x 16

Fig 60: Identifying Water Pump Pulley
89. Fit drive belt and then tighten it (manipulate belt tensioner using socket or ring wrench). →
INSTALLING DRIVE BELT
90. Fit heat protection panels on generator and on exhaust manifold.

Fig 61: Locating Heat Protection Panels - V8 Naturally Aspirated Engine
91. Check to ensure that all the lines and connections have been routed and tightened correctly.
Check that no lines were forgotten.
WM 100431 CONVERTING RECONDITIONED ENGINE (REPLACING ENGINE)

(CAYENNE GTS, CAYENNE S HYBRID) > TOOLS
spring band clamp Workshop WE 1648

pliers equipment

(CAYENNE GTS, CAYENNE S HYBRID) > PRELIMINARY WORK
1. Remove engine from transmission. → Removing Engine From Transmission 100127

TRANSMISSION
2. Support engine on assembly support.

(CAYENNE GTS, CAYENNE S HYBRID) > CONVERTING RECONDITIONED ENGINE
Information
Tightening torques, tightening sequence and assembly overviews for the engine and transmission:
Information
All components listed must be removed from the old engine and installed on the new engine .
Replace seals and O-rings .
Replace aluminum screws and torque angle-tightened screws .
1. Convert engine carrier. → 103019 REMOVING AND INSTALLING ENGINE CARRIER
2. Convert pressure pipes -1- .
1. 2.1. Release retaining clip -2- and pull it off the turbocharger -3- .
2. 2.2. Loosen clamp -4- and pull change-over valve -5- off the intake manifold -6- .
3. 2.3. Remove pressure pipe -1- with change-over valve -5- .

Fig 1: Identifying Engine Pressure Pipes
3. Fit new intake pipes on new engine.
1. 3.1. Replace intake pipes -1- after loosening the screw-type clamp -arrow- securing
intake pipe to turbocharger.
2. 3.2. Release positive crankcase ventilation line -2- and pull it off the intake pipe.
3. 3.3. Release tank vent line -3- and pull it off.
4. 3.4. Loosen clamp -4- and pull off line -5- .

Fig 2: Identifying Intake Pipe, Tank Vent Line And Clamp
4. Convert coolant hoses.
1. 4.1. Loosen clamps -arrows- and pull off coolant hoses -1- and -2- .
2. 4.2. Collect emerging coolant.

Fig 3: Locating Coolant Regulator Housing Coolant Hoses
5. Convert secondary air valves with lines.
1. 5.1. Unscrew screws -1- securing secondary air line to cylinder head.
2. 5.2. Unscrew screws -2- on holder -3- securing secondary air valve to cylinder
head.
3. 5.3. Unscrew screw -4- securing secondary air line -5- to coolant distributor -6- .
4. 5.4. Loosen clamp -arrow- using spring band clamp pliers WE 1648 and pull off
secondary air hose -7- .
Fig 4: Identifying Engine Secondary Air Lines
6. Convert secondary-air pump. → 266519 REMOVING AND INSTALLING SECONDARY-AIR

PUMP
7. Convert drive plate. → 136319 REMOVING AND INSTALLING DRIVE PLATE FOR TORQUE
CONVERTER
8. Convert drive belt. → 137819 REMOVING AND INSTALLING DRIVE BELT
9. Convert hydraulic pump with PDCC lines. → 489819 REMOVING AND INSTALLING
HYDRAULIC PUMP
10. Convert air-conditioning compressor. → 873419 REMOVING AND INSTALLING

11. Convert the generator. → 272219 REMOVING AND INSTALLING GENERATOR

(CAYENNE GTS, CAYENNE S HYBRID) > SUBSEQUENT WORK
1. Mount engine on transmission. → 100127 REMOVING ENGINE FROM TRANSMISSION AND

2. Check engine-oil level. → 170101 CHECKING ENGINE-OIL LEVEL USING THE PIWIS
TESTER
3. Write new engine number in the service booklet.
WM 100433 CONVERTING RECONDITIONED ENGINE (CAYENNE S E) >

PRELIMINARY WORK
1. Engine removed. → Removing Engine 100119 REMOVING AND INSTALLING ENGINE
2. Transmission removed. → Removing Engine From Transmission 100127 REMOVING

ENGINE FROM TRANSMISSION AND MOUNTING ENGINE ON TRANSMISSION
3. Engine supported on mounting bracket. → 1001IN SUPPORTING ENGINE ON MOUNTING

BRACKET

CONVERTING RECONDITIONED ENGINE
Information
Some modifications are required in order to replace the old, removed engine with a new one .
Starting point for conversion work: Old engine is secured to assembly support and the new one is
in the transport cradle .
At higher mileages, components (coolant hoses, clips, etc.) must be checked for damage and
replaced if necessary .
Seals must be checked and replaced if necessary .
Information
For tightening torques, tightening sequence and assembly overview, see → 1001IN TIGHTENING
TORQUES, TIGHTENING SEQUENCES, ASSEMBLY OVERVIEWS
Information
Tightening torque, tightening sequence and assembly overview. → 3X00IN TIGHTENING TORQUE,
TIGHTENING SEQUENCE AND ASSEMBLY OVERVIEW
1. Remove numerous transport stoppers on water and vacuum connection pieces on the new
engine.
2. Re-fit poly-V-belt and poly-V-belt for compressor. → INSTALLING DRIVE BELT

3. Re-fit belt tensioner for compressor. → INSTALLING BELT TENSIONER
4. Re-fit tensioner and deflection roller. → INSTALLING BELT TENSIONER
5. Re-fit air-conditioning compressor. → INSTALLING AIR-CONDITIONING

COMPRESSOR/CONDENSER LINE
6. Re-fit the drive plate. → INSTALLING DRIVE PLATE FOR TORQUE CONVERTER
7. Re-fit the starter. → INSTALLING STARTER
8. Re-fit the generator. → INSTALLING GENERATOR
9. Re-fit oxygen sensors upstream of catalytic converter. → INSTALLING OXYGEN SENSOR

UPSTREAM OF CATALYTIC CONVERTER
10. Check that all lines and hoses between the engines have been re-fitted and no components
have been forgotten.

SUBSEQUENT WORK
1. Mount the transmission on the engine. → Installing Engine 100127 REMOVING ENGINE
FROM TRANSMISSION AND MOUNTING ENGINE ON TRANSMISSION
2. Install engine and transmission. → Installing Engine 100119 REMOVING AND INSTALLING
ENGINE
WM 101001 ASSESSMENT OF CYLINDER LINERS (CHECKING CRANKCASE)

(CAYENNE TIP, CAYENNE MAN, CAYENNE S, CAYENNE GTS, CAYENNE S HYBRID,
TOOLS
video endoscope Workshop WE 1456

equipment

ASSESSMENT OF CYLINDER LINERS (CHECKING CRANKCASE)
Information
The symptoms of cylinder liner damage and in the worst case scenario, piston seizure, are generally
rather inconspicuous. At an advanced stage, the most common symptoms include the following:
Blue smoke in the exhaust gas (burned engine oil); rule out alternative causes (leaking
turbocharger, leaking valve-stem seals, etc.)
Piston knocking when the engine is cold (inadequate piston control in the cylinder); rule out
alternative causes and noise sources
Strong rattling and clicking noise when the engine is idling
Mechanical noise during acceleration
High engine oil consumption
Check Engine light comes on when engine oil level is low
Loss of power
Rough idling
Bad cold-start behavior
and so on...
Information
The following steps must be carried out before assessing the cylinder liners.
Create Fault Analysis Protocol FAP and check ACTUAL values .
Read out DME fault memory and correct faults .
Mechanical engine diagnosis:
NOTE: Turning the crankshaft
Risk of irreparable damage to endoscope
→ Disconnect the battery and make sure the vehicle cannot start.
→ Pull the endoscope out of the spark plug recess before turning the crankshaft with your hand.
→ Only observe a downward-moving piston using the endoscope.
1. Light up conspicuous, suspect cylinders with the endoscope and examine them. Use video
endoscope WE 1456 or a similar endoscope for this.
1. 1.1. Remove spark plugs (if you have not already done so, or if you have re-installed
them).
2. 1.2. Turn the piston in the relevant cylinder to the bottom dead center. To do this, turn
the crankshaft clockwise at the vibration balancer until the piston crown is positioned
as far down as possible when viewed through the endoscope.
3. 1.3. Adjust the endoscope to its brightest setting and have a good look all around the
cylinder liner. You can also shine a torch into the spark plug recess to help you check
for damage.
4. 1.4. Examine the cylinder liner all the way around. → 101001 ASSESSMENT OF
CYLINDER LINERS (CHECKING CRANKCASE)
2. If you suspect engine damage, drain the engine oil and remove the oil filter. For details of how
to do this, see → 170117 CHANGING ENGINE OIL AND OIL FILTER . Check for metallic
wear, breaks and similar problems.
3. Check for loss of pressure. → 101802 Testing pressure loss from the engine

ASSESSMENT OF CYLINDER LINERS (CHECKING CRANKCASE) > SIGNS OF
DAMAGE TO CYLINDER LINERS IN THE ENDOSCOPE
Ideal condition of used cylinder!=> Continued use acceptable! The typical fine-marking that
develops at a very early stage is apparent. The liners are a yellow-brown color with a slight speckled
effect in places. The liner keeps its silver color in places with more intense lateral force transmission. →
Perfect cylinder liner
Fig 1: Identifying Cylinder Liner
Ideal condition of used cylinder!=> Continued use acceptable! The typical fine-scoring that
develops at a very early stage is apparent. The liners are a yellow-brown color with a slight speckled
effect in places. The liner keeps its silver color in places with more intense lateral force transmission.
Minor visible marks can be ignored. -arrow-
Fig 2: Locating Engine Ideal Condition
Ideal condition of used cylinder! = > Continued use acceptable! (4 illustrations) A typical polished
cylinder liner, which develops at an early stage, is evident. The liners have several polished, shiny silver
areas. The liner retains its silver color in areas subject to higher lateral force transmission. Minor visible
marks can be ignored. → Ideal condition of used engine with polished running tracks 1 → Ideal condition
of used engine with polished running tracks 2 → Ideal condition of used engine with polished running
tracks 3 → Ideal condition of used engine with polished running tracks 4
Fig 3: Identifying Engine Ideal Condition With Polished Running Tracks 1



Damaged cylinder liner!=> Engine damage! Extensive areas of deeper scoring are apparent in this
state -arrows- .
Fig 7: Locating Damaged Cylinder Liner With Deep Scoring
Damaged cylinder liner! => Engine damage! Liner damage, piston seizure → Piston seizure . Signs
of this type of damage include knocking noises due to inadequate piston guidance in the cylinder, rough
idling, blue smoke, the Check Engine light may come on. Negative pressure loss test.
Fig 8: Identifying Piston Seizure
WM 101802 CHECKING PRESSURE LOSS OF CYLINDERS (CAYENNE TIP, CAYENNE

MAN, CAYENNE S, CAYENNE TURBO, CAYENNE GTS, CAYENNE TURBO S) > TOOLS

Pressure loss Workshop WE 1066
tester Bosch equipment
EFAW 210 A

MAN, CAYENNE S, CAYENNE TURBO, CAYENNE GTS, CAYENNE TURBO S) >
PRELIMINARY WORK
Information
1. Unscrew and remove all spark plugs. → REMOVING SPARK PLUGS
2. Position cylinder to be tested to ignition TDC and remove tool (dead center finder).
1. 2.1. The dead center finder or "cylinder pipe" consists of a glass tube (inspection
glass) with a plunger -1- , hose and a rubber cone -2- .
Fig 1: Identifying Dead Centre Finder - Cylinder Pipe
2. 2.2. The rubber cone is pressed onto the spark plug hole. The inspection glass is
either held by a helper → Tool setup - dead center finder or is secured vertically in a
clearly visible position with a magnet.
Fig 2: Installing Tool (Dead Centre Finder)
3. 2.3. If the engine is now turned in direction of rotation on the crankshaft, the plunger
in the inspection glass is pressed up in the compression cycle → Plunger up in order
to go back down immediately upon reaching the TDC. The plunger in the inspection
glass stays down in overlapping TDC → Plunger down .
Fig 3: Identifying Plunger Up Position

Fig 4: Identifying Plunger Down Position

INFORMATION > TEST EVALUATION
The test does not show any meaningful result on a new engine (i.e. one that hasn't been run in).
A difference in pressure loss between the individual cylinders of approx. 5% is not significant.
If the test shows an excessive loss of pressure (> 30%), a few drops of oil can be sprayed into the
combustion chamber. Repeat the test. If the loss in pressure is now significantly less, the seal
between the piston and cylinder is damaged.
The air that is escaping causes hissing noises, which provide information about the component
that is causing the damage.
If the limit values are exceeded, the engine must be started and the test repeated .
Potentially faulty component Location of noise
Pistons, piston rings, cylinder line Oil filler neck, positive crankcase ventilation
Cylinder head gasket, cylinder head Coolant expansion tank
Exhaust valve Exhaust system

Inlet valve Intake system

CHECKING PRESSURE LOSS ON THE ENGINE
WARNING: Rotating components
Information
The check for loss of pressure can be used to assess the mechanical condition of a combustion
engine .
A pressure loss test is more meaningful than the compression pressure check .
The percentage leakage quantity can be used to establish whether the leaks in the combustion
chamber in question are so large that the combustion chamber must be repaired .
The worn components (e.g. piston rings) can be identified by the compressed air that is escaping .
Information
The piston must be exactly at the upper return point when checking pressure loss. Do not touch any
components of the belt drive and do not put any tools on the crankshaft pulley while performing the
check.
Information
Information
Read the work steps and tips in the operating instructions for the Bosch tester before performing the
pressure loss test. The described Bosch tester is used as an example for all suitable pressure loss
testers. Details of calibration and use can be found in the relevant operating instructions.
1. Get the tester ready. Pressure loss tester Bosch EFAW 210 A WE 1066
2. Screw the test hose into the spark plug thread of cylinder 1 by hand (compression TDC) and
tighten hand-tight.
Fig 1: Installing Test Hose Into Spark Plug Thread
3. Connect the pressure loss tester to the compressed air system.
4. Adjust the scale. To do this, insert the test nozzle at the front into the device.
Fig 2: Adjusting Nozzle Check Scale
5. Turn the adjusting wheel until the scale pointer is at the "cal." marking or "23%". The pressure
is then equal in the two test chambers of the tool.
Fig 3: Adjusting Wheel
6. Remove test nozzle and check that the pointer falls back. Then connect the test hose. The
value that is displayed should not be greater than 25%. If the pressure loss is greater, it is safe
to assume that the engine needs an overhaul.
Fig 4: Checking Pressure Loss
7. Interrupt the compressed air supply and unscrew the test hose.
8. Check the next cylinder by turning the crankshaft through another 90° and check the next
cylinder in the firing order following the instructions provided.

SUBSEQUENT WORK
1. Remove the test hose once the test is complete.
2. Fit all spark plugs. → INSTALLING SPARK PLUGS
WM 101802 TESTING PRESSURE LOSS ON THE ENGINE (CAYENNE, CAYENNE GTS,

CAYENNE TURBO S, CAYENNE S HYBRID, CAYENNE TURBO) > TOOLS

Pressure loss Workshop WE 1066
tester Bosch equipment
EFAW 210 A

CAYENNE TURBO S, CAYENNE S HYBRID, CAYENNE TURBO) > PRELIMINARY
WORK
Information
1. Unscrew and remove all spark plugs. → REMOVING SPARK PLUGS
Fig 1: Identifying Dead Centre Finder (Cylinder Pipe)
either held by a helper → Tool setup - dead center finder or is secured vertically in a
clearly visible position with a magnet.
Fig 2: Installing Tool (Dead Centre Finder)


CAYENNE TURBO S, CAYENNE S HYBRID, CAYENNE TURBO) > INFORMATION >
TEST EVALUATION


CAYENNE TURBO S, CAYENNE S HYBRID, CAYENNE TURBO) > TESTING
PRESSURE LOSS ON THE ENGINE > CHECKING PRESSURE LOSS ON THE ENGINE
Information
engine .
Information
check.
Information
Information
1. Get the tester ready. Pressure loss tester Bosch EFAW 210 A WE 1066
tighten hand-tight.
Fig 1: Installing Test Hose Into Spark Plug Thread
Fig 2: Adjusting Nozzle Test Scale
5. Turn the adjusting wheel until the scale pointer is at the "cal." marking or "23%". The pressure
is then equal in the two test chambers of the tool.
Fig 3: Adjusting Wheel
6. Remove test nozzle and check that the pointer falls back. Then connect the test hose. The
value that is displayed should not be greater than 25%. If the pressure loss is greater, it is safe
to assume that the engine needs an overhaul.
cylinder in the firing order following the instructions provided.

CAYENNE TURBO S, CAYENNE S HYBRID, CAYENNE TURBO) > SUBSEQUENT
WORK
2. Fit all spark plugs. → INSTALLING SPARK PLUGS
WM 101802 TESTING PRESSURE LOSS FROM THE ENGINE (CAYENNE TIP

1. Unscrew all spark plugs. → REMOVING SPARK PLUGS
glass) with a piston -1- , hose and a rubber cone -2- .
Fig 1: Identifying Cylinder Dead Centre Finder
either held by a helper → Tool setup for dead center finder or is secured vertically in
a clearly visible position with a magnet.
Fig 2: Installing Dead Centre Finder Tool
3. 2.3. If the engine is now turned in direction of rotation on the crankshaft, the piston in
the inspection glass is pressed up in the compression cycle → Piston up in order to
go back down immediately upon reaching the TDC. The piston in the inspection
glass stays down in overlapping TDC → Piston down .
Fig 3: Identifying Piston Up Position

Fig 4: Identifying Piston Down Position

"PLATINUM EDITION", CAYENNE TIP, CAYENNE MAN) > TOOLS AND MATERIALS >
TOOLS
Information
The tool described here is an example of a pressure loss tester available from various
manufacturers .
The procedure is essentially the same for all pressure loss testers .
Fig 1: Identifying Pressure Loss Check Tool Kit
-A- Test hose with spark plug

thread WE1066
pressure loss tester
Bosch EFAW 210 A
-B- Test nozzle WE1066 Test nozzle for adjusting display scale. This
pressure loss tester must be done before every test.
Bosch EFAW 210 A
-C- Pressure loss tester

WE1066 pressure loss
tester Bosch EFAW 210
A

"PLATINUM EDITION", CAYENNE TIP, CAYENNE MAN) > INFORMATION > TEST
EVALUATION

"PLATINUM EDITION", CAYENNE TIP, CAYENNE MAN) > TESTING PRESSURE LOSS
FROM THE ENGINE > CHECKING PRESSURE LOSS
Information
Information
check.
Information
engine .
1. Position cylinder to be tested to ignition TDC and remove tool. The ignition TDC of cylinder 1
(and the remaining cylinders) can be tested using the "dead center finder" contained in
WE1066 pressure loss tester Bosch EFAW 210 A.
Fig 1: Locating Cylinder 1 TDC
tighten hand-tight.
Fig 2: Installing Test Hose Into Spark Plug
Fig 3: Adjusting Test Nozzle Scale
5. Turn the adjusting wheel until the scale pointer is at the "cal." marking or "23%".
Fig 4: Adjusting Test Nozzle Scale Wheel
6. Remove the test nozzle and check that the pointer falls back. Connect the test hose. The value
that is displayed should not be greater than 25 %. If the loss in pressure is greater, it is safe to
assume that the engine needs an overhaul.
cylinder in the firing order.
V6 firing order: 1 - 5 - 3 - 6 - 2 - 4

1. Remove the test hose once the test is complete and install the spark plugs. → INSTALLING
SPARK PLUGS
WM 101802 TESTING PRESSURE LOSS FROM THE ENGINE > TOOLS

II
WM 101802 TESTING PRESSURE LOSS FROM THE ENGINE > PRELIMINARY WORK
1. Remove engine cover. → Removing Engine Cover (Design Cover) 108319 REMOVING AND
INSTALLING ENGINE COVER (DESIGN COVER)
2. Remove all glow plugs.
Fig 1: Identifying Dead Centre Finder Tool

2. 3.2. The rubber cone is pressed onto the glow plug hole. The inspection glass is
either held by a helper → Tool setup for dead center finder or is secured vertically in
a clearly visible position with a magnet.
Fig 2: Identifying Dead Centre Finder Tool

WM 101802 TESTING PRESSURE LOSS FROM THE ENGINE > TOOLS AND
MATERIALS > TOOLS
Information
The tool described here is an example of a pressure loss tester available from various
manufacturers .
The procedure is essentially the same for all pressure loss testers .
Fig 1: Identifying Pressure Loss Check Tool Kit
-A- Test hose with glow plug

thread WE1066
Pressure loss tester
Bosch EFAW 210 A
-B- Test nozzle WE1066 Test nozzle for adjusting display scale. This
Pressure loss tester must be done before every test.
Bosch EFAW 210 A
-C- Pressure loss tester

WE1066 Pressure loss
tester Bosch EFAW 210
A
WM 101802 TESTING PRESSURE LOSS FROM THE ENGINE > INFORMATION > TEST
EVALUATION
WM 101802 TESTING PRESSURE LOSS FROM THE ENGINE > TESTING PRESSURE
LOSS FROM THE ENGINE
Information
Information
check.
Information
engine .
1. Position cylinder to be tested to ignition TDC and remove tool. The ignition TDC of cylinder 1
(and the remaining cylinders) can be tested using the "dead center finder" contained in
WE1066 pressure loss tester Bosch EFAW 210 A.
2. Screw the test hose into the glow plug thread of cylinder 1 by hand (compression TDC) and
tighten hand-tight.

4. Adjust the scale.
To do this, insert the test nozzle at the front into the device.
Fig 1: Adjusting Test Nozzle Scale
5. Turn the adjusting wheel until the scale pointer is at the "cal." marking or "23%".
Fig 2: Adjusting Test Nozzle Scale Wheel
6. Remove the test nozzle and check that the pointer falls back. Connect the test hose. The value
that is displayed should not be greater than 25 %. If the loss in pressure is greater, it is safe to
assume that the engine needs an overhaul.
cylinder in the firing order.
Firing order - V6: 1 - 4 - 3 - 6 - 2 - 5
WM 101802 TESTING PRESSURE LOSS FROM THE ENGINE > SUBSEQUENT WORK
1. Install all glow plugs.
2. Install engine cover. → Installing Engine Cover (Design Cover) 108319 REMOVING AND
3. Check the fault memory of the engine control unit using PIWIS Tester II 9818 and erase it
because faults will have been stored when you disconnected the plug connections.
WM 101902 CHECKING COMPRESSION OF CYLINDERS (CAYENNE DIESEL

"PLATINUM EDITION", CAYENNE DIESEL) > TOOLS
compression Workshop WE 1333

tester and equipment
recorder

II

"PLATINUM EDITION", CAYENNE DIESEL) > PRELIMINARY WORK
Information
Test conditions for compression pressure check
Engine oil temperature: approx. 80 °C.

Battery voltage: at least 12.5 V.
1. Remove engine cover. → Removing Engine Cover (Design Cover) 108319 REMOVING AND
2. Disconnect electric plug connections at the glow plugs.
3. Disconnect electric plug connection at the fuel pressure regulator -arrow- on the fuel
distributor (cylinders 1-3).
Fig 1: Locating Pressure Regulator Electric Plug Connection
4. Reduce the fuel pressure in the fuel distributor.
To do this, start the engine briefly.
5. Remove all glow plugs.

"PLATINUM EDITION", CAYENNE DIESEL) > CHECKING COMPRESSION LEVEL
Information
For information on using the tester ==> Operating instructions
1. Screw in adapter for the compression tester and recorder WE 1333 (-2- ) instead of the
glow plug for cylinder 1 and connect the compression tester -1- .
Fig 1: Identifying Compression Tester And Recorder WE 1333
Information
Test conditions for compression pressure check
1. Engine oil temperature: approx. 80 °C.
2. Battery voltage: at least 12.5 V.
2. Get a second worker to actuate the starter until the reading on the tester shows that there is no
longer any increase in pressure.
3. Save the test value.
4. Repeat steps 1, 2 and 3 for cylinders 2 - 6.
5. Print test log.
Compression values bar overpressure
New 28....33
Wear limit 21
Difference between the cylinders Max. 5

"PLATINUM EDITION", CAYENNE DIESEL) > SUBSEQUENT WORK
1. Install all glow plugs.
2. Connect electric plug connection to the fuel pressure regulator -arrow- .

Fig 1: Locating Pressure Regulator Electric Plug Connection
3. Install engine cover. → Installing Engine Cover (Design Cover) 108319 REMOVING AND
4. Check the fault memory of the engine control unit using PIWIS Tester II 9818 and erase it
because faults will have been stored when you disconnected the plug connections.
WM 103019 REMOVING AND INSTALLING ENGINE CARRIER (CAYENNE TIP,

TIP (3.0)) > TECHNICAL VALUES
Fastening Tightening 60 Nm (44 +/-8 Nm (+/- 6

screw on torque ftlb.) ftlb.)
hydraulic
mount

TIP (3.0)) > PRELIMINARY WORK
1. Support the engine on the body. → 1001IN SUPPORTING ENGINE ON THE BODY
2. Remove engine guard. → Removing Engine Guard
3. Remove the front-axle carrier. → REMOVING FRONT-AXLE CARRIER

TIP (3.0)) > INFORMATION > COMPONENT INFORMATION
Fig 1: Identifying Engine Carrier And Accessories
1. Engine carrier
2. Hydraulic mount
3. Fastening screws

TIP (3.0)) > REMOVING ENGINE CARRIER
Information
This task can only be performed if the engine has been removed or suspended on the body .
1. Unscrew the two fastening screws -3- at the left and right on the hydraulic mounts from below.
Fig 1: Identifying Hydraulic Mounts Screws
2. Remove engine carrier by pulling it downwards.

TIP (3.0)) > INSTALLING ENGINE CARRIER
1. The engine carrier is installed in reverse order to removal.

2. Tighten the fastening screws on the hydraulic mounts to → Tightening torque: 60 Nm (44
ftlb.)+/-8 Nm (+/-6 ftlb.)

TIP (3.0)) > SUBSEQUENT WORK
1. Install the front-axle carrier. → INSTALLING FRONT-AXLE CARRIER
2. Install engine guard. → Installing Engine Guard
WM 103519 REMOVING AND INSTALLING ENGINE MOUNTING (HYDRAULIC MOUNT)

(CAYENNE TIP (3.0) "PLATINUM EDITION", CAYENNE TIP (3.0)) > TECHNICAL
VALUES
Fastening Replace Initial tightening 120 Nm (89

screws for ftlb.)
engine carrier
Fastening Final tightening +180°

screws for
engine carrier

engine
mounting to
engine carrier

right engine
support to
engine
Fastening Initial tightening 50 Nm (37

screw securing ftlb.)
right engine
support to
engine

screw securing
right engine
support to
engine

engine support
to engine
mounting

left engine
support to
engine

left engine
support to
engine

engine
mounting to
engine carrier

(CAYENNE TIP (3.0) "PLATINUM EDITION", CAYENNE TIP (3.0)) > PRELIMINARY
WORK
COMPARTMENT)
3. Remove the complete air cleaner housing. → REMOVING AIR CLEANER HOUSING
5. Screw off nut -arrow- for left engine mounting.

Fig 1: Locating Left Engine Mounting
6. Screw off nut -arrow- for right engine mounting.

Fig 2: Locating Right Engine Mounting

(CAYENNE TIP (3.0) "PLATINUM EDITION", CAYENNE TIP (3.0)) > REMOVING ENGINE
MOUNTING > ASSEMBLY OVERVIEW - ANCILLARY UNIT MOUNTS
Information
For more information, see P ORSCHE E LECTRONIC PAR T "PET"
+180°
2. Engine mounting

12 - Engine carrier
-

MOUNTING > REMOVING LEFT ENGINE MOUNTING
1. Drain refrigerant. → DRAINING AND FILLING REFRIGERANT
2. Disconnect air-conditioning line -arrow- at the compressor. → REMOVING ELECTRIC

Fig 1: Locating Air-Conditioning Line (Compressor)
3. Raise the engine with the engine support.
4. Unscrew fastening screws -arrows- for the engine mounting. Remove engine mounting.
Fig 2: Locating Left Engine Mounting Point

MOUNTING > REMOVING RIGHT ENGINE MOUNTING
1. Remove the generator. → REMOVING GENERATOR
Fig 1: Locating Right Engine Mounting Point

(CAYENNE TIP (3.0) "PLATINUM EDITION", CAYENNE TIP (3.0)) > INSTALLING
ENGINE MOUNTING > INSTALLING LEFT ENGINE MOUNTING
Information
1. Insert and tighten engine mounting -arrows- .

Fig 1: Locating Left Engine Mounting Points
2. Slowly lower the engine and guide the threaded bolt into the engine support.
3. Screw on and tighten nut -arrow- for engine mounting.

4. Secure air-conditioning line -arrow- at the compressor → INSTALLING ELECTRIC

1. 4.1. Replace sealing ring for air-conditioning line.

Fig 3: Locating Air-Conditioning Line At Compressor
5. Fill in refrigerant. → DRAINING AND FILLING REFRIGERANT

(CAYENNE TIP (3.0) "PLATINUM EDITION", CAYENNE TIP (3.0)) > INSTALLING
ENGINE MOUNTING > INSTALLING RIGHT ENGINE MOUNTING
Information

Fig 1: Locating Right Engine Mounting Points
3. Screw on and tighten nut -arrow- for engine mounting.


(CAYENNE TIP (3.0) "PLATINUM EDITION", CAYENNE TIP (3.0)) > SUBSEQUENT
WORK
1. Remove engine support. → 1001IN SUPPORTING THE ENGINE ON THE BODY
2. Fit air cleaner housing. → INSTALLING AIR CLEANER HOUSING
3. Install engine compartment trim panel. → INSTALLING FRONT TRIM PANEL (ENGINE
COMPARTMENT)

ON V6 DFI ENGINES (CAYENNE TIP "PLATINUM EDITION", CAYENNE TIP, CAYENNE
MAN) > TECHNICAL VALUES
Hexagon nut M12 x 1.5 Tightening 75 Nm (56

on engine torque ftlb.)
mounting

MAN) > PRELIMINARY WORK
1. Remove engine carrier. → Removing Engine Carrier 103019 REMOVING AND INSTALLING
ENGINE CARRIER ON DFI ENGINES

MAN) > REMOVING ENGINE MOUNTING
1. Remove engine mounting.
1. 1.1. Loosen hexagon nut -A- .
2. 1.2. Remove engine mounting.

Fig 1: Locating Engine Mounting Nut

MAN) > INSTALLING ENGINE MOUNTING
Information
The engine mounts must be aligned using the engine carrier .
The engine mounts differ (left/right) and must not be interchanged .
1. Install engine mounting.
1. 1.1. Fit engine mounting.
2. 1.2. The dowel pin of the engine mounting must sit correctly into the cut-out on the
engine carrier.
3. 1.3. Fit fastening screws -arrows- but do not tighten yet.
4. 1.4. The hexagon nut -A- must always be replaced and tightened to → Tightening
Fit the engine carrier to prevent the bearing from turning.
Fig 1: Locating Engine Mountings Nut

MAN) > SUBSEQUENT WORK
1. Install engine carrier. → Installing Engine Carrier 103019 REMOVING AND INSTALLING
ENGINE CARRIER ON DFI ENGINES
WM 103519 REMOVING AND INSTALLING ENGINE MOUNT (CAYENNE GTS,

CAYENNE S HYBRID) > TECHNICAL VALUES
Fastening M10 x 45 Tightening 65 Nm (48

bracket for
engine mount
to engine

bracket for
engine mount
to engine
Fastening M12 x 1.5/replace Initial tightening 90 Nm (67

engine mount
to bracket

screw securing
engine mount
to bracket

CAYENNE S HYBRID) > TECHNICAL VALUES > ENGINE MOUNTING
1. Bracket for engine mount, right
3. Right engine mount
4. Left engine mount
6. Bracket for engine mount, left
7. Dowel sleeve, 14m 6x 15

Fig 1: Identifying Engine Mounting Bracket And Screw
Not shown - Screw (M12 x 1.5) securing engine mount to bracket/replace → Initial tightening: 90 Nm
(67 ftlb.) → Final tightening: +90°

CAYENNE S HYBRID) > PRELIMINARY WORK
1. Remove engine carrier. → Removing Engine Carrier 103019 REMOVING AND INSTALLING
ENGINE CARRIER

CAYENNE S HYBRID) > REMOVING ENGINE MOUNT
Information
The procedure for removing and installing is described for one side as an example. The procedure for
the other side is practically identical.
Information
1. Remove engine mount -1- .
1. 1.1. Lift and secure the cover -2- .
2. 1.2. Unscrew screw -3- and remove engine mount -1- .

Fig 1: Identifying Engine Mount

CAYENNE S HYBRID) > INSTALLING ENGINE MOUNT
Information
1. Install engine mount.
1. 1.1. Position engine mount and fit screw.
2. 1.2. Tighten screw to the specified torque.

CAYENNE S HYBRID) > SUBSEQUENT WORK
1. Install engine carrier. → Installing Engine Carrier 103019 REMOVING AND INSTALLING
ENGINE CARRIER
WM 103519 REMOVING AND INSTALLING ENGINE MOUNTING (CAYENNE S E) >
TECHNICAL VALUES
Fastening Replace Initial tightening 120 Nm (89

screws for ftlb.)
engine carrier

screws for
engine carrier

engine
mounting to
engine carrier

right engine
support to
engine

right engine
support to
engine

screw securing
right engine
support to
engine

engine support
to engine
mounting

left engine
support to
engine

left engine
support to
engine
engine
mounting to
engine carrier

PRELIMINARY WORK
COMPARTMENT)
3. Remove the complete air cleaner housing. → REMOVING AIR CLEANER HOUSING
4. Remove power-steering reservoir and set it aside. → REMOVING RESERVOIR
5. Remove power electronics. → REMOVING FUSE FOR POWER ELECTRONICS UNIT
7. Screw off nut -arrow- for left engine mounting.


8. Screw off nut -arrow- for right engine mounting.

ASSEMBLY OVERVIEW - ANCILLARY UNIT MOUNTS
Information
For more information, see P ORSCHE E LECTRONIC PAR T "PET"
+180°
2. Engine mounting

12 - Engine carrier
-

REMOVING LEFT ENGINE MOUNT
1. Remove air-conditioning compressor. → REMOVING ELECTRIC AIR-CONDITIONING

COMPRESSOR
3. Unscrew fastening screws -arrows- for the engine mount. Remove engine mount.

REMOVING RIGHT ENGINE MOUNTING

INSTALLING LEFT ENGINE MOUNTING
Information

3. Install air-conditioning compressor. → INSTALLING ELECTRIC AIR-CONDITIONING

COMPRESSOR

INSTALLING RIGHT ENGINE MOUNTING
Information

Fig 1: Locating Right Engine Mounting Point

SUBSEQUENT WORK
1. Screw on and tighten nut -arrow- for right engine mounting.

2. Screw on and tighten nut -arrow- for left engine mounting.

3. Remove engine support. → 1001IN SUPPORTING THE ENGINE ON THE BODY
4. Install power electronics. → INSTALLING FUSE FOR POWER ELECTRONICS UNIT
5. Fit air cleaner housing. → INSTALLING AIR CLEANER HOUSING
6. Install engine compartment trim panel. → INSTALLING FRONT TRIM PANEL (ENGINE
COMPARTMENT)
WM 103719 REMOVING AND INSTALLING TORQUE SUPPORT (CAYENNE GTS,

CAYENNE S HYBRID) > TECHNICAL VALUES
Torque support Always replace Initial 20 Nm (15

to body and aluminum screws tightening ftlb.)
valve cover and nuts
Torque support Final tightening 180°
to body and
valve cover
WM 1052IN INFORMATION ON ENGINE VENTILATION SYSTEMS ON TURBO

ENGINES (OBD2) - ESPECIALLY FOR USA (CAYENNE TIP "PLATINUM EDITION",
CAYENNE TURBO S) > INFORMATION > GENERAL INFORMATION
Information
More stringent exhaust emission laws worldwide now mean that gas-conducting lines and vent
lines must increasingly undergo diagnosis (checking for leaks) .
It is technically possible to monitor the lines and connection points using additional sensors, but
this is technically complex .
Lines and line connection points are increasingly designed as hard-to-open one-way connections
.
One-way connections or hard-to-open joints are jointed once in the assembly plant or following
reinstallation and can only be opened by damaging them irreparably .
One-way connections or hard-to-open joints are a means of preventing you from inadvertently
forgetting a plug-in connection following repairs .
One-way connections or hard-to-open joints can only be removed as a complete unit or by

damaging them irreparably. Following irreparable damage, the individual parts must be replaced
one by one and fitted once during assembly. This will restore the original joint again .
One-way connections or hard-to-open joints are no longer required if the connection was
inadvertently installed incorrectly and as a result, the engine cuts out/will not start, traces of fluid/oil
are visible or the line is monitored by vehicle diagnosis (Check Engine light comes on, P code
stored in the fault memory) .
Naturally aspirated engines are currently not affected as leaks can be detected .
Fig 1: Identifying Ventilation System One-Way Connections (Panamera Turbo)
1. Turbocharger/manifold module
2. Check valve on vent line for oil mist separator and intake-air distributor
3. Full-throttle ventilation one-way connection => Cannot be refitted. Check that the markings are
positioned correctly during initial assembly.
4. Full-throttle ventilation one-way connection for intake manifold => Cannot be refitted. Check
that the markings are positioned correctly during initial assembly.
General information =>
Vacuum lines, vent lines and gas-conducting lines are increasingly fitted with hard-to-open joiners
or one-way connections.
Some ends of hoses are bonded to connection pieces, shrink-fit or fitted with one-way clamps.
If affected one-way connections need to be removed or disassembled in order to replace

components or carry out repairs, the circuits and routings must be removed unopened along with
several components in the complete assembly or they must be disassembled and thereby
damaged irreparably. This involves using new one-way joiners or replacing entire pipes and lines.
WM 1052IN INFORMATION ON ENGINE VENTILATION SYSTEMS ON TURBO

ENGINES (OBD2) - ESPECIALLY FOR USA (CAYENNE TIP "PLATINUM EDITION",
CAYENNE TURBO S) > INFORMATION > OVERVIEW OF AFFECTED LINE
CONNECTIONS - CAYENNE TURBO
1. Do not open clamp! Leaks cannot be detected!
2. Do not open clamp! Leaks cannot be detected!

Fig 1: Identifying PCV Engine Ventilation
1. Full-throttle ventilation one-way connection => Can be opened but will be damaged irreparably,
so cannot be refitted. Make sure the markings are positioned correctly with respect to each
other during initial fitting. => Leaks cannot be detected!
2. Full-throttle ventilation one-way connection to intake manifold => Can be opened but will be
damaged irreparably, so cannot be refitted. Make sure the markings are positioned correctly
with respect to each other during initial fitting. => Leaks cannot be detected!
Fig 2: Identifying Throttle Ventilation
WM 105119 REMOVING AND INSTALLING POSITIVE CRANKCASE VENTILATION

VALVE (CAYENNE GTS, CAYENNE S HYBRID) > TECHNICAL VALUES
Fastening screw M6 x 30 Tightening 10 Nm (7.5

for positive torque ftlb.)
crankcase
ventilation valve
Fastening screw M6 x 16; replace Initial tightening 4 Nm (3 ftlb.)

securing positive aluminum screw
crankcase
ventilation line to
timing-case
cover
Fastening screw Final tightening 90°

securing positive
crankcase
ventilation line to
timing-case
cover

VALVE (CAYENNE GTS, CAYENNE S HYBRID) > TECHNICAL VALUES > POSITIVE
CRANKCASE VENTILATION
1. Positive crankcase ventilation valve → Tightening torque: 10 Nm (7.5 ftlb.)

2. Positive crankcase ventilation line
3. O-ring, 22.5 x 2.5 FPM
4. O-ring, 22.5 x 2.5 HNBR
5. Aluminum screw, M6 x 16 → Initial tightening: 4 Nm (3 ftlb.) → Final tightening: 90°
6. Holder
Fig 1: Identifying Positive Crankcase Ventilation Valve And O-Ring

VALVE (CAYENNE GTS, CAYENNE S HYBRID) > PRELIMINARY WORK
1. Remove engine cover.
→ Removing Engine Cover (Design Cover) 108319 REMOVING AND INSTALLING ENGINE
COVER (DESIGN COVER)

VALVE (CAYENNE GTS, CAYENNE S HYBRID) > REMOVING POSITIVE CRANKCASE
VENTILATION VALVE
1. Remove positive crankcase ventilation valve -1- .
1. 1.1. Unclip line -2- from positive crankcase ventilation valve.
2. 1.2. Unscrew screw on positive crankcase ventilation valve.
3. 1.3. Pull positive crankcase ventilation valve -1- off the cylinder head cover.
Fig 1: Identifying Positive Crankcase Ventilation Valve And Line

VALVE (CAYENNE GTS, CAYENNE S HYBRID) > INSTALLING POSITIVE CRANKCASE
VENTILATION VALVE
1. Install positive crankcase ventilation valve -1- .
1. 1.1. Check sealing rings -3- and -4- and replace them if necessary.
2. 1.2. Position positive crankcase ventilation valve -1- on the cylinder head cover.
3. 1.3. Secure line -2- .
4. 1.4. Screw in screw and tighten it Tightening torque 10 Nm (7.5 ftlb.)

Fig 1: Identifying Positive Crankcase Ventilation Sealing Ring And Line

VALVE (CAYENNE GTS, CAYENNE S HYBRID) > SUBSEQUENT WORK
1. Install engine cover.
→ Installing Engine Cover (Design Cover) 108319 REMOVING AND INSTALLING ENGINE

HOSE (CAYENNE S E, CAYENNE (3.0)) > PRELIMINARY WORK
1. Remove compressor. → REMOVING COMPRESSOR

HOSE (CAYENNE S E, CAYENNE (3.0)) > REMOVING POSITIVE CRANKCASE
VENTILATION HOSE
1. Remove positive crankcase ventilation hoses -arrows- from the cylinder head covers by
pressing the release buttons.
Unscrew screw -1- and remove adapter with positive crankcase ventilation hoses.
Fig 1: Locating Positive Crankcase Ventilation Hose

HOSE (CAYENNE S E, CAYENNE (3.0)) > INSTALLING POSITIVE CRANKCASE
VENTILATION HOSE
Information
1. Installation is performed in reverse order. Pay particular attention to the following:
1. 1.1. Replace O-rings.
2. 1.2. Attach all tie-wraps at the same places during installation.

HOSE (CAYENNE S E, CAYENNE (3.0)) > SUBSEQUENT WORK
1. Install compressor. → INSTALLING COMPRESSOR
WM 105519 REMOVING AND INSTALLING OIL SEPARATOR (CAYENNE S E,

Oil non-return Tightening 20 Nm (15

valve torque ftlb.)

screw on cover torque
with oil
separator

screw on cover torque
with oil
separator

screw for torque
positive
crankcase
ventilation
pipes
Oil non-return Tightening 20 Nm (15

valve torque ftlb.)

1. Remove positive crankcase ventilation hoses. → 105219 REMOVING AND INSTALLING

POSITIVE CRANKCASE VENTILATION HOSE
2. Remove upper coolant pipe. → REMOVING UPPER COOLANT PIPE
3. Remove lower part of intake manifold at the left. → REMOVING LOWER PART OF INTAKE
MANIFOLD WITH FUEL DISTRIBUTOR

CAYENNE (3.0)) > REMOVING OIL SEPARATOR > ASSEMBLY OVERVIEW - OIL
NON-RETURN VALVE, OIL SEPARATOR
1. O-ring/replace
2. Oil non-return valve, for oil supply for right cylinder head → Tightening torque: 20 Nm (15
ftlb.)
3. Seal/replace
4. Cover with oil separator
1. With connection for positive crankcase ventilation

6. O-ring/replace
7. Adapter, for positive crankcase ventilation
8. O-ring/replace
11. Pipes for positive crankcase ventilation
1. To cylinder head covers
12. O-ring/replace
13. Positive crankcase ventilation hose to air guide pipe
14. Hose clamp
15. Oil non-return valve, for oil supply for left cylinder head → Tightening torque: 20 Nm (15
ftlb.)
16. O-ring/replace
Fig 1: Overview Of Oil Non-Return Valve And Oil Separator

CAYENNE (3.0)) > REMOVING OIL SEPARATOR > REMOVING OIL SEPARATOR
1. Remove screws -arrows- .
Remove holder for high-pressure lines and cover -1- with oil separator.
Fig 1: Locating Oil Separator

CAYENNE (3.0)) > INSTALLING OIL SEPARATOR
Information
1. 1.1. Replace the seal.

1. Install lower part of intake manifold on the left. → INSTALLING LOWER PART OF INTAKE
2. Install upper coolant pipe. → INSTALLING UPPER COOLANT PIPE
3. Install positive crankcase ventilation hoses. → 105219 REMOVING AND INSTALLING

POSITIVE CRANKCASE VENTILATION HOSE
WM 105619 REMOVING AND INSTALLING BEARING COVER FOR BALANCE SHAFT

(CAYENNE) > TECHNICAL VALUES
Fastening Tighten crosswise Tightening 9 Nm (6.5 ftlb.)

screw securing in several steps torque
bearing cover
to crankcase

deflection roller
to bearing
cover
Double screw Tightening 9 Nm (6.5 ftlb.)

torque

securing torque
coolant pipe to
bearing cover
Fastening Tighten crosswise Tightening 9 Nm (6.5 ftlb.)

screw for in several steps torque
bearing cover

deflection roller
to bearing
cover

coolant pipe to
engine

(CAYENNE) > PRELIMINARY WORK > REMOVING AND INSTALLING BEARING
COVER FOR BALANCE SHAFT
1. Remove pulley for coolant pump. → REMOVING COOLANT PUMP
2. Remove vibration damper (crankshaft pulley). → REMOVING VIBRATION DAMPER

(CAYENNE) > INFORMATION > COMPONENT OVERVIEW
1. Fastening screw → Tightening torque: 9 Nm (6.5 ftlb.)
2. Sealing ring for crankshaft pulley
3. Bearing cover for balance shaft
4. Cover for deflection roller
5. Fastening screw → Tightening torque: 23 Nm (17 ftlb.)
6. Drive-belt deflection roller
7. Double screw → Tightening torque: 9 Nm (6.5 ftlb.)
8. Fastening nut → Tightening torque: 9 Nm (6.5 ftlb.)
9. Right coolant pipe
10. O-ring
11. Dowel pins
12. O-rings
13. Seal
Fig 1: Overview Of Balance Shaft Bearing Cover

(CAYENNE) > REMOVING BEARING COVER FOR BALANCE SHAFT
1. Unscrew the fastening screws to the right -1- of the coolant pipe -2- .
Fig 1: Identifying Coolant Pipe
2. Lever the fastening clip on the coolant pipe -2- up as far as necessary to allow the bearing
cover to be removed later.
3. Lever the cap off the drive-belt deflection roller.

Fig 2: Locating Drive-Belt Deflection Roller
4. Unscrew the fastening screws -arrow- and remove the deflection roller from the bearing
cover.
5. Unscrew the fastening screws from the bearing cover.
6. Pull off the front bearing cover first at the right -arrows 1- and then at the left -arrows 2- .
Fig 3: Removing Bearing Cover
7. Drive out the sealing ring for the crankshaft pulley when the bearing cover is removed.

(CAYENNE) > INSTALLING BEARING COVER FOR BALANCE SHAFT
WARNING: Risk of damage or injury from foreign bodies flying around during grinding,
drilling and milling
Information
Risk of contaminating the lubricating system.
Cover open parts of the engine .
1. Remove old sealant and sealant residue from the grooves and sealing faces on the bearing
cover and on the crankcase and/or upper part of the oil pan. Use a rotating plastic brush, for
example, to do this. → Cleaning sealing faces with a plastic brush
Fig 1: Cleaning Sealing Faces Using Plastic Brush
2. Clean the sealing faces to remove any oil and grease.
3. Cut off the nozzle on the tube at the front marking (nozzle diameter is approx. 2 mm).
Fig 2: Cutting Tube Nozzle
4. Fit the seals -2 and 4- and sealing rings -1 and 3- .
5. Apply the bead of sealant to the clean sealing face of the bearing cover as shown in the
illustration below.
Information
1. The bead of sealant must not be thicker than the specified thickness because otherwise
excess sealant can get into the oil pan and can block the strainer in the oil pump .
2. The bearing cover must be installed within 5 minutes of applying the sealant .
The bead of sealant must be between 1.5 and 2.0 mm high .

Fig 3: Locating Sealant Applying Bead
6. Position the bearing cover and tighten the fastening screws. → Tightening torque: 9 Nm (6.5
ftlb.)
7. Position the deflection roller on the bearing cover and tighten the fastening screw -arrow- . →
Fig 4: Locating Drive-Belt Deflection Roller
8. Fit cap on the drive-belt deflection roller.
9. Bend the fastening clip on the coolant pipe -2- back to its original position.
Fig 5: Identifying Coolant Pipe
10. Tighten the fastening screws to the right -1- of the coolant pipe -2- . → Tightening torque: 9
Nm (6.5 ftlb.)

(CAYENNE) > SUBSEQUENT WORK > REMOVING AND INSTALLING BEARING
COVER FOR BALANCE SHAFT
1. Install the sealing ring for the crankshaft pulley. → INSTALLING CRANKSHAFT SEALING
RING FOR PULLEY/VIBRATION BALANCER
2. Install the coolant pump pulley. → INSTALLING COOLANT PUMP
WM 108019 REMOVING AND INSTALLING ENGINE GUARD (CAYENNE TIP, CAYENNE

TECHNICAL VALUES

Engine guard M6 Tightening 9 Nm (6.5 ftlb.)
torque

REMOVING ENGINE GUARD
1. Unscrew side fastening screws -1- for the front part of the engine guard.
Fig 1: Loosening Engine Guard Screws
2. Unscrew rear -2- and front fastening screws -3- for the front part of the engine guard.
Fig 2: Loosening Engine Guard Screws - Front
3. Remove front part of engine guard.
4. Unscrew rear -5- and front fastening screws -4- for the rear part of the engine guard.
Fig 3: Loosening Engine Guard Screws - Rear
5. Remove rear part of engine guard.

Fig 4: Removing Rear Engine Guard

INSTALLING ENGINE GUARD
The engine guard is installed in reverse order to removal. → Tightening torque: 9 Nm (6.5 ftlb.)
WM 108319 REMOVING AND INSTALLING ENGINE COVER (DESIGN COVER)

(CAYENNE S, CAYENNE TURBO, CAYENNE GTS, CAYENNE TURBO S) > TOOLS

flexible-head Special tool 9824
socket wrench
Torx Micro Bit Special tool 9824/2

PRELIMINARY WORK
1. Remove secondary-air pump (if installed) and bracket on cylinder bank 1 to 4. → 266519
REMOVING AND INSTALLING SECONDARY-AIR PUMP WITH BRACKET
2. Detach torque support on the valve cover and at the body on cylinder bank 1 to 4. For details,
see → 103719 REMOVING AND INSTALLING TORQUE SUPPORT Removing Torque
Support

ENGINE COVER (DESIGN COVER)
Information
For easier access to components, use the tool flexible-head socket wrench 9824 together with
Torx Micro Bit 9824/2 if necessary .
3. Screw for securing design cover to bar ignition module
4. Mounting points (ball joints)

Fig 1: Identifying Engine Cover Screws And Mounting
1. Remove fastening screws for the engine cover at the bar ignition modules -3- .
2. Lift up the torque support on the valve cover. Pull engine cover upwards and off the mounting
points.
3. Remove design cover on throttle valve.
1. 3.1. Pull cover off the throttle valve → Design cover on throttle valve .
1. Design cover on throttle valve (view from above)
2. Design cover on throttle valve (view from below)
3. Ball joints under design cover
4. Bonding area, Velcro fastener

Fig 2: Removing Throttle Valve Cover

ENGINE COVER (DESIGN COVER)
Information
1. Lift up the torque support on the valve cover. Move engine cover into installation position and
press it onto the ball joints on the valve cover.
3. Screw for securing design cover to bar ignition module
4. Mounting points (ball joints)

Fig 1: Identifying Engine Cover, Screws And Mounting Points
2. Fit fastening screws for the engine cover at the bar ignition modules.
3. Fit design cover for throttle valve.
1. 3.1. Place cover over the throttle valve and press it onto the Velcro strip → Design
cover on throttle valve .
1. Design cover on throttle valve (view from above)
2. Design cover on throttle valve (view from below)
3. Ball joints under design cover
4. Bonding area, Velcro fastener

Fig 2: Placing Throttle Valve Cover

SUBSEQUENT WORK
1. Fit secondary-air pump (if installed) and bracket on cylinder bank 1 to 4. → 266519
REMOVING AND INSTALLING SECONDARY-AIR PUMP WITH BRACKET
2. Secure torque support on valve cover on cylinder bank 1 to 4. → Installing Torque

Support 103719 REMOVING AND INSTALLING TORQUE SUPPORT
Service Manual: 13 - ENGINE - CRANKGEAR, PISTONS -- 92A CAYENNE
WM 131003 MEASURING PISTONS (INCLUDES MEASURING CYLINDER BORE)
[EXCEPT CAYENNE S E-HYBRID & CAYENNE (3.0)] > INFORMATION > COMPONENT
OVERVIEW OF PISTONS AND CONNECTING RODS
Fig 1: Overview Of Piston

No. Designation Qty. Removal Installation
ReplaceOil Thread And

Contact SurfaceTighten To 30
Connecting-Rod Nm (22 Ft. Lb.) For Measuring
-1- 2
Bearing Screws Radial Play, But Do Not Turn
Any FurtherMeasure Radial
Play
Connecting Rod Do Not ConfuseMark Allocation To Check Installation Position Of

-2- 1
Bearing Cap Cylinder -B- . Welded Marking -A- .
Check Installation Position! Upper

Bearing Shell (Towards The Piston) Is Tighten To 30 Nm (22 Ft. Lb.)
2 Per
-3- Bearing Shells Made Of Wear-Resistant Material. New For Measuring Radial Play, But
Piston
Bearing Shell Is Identified By A Black Do Not Turn Any Further
Line.Replace Worn Bearing Shells!
Only replace in setsCheck

Installation Position Of Welded
-4- Connecting Rod 1 Mark Allocation To Cylinder -B- . Marking -A- .Axial Play For
Each Con-Rod Pair, New:
0.20....0.44 Mm
2 Per
-5- Circlip
Piston
Heat Stiff Pistons To Approx.

-6- Piston Pin 1 Install With A Mandrel
60°CRemove With A Mandrel
Install With Piston-Ring

With Combustion ChamberMark Restraining StrapCheck Piston
Installation Position And Allocation To And Cylinder
-7- Pistons 1
CylinderCheckReplace If Piston Shank DimensionsCheck Condition Of
Is Cracked Piston In TDC PositionCheck
Cylinder Bore
Offset Gap By 120°Install

Using Piston-Ring Pliers"TOP"
3 Per Marking Must Be Facing The
-8- Piston Rings Remove Using Piston-Ring Pliers
Piston Piston CrownCheck End
ClearanceCheck Vertical
Clearance

[EXCEPT CAYENNE S E-HYBRID & CAYENNE (3.0)] > PRELIMINARY WORK >
MEASURING PISTONS (INCLUDES MEASURING CYLINDER BORE)
1. Remove piston. → REMOVING PISTONS - section on "Removing"

[EXCEPT CAYENNE S E-HYBRID & CAYENNE (3.0)] > PRELIMINARY WORK > PISTON
AND CYLINDER DIMENSIONS
Grinding Dimension In mm Piston Diameter In mm Cylinder Bore Diameter In mm
Basic Dimension 82.924...82.936 (1) 83.006...83.014 (2)
Repair Stage 82.964...82.976 (1) 83.046...83.054 (2)
(1) Dimensions without graphite coating (thickness = 0.02 mm). Some of the graphite coating wears off
.
(2)
Measure cylinder bore depth of 50 mm .

MEASURING PISTONS (INCLUDES MEASURING CYLINDER BORE)
CAUTION: Pointed or sharp objects
Risk of cracks, pricks or cuts
CAUTION: Damage to sensitive engine components!
→ Conscientious and precise work
NOTE: Incorrect handling of piston rings
Risk of strain and damage to piston rings
→ Only open up the piston ring using the piston ring pliers sufficiently to allow you to remove or fit it.
→ Do not use force to install pistons.

Slide in the ring at a right angle to the cylinder wall from above until it is approx. 50 mm away from
the edge of the cylinder. Use a piston with no rings for sliding into the cylinder.
Piston-Ring Dimensions In mm New In mm Wear Limit In mm
1st Compression Ring 0.25... 0.40 0.60
2nd Compression Ring 0.70... 0.90 1.20
Oil Scraper Ring 0.25... 0.50 0.70

[EXCEPT CAYENNE S E-HYBRID & CAYENNE (3.0)] > PRELIMINARY WORK > CHECK
PISTON-RING VERTICAL CLEARANCE
Clean the piston ring groove before checking the clearance.

Piston-Ring Dimensions In mm New In mm Wear Limit In mm
Oil Scraper Ring 0.030... 0.070 0.100

PISTONS
Using a 75... 100 mm outside micrometer, measure approx. 10 mm from the lower edge,
perpendicular to the piston pin axis.
Max. deviation from nominal measurement: 0.05 mm.

Fig 1: Checking Pistons
Grinding Dimension In mm Piston Diameter In mm
Basic Dimension 82.924... 82.936 (1)
Repair Stage 82.964... 82.976 (1)
(1) Dimensions without graphite coating (thickness = 0.02 mm). Some of the graphite coating wears off
.

THE CYLINDER BORE
Using a 50... 100-mm internal vernier gauge, take measurements at 3 positions diagonally in
lateral direction -A- and longitudinal direction -B- .
Max. deviation from nominal measurement: 0.08 mm.

Fig 1: Identifying Cylinder Bore Dimension
Grinding Dimension In mm Cylinder Bore Diameter In mm
Basic Dimension 83.006... 83.014
Repair Stage 83.046... 83.054

CYLINDER-HEAD GASKET IDENTIFICATION
Part No. -arrow 1-
Holes -arrow 2-
Fig 1: Locating Cylinder-Head Gasket Identification

CYLINDER-HEAD GASKET - PISTON PROJECTION ALLOCATION
Piston Projection Over Top Edge Of Cylinder Block Hole Designation
0.835... 0.97 1
0.97... 1.02 2
1.02... 1.13 3
Information
The cylinder head gaskets for the left and right cylinder head are shaped differently to ensure that they
cannot be confused.

[CAYENNE S HYBRID & CAYENNE TIP (3.0] > TOOLS
Subito Precision Commercially

Nr. 134
Bore Gauge Available Tool

Micrometer
Commercially Nr. 52
Plastigage

[CAYENNE S HYBRID & CAYENNE TIP (3.0] > CHECKING PISTON-RING END
CLEARANCE
1. Slide the piston ring at a right angle to the cylinder wall from above until it is approx. 15 mm
away from the edge of the cylinder.
2. Use a piston with no piston rings to slide it in.


Piston Ring New mm Wear Limit mm
Oil Scraper Ring 0.25... 0.50 -(1)
(1)
Not determined yet

[CAYENNE S HYBRID & CAYENNE TIP (3.0] > CHECKING PISTON-RING VERTICAL
CLEARANCE
1. Clean ring groove on piston before checking clearance.

Piston Ring New mm Wear Limit mm


[CAYENNE S HYBRID & CAYENNE TIP (3.0] > CHECKING PISTONS
1. Using a Micrometer Nr. 135 Pos. 4 , measure approx. 10 mm from the lower edge,
perpendicular to the piston pin axis.
Maximum deviation from nominal size: 0.03 mm .
Fig 1: Checking Pistons
Grinding Size Piston Diameter mm Cylinder Bore mm
Basic Size 84.49 84.51

[CAYENNE S HYBRID & CAYENNE TIP (3.0] > MEASURING CYLINDER BORE
1. Using a Subito Precision Bore Gauge Nr. 134 , measure the cylinder bore crosswise at
three places in transverse direction -A- and longitudinal direction -B- .
Maximum deviation from nominal size: 0.08 mm .

Fig 1: Identifying Cylinder Bore Dimension

[CAYENNE S HYBRID & CAYENNE TIP (3.0] > INSTALLATION POSITION OF PISTONS
AND CONNECTING RODS
Information
For Tightening Torques, tightening sequence and assembly overview, see → 1001IN TIGHTENING

AND CONNECTING RODS > INSTALLATION POSITION OF PISTONS
Installation position: Arrow on piston crown is pointing to the pulley side.
Fig 1: Identifying Pistons Installation Position

AND CONNECTING RODS > MARK CONNECTING RODS
Information
Only replace connecting rods in sets.
For re-installation, use paint to mark the allocation of connecting rods to connecting-rod bearing caps
and the cylinder -arrow- .
Fig 1: Locating Connecting Rods Marking

AND CONNECTING RODS > INSTALLATION POSITION OF CONNECTING RODS
The cast lugs -arrows- on the ground surfaces of connecting-rod pairs "1 and 2", "3 and 4" and "5 and
6" must be facing each another.
Fig 1: Identifying Connecting Rods Installation Position

[CAYENNE S HYBRID & CAYENNE TIP (3.0] > MEASURING RADIAL PLAY OF
CONNECTING RODS
Information
Information
Recommended tool for measuring radial play of connecting rods: Plastigage Nr. 52 Pos. 1
1. Remove connecting-rod bearing cap. → 131020 REMOVING AND INSTALLING PISTONS
2. Clean the bearing cover and bearing journal.
3. Place Plastigage corresponding to the width of the bearing on the bearing journal or into the
bearing shells.
4. Fit connecting-rod bearing cap and tighten old screws to 50 Nm, 37 ft. lb . without additional
torque angle. Do not turn the crankshaft.
5. Remove connecting-rod bearing cap again.
6. Compare the width of the Plastigage with the graduations.
New Wear limit
0.010... 0.052 mm 0.12 mm
BEARING SHELL COLOR IDENTIFICATION
Color Identification Wall Thickness
Blue 1, 401 mm
Yellow 1, 396 mm
Red 1, 391 mm
WM 131019 REMOVING AND INSTALLING PISTONS (EXCEPT CAYENNE TIP) >

TOOLS
Universal Piston
Commercially
Ring Restraining Nr. 55
Available Tool
Strap, 75 - 125 mm
VW 222
Drift VW Tool
A

TECHNICAL VALUES
Tolerance Tolerance
Location Description Type Basic Value
1 2
Fastening Screw For Bearing Tightening 35 Nm (26 ft.

Cover Torque lb.) +90°
Screw Securing Oil Spray Jet Tightening 9 Nm (6.5 ft.

For Piston Cooling Torque lb.)

Connecting Rod Bolt
Torque lb.)
Connecting Rod Bolt Torque Angle 90°

INFORMATION > ASSEMBLY OVERVIEW - PISTONS AND CONNECTING RODS
1. Fastening Screw For Bearing Cover → Tightening Torque: 35 Nm (26 ft. lb.) +90°
1. Oil thread and contact surface
2. Connecting-Rod Bearing Cap
1. Mark allocation with paint/colored marker for re-installation -B-

2. Always check the following during fitting: The wide collar -A- must be facing the same
side on the connecting rod and connecting-rod bearing cap
3. Bearing Shells/Worn Bearing Shells Must Be Replaced
1. Check installation position
2. Check version: Upper bearing shell (towards the piston) must be made of wear-resistant
material.
3. Identifying feature of new bearing shells: Black line on running surface close to the
connection point
4. Check that retaining lugs are seated securely.
4. Connecting Rod
1. Mark cylinder allocation with paint/colored marker -B-
2. Axial play for each con-rod pair: new: 0.20....0.44 mm
3. Only replace in sets
4. Always check the following during fitting: The wide collar -A- must be facing the same
side on the connecting rod and connecting-rod bearing cap
5. Piston-Pin Circlip Replace
6. Piston Pin
1. Heat stiff pistons to 60 °C
2. Remove and install using Drift VW 222 A .
7. Piston
2. Replace piston if piston crown or shank is cracked
8. Piston-Pin Circlip Replace
9. Piston Rings
2. Remove and install using piston ring pliers
3. Installation position: "TOP" marking or side with lettering towards piston crown

PRELIMINARY WORK
1. Remove upper part of oil pan. → REMOVING OIL PAN - section on "Removing"
2. Remove cylinder head (cylinders 1-3 and 4-6). → REMOVING CYLINDER HEAD - section on
"Removing" and → REMOVING CYLINDER HEAD - section on "Removing"
REMOVING PISTONS
Information
The pistons are removed one after the other .
Mark the pistons, connecting rods/connecting rod caps and their assignment to each cylinder .
Pay attention to installation position of welded markings .
Pistons and connecting rods are laid on a clean surface, arranged by cylinder .
Connecting rod bolts must always be replaced .
Do not confuse worn bearing shells (mark them accordingly) .
Bearing shells that are worn down to the nickel layer must be replaced .
Connecting rod bearing shells should always be replaced .
Information
Mark the installation position and cylinder assignment with chalk or a water-resistant felt-tip pen to
facilitate re-installation of used pistons .
Never use a prick punch or scriber as these will damage the coating on the piston crown .
1. Mark installation position of pistons before removal.
Installation position: Arrow -1- on piston crown is pointing to the pulley.

Fig 1: Identifying Piston Crown Marking
Information
1. Only replace connecting rods in sets .
2. Do not confuse connecting rod bearings .
2. Mark connecting rods and connecting-rod bearing caps before removal -arrow- .
Fig 2: Locating Connecting Rods Marking
3. Turn the crankshaft so that the crank pin of the piston to be removed is standing straight up.
4. Remove piston of cylinder 1 by unscrewing the connecting rod bolts.
5. Remove the connecting rod bearing cap and place it on a clean surface.
6. Press piston up out of the cylinder and counter with your other hand.
7. 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.
Fig 3: Identifying Connecting Rod Bearings Retaining Lugs
8. Remove pistons for cylinders 2-6 using the same procedure.

Fig 4: Identifying Connecting Rod Numbers
9. Remove oil spray jets if necessary. →
Opening pressure: 1.3 bar.
10. Measure pistons and cylinder bore. → 131003 MEASURING PISTONS (INCLUDES
MEASURING CYLINDER BORE) - section on "Measuring"

INSTALLING PISTONS
CAUTION: Damage to sensitive engine components!

→ Conscientious and precise work
Information
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 .
Fig 1: Identifying Connecting-Rod Bearings Retaining Lugs
The connecting rod bearing cap and the connecting-rod big end have cast lugs which must be
aligned. 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
.
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 .
Information
Oil the bearing shells and bearing with engine oil .
Information
The cylinder head gaskets for the left and right cylinder head are shaped differently to ensure that they
cannot be confused.
1. Install oil spray jets if necessary. → Tightening Torque: 9 Nm (6.5 ft. lb.)
2. Move piston ring gaps by 120°.
3. Coat the cylinder liners, piston liners, bearings and piston ring restraining strap with engine oil.
4. Pre-fit upper bearing shell in the connecting-rod big end.
The retaining lug on the bearing shell must fit into the corresponding cut-out on the
connecting-rod big end.
5. Turn the gaps of the oil scraper ring so that the gaps are located at the oil piston shank area.
The gaps of both rings and the springs must not be on top of one another (they should be
offset slightly).
6. Universal Piston Ring Restraining Strap, 75 - 125 mm Nr. 55 must be positioned on the
piston.
Check that the piston rings are positioned correctly. Adjust restraining strap to the piston
diameter, use tensioning lever -1- and tensioning screw -2- to fine-tune the adjustments.
Fig 2: Positioning Piston Ring Restraining Strap
7. Insert piston, together with connecting rod, into cylinder bore 1.
Universal Piston Ring Restraining Strap, 75-125 mm Nr. 55 must be positioned evenly on
the cylinder surface.
Fig 3: Inserting Piston In Cylinder Bore
8. Installation Position Of Piston
Installation position: Arrow -1- on piston crown is pointing to the pulley.

Fig 4: Identifying Piston Installation Position
NOTE: Incorrect handling of piston rings
1. Risk of strain and damage to piston rings
→ Only open up the piston ring using the piston ring pliers sufficiently to allow you to remove
or fit it.
→ Do not use force to install pistons.
9. Hold the piston ring restraining strap firmly and press the piston into the cylinder bore using a
plastic mandrel.
Fig 5: Pressing Piston Into Cylinder Bore
10. Installation Position Of Connecting Rod
The larger collar on the connecting rods -arrows- is facing the adjacent main bearing (shown
on the front con-rod pair in the illustration).
Fig 6: Locating Connecting Rod Installation Position
11. 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.
12. Tighten New connecting rod bearing screws hand-tight. Then tighten to the specified
Tightening Torque. → Tightening Torque: 35 Nm (26 ft. lb.) → Torque angle: 90°
13. Turn the crankshaft further so that the crank pin of the next piston to be installed is standing
straight up.
14. Install the other pistons in the same way.

SUBSEQUENT WORK
1. Install upper part of oil pan. → INSTALLING PISTONS - section on "Installing"
2. Install cylinder head (cylinders 1-3 and 4-6). → INSTALLING CYLINDER HEAD - section on
"Installing" and → INSTALLING CYLINDER HEAD - section on "Installing"
WM 131020 REMOVING AND INSTALLING PISTONS (CAYENNE TIP) > TOOLS

Funnel VW Tool T10333
WM 131020 REMOVING AND INSTALLING PISTONS (CAYENNE TIP) > TECHNICAL

VALUES

Value 1 2
30 Nm
Initial
Connecting Rod Bolts M9 x 1 x 50 (always Replace) (22 ft.
Tightening
lb.)
Torque
Connecting Rod Bolts 90°
Angle
M9 x 1.25 x 141 (7 Ea.,

Cylinder-Head Screws Centre) and M9 x 1.25 x 111 Initial 15 Nm
(Internal Serration) (13 Ea., Outer), Always Tightening (11 ft. lb.)
Replace
30 Nm
Cylinder-Head Screws Tightening
(22 ft.
(Internal Serration) Torque
lb.)
Cylinder-Head Screws Torque

180°
(Internal Serration) Angle
Oval-Head Screw On Tightening 8 Nm (6

M6 x 25
Timing Chain Housing Torque ft. lb.)
Hexagon-Head Bolts On Tightening 8 Nm (6

M8 x 20
Oil Pump Torque ft. lb.)
40 Nm
Tightening
Chain Tensioner M22 x 1.5 x 18.7 (30 ft.
Torque
lb.)
10 Nm
Bearing Pin On Guide Tightening
M8 x 11.5 (7.5 ft.
Rail For Drive Chain Torque
lb.)
Hexagon-Head Bolt On 60 Nm
Initial
Drive Wheel For Timing M10 x 40 (Always Replace) (44 ft.
Tightening
Chain lb.)
Hexagon-Head Bolt On
Torque
Drive Wheel For Timing 90°
Angle
Chain
10 Nm
Tightening
Bolt For Guide Rail (7.5 ft.
Torque
lb.)
20 Nm
Fastening Screw On Tightening
(15 ft.
Guide Rail Torque
lb.)
23 Nm
Hexagon-Head Bolt On Tightening
M8 x 45 (17 ft.
Guide Rail Torque
lb.)
60 Nm
Hexagon-Head Bolts On M12 x 1.5 x 85 (Always Initial
(44 ft.
Camshaft Controllers Replace) Tightening
lb.)
Hexagon-Head Bolts On Torque

90°
Camshaft Controllers Angle
M6 x 16 (20 ea.); M6 x 58 (2 Tightening
Lower Timing-Case (7.5 ft.
ea.) Torque
Cover lb.)

M6 x 20
Vacuum Pump Torque ft. lb.)

M6 x 40

M6 x 20
Oil Pan Torque ft. lb.)
10 Nm
With Guide Sleeve (7.5 ft.
Cylinder Head Cover Torque
lb.)
22 Nm
Fuel Line To Fuel Tightening
(16 ft.
Distributor Pipe Torque
lb.)
35 Nm
Fuel Line At Plenum Tightening
(26 ft.
Panel Torque
lb.)
30 Nm
Cheese Head Bolts On Initial
M8 x 55 (Always Replace) (22 ft.
Fuel Distributor Pipe Tightening
lb.)
Cheese Head Bolts On Torque

90°
Fuel Distributor Pipe Angle
WM 131020 REMOVING AND INSTALLING PISTONS (CAYENNE TIP) > PRELIMINARY
WORK
Information
1. Remove engine.
2. Remove engine from transmission. → 100127 REMOVING ENGINE FROM TRANSMISSION

AND MOUNTING ENGINE ON TRANSMISSION
3. Secure engine on mounting bracket.
4. Remove engine retaining eyebolts at the front and rear.
5. Remove the engine wire harness. → REMOVING WIRE HARNESS FOR ENGINE
6. Remove bar ignition modules. → 282020 REMOVING AND INSTALLING DFI BAR IGNITION
MODULES
7. Remove intake-air distributor. → REMOVING INTAKE-AIR DISTRIBUTOR - section on

"Removing"
8. Remove oil pan. → REMOVING OIL PAN - section on "Removing"
9. Remove cylinder head. → REMOVING CYLINDER HEAD - section on "Removing"
1. 9.1. Remove and dispose of cylinder head gasket.
2. 9.2. Pull oil retaining valve -arrow- out using an M8 screw if necessary.
Fig 1: Locating Oil Retaining Valve
WM 131020 REMOVING AND INSTALLING PISTONS (CAYENNE TIP) > REMOVING

PISTONS
Information
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 .
1. Remove piston.
1. Connecting Rods
2. Pistons
Fig 1: Locating Piston And Connecting Rods
1. 1.1. Turn the crankshaft so that the crankshaft journal of the piston to be removed is
standing straight up.
2. 1.2. Remove connecting rod bolts. Remove connecting rod bearing caps and place
on a clean surface, arranged according to cylinder.
3. 1.3. Press the piston out of the cylinder from above (using the handle of a hammer
for example) and support it from below with your hand.
4. 1.4. Remove one piston after another and mark them according to the respective
cylinder. Place the pistons on a clean surface.
5. 1.5. Repeat this procedure for all pistons.
WM 131020 REMOVING AND INSTALLING PISTONS (CAYENNE TIP) > INSTALLING

PISTONS
1. Install piston.
Fig 1: Overview Of Piston/Connecting Rod
1. Piston Rings (Move Gap By 120°)
2. Pistons
3. Circlip
4. Connecting Rod
5. Connecting Rod Bearings Must Always Be Replaced . Observe Relevant

Classification.
6. Connecting Rod Bearing Cap
7. Connecting Rod Bolts → Initial Tightening: 30 Nm (22 ft. lb.) → Torque Angle:
90°
8. Cylinder Block
9. Piston Pins
1. 1.1. Pull dowel sleeve -arrow- out of the bore hole so that special tool Funnel
-Arrow- - Dowel pin
damper.
Fig 3: Identifying Pistons Installation Position (V6 DFI Engine)
3. Arrow pointing towards vibration balancer
6. 1.6. Insert dowel sleeves back into the bore holes -arrow- .
Information
1. Oil the bearing shells and bearing with engine oil .
Information
1. The pistons must already be pre-fitted (pistons, piston rings, connecting rods
and fastening material) before performing the next step .
2. Note the association between the connecting-rod big end and the
connecting-rod bearing cap .
3. 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 .
Fig 5: Identifying Connecting-Rod Bearing Retaining Lugs
4. 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 .
5. The cast lugs, twist lock (retaining lugs) and the flat side of the piston crown are
on the same side .
Fig 6: Locating Connecting-Rod And Piston
6. The flat side of the piston crown always points to the center of the cylinder
block .
7. Refit pistons according to removal markings (if being reused) .
8. 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 .
shells are aligned.
9. 1.9. Carefully tap the connecting rod bearing caps -6- with a plastic hammer until
they are seated correctly so that the Tightening Torque will be accurate.
10. 1.10. Tighten all connecting rod bearing screws -7- to the specified Tightening
Torque.
Arrow - Setting of gap on drive plate for inductive pickup (speed sender)
Fig 7: Locating Drive Plate Gap
WM 131020 REMOVING AND INSTALLING PISTONS (CAYENNE TIP) > SUBSEQUENT

WORK
Arrow - Crankshaft/vibration balancer marking

2. Install cylinder head. → 157019 REMOVING AND INSTALLING CYLINDER HEAD ON V6 DFI
ENGINES
Fig 2: Identifying Cylinder Head Numbers
1-6 - Pistons of cylinders 1 - 6
1-20 - Tightening sequence for cylinder-head screws → Initial tightening: 15 Nm (11 ft. lb.)
→ Tightening Torque: 30 Nm (22 ft. lb.) → Torque angle: 180°
2. 2.2. Cylinder head gasket must always be replaced .
1. 2.3.1. Tighten cylinder-head screws to an initial Tightening Torque of 15 Nm

(11 ft. lb.).
2. 2.3.2. Tighten cylinder-head screws to 30 Nm (22 ft. lb.).
3. 2.3.3. Then tighten all cylinder-head screws a second time to 30 Nm (22

ft. lb.).
4. 2.3.4. And finally, tighten cylinder-head screws to a torque angle of 180°.
3. Fit timing chains. → 153519 REMOVING AND INSTALLING TIMING CHAIN (AUXILIARY
DRIVE MECHANISM)
1. Timing Chain Housing
2. Oval-Head Screw On Timing Chain Housing → Tightening Torque: 8 Nm (6 ft. lb.)
3. Timing Chain
4. Outlet Camshaft Controller (Marking 32 A)
5. Sealing Ring
6. Oil Pump
7. Fastening Screw On Oil Pump → Tightening Torque: 8 Nm (6 ft. lb.)
8. Tensioning Rail
9. Chain Tensioner On Timing Chain → Tightening Torque: 40 Nm (30 ft. lb.)
10. Sealing Ring (A22 x 27), Always Replace
11. Bearing Pin On Guide Rail → Tightening Torque: 10 Nm (7.5 ft. lb.)
12. Sprocket
13. Drive Wheel For Timing Chain
14. Hexagon-Head Bolt → Initial Tightening: 60 Nm (44 ft. lb.) → Torque Angle: 90°
15. Chain Tensioner For Drive Chain
16. Drive Gear Wheel For Drive Chain
17. Drive Chain
18. Guide Rail For Drive Chain
19. Bolt For Guide Rail → Tightening Torque: 10 Nm (7.5 ft. lb.)
20. Fastening Screw On Guide Rail → Tightening Torque: 20 Nm (15 ft. lb.)
21. Hexagon-Head Bolt On Guide Rail → Tightening Torque: 23 Nm (17 ft. lb.)
22. Hexagon-Head Bolts On Camshaft Controllers → Initial Tightening: 60 Nm (44 ft.

lb.) → Torque Angle: 90°
23. Guide Rail For Timing Chain
24. Drive Gear Wheel For High-Pressure Pump
25. Intake Camshaft Controller (Marking 24 E)
26. Valve For Outlet Camshaft Controller
27. Valve For Intake Camshaft Controller
28. Guide Rail
1. 3.1. Install chain tensioner. → 153619 REMOVING AND INSTALLING CHAIN

TENSIONER
2. 3.2. Install camshaft controllers. → 158419 REMOVING AND INSTALLING

CAMSHAFT CONTROLLER ON V6 DFI ENGINES
5. Fit upper and lower timing-case cover. → 153319 REMOVING AND INSTALLING
TIMING-CASE COVER ON V6 DFI ENGINES

Fig 4: Identifying Cylinder Block And Vibration Balancer Joint Flange
1. Cylinder Block
2. Vibration Balancer Joint Flange
3. Hexagon-Head Bolt On Vibration Balancer Joint Flange
4. Straight Pin, M8 x 18
5. Lower Timing-Case Cover
6. Hexagon-Head Bolt On Lower Timing-Case Cover → Tightening Torque:

10 Nm (7.5 ft. lb.)
1. Drive Shaft
2. Upper Timing-Case Cover
3. Oval-Head Screw → Tightening Torque: 8 Nm (6 ft. lb.)
4. Oval-Head Screw On Vacuum Pump → Tightening Torque: 8 Nm (6 ft.

lb.)
5. Housing
6. Seal
7. Sealing Ring
6. Install oil pan. → 175019 REMOVING AND INSTALLING OIL PAN ON V6 DFI ENGINES
Fig 6: Oil Pan Bolt Tightening Sequence
1-25 - Hexagon-head bolts on oil pan → Tightening Torque: 12 Nm (9 ft. lb.)
7. Install cylinder head cover. → 158219 REMOVING AND INSTALLING CYLINDER HEAD
COVER ON V6 DFI ENGINES
Fig 7: Identifying Cylinder Head Cover And Valve Cover Seal
2. Cylinder head gasket
3. Fastening screw on cylinder head cover → Tightening Torque: 10 Nm (7.5 ft. lb.)
4. Cap
8. Install fuel distributor pipe and fuel injectors. → 243019 REMOVING AND INSTALLING FUEL
DISTRIBUTOR PIPE (FUEL RAIL) ON DFI ENGINES
Fig 8: Identifying Fuel Distributor Pipe And Fuel Injectors
1. Fuel Low-Pressure Line → Tightening Torque: 22 Nm (16 ft. lb.) → Tightening

2. Cheese Head Bolts On Fuel Distributor Pipe → Initial Tightening: 30 Nm (22 ft. lb.)
→ Torque Angle: 90°
3. Fuel Injectors
9. Install intake-air distributor. → 244619 REMOVING AND INSTALLING DFI INTAKE-AIR

DISTRIBUTOR
10. Install guide tube for oil dipstick. Sealing ring must always be replaced . → 171719
REMOVING AND INSTALLING GUIDE TUBE FOR OIL DIPSTICK ON DFI ENGINES
11. Install bar ignition modules. → 282020 REMOVING AND INSTALLING DFI BAR IGNITION
MODULES
Fig 9: Identifying Bar Ignition Modules And Clips
1. Connectors For Bar Ignition Modules
2. Retaining Clips
3. Engine Wire Harness
12. Fit engine wire harness. → INSTALLING WIRE HARNESS FOR ENGINE
13. Remove engine from the mounting bracket.
14. Mount the transmission. → 100127 REMOVING ENGINE FROM TRANSMISSION AND
15. Install the engine.
16. Perform a test drive and check for leaks and correct function.
1. 16.1. Clean the engine and carry out a thorough check for leaks after the test drive.
WM 131037 DISASSEMBLING AND ASSEMBLING PISTONS [CAYENNE S E-HYBRID

& CAYENNE (3.0)] > TECHNICAL VALUES
value 1 2
Oil Thread And Contact Initial 50 Nm (37

Connecting Rod Bolts
Surface tightening ft. lb.)
Oil Thread And Contact Final

Connecting Rod Bolts +90°
Surface Tightening
Fastening Screw For Oil Tightening 9 Nm (6.5 ft.

Spray Jet Torque lb.)

& CAYENNE (3.0)] > ASSEMBLY OVERVIEW - PISTONS AND CONNECTING RODS
1. Screws Replace → Initial Tightening: 50 Nm (37 ft. lb.) → Final Tightening: +90°
1. Oil thread and contact surface
2. Use old screw to measure radial clearance, tighten to 50 Nm (37 ft. lb.) but do not
tighten further.
2. Connecting-Rod Bearing Cap

1. Mark for re-installation
2. Mark cylinder allocation with paint/colored marker
3. Bearing Shells
1. Check that retaining lugs are seated securely
2. Mark used bearing shells for re-installation, but not on the running surface.
3. Oversize bearing shells are available for re-machined crankshaft con-rod journals
4. Connecting-rod bearing lugs are aligned
4. Connecting Rod
5. Circlip Replace
6. Piston Pin
1. Heat stiff pistons to approx. 60°C
7. Pistons
8. Piston Rings
2. Installation position: "TOP" marking or side with lettering towards piston crown

& CAYENNE (3.0)] > ASSEMBLY OVERVIEW - PISTONS AND CONNECTING RODS >
Push in the piston ring at a right angle to the cylinder wall from above until it is approx. 15 mm away
from the edge of the cylinder.
Piston Ring New [mm] Wear Limit [mm]
Oil Scraper Ring 0.25... 0.50 Not Yet Determined


CHECKING PISTON-RING VERTICAL CLEARANCE
Clean ring groove on piston before checking clearance.
Piston Ring New [mm] Wear Limit [mm]


OIL SPRAY JET FOR PISTON COOLING
-1- - Screw, fit with securing liquid → Tightening Torque: 9 Nm (6.5 ft. lb.)
-2- - Oil spray jet with spray jet valve (opening pressure: 2...2.4 bar overpressure)
Fig 1: Identifying Piston Cooling Oil Spray Jet

& CAYENNE (3.0)] > DISASSEMBLING PISTONS
CAUTION: Engine damage if piston rings overstretched!
→ Do not overstretch piston rings with piston ring pliers. Spread the piston ring until it just fits over the
piston.
Information
If reusing a piston, do not remove combustion residues on the piston crown are mechanically!
Information
When disassembling the piston/connecting rod unit, note or mark the position, relationship to
cylinder and installation position using a waterproof felt tip pen .

& CAYENNE (3.0)] > ASSEMBLING PISTONS
piston.
WM 131037 DISASSEMBLING AND ASSEMBLING PISTONS (CAYENNE, CAYENNE S,

CAYENNE S DIESEL, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE (3.0),
CAYENNE GTS & CAYENNE TURBO S) > TOOLS
Retaining Device Special Tool 9597
Piston Ring Commercially

Nr. 58
Pliers Gr. 1 Available Tool

CAYENNE GTS & CAYENNE TURBO S) > PRELIMINARY WORK
1. Remove piston. → 131020 REMOVING AND INSTALLING PISTONS

CAYENNE GTS & CAYENNE TURBO S) > DISASSEMBLING PISTONS

piston.
Information
If reusing a piston, do not remove combustion residues on the piston crown are mechanically!
1. Piston-Ring Set; Oil With Engine Oil; TOP Marking Facing Upwards; Oil Scraper Ring Down;
Ring Gaps Offset By 120°
2. Piston; Different On Naturally Aspirated And Turbo Engines; Combustion Chamber Recess
Facing Centre Of Engine; Left And Right Different; Direction Of Travel Arrow In Direction Of
Travel
3. Piston-pin Circlip (Positioned At 6 O'clock Or 11 O'clock)
4. Piston pin; Oil
5. Connecting Rod
6. Connecting Rod Bolt; Replace As It Must Be Tightened In The Plastic Area; Oil Screw
7. Connecting Rod Bearing Shells; Oil With Engine Oil

Fig 2: Identifying Connecting-Rod Assembly And Bearing Shells
A. View A (Identification Area For Connecting-Rod Number; Fit Connecting Rod With
Identification Area Facing Exhaust Side; Markings On Rod And Cap Must Be On The Same
Side)
B. View B (Fit Bearing Shells Flush And Press In By Hand)
C. View C (Fit Bearing Shells Flush And Press In By Hand)

1. Marking For Dimension Group (Just One Permitted Per Engine, In This Case x)
2. Porsche Short Numeric Code Without Main Or Middle Number
3. Short Numeric Code (Supplier)
4. Marking Area For Weight Group (Just One Permitted Per Engine, + Or -)
5. Cylinder Bank Identification (V6 1-3 And 4-6) (V8 1-4 And 5-8)
6. Barcode 128 (Short Numeric Code Without Main Group Or Weight Group)
7. Arrow Marking In Direction Of Travel
8. Identification For Dimension Group
10. Inspection Stamp (Supplier)

4. Cylinder Bank Identification (V8 1-4 And 5-8)
Information
When disassembling the piston/connecting rod unit, note or mark the position, relationship to
cylinder and installation position using a waterproof felt tip pen .
1. Secure piston on Retaining Device 9597 (→ Piston on retaining device ).

Fig 5: Identifying Piston On Retaining Device
2. Remove both piston-pin circlips using a small screwdriver. To do this, guide the screwdriver
through the small cut-out and carefully lever out the piston-pin circlip → Levering out piston-pin
circlips with a small screwdriver .
Fig 6: Removing Piston-Pin Circlips Using Screwdriver
3. Insert piston into the Retaining Device 9597 (leave space below for the piston pins) and drive
out piston pins using a suitable pressure piece. → Piston pin with plunger
Fig 7: Inserting Piston Pin With Plunger
4. Remove connecting rod from the piston and place to one side.
Information
1. Compression rings and oil scraper rings are installed and removed differently .
5. Remove piston rings.
1. 5.1. Place the piston on a clean surface and look for the gaps in the piston rings.
2. 5.2. Remove the piston rings, starting at 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!
Fig 8: Removing Piston Ring
3. 5.3. Relieve the piston ring pliers and remove the piston ring from the pliers.
4. 5.4. Remove the two-piece oil scraper ring as follows: First, remove the outer ring by
hand by carefully prying it away from the piston. Then remove the inner oil scraper
spring in the same way.

CAYENNE GTS & CAYENNE TURBO S) > ASSEMBLING PISTONS
Information
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 marking on the connecting rod bearings is located on the flywheel or drive plate flange of the
crankshaft . → 134819 REMOVING AND INSTALLING CRANKSHAFT
Information
Tightening Torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission
1. Piston-Ring Set; Oil With Engine Oil; TOP Marking Facing Upwards; Oil Scraper Ring Down;
Ring Gaps Offset By 120°
2. Piston; Different On Naturally Aspirated And Turbo Engines; Combustion Chamber Recess
Facing Centre Of Engine; Left And Right Different; Direction Of Travel Arrow In Direction Of
Travel
3. Piston-Pin Circlip (Positioned At 6 O'clock Or 11 O'clock)
4. Piston Pin; Oil
5. Connecting Rod
6. Connecting Rod Bolt; Replace As It Must Be Tightened In The Plastic Area; Oil Screw
7. Connecting Rod Bearing Shells; Oil With Engine Oil

Fig 2: Locating Connecting-Rod Assembly And Bearing Shells
A. View A (Identification Area For Connecting-Rod Number; Fit Connecting Rod With
Identification Area Facing Exhaust Side; Markings On Rod And Cap Must Be On The Same
Side)
B. View B (Fit Bearing Shells Flush And Press In By Hand)
C. View C (Fit Bearing Shells Flush And Press In By Hand)

5. Cylinder Bank Identification (V6 1-3 And 4-6) (V8 1-4 And 5-8)
8. Identification For Dimension Group

4. Cylinder Bank Identification (V8 1-4 And 5-8)
1. First fit the two-piece oil scraper ring. To do this, insert the oil scraper spring into ring groove 3.
Carefully force the oil scraper ring (TOP marking facing up towards the piston crown -A- )
apart with your hand and fit it into the third piston ring groove above the oil scraper spring.
Fig 5: Locating Piston Ring Marking
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.
→ Do not overstretch piston rings with piston ring pliers. Spread the piston ring until it just fits
over the piston.
Information
1. The two compression rings have different strengths and can only be installed in the
appropriate groove .
2. 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 marking on the
piston rings is pointing in the direction of the piston crown -A- . Spread the piston ring until it
fits across the piston. → Piston ring pliers on piston ring
Fig 6: Inserting Piston Ring Into The Piston Ring Pliers

Fig 7: Locating Piston Ring Marking
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°.
6. Fit a piston-pin circlip. To do this, insert the piston-pin circlip into the ring groove of the piston
pin eye so that the ring gap is offset with respect to the piston crown (6 or 11 o'clock position).
Press this end into the ring groove with your thumb -1- .
Fig 8: Pressing Piston Circlip
7. Lever the piston circlip into the ring groove using a small screwdriver while continuing to press
it down.
Fig 9: Inserting Piston Circlip
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.
Fig 10: Pressing Piston Circlip Into Ring Groove
9. Secure piston with fitted piston-pin circlip facing downwards and connecting rod on Retaining
Device 9597 (→ Retaining device ).
Fig 11: Identifying Piston Retaining Device
10. Place piston pin and connecting rod in installation position. Ensure that the connecting rod
marking is facing the exhaust side and the combustion chamber recess is facing the center of
the engine during assembly. Direction of travel arrow on the piston must be in direction of
travel.
11. Slide the oiled piston pin through the piston pin eye and through the connecting rod eye. Tap in
carefully with a rubber hammer if necessary.
12. Fit the second piston-pin circlip using the same procedure. Align the ring gap so that it is facing
downwards, away from the piston crown (6 o'clock position, 11 o'clock position optional).
13. Check connecting rod and piston for smooth operation.
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- . The matching numbers -A- must be the same and must be on the same side (pointing to
the exhaust side when installed). Tighten the connecting-rod bolts by hand and position the
complete connecting rod ready for assembly.
Fig 12: Identifying Bearing Shells Position

Fig 13: Identifying Connecting Rod Number Marking (Exhaust Side)

CAYENNE GTS & CAYENNE TURBO S) > SUBSEQUENT WORK
1. Install piston. → 131020 REMOVING AND INSTALLING PISTONS
WM 134801 CHECKING CRANKSHAFT (CHECKING BEARING CLEARANCE)

[CAYENNE S E-HYBRID & CAYENNE (3.0)] > TOOLS

Dial Gauge
Universal Dial
VW Tool VW 387
Gauge Bracket

[CAYENNE S E-HYBRID & CAYENNE (3.0)] > CRANKSHAFT DIMENSIONS
Abrasion Crankshaft Bearing Journal Diameter Connecting-Rod Bearing Pin Diameter

Measurement [mm] [mm]
Basic Dimension 65.00 0,-0.022-0.042 56.00-0.022-0.042

[CAYENNE S E-HYBRID & CAYENNE (3.0)] > MEASURING AXIAL PLAY OF
CRANKSHAFT
1. Dial Gauge Nr. 136 Pos. 1 with Universal Dial Gauge Bracket VW 387 must be screwed to
the cylinder block and placed against the crank arm.
Fig 1: Checking Crankshaft Axial Play
2. Press the crankshaft against the dial gauge by hand.
3. Set the dial gauge to "0 ".
4. Press the crankshaft off the dial gauge and read off the measured value.
Axial Play: 0.15...0.25 mm

[CAYENNE S E-HYBRID & CAYENNE (3.0)] > MEASURING RADIAL PLAY OF
CRANKSHAFT
Information
Mark used bearings for re-installation but not on bearing surface .
If bearing shells have worn down to base material, they must be replaced .
1. Remove guide frame and clean crankshaft journal.
2. Place a length of Plastigage corresponding to the width of the bearing on the bearing journal
or into the bearing shells.
3. The Plastigage must be positioned in the middle of the bearing shell.
4. Fit the guide frame and tighten to 50 Nm (37 ft. lb.) . Do not turn the crankshaft.
5. Remove the guide frame again.
6. Compare the width of the Plastigage with the graduations.
RadialClearance
New: 0.015...0.055mm
Wear Limit: 0.08mm
WM 134801 CHECKING CRANKSHAFT (CHECKING BEARING CLEARANCE) (ALL

MODELS) > TOOLS

Dial Gauge
Commercially Nr. 52
Plastigage
Universal Dial
VW Tool VW 387
Gauge Bracket


Value 1 2
Screw For Guide Frame To Cylinder Block. Initial 30 Nm (22

Guide Frame Observe Specified Sequence! tightening ft. lb.)
Screw For Guide Frame To Cylinder Block. Final 50 Nm (37

+180°
Guide Frame Observe Specified Sequence! Tightening ft. lb.)
Crankshaft Basic
65 mm -0.022 mm -0.042 mm
Bearing Pin Dimension
Crankshaft Basic
60 mm -0.022 mm -0.042 mm
Bearing Pin Dimension
Screw For For Measuring Radial Play On Tightening 30 Nm (22

Guide Frame Crankshaft Torque ft. lb.)

MODELS) > INFORMATION > COMPONENT OVERVIEW OF CRANKSHAFT
1. Crankshaft
2. Dowel Sleeve
3. Guide Frame
4. Screw → Initial Tightening: 30 Nm (22 ft. lb.) → Final Tightening: 50 Nm (37 ft. lb.) +180°
5. Thrust Washer
6. Bearing Shell, Guide Frame
7. Dowel Pin
8. Thrust Washer
9. Bearing Shell, Cylinder Block

MODELS) > PRELIMINARY WORK > CHECKING CRANKSHAFT
1. Remove crankshaft. → REMOVING CRANKSHAFT - section on "Removing"

MODELS) > CHECKING CRANKSHAFT
CRANKSHAFT DESCRIPTION
Grinding Dimension Crankshaft Bearing Pin Diameter In Crankshaft Con-Rod Journal

In mm mm Diameter In mm
→ Basic Dimension: 65 mm-0.022 → Basic Dimension: 60 mm-0.022

Basic Dimension
mm-0.042 mm mm-0.042 mm

MODELS) > CHECKING CRANKSHAFT > CHECKING CRANKSHAFT > TEST
PROCEDURE
Dial Gauge Nr. 136 Pos. 1 -1- with Universal Dial Gauge Bracket VW 387 -2- must be
screwed to the cylinder block and placed against the crank arm.
Fig 1: Measuring Axial Play
Press crankshaft by hand against the dial gauge and set the dial gauge to "0".
Press the crankshaft away from the dial gauge and read off the value:
Axial play, new: 0.090... 0.251 mm.

MODELS) > CHECKING CRANKSHAFT > CHECKING CRANKSHAFT
Information
TORQUES FOR ENGINE
Procedure:
Information
Bearing shells that are worn down to the nickel layer must be replaced .
Do not confuse worn bearing shells (mark them accordingly) .

1. Remove guide frame.
2. Clean bearing pins.
3. Plastigage Nr. 52 Pos. 1 (Plastigage thread) corresponding to the width of the bearing must
be placed on the pin or into the bearing shells.
1. The Plastigage must be in the middle of the bearing shell.
4. Position guide frame on the dowel sleeves and tighten screws → Tightening Torque: 30 Nm
(22 ft. lb.) . Do Not Turn The Crankshaft!
5. Remove the guide frame again.
6. Compare the width of the Plastigage with the measurement scale:
1. Radial play, new: 0.020... 0.050 mm.

MODELS) > SUBSEQUENT WORK > CHECKING CRANKSHAFT
1. Install crankshaft. → INSTALLING CRANKSHAFT - section on "Installing"
WM 134801 CHECKING CRANKSHAFT ON V6 DFI ENGINES (CHECKING BEARING

CLEARANCE) (CAYENNE TIP) > TOOLS
Plastigage For
Commercially
Measuring Bearing Nr. 52
Available Tool
Clearance

CLEARANCE) (CAYENNE TIP) > TECHNICAL VALUES
Tolerance Tolerance
1 2
Bearing Cover Replace, 14 Initial 30 Nm (22 ft.

Screws Screws Tightening lb.)
Bearing Cover Replace, 14

Final Tightening 90°
Screws Screws
Replace, 14
Baring Cover Screws Final Tightening 90°
Screws

CLEARANCE) (CAYENNE TIP) > PRELIMINARY WORK
2. Remove oil pump. → REMOVING OIL PUMP - section on "Removing"

CLEARANCE) (CAYENNE TIP) > TOOLS AND MATERIALS > TOOLS AND
MEASURING/TEST EQUIPMENT
Designation Source Explanation
Used for the simple measurement of radial play in plain bearings; available
Plastigage For
in three sizes and thicknesses; select thickness according to the bearing
Measuring Bearing
clearance expected (in this case: measuring range from 0.051 to 0.152
Clearance Nr. 52
mm, red).

CLEARANCE) (CAYENNE TIP) > INFORMATION > COMPONENT OVERVIEW
Bearing Cover 1 On The Side Of

The Vibration Damper, Bearing
Bearing Cover 5 With Recess For Thrust
-1- 7
Cover Washers, Retaining Lugs For
Bearing Shells On The Same
Side
→ Initial Tightening: 30 Nm (22

Bearing
-2- 14 ft. lb.) → Final Tightening: 90°
Cover Screws
+ → Final Tightening: 90°
Fit Used Shells At The Same

Used Bearing Shells Should Be Position (When Not Replacing).
Marked With A Felt-Tip Pen (When When Replacing Bearing Shells,
Bearing
-3- 14 Not Replacing). If The Bearing Use Only Shells With The Same
Shells
Shells Are Replaced, Use Only Color Markings. Retaining Lugs
Identical Color Markings. For Bearing Shells On The Same
Side.
Replace; Only In Bearing Cover

Thrust 5; Check Secure Attachment,
-4- 2
Washer Affix With Lubricant; Lubricating
Groove Facing Outwards
Position The Crankshaft So That

The Sensor Wheel Does Not
Impinge Or Become Damaged. Subsequent Work On The
-5- Crankshaft 1 Replace The Sensor Wheel For Crankshaft Is Not Permitted.
Speed Measurement→ 134819 Replace Bearing Shells
REMOVING AND INSTALLING
CRANKSHAFT .
Pickup Redo Test If Necessary.→ 134819 Redo Test If Necessary.→

-6- (Sensor) 1 REMOVING AND INSTALLING 134819 REMOVING AND
Wheel CRANKSHAFT INSTALLING CRANKSHAFT
Replace → 134819 REMOVING

Fastening Replace→ 134819 REMOVING
-7- 3 AND INSTALLING
Screws AND INSTALLING CRANKSHAFT
CRANKSHAFT
If The Oil Circuit Is Dirty,

For
Replacement Is Essential.
Crankshaft Push In And Out (By Hand) Using
-8- Oil Spray Jet Opening Pressure 2 Bars. Push In
Bearings 2 A Suitable Mandrel.
And Out (By Hand) Using A
To 7
Suitable Mandrel.

CLEARANCE) (CAYENNE TIP) > CHECKING RADIAL PLAY AND AXIAL PLAY OF
CRANKSHAFT > CHECKING RADIAL PLAY OF CRANKSHAFT
1. Dismantle bearing cover for shaft journals and remove along with bearing shell.
2. Clean shaft journal and bearing shell with a lint-free cloth.
Information
1. When measuring radial play, do not rotate the crankshaft .
2. Plastigage is highly susceptible to damage Insert Plastigage carefully .
3. 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 red Plastigage on the shaft journal or on the bearing shell. -arrow-
Fig 1: Identifying Plastigage On Shaft Journal
4. Fit the bearing cover along with the bearing shell and tighten to the specified Tightening
Torque. For details, see → 134819 REMOVING AND INSTALLING CRANKSHAFT
Information
1. 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 cover again and compare the thickness of the Plastigage with the scale
on the packaging - see Fig 2-. If the wear limit is reached or exceeded, replace the crankshaft
and bearing shells. → 134819 REMOVING AND INSTALLING CRANKSHAFT .
Fig 2: Checking Plastigage Strip Using Scale
Connecting Rod Bearings (Crankshaft Journals) Main Bearing (Shaft Journals)
53.968 mm 59.958 mm
Crankshaft Radial Play Measured Using Plastigage
New Wear Limit
Main Bearing (Shaft Journals) 0.02....0.06 mm 0.10 mm

CLEARANCE) (CAYENNE TIP) > CHECKING RADIAL PLAY AND AXIAL PLAY OF
CRANKSHAFT > CHECKING AXIAL PLAY OF CRANKSHAFT
1. Measure the axial bearing play (bearing cover 5) between the thrust washer and the crank web
with a feeler gauge - see Fig 1-. When measuring the amount of play, turn the crankshaft by
hand in the direction of travel. If the wear limit is reached 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 must be
replaced.
Fig 1: Checking Axial Play Of Crankshaft
Connecting Rod Bearings (Crankshaft Journals) Main Bearing (Shaft Journals)
53.968 mm 59.958 mm
Crankshaft Axial Play
New Wear limit
Bearing 5 (guide bearing) 0.07 mm 0.30 mm

CLEARANCE) (CAYENNE TIP) > SUBSEQUENT WORK
1. Install oil pump. → INSTALLING OIL PUMP - section on "Installing"
2. Install oil pan. → INSTALLING OIL PAN - section on "Installing"
WM 134819 REMOVING AND INSTALLING CRANKSHAFT (CAYENNE TIP) > TOOLS

Assembly Tool VW Tool T10215
Funnel VW Tool T10333
WM 134819 REMOVING AND INSTALLING CRANKSHAFT (CAYENNE TIP) >

TECHNICAL VALUES

value 1 2
Internal Serration Screw 30 Nm

Initial
On Crankshaft Bearing M10 x 78 (always Replace) (22 ft.
Tightening
Cover lb.)
Internal Serration Screw

On Crankshaft Bearing Torque Angle 180°
Cover
Countersunk Screw On 10 Nm
Initial
Drive Plate For M6 X 13 (Always Replace) (7.5 ft.
Tightening
Inductive Pickup lb.)
Countersunk Screw On
Drive Plate For Torque Angle 90°
Inductive Pickup
Countersunk Screw On 10 Nm
Initial
Drive Plate For M6 X 13 (Always Replace) (7.5 ft.
Tightening
Inductive Pickup lb.)
Countersunk Screw On
Drive Plate For Torque Angle 90°
Inductive Pickup
Components Temperature 17° C
30 Nm
M9 X 1 X 50 (Always Initial
Connecting Rod Bolts (22 ft.
Replace) Tightening
lb.)
Connecting Rod Bolts Torque Angle 90°
Tightening
Vibration Balancer Joint M6 x 16 (7.5 ft.
Torque
Flange lb.)
Tightening 8 Nm (6
Lower Timing-Case
Torque ft. lb.)
Cover

M18 X 1.5 X 40 (Always Initial
Crankshaft Vibration (74 ft.
Replace) Tightening
Balancer lb.)
Crankshaft Vibration Torque Angle 180°
Balancer
M9 X 1.25 X 141 (7 Ea.,

Cylinder-Head Screws Centre) And M9 X 1.25 X 111 Initial 15 Nm
(Internal Serration) (13 Ea., Outer), Always Tightening (11 ft. lb.)
Replace
30 Nm
(22 ft.
lb.)
Cylinder-Head Screws
Torque Angle 180°
(Internal Serration)

M6 x 25

M8 x 20
Oil Pump Torque ft. lb.)
40 Nm
Tightening
Torque
lb.)
10 Nm
M8 x 11.5 (7.5 ft.
lb.)
Initial
Drive Wheel For Timing M10 X 40 (Always Replace) (44 ft.
Tightening
Chain lb.)
Drive Wheel For Timing Torque Angle 90°
Chain
10 Nm
Tightening
Torque
lb.)
20 Nm
(15 ft.
Guide Rail Torque
lb.)
23 Nm
M8 x 45 (17 ft.
Guide Rail Torque
lb.)
60 Nm
Hexagon-Head Bolts On M12 X 1.5 X 85 (Always Initial
(44 ft.
Camshaft Controllers Replace) Tightening
lb.)
Hexagon-Head Bolts On
Torque Angle 90°
Camshaft Controllers
Tightening 8 Nm (6
Cheese Head Bolt M6 x 30
Torque ft. lb.)
Hexagon-Head Bolts On 10 Nm
M6 x 16 (20 ea.); M6 x 58 (2 Tightening
Lower Timing-Case (7.5 ft.
ea.) Torque
Cover lb.)

M6 x 20

M6 x 40

M6 x 20
Oil Pan Torque ft. lb.)
10 Nm
With Guide Sleeve (7.5 ft.
Cylinder Head Cover Torque
lb.)
25 Nm
Tightening
Oil Cooler Cover (19 ft.
Torque
lb.)
20 Nm
Tightening
Oil Pressure Switch (15 ft.
Torque
lb.)
25 Nm
Tightening
Lower Part Of Oil Filter (19 ft.
Torque
lb.)
10 Nm
Tightening
Oil Drain Plug (7.5 ft.
Torque
lb.)
Tightening
Oil/Water Heat M6 x 65 (17 ft.
Torque
Exchanger lb.)
22 Nm
Fuel Line To Fuel Tightening
(16 ft.
Distributor Pipe Torque
lb.)
35 Nm
Fuel Line At Plenum Tightening
(26 ft.
Panel Torque
lb.)
30 Nm
Cheese Head Bolts On Initial
M8 x 55 (Always Replace) (22 ft.
Fuel Distributor Pipe Tightening
lb.)
Cheese Head Bolts On

Torque Angle 90°
Fuel Distributor Pipe

M6 x 18 (Always Replace)
Coolant Pump Torque ft. lb.)
25 Nm
Hexagon Nut On Tightening
M8 (Always Replace) (19 ft.
Exhaust Manifold Torque
lb.)
23 Nm
Tightening
Fit Bolt On Unit Carrier M8 x 28 (17 ft.
Torque
lb.)
23 Nm
Cheese Head Bolt On Tightening
M8 x 40 (17 ft.
Unit Carrier Torque
lb.)
25 Nm
Cheese Head Bolts On Tightening
M8 x 30 (19 ft.
Belt Tensioner Torque
lb.)

INFORMATION > ALLOCATION AND MARKING OF BEARING SHELLS ON
CRANKSHAFT
The bearing shell for the cylinder block (top bearing shell) must always be inserted in the yellow color.
Color Identification Of The Color Identification Of The

Letter On The Letter On The
Bearing Shell For Bearing Bearing Shell For Cylinder
Cylinder Block Crankshaft Web
Cover Block
A, B, C, D, E R Red Yellow
A, B, C, D, E G Red Yellow
A, B, C, D, E B Yellow Yellow
A, B, C, D, E V Blue Yellow
G, H, I R Red Yellow
G, H, I G Red Yellow
G, H, I B Yellow Yellow
G, H, I V Blue Yellow
K, L, M R Red Yellow
K, L, M G Yellow Yellow
K, L, M B Blue Yellow
K, L, M V Violet Yellow
Bearing Cover 1 2 3 4 5 6 7
Letters On The Cylinder Block G H H H G E G
Letters On The Crankshaft Web G B B V B B G
Color Identification Of The Bearing Shell For Bearing Cover Red Yellow Yellow Blue Yellow Yellow Red
The first letter is for bearing cover one, the second for bearing cover two, and so on.
Marking On Cylinder Block:
Letters are shown on the sealing face of the oil pan.

Fig 1: Identifying Cylinder Block Marking

INFORMATION > MARKING ON CRANKSHAFT
Letters must be stamped on the outer crankshaft web of cylinder 1.

Fig 1: Locating Crankshaft Marking

PRELIMINARY WORK
Information

1. Remove engine.
2. Remove the transmission. → 100127 REMOVING ENGINE FROM TRANSMISSION AND

3. Secure engine on mounting bracket.
4. Remove engine carrier eyebolt at the front and rear.
5. Remove the engine wire harness. → REMOVING WIRE HARNESS FOR ENGINE
6. Remove bar ignition modules. → 282020 REMOVING AND INSTALLING BAR IGNITION
MODULES ON DFI ENGINES

"Removing"
8. Remove drive belt. → REMOVING DRIVE BELT - section on "Removing"
Arrow - Belt tensioner
Fig 1: Locating Belt Tensioner Bolts

10. Remove cylinder head cover.→ 158219 REMOVING AND INSTALLING CYLINDER HEAD
11. Remove drive plate on vehicles with automatic transmission. → 136319 REMOVING AND
INSTALLING DRIVE PLATE FOR TORQUE CONVERTER
1.
13. Remove upper and lower timing-case cover. → REMOVING TIMING-CASE COVER - section
on "Removing"
14. Position crankshaft to the compression TDC for cylinder 1. → 150502 CHECKING THE
TIMING ON V6 DFI ENGINES
Information

PRELIMINARY WORK > REMOVAL OF CHAIN TENSIONER
Press the bottom chain tensioner together during removal because otherwise it will push out due to
spring tensioning. Secure chain tensioner with a tie-wrap in tensioned state .
15. Remove chain tensioner. → REMOVING CHAIN TENSIONER - section on "Removing"
16. Remove timing chains. → REMOVING AND INSTALLING DRIVE CHAIN FOR AUXILIARY
DRIVES - section on "Removing"
17. Remove cylinder head. → REMOVING CYLINDER HEAD - section on "Removing"
18. Remove pistons. → REMOVING PISTONS - section on "Removing"
19. Remove vibration balancer. → REMOVING VIBRATION DAMPER

Fig 1: Turning Crankshaft Vibration Balancer Hold Tool
20. Remove joint flange behind the vibration balancer.
20.1. Unscrew hexagon-head bolts -3- .
20.2. Carefully lever off the joint flange -2- with a screwdriver.
Fig 2: Identifying Cylinder Block, Crankshaft And Vibration Balancer Joint Flange
1. Cylinder Block
4. Straight Pin
6. Fastening Screw On Lower Timing-Case Cover

REMOVING CRANKSHAFT
Information

REMOVING CRANKSHAFT > REMOVAL OF CRANKSHAFT
Before removing the crankshaft, have a suitable tray ready so that the pulse-generating wheel is not
damaged as a result of excessive contact.
The engine is secured on the engine support to facilitate assembly work.
When replacing bearing shells, only use bearing shells with the same color coding.
1. Remove crankshaft.
1. 1.1. Prepare a clean surface for laying down the crankshaft. Make sure not to
damage the drive plate for the inductive pickup (speed sender) when laying down the
crankshaft.
2. 1.2. Remove crankshaft bearing covers -1- and lay them down arranged according
to cylinder.
3. 1.3. Dispose of thrust washers -4- and crankshaft bearing shells -3- .
4. 1.4. Remove the crankshaft and lay it down on the prepared surface.
5. 1.5. Remove oil spray nozzles -8- if necessary.

1. Crankshaft Bearing Covers
2. Internal Serration Screws On Crankshaft Bearing Covers
3. Crankshaft Bearing Shells Must Always Be Replaced
4. Thrust Washer For Bearing Cover 5 Must Always Be Replaced
5. Crankshaft
6. Drive Plate For Inductive Pickup (Speed Sender)
7. Fastening Screw On Drive Plate For Inductive Pickup (Speed Sender)

8. Oil Spray Nozzle

INSTALLING CRANKSHAFT
1. Install the crankshaft.
1. 1.1. Oil bearing shells with engine oil and place them on the crankshaft/crankcase.
2. 1.2. Always replace bearing shells. Observe relevant classification.
3. 1.3. Fit thrust bearing no. 5 with thrust washers -4- (insert using grease, lubricating
groove facing outwards) and then fit the remaining bearing covers.
4. 1.4. Tap crankshaft bearing covers on securely as far as they will go using a rubber
hammer so that the Tightening Torque will be accurate.
5. 1.5. Internal serration screws on the crankshaft bearing covers -2- must always be
replaced and screwed in by hand.
6. 1.6. Then gradually tighten the bearing covers from the inside out to the specified
torque -2- .
7. 1.7. As a test, turn the crankshaft several times to check that it turns smoothly.
2. Internal Serration Screw On Crankshaft Bearing Cover → Initial

Tightening: 30 Nm (22 ft. lb.) → Torque Angle: 180°
3. Bearing Shell Must Always Be Replaced
4. Thrust Washer For Bearing Cover 5 Must Always Be Replaced
5. Crankshaft
6. Drive Plate For Inductive Pickup

7. Countersunk Screw On Drive Plate For Inductive Pickup → Initial
Tightening: 10 Nm (7.5 ft. lb.) → Torque Angle: 90°
8. Oil Spray Nozzle

Fig 2: Identifying Crankshaft Bearing Lugs

REPLACING SPEED SENSOR WHEEL
1. If the drive plate -6- for the inductive pickup (speed sender) was removed from the crankshaft,
it must always be replaced . The drive plate must never be reused.
2. Internal Serration Screw On Crankshaft Bearing Cover
3. Bearing Shell
4. Thrust Washer For Bearing Cover 5

5. Crankshaft
6. Drive Plate For Inductive Pickup
7. Countersunk Screw On Drive Plate For Inductive Pickup → Initial Tightening: 10

Nm (7.5 ft. lb.) → Torque Angle: 90°
8. Oil Spray Nozzle
2. Tighten the countersunk screws -7- on the drive plate to the specified Tightening Torque.

SUBSEQUENT WORK
Information
Information
Detailed instructions for installing pistons must be observed at all times .
The cast lugs, the twist lock (locking lugs) -1- and the flat side of the piston crown -2- are on the
same side .
Fig 1: Locating Connecting Rods Cast Lugs And Pistons
1. Install pistons. → 131019 REMOVING AND INSTALLING PISTONS ON V6 DFI ENGINES
1. 1.1. Pull dowel sleeve -arrow- out of the bore hole so that special tool Funnel
damper.
6. 1.6. Insert dowel sleeves back into the bore holes -arrow- .

Information
1. Always replace the connecting-rod bearing shells and oil them before inserting
them into the bearing covers .
2. 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 .
Fig 2: Identifying Connecting-Rod And Cap Alignment
3. 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 .
shells are aligned.
9. 1.9. Carefully tap the connecting rod bearing caps -6- with a plastic hammer until
they are seated correctly so that the Tightening Torque will be accurate.
10. 1.10. Tighten all connecting rod bearing screws -7- to the specified Tightening
Torque.
Fig 3: Overview Of Piston And Connecting Rod
1. Piston Rings (Move Gap By 120°)
2. Piston
3. Circlip
4. Bearing Shells Must Always Be Replaced . Observe Relevant

Classification.
5. Con-Rod Bearings
6. Connecting Rod Bearing Cap
7. Connecting Rod Bolts → Initial Tightening: 30 Nm (22 ft. lb.) → Torque

Angle: 90°
8. Cylinder Block
9. Piston Pin
Arrow - Dowel pin

Fig 5: Identifying Pistons Installation Position (V6 DFI Engine)
1. Valve Recesses On Cylinders 1, 3 And 5
2. Valve Recesses On Cylinders 2, 4 And 6
3. Arrow Pointing Towards Vibration Balancer

Arrow - Setting of gap on drive plate for inductive pickup (speed sender)
Fig 7: Locating Drive Plate Gap
2. Fit joint flange for vibration balancer. → 137419 REMOVING AND INSTALLING SEALING
RING FOR VIBRATION BALANCER ON DFI ENGINES
1. 2.1. Apply 2-mm thick bead of sealant -arrows- .
2. 2.2. Assembly Tool T10215 (guide sleeve) -1- must be fitted on the crank pin -3-
to prevent damage to the vibration balancer joint flange.
3. 2.3. Slide the joint flange -2- over the guide sleeve -1- until it is touching the cylinder
block.
4. 2.4. Tighten hexagon-head bolts -3- on joint flange -2- to the specified torque.
Fig 8: Identifying Crankshaft Joint Flange And Cylinder Block
1. Cylinder Block
3. Hexagon-Head Bolt On Vibration Balancer Joint Flange → Tightening


8 Nm (6 ft. lb.)
Fig 9: Applying Sealant To Joint Flange
1. Assembly Tool (Guide Sleeve)
3. Crankshaft Flange
Fig 10: Identifying Front Crankshaft Joint Flange
3. Fit vibration balancer for crankshaft. → 137619 REMOVING AND INSTALLING VIBRATION
BALANCER (CRANKSHAFT PULLEY) ON V6 DFI ENGINES
1. 3.1. Tighten hexagon-head bolt on crankshaft vibration balancer → Initial

tightening: 100 Nm (74 ft. lb.) → Torque angle: 180° .
Fig 11: Tightening Crankshaft Vibration Balancer Bolt
Arrow - Crankshaft/vibration balancer marking

5. If the oil retaining valve was removed during removal, fit a New sealing ring on the oil retaining
valve before inserting it into the crankcase -arrow- .
Arrow - Oil retaining valve

Fig 13: Identifying Oil Retaining Valve
6. Install cylinder head. → 157019 REMOVING AND INSTALLING CYLINDER HEAD ON V6 DFI
ENGINES
2. 6.2. Cylinder head gasket Must Always Be Replaced .

(11 ft. lb.).
3. 6.3.3. Then tighten all cylinder-head screws a Second Time to 30 Nm (22

ft. lb.).

180°.
Fig 14: Identifying Cylinder-Head Screw Tightening Sequence
1-20 - Tightening sequence for cylinder-head screws → Initial Tightening:

15 Nm (11 ft. lb.) → Tightening Torque: 30 Nm (22 ft. lb.) → Torque
angle: 180°
7. Fit timing chains. → 153519 REMOVING AND INSTALLING TIMING CHAIN (AUXILIARY
DRIVE MECHANISM)
1. 7.1. Install timing chain housing.

TENSIONER
3. 7.3. Install camshaft controllers. → 158419 REMOVING AND INSTALLING

CAMSHAFT CONTROLLER ON V6 DFI ENGINES
2. Oval-Head Screw On Timing Chain Housing → Tightening Torque: 8 Nm

(6 ft. lb.)
3. Timing Chain
5. Sealing Ring
6. Oil Pump
8. Tensioning Rail
9. Chain Tensioner On Timing Chain → Tightening Torque: 40 Nm (30 ft.
lb.)
10. Sealing Ring (A22 x 27), always replace
12. Sprocket
14. Hexagon-Head Bolt → Initial tightening: 60 Nm (44 ft. lb.) → Torque

angle: 90°
17. Drive Chain
21. Hexagon-Head Bolt On Guide Rail → Tightening Torque: 23 Nm (17 ft.

lb.)
22. Hexagon-Head Bolts On Camshaft Controllers → Initial Tightening: 60

Nm (44 ft. lb.) → Torque angle: 90°
28. Guide Rail

Fig 16: Identifying Timing Chain Housing Bolts
1. Cheese head bolt → Tightening Torque: 8 Nm (6 ft. lb.)

Fig 17: Identifying Cylinder Block And Crankshaft Joint Flange
1. Cylinder Block

10 Nm (7.5 ft. lb.)
1. Drive Shaft
2. Upper Timing-Case Cover
3. Oval-Head Screw → Tightening Torque: 8 Nm (6 Ft. Lb.)
4. Oval-Head Screw On Vacuum Pump → Tightening Torque: 8 Nm (6 ft.

lb.)
5. Housing
6. Seal
7. Sealing Ring
Information

SUBSEQUENT WORK > INSTALLATION OF OIL PAN
Check the best-before date on the sealing compound.
The oil pan must be installed within 5 minutes of applying the silicone sealant.
The bead of sealant that is applied must not be thicker than the specified thickness because otherwise
excess sealant can get into the oil pan and can block the strainer in the oil pump intake pipe.
Allow the sealant to dry for at least 30 minutes after installing the oil pan. Only then can engine oil be
filled in.
10. Install oil pan. → 175019 REMOVING AND INSTALLING OIL PAN ON V6 DFI ENGINES
Observe tightening sequence for hexagon-head bolts (1 to 25) on oil pan.
Fig 1: Identifying Oil Pan Bolt Tightening Sequence
1-25 - Hexagon-head bolts on oil pan → Tightening Torque: 12 Nm (9 ft. lb.)
Fig 2: Identifying Cylinder Head Cover And Valve Cover Seal
1. 1 - Cylinder head cover
2. 2 - Cylinder-head gasket
3. 3 - Fastening screw on cylinder head cover → Tightening Torque: 10 Nm (7.5 ft.

lb.)
4. 4 - Cover
12. Install drive plate on vehicles with automatic transmission. → 136319 REMOVING AND
INSTALLING DRIVE PLATE FOR TORQUE CONVERTER
Install oil/water heat exchanger. → 174019 REMOVING AND INSTALLING OIL/WATER HEAT
EXCHANGER (OIL COOLER) ON V6 DFI ENGINES
Fig 3: Identifying Oil-Filter Housing
1. Oil-Filter Housing
2. Seal Must Always Be Replaced
3. Sealing rings Must Always Be Replaced
4. Oil Cooler
5. Oil Cooler Cover → Tightening Torque: 25 Nm (19 ft. lb.)
6. Oil Pressure Switch → Tightening Torque: 20 Nm (15 ft. lb.)
7. Oil Filter
8. Lower Part Of Oil Filter → Tightening Torque: 25 Nm (19 ft. lb.)
9. Oil Drain Plug → Tightening Torque: 10 Nm (7.5 ft. lb.)
10. Hexagon-Head Bolt On Oil/Water Heat Exchanger → Tightening Torque: 23 Nm

(17 ft. lb.)
Install coolant regulator. → 195819 REMOVING AND INSTALLING COOLANT REGULATOR

(THERMOSTAT) ON DFI ENGINES
14.1. Fit thermostat housing -1- completely into the cylinder block.
14.2. Slide coolant hose -3- onto the thermostat housing.
14.3. Fasten spring band clamp -2- .

Fig 4: Identifying Coolant Regulator
3. Coolant hose
Install fuel distribution pipe and fuel injectors. → 243019 REMOVING AND INSTALLING FUEL
DISTRIBUTION PIPE (FUEL RAIL) ON DFI ENGINES
Fig 5: Identifying Fuel Distributor Pipe And Fuel Injectors
1. Fuel low-pressure line → Tightening Torque: 22 Nm (16 ft. lb.) → Tightening

2. Cheese head bolts on fuel distributor pipe → Initial tightening: 30 Nm (22 ft. lb.) →
Torque angle: 90°
3. Fuel injectors
Install coolant pump.→ 195019 REMOVING AND INSTALLING COOLANT PUMP ON DFI
ENGINES
Arrow - Oval-head screw (coolant pump) → Tightening Torque: 8 Nm (6 ft. lb.)

Install exhaust manifold.
→ INSTALLING EXHAUST MANIFOLD - section on "Installing"
Arrow - Hexagon nut on exhaust manifold → Tightening Torque: 25 Nm (19 ft. lb.)
Fig 7: Locating Exhaust Manifold Nut
Install intake-air distributor. → 244619 REMOVING AND INSTALLING DFI INTAKE-AIR

DISTRIBUTOR
Install guide tube for oil dipstick. Sealing ring must always be replaced . → 171719
REMOVING AND INSTALLING GUIDE TUBE FOR OIL DIPSTICK ON DFI ENGINES
Install unit carrier.

Fig 8: Identifying Unit Carrier, Belt Tensioner And Generator
1. Belt Tensioner
2. Cheese Head Bolt On Belt Tensioner
3. Unit Carrier
4. Fit Bolt On Unit Carrier → Tightening Torque: 23 Nm (17 ft. lb.)

5. Cheese Head Bolt On Unit Carrier → Tightening Torque: 23 Nm (17 ft. lb.)
6. Dowel Sleeve For Unit Carrier
7. Deflection Roller With Fastening Screw
8. Drive Belt (Poly-Rib Belt)
9. Generator
10. Coolant Pump Pulley
11. Drive Wheel For Air-Conditioning Compressor
12. Power-Steering Pump Pulley
13. Crankshaft Vibration Damper
Install the generator. → 272219 REMOVING AND INSTALLING THE GENERATOR
Install hydraulic pump (power-steering pump). → 48981900 REMOVING AND INSTALLING

HYDRAULIC PUMP (CAYENNE V6)
Install belt tensioner. → 137319 REMOVING AND INSTALLING BELT TENSIONER ON DFI
ENGINES
Arrow - Cheese head bolts on belt tensioner → Tightening Torque: 25 Nm (19 ft. lb.)
Fit and tension the drive belt.
→ 137819 REMOVING AND INSTALLING DRIVE BELT

Fig 10: Drive Belt Routing Diagram
1. Crankshaft Vibration Balancer
2. Coolant Pump
3. Drive Belt Tensioning Roller
4. Air-Conditioning Compressor
5. Power-Steering Pump/Tandem Pump
6. Generator
7. Deflection Roller
Install bar ignition modules. → 282020 REMOVING AND INSTALLING BAR IGNITION
MODULES ON DFI ENGINES
Fig 11: Identifying Bar Ignition Modules
1. Connectors For Bar Ignition Modules
2. Retaining Clips
3. Engine Wire Harness
Fit engine wire harness. → INSTALLING WIRE HARNESS FOR ENGINE
26.1. Clip in engine wire harness at the rear engine housing using the retaining clips
-arrows- .
26.2. Connect engine wire harness to the oil/water heat exchanger.
Arrow - Retaining clips

Fig 12: Locating Engine Wire Harness - Rear

Fig 13: Locating Engine Wire Harness - Front
WM 135919 REMOVING AND INSTALLING SEALING RING FOR CRANKSHAFT -

FLYWHEEL SIDE (CAYENNE S, CAYENNE TURBO, CAYENNE TURBO S & CAYENNE
GTS) > TOOLS
Pressure Piece Special Tool 9609/1

Spacer Special Tool 9609/2
Drift Punch, Commercially

Nr. 167
1-mm Tip Available Tool
Slide Hammer Commercially

Nr. 168
Kit Available Tool

GTS) > PRELIMINARY WORK
1. Remove drive plate for converter. → 136319 REMOVING AND INSTALLING DRIVE PLATE
FOR TORQUE CONVERTER

GTS) > REMOVING SEALING RING FOR CRANKSHAFT (TRANSMISSION SIDE)
1. Radial Shaft Seal (Use Protection Cap For Radial Shaft Seal For Fitting; Only Fit When
Crankcase Is Screwed On)
2. Crankcase
3. Crankshaft
4. Radial Shaft Seal (Sectional View)
A. Direction Of Travel
1. Use the Drift Punch, 1-mm tip Nr. 167 to drive a small hole at a non-rubberised spot
(rectangular window in the ring) on the sealing ring. → Drift punch
Fig 2: Driving Small Hole At A Non-Rubberised Spot
2. Screw in the extractor tip. Use the Slide Hammer Kit Nr. 168 to knock out the extractor tip
together with the sealing ring. Alternatively, you can screw in a suitable tapping screw and pull
out the sealing ring using a pliers. → Knocking out sealing ring
Fig 3: Screwing In Extractor Tip
3. Clean the crankshaft flange. The crankshaft flange must not be dirty or rusty. Clean it with
brake cleaner and sand off any rust with a metal-polishing pad (e.g. Never Dull) if necessary.
→ Cleaning the crankshaft flange
Fig 4: Cleaning Crankshaft Flange

GTS) > INSTALLING SEALING RING FOR CRANKSHAFT (TRANSMISSION SIDE)
Information
Sealing rings become damaged as a result of improper fitting. Do not oil sealing rings on the running
surface and do not pull sealing rings off the plastic sleeve.
2. Crankcase
3. Crankshaft
1. Fit the sealing ring and sleeve on the tool Spacer 9609/2 . → Pushing on sealing ring
Fig 2: Pushing Sealing Ring Onto Tool
2. Position the centering tool Spacer 9609/2 on the crankshaft flange. Pay attention to the
centering pin when doing this. Then tighten the two fastening screws to 23 Nm (17 ft. lb.). →
Centering tool
Fig 3: Identifying Crankshaft Centering Tool
3. Position the retracting bell Pressure Piece 9609/1 and tighten the central screw (a/f 19) to 25
Nm (19 ft. lb.). → Retracting bell
Fig 4: Identifying Retracting Bell
4. Loosen the retracting bell and screw it down.
5. Loosen the two fastening screws on the centering device and remove the tool. Remove sleeve
from the tool.

GTS) > SUBSEQUENT WORK
1. Fit drive plate for converter. → 136319 REMOVING AND INSTALLING DRIVE PLATE FOR
TORQUE CONVERTER
WM 135919 REMOVING AND INSTALLING CRANKSHAFT SEALING RING

(TRANSMISSION SIDE) (CAYENNE S E-HYBRID) > TOOLS

Fitting Tool VW Tool T10122
Extractor Tool VW Tool T20143

(TRANSMISSION SIDE) (CAYENNE S E-HYBRID) > PRELIMINARY WORK
1. Electric drive motor removed. → 100127 REMOVING ENGINE FROM TRANSMISSION AND
2. Remove drive plate. → 136319 REMOVING AND INSTALLING DRIVE PLATE FOR TORQUE
CONVERTER

(TRANSMISSION SIDE) (CAYENNE S E-HYBRID) > REPLACING CRANKSHAFT
SEALING RING AT TRANSMISSION SIDE
1. Remove pulse sender wheel from the crankshaft stub.
2. Pry out shaft sealing ring using Extractor Tool T20143 .
Clean running surfaces and sealing faces.

Fig 1: Prying Out Crankshaft Sealing Ring
3. Then drill a hole for the dowel pin in the Fitting Tool T10122 . The hole should have a
diameter of 8 mm -arrow 2- . Use the bore hole -arrow 1- in the pulse sender wheel as a
drilling template.
Fig 2: Drilling Hole In Fitting Tool
4. Fit the assembly aid -T10122/1- on the fitting sleeve -T10122/2- and slide the shaft sealing
ring -A- onto the fitting sleeve.
Remove assembly aid.

Fig 3: Installing Crankshaft Sealing Ring
5. Fit the fitting sleeve -T10122/2- with the shaft sealing ring -1- onto the crankshaft.
Fig 4: Installing Sleeve Onto Crankshaft
6. Press in shaft sealing ring uniformly until flush all round using Pressure Sleeve -T10122/3- .
Fig 5: Identifying Pressure Sleeve (T10122/3)

(TRANSMISSION SIDE) (CAYENNE S E-HYBRID) > SUBSEQUENT WORK
1. Install drive plate. → 136319 REMOVING AND INSTALLING DRIVE PLATE FOR TORQUE
CONVERTER
WM 135919 REPLACING CRANKSHAFT SEALING RING (ON TRANSMISSION SIDE)

(CAYENNE, CAYENNE S, CAYENNE S DIESEL, CAYENNE S E-HYBRID, CAYENNE
TURBO, CAYENNE GTS, CAYENNE (3.0) & CAYENNE TURBO S) > TOOLS


Nr. 167

Nr. 168
Kit Available Tool

TURBO, CAYENNE GTS, CAYENNE (3.0) & CAYENNE TURBO S) > PRELIMINARY
WORK
1. Remove hall-sender rotor. → 284419 REMOVING AND INSTALLING HALL-SENDER ROTOR

TURBO, CAYENNE GTS, CAYENNE (3.0) & CAYENNE TURBO S) > REMOVING
CRANKSHAFT SEALING RING (ON TRANSMISSION SIDE) > REMOVING SEALING
RING FOR CRANKSHAFT (ON TRANSMISSION SIDE)
2. Crankcase
3. Crankshaft
1. Use the Drift Punch, 1-mm Tip Nr. 167 to beat a small hole at a non-rubberised spot
Fig 2: Drilling Hole Using Drift Punch
out the sealing ring using a pliers. → Punching out sealing ring
3. Clean the crankshaft flange. The crankshaft flange must not be dirty or rusty. If necessary,
clean it with brake cleaner and sand off any rust with a metal-polishing pad (e.g. Never Dull).
→ Cleaning crankshaft flange

TURBO, CAYENNE GTS, CAYENNE (3.0) & CAYENNE TURBO S) > INSTALLING
CRANKSHAFT SEALING RING (ON TRANSMISSION SIDE) > INSTALLING SEALING
RING FOR CRANKSHAFT (ON TRANSMISSION SIDE)
Information
2. Crankcase
3. Crankshaft
1. Connect the sealing ring and sleeve to the tool Spacer 9609/2 . → Fitting sealing ring
Fig 2: Installing Sealing Ring Onto Tool
2. Position the centering device Spacer 9609/2 on the crankshaft flange. Pay attention to the
Centering tool
Fig 3: Positioning Centering Device
from the tool.

TURBO, CAYENNE GTS, CAYENNE (3.0) & CAYENNE TURBO S) > SUBSEQUENT
WORK
1. Install hall-sender rotor. → 284419 REMOVING AND INSTALLING HALL-SENDER ROTOR
WM 135955 REPLACING CRANKSHAFT SEALING RING ON TRANSMISSION SIDE

(CAYENNE S & CAYENNE GTS) > PRELIMINARY WORK
1. Remove vibration balancer → REMOVING VIBRATION DAMPER - section on "Removing".

(CAYENNE S & CAYENNE GTS) > REMOVING CRANKSHAFT SEALING RING FOR
1. Loosen the four fastening screws -arrows- and remove the cover with sealing ring.
Fig 1: Removing Crankshaft Cover With Sealing Ring
2. Clean the sealing surface of the sheetmetal cover.

(CAYENNE S & CAYENNE GTS) > INSTALLING CRANKSHAFT SEALING RING FOR
Information
Information
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 .
Information
1. Place seal with plastic sleeve over the crankshaft.

Fig 1: Identifying Crankshaft Seal With Plastic Sleeve
2. Tighten the two upper fastening screws and then the lower fastening screws by hand. Then
tighten the screws in diagonally opposite sequence to the specified torque (Aluminum
Screws ).
Fig 2: Identifying Crankshaft Cover Screws

Fig 3: Identifying Chain Tensioner, Sealing Ring And Joint Flange
1. Joint Flange (Oil Sealing Lip With Engine Oil); Align With Sleeve Or Vibration
Balancer
2. Aluminum Screw , M6 x 20; Always Use New Aluminum Screws;
3. Aluminum Screw , M6 x 55; Always Use New Aluminum Screws;
4. Sealing Ring
5. Chain Tensioner
3. Pull plastic sleeve straight off the joint flange.

Fig 4: Identifying Crankshaft Plastic Sleeve

(CAYENNE S & CAYENNE GTS) > SUBSEQUENT WORK
1. Install vibration balancer → INSTALLING VIBRATION DAMPER - section on "Installing".
WM 136319 REMOVING AND INSTALLING DRIVE PLATE FOR TORQUE CONVERTER

(CAYENNE S, CAYENNE TURBO, CAYENNE GTS, CAYENNE TURBO S & CAYENNE
TIP) > TOOLS

Toothed Segment Special Tool 95381

TIP) > TECHNICAL VALUES
Drive Plate M10 Tightening Torque 60 Nm (44 ft. lb.)
Drive Plate M10 Torque angle 90°

TIP) > PRELIMINARY WORK
1. Remove the transmission → REMOVING AUTOMATIC TRANSMISSION - section on

"Removing" or, with the engine removed, remove the transmission → REMOVING
AUTOMATIC TRANSMISSION - section on "Removing"

TIP) > REMOVING DRIVE PLATE FOR TORQUE CONVERTER
1. Mark installation position of the drive plate relative to the crankshaft using a felt-tip pen.
Information
The threaded bore in the oil guide housing is a blind hole.
1. The toothed segment must be secured to the oil guide housing using a screw (M12 x 50)
. -2- This screw ensures that the toothed segment is secured well and prevents damage
to the blind hole thread because the thread is the correct length .
2. The engagement point of the toothed segment must be facing the crankcase . -1-
Fig 1: Identifying Toothed Segment And Screw
3. Position toothed segment at the bottom two threaded bores of the oil guide housing. →
Toothed segment on oil guide housing
Fig 2: Positioning Toothed Segment And Screw
2. Block drive plate. To do this, attach Toothed Segment 95381 to a threaded bore at the bottom
of the oil guide housing so that at least one tooth engages with the ring gear. → Toothed
segment
Fig 3: Identifying Toothed Segment And Ring Gear
3. Remove drive plate. To do this, loosen the 10 fastening screws crosswise. → Drive plate
Fig 4: Removing Drive Plate
4. Remove drive plate.
5. If the drive plate is stuck, remove it using an internal puller and a slide hammer.
1. 5.1. To do this, insert internal puller into the middle of the drive plate and tighten it. →
Internal puller
Fig 5: Identifying Drive Plate Internal Puller
2. 5.2. Then screw on the slide hammer and knock off the drive plate. → Slide hammer
Fig 6: Identifying Slide Hammer

TIP) > INSTALLING DRIVE PLATE FOR TORQUE CONVERTER
Information
Clean the crankshaft stub before installing the drive plate (remove rust) .
Use a special metal-polishing pad (e.g. Never Dull) for this .
Because of the bearing classification, cleaning at the crankshaft flange must be done gently and, if
necessary, the bearing classification must be documented on a separate document and kept in the
service booklet .
1. Fit drive plate. Fit new screws.
Information
The threaded bore in the oil guide housing is a blind hole.
1. The toothed segment must be secured to the oil guide housing using a screw (M12 x 50)
. -2- This screw ensures that the toothed segment is secured well and prevents damage
to the blind hole thread because the thread is the correct length .
2. The engagement point of the toothed segment must be facing the crankcase . -1-
Fig 1: Identifying Drive Plate Toothed Segment
3. Position toothed segment at the bottom two threaded bores of the oil guide housing. →
Toothed segment on oil guide housing
Fig 2: Positioning Toothed Segment
2. Block drive plate. To do this, attach Toothed Segment 95381 to a screw hole in the crankcase
so that at least one tooth engages with the starter teeth. → Toothed segment
Fig 3: Identifying Toothed Segment And Ring Gear
3. Tighten the 10 new fastening screws crosswise. → Fastening screws → Tightening Torque:
60 Nm (44 ft. lb.) , then → Torque angle: 90°
Fig 4: Tightening Torque Converter Screws
4. Toothed Segment 95381 must be removed.

TIP) > SUBSEQUENT WORK
1. Install transmission. → INSTALLING AUTOMATIC TRANSMISSION - section on "Installing" or,

with the engine removed, mount the transmission → MOUNTING AUTOMATIC
TRANSMISSION - section on "Mounting"

ON V6 DFI ENGINES (CAYENNE TIP & CAYENNE TIP "PLATINUM EDITION") > TOOLS

Counter-Hold Tool VW Tool T10069

ON V6 DFI ENGINES (CAYENNE TIP & CAYENNE TIP "PLATINUM EDITION") >
TECHNICAL VALUES
Drive Plate To Crankshaft M10 Initial Tightening 60 Nm (44 ft. lb.)
Drive Plate To Crankshaft M10 Torque Angle 90°

PRELIMINARY WORK
1. Remove transmission → REMOVING AUTOMATIC TRANSMISSION - section on "Removing"

or, with the engine removed, remove the transmission → REMOVING AUTOMATIC
TRANSMISSION - section on "Removing"

REMOVING DRIVE PLATE FOR TORQUE CONVERTER ON V6 DFI ENGINES
1. Mark installation position of the drive plate relative to the crankshaft using a felt-tip pen.
2. Block drive plate. To do this, block the crankshaft at the pulley using the counter-hold tool
Counter-Hold Tool T10069 . → Counter-hold tool
Fig 1: Identifying Counter-Hold Tool
3. Remove drive plate. To do this, loosen the fastening screws crosswise. → Drive plate
Fig 2: Removing Drive Plate Bolts
Information
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.
4. Remove drive plate.
5. If the drive plate is tight, carefully lever it off using a screwdriver if necessary.

INSTALLING DRIVE PLATE FOR TORQUE CONVERTER ON V6 DFI ENGINES
Information
Clean the crankshaft flange before installing the drive plate (remove rust) .
1. Fit drive plate.

2. Block the drive plate → Counter-hold tool . Block the crankshaft at the pulley with the
counter-hold tool Counter-Hold Tool T10069 .
3. Correctly fit the shims according to the removal marking.
4. Tighten the new fastening screws crosswise. → Fitting drive plate → Initial Tightening: 60
Nm (44 ft. lb.)
→ Torque angle: 90°

Fig 2: Installing Drive Plate Bolts

SUBSEQUENT WORK
1. Install transmission. → INSTALLING AUTOMATIC TRANSMISSION - section on "Installing" or,

with the engine removed, mount the transmission → MOUNTING AUTOMATIC
TRANSMISSION - section on "Mounting"
WM 136319 REMOVING AND INSTALLING DRIVE PLATE (CAYENNE S & CAYENNE

GTS) > TOOLS

Toothed Segment Special Tool 95381

GTS) > TECHNICAL VALUES

Value 1 2
M10 x 1 x 29 (10 ea.) Tighten

Fastening Screw Initial 60 Nm (44
Screws In Diagonally Opposite
For Drive Plate Tightening ft. lb.)
Sequence
Fastening Screw Final

+90° +/-10°
For Drive Plate Tightening

GTS) > INFORMATION > DRIVE PLATE
Fig 1: Identifying Drive Plate Screws

1. Drive Plate To Engine. Tighten Screws In Diagonally Opposite Sequence/Screw In All Screws
By Hand → Initial Tightening: 60 Nm (44 ft. lb.) → Final Tightening: +90°+/-10°
2. Drive Plate

1. Remove automatic transmission. → 373519 REMOVING AND INSTALLING AUTOMATIC

TRANSMISSION

GTS) > REMOVING DRIVE PLATE
1. Mark installation position of the drive plate with respect to the crankshaft using a felt-tip pen.
2. Block drive plate.
1. 2.1. Toothed Segment 95381 must be attached to a threaded bore at the bottom of
the oil guide housing so that at least one tooth engages with the ring gear.
3. Remove drive plate -2- .
1. 3.1. Loosen and unscrew screws -1- in diagonally opposite sequence and in several
steps.
2. 3.2. Remove drive plate.

Fig 1: Identifying Drive Plate Screws

GTS) > INSTALLING DRIVE PLATE
Information
Clean the crankshaft stub before installing the drive plate (remove rust) .
Because of the bearing classification, cleaning at the crankshaft flange must be done gently and, if
necessary, the bearing classification must be documented on a separate document and kept in the
service booklet .
Information
1. Fit drive plate on crankshaft.
1. 1.1. Position old drive plate according to the marking made during removal.
2. Block drive plate.
1. 2.1. Toothed Segment 95381 must be attached to a threaded bore at the bottom of
the oil guide housing so that at least one tooth engages with the ring gear.
3. Secure drive plate.
1. 3.1. Replace screws.
2. 3.2. Fit screws in diagonally opposite sequence in several steps and tighten
hand-tight.
3. 3.3. Tighten screws to the specified torque in diagonally opposite sequence.

1. Install automatic transmission. → 373519 REMOVING AND INSTALLING AUTOMATIC

TRANSMISSION

(CAYENNE) > TOOLS

Counter-Hold Tool VW Tool 3435

Tolerance Tolerance
1 2
Fastening Screw For Drive Initial 60 Nm (44 ft.

Replace
Plate Tightening lb.)
Fastening Screw For Drive Final

+90°
Plate Tightening

(CAYENNE) > PRELIMINARY WORK
1. Remove transmission with electric drive motor from the engine. → 100127 REMOVING
ENGINE FROM TRANSMISSION AND MOUNTING ENGINE ON TRANSMISSION
2. Remove the clutch. → 305019 REMOVING AND INSTALLING CLUTCH

(CAYENNE) > REMOVING DRIVE PLATE > ASSEMBLY OVERVIEW - DRIVE PLATE
1. Drive Plate
2. Screw Replace → Initial Tightening: 60 Nm (44 ft. lb.) → Final Tightening: +90°
3. Dowel Pin
4. Sensor Wheel For Engine Speed Sender

5. Needle-Roller Bearing
6. Shaft Sealing Ring Replace
7. Crankshaft
8. Rubber Stopper
9. Engine Speed Sender

(CAYENNE) > REMOVING DRIVE PLATE > REMOVING DRIVE PLATE
1. Counter-Hold Tool 3435 must be secured to the drive plate with two M8 x 20 screws
-arrows- .
Fig 1: Removing Drive Plate
2. Unscrew drive plate screws and remove the drive plate.

(CAYENNE) > INSTALLING DRIVE PLATE
Information
Information
Tightening Torque, tightening sequence and assembly overview. → 3X00IN TIGHTENING TORQUE,
TIGHTENING SEQUENCE AND ASSEMBLY OVERVIEW
1. 1.1. Use new drive plate screws.

(CAYENNE) > SUBSEQUENT WORK
1. Install clutch. → 305019 REMOVING AND INSTALLING CLUTCH
2. Mount transmission with electric drive motor on the engine. → 100127 REMOVING ENGINE
FROM TRANSMISSION AND MOUNTING ENGINE ON TRANSMISSION
WM 137319 REMOVING AND INSTALLING BELT TENSIONER ON DFI ENGINES

(CAYENNE TIP & CAYENNE TIP "PLATINUM EDITION") > TECHNICAL VALUES
Belt Tensioner M8 x 30 Tightening Torque 25 Nm (19 ft. lb.)

(CAYENNE TIP & CAYENNE TIP "PLATINUM EDITION") > PRELIMINARY WORK
Information
1. Slacken the drive belt. → REMOVING DRIVE BELT - section on "Removing"

(CAYENNE TIP & CAYENNE TIP "PLATINUM EDITION") > REMOVING BELT
TENSIONER
1. Screw M8 x 50 screw -arrow- into the belt tensioner.
Slacken the belt tensioner until the drive belt is loose.

Fig 1: Locating Belt Tensioner
2. Loosen fastening screws for belt tensioner. -arrows-

Fig 2: Locating Belt Tensioner Screws
3. Remove belt tensioner.

(CAYENNE TIP & CAYENNE TIP "PLATINUM EDITION") > INSTALLING BELT
TENSIONER
1. Screw a screw (M8 x 50) into the new belt tensioner until the belt tensioner is slightly
tensioned. -arrow-
Fig 1: Locating Belt Tensioner Screw
2. Fit belt tensioner.
3. Tighten fastening screws for the belt tensioner. -arrows- → Tightening Torque: 25 Nm (19 ft.
lb.)
Fig 2: Locating Belt Tensioner Screws

(CAYENNE TIP & CAYENNE TIP "PLATINUM EDITION") > SUBSEQUENT WORK
1. Fit drive belt. → INSTALLING DRIVE BELT - section on "Installing"
WM 137319 REMOVING AND INSTALLING BELT TENSIONER (CAYENNE S &

CAYENNE GTS) > TECHNICAL VALUES

CAYENNE GTS) > PRELIMINARY WORK
1. Loosen drive belt. → 137819 REMOVING AND INSTALLING DRIVE BELT

CAYENNE GTS) > REMOVING BELT TENSIONER
1. Unscrew screws -3- and remove belt tensioner.

Fig 1: Identifying Belt Drive Components
2. The connecting screw -arrow- does Not have to be loosened in order to remove the belt
tensioner.
Fig 2: Locating Connecting Screw

CAYENNE GTS) > INSTALLING BELT TENSIONER
1. Install belt tensioner.
1. 1.1. Position belt tensioner -2- .
2. 1.2. Tighten screws -3- .

Fig 1: Identifying Drive Belt, Belt Tensioner And Screws

CAYENNE GTS) > SUBSEQUENT WORK
1. Secure the drive belt. → 137819 REMOVING AND INSTALLING DRIVE BELT
WM 137319 REMOVING AND INSTALLING BELT TENSIONER FOR COMPRESSOR

[CAYENNE S E-HYBRID & CAYENNE (3.0)] > TECHNICAL VALUES
Tolerance Tolerance
1 2

Deflection Roller For Poly-V-Belt
Torque lb.)
Initial 20 Nm (15 ft.

Vibration Damper To Crankcase Replace
Tightening lb.)
Vibration Damper To Crankcase Final Tightening 90°
Tensioner For Poly-V-Belt To Tightening 40 Nm (30 ft.

Crankcase Torque lb.)

[CAYENNE S E-HYBRID & CAYENNE (3.0)] > PRELIMINARY WORK
1. Remove poly-V-belt for compressor. → 137819 REMOVING AND INSTALLING DRIVE BELT

[CAYENNE S E-HYBRID & CAYENNE (3.0)] > REMOVING TENSIONING ELEMENT FOR
POLY-V-BELT FOR COMPRESSOR > ASSEMBLY OVERVIEW - POLY-V-BELT DRIVE
FOR COMPRESSOR
Fig 1: Overview Of Poly-V-Belt Drive For Compressor
1. Poly-V-Belt For Compressor
2. Screw → Tightening Torque: 42 Nm (31 ft. lb.)
3. Washer
4. Cover
5. Compressor
6. Deflection Roller For Poly-V-Belt
7. Vibration Damper
8. Screw Replace → Initial Tightening: 20 Nm (15 ft. lb.) → Final Tightening: 90°
9. Tensioning Element For Poly-V-Belt

[CAYENNE S E-HYBRID & CAYENNE (3.0)] > REMOVING TENSIONING ELEMENT FOR
POLY-V-BELT FOR COMPRESSOR > REMOVING TENSIONING ELEMENT FOR
POLY-V-BELT FOR COMPRESSOR
1. Unscrew screw -1- and remove tensioning element -2- for poly-V-belt.
Fig 1: Identifying Poly-V-Belt Tensioning Element

[CAYENNE S E-HYBRID & CAYENNE (3.0)] > INSTALLING TENSIONING ELEMENT
FOR POLY-V-BELT FOR COMPRESSOR
Information

[CAYENNE S E-HYBRID & CAYENNE (3.0)] > SUBSEQUENT WORK
1. Install poly-V-belt for compressor. → 137819 REMOVING AND INSTALLING DRIVE BELT
WM 137419 REMOVING AND INSTALLING SEALING RING FOR VIBRATION

BALANCER [CAYENNE S E-HYBRID & CAYENNE (3.0)] > TOOLS
Pin Wrench VW Tool 3212
Assembly Tool VW Tool T40048

BALANCER [CAYENNE S E-HYBRID & CAYENNE (3.0)] > PRELIMINARY WORK
1. Remove poly-V-belt. → 137819 REMOVING AND INSTALLING DRIVE BELT
2. Remove vibration damper. → 137619 REMOVING AND INSTALLING VIBRATION DAMPER

(CRANKSHAFT PULLEY)
3. Remove deflection roller for poly-V-belt for compressor.

BALANCER [CAYENNE S E-HYBRID & CAYENNE (3.0)] > REPLACING JOINT FLANGE
ON PULLEY SIDE WITH CRANKSHAFT SEALING RING
1. Unscrew screws for poly-V-belt pulley for coolant pump and counter using Pin Wrench 3212 .
Remove poly-V-belt pulley.
Fig 1: Removing Poly-V-Belt Pulley For Coolant Pump
2. Remove screws -arrows- .
Information
The joint flange on the pulley side must always be replaced.
Carefully detach joint flange at the pulley side from the bonding.
Fig 2: Locating Pulley Side Joint Flange Screws
3. Remove sealant residue from the cylinder block and joint flange on the pulley using a rotating
plastic brush for example.
WARNING: Risk of damage or injury from foreign bodies flying around during
grinding, drilling and milling
NOTE: Residual sealant
1. Oil bores blocked
→ Ensure that they are cleaned thoroughly and that any remaining sealant is removed
completely.
Clean sealing faces to remove any oil and grease.
Fig 3: Removing Sealant Residue
Fig 4: Cutting Nozzle On Tube
Information
The joint flange must be fitted within 5 minutes of applying the sealant.
5. Apply a bead of sealant to the clean sealing face of the joint flange as shown.
1. 5.1. The groove -arrow- on the sealing face must be filled completely with sealant.
1. Oil bores blocked
→ Ensure that they are cleaned thoroughly and that any remaining sealant is
removed completely.
2. 5.2. The bead of sealant must project 1.5 to 2.0 mm over the sealing face.
Fig 5: Locating Sealant Bead On Pulley Joint Flange
6. Assembly Tool T40048 must be fitted onto the fitting aid -T40048/2- . Then slide the joint
flange -1- onto the fitting sleeve.
Remove assembly aid.

Fig 6: Assembling Pulley Joint Flange Tool
7. First fit the joint flange -1- (with fitting sleeve -T40048/2- inserted) on crankshaft.
Slide the joint flange onto the sealing face of the engine without tilting it.
Fig 7: Installing Joint Flange
Information
For Tightening Torques, tightening sequence and assembly overview, see → 1001IN
TIGHTENING TORQUES, TIGHTENING SEQUENCES, ASSEMBLY OVERVIEWS
8. Tighten fastening screws -arrows- crosswise and in several steps.

Fig 8: Locating Pulley Side Joint Flange Screws
Information
For Tightening Torques, tightening sequence and assembly overview, see → 1001IN
TIGHTENING TORQUES, TIGHTENING SEQUENCES, ASSEMBLY OVERVIEWS
9. Further installation is performed in reverse order.

BALANCER [CAYENNE S E-HYBRID & CAYENNE (3.0)] > SUBSEQUENT WORK
1. Install poly-V-belt pulley for coolant pump. → 195019 REMOVING AND INSTALLING
COOLANT PUMP
2. Install vibration damper. → 137619 REMOVING AND INSTALLING VIBRATION DAMPER

(CRANKSHAFT PULLEY)
3. Install poly-V-belt. → 137819 REMOVING AND INSTALLING DRIVE BELT
WM 137419 REPLACING SEALING RING FOR CRANKSHAFT PULLEY (ALL MODELS)

> PRELIMINARY WORK
1. Remove vibration balancer → REMOVING VIBRATION DAMPER - section on "Removing".

> REMOVING CRANKSHAFT SEALING RING FOR PULLEY/VIBRATION BALANCER
1. Loosen the four fastening screws -arrows- and remove the cover with sealing ring.
Fig 1: Removing Crankshaft Cover
2. Clean the sealing surface of the sheetmetal cover.

> INSTALLING CRANKSHAFT SEALING RING FOR PULLEY/VIBRATION BALANCER
Information
Information
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 .
Information
1. Place seal with plastic sleeve over the crankshaft.

Fig 1: Identifying Crankshaft Seal

2. Tighten the two upper fastening screws and then the lower fastening screws by hand. Then
tighten the screws in diagonally opposite sequence to the specified torque (aluminum screws
).
Fig 2: Identifying Crankshaft Pulley Cover Screws

Fig 3: Identifying Chain Tensioner, Joint Flange And Screws
1. Joint Flange (Oil Sealing Lip With Engine Oil); Align With Sleeve Or Vibration
Balancer
2. Aluminum Screw , M6 X 20; Always Use New Aluminum Screws;
3. Aluminum Screw , M6 X 55; Always Use New Aluminum Screws;
4. Sealing Ring
5. Chain Tensioner
3. Pull plastic sleeve straight off the joint flange.

Fig 4: Identifying Crankshaft Plastic Sleeve

> SUBSEQUENT WORK
1. Install vibration balancer → INSTALLING VIBRATION DAMPER - section on "Installing".
WM 137455 REPLACING SEALING RING FOR CRANKSHAFT PULLEY (CAYENNE S &

CAYENNE GTS) > TOOLS


Nr. 167

Nr. 168
Kit Available Tool

1. Remove hall-sender rotor. → 284419 REMOVING AND INSTALLING HALL-SENDER ROTOR

CAYENNE GTS) > REMOVING CRANKSHAFT SEALING RING (ON TRANSMISSION
SIDE) > REMOVING SEALING RING FOR CRANKSHAFT (ON TRANSMISSION SIDE)
2. Crankcase
3. Crankshaft
1. Use the Drift Punch, 1-mm Tip Nr. 167 to beat a small hole at a non-rubberised spot
Fig 2: Punching Hole With Drift Punch
out the sealing ring using a pliers. → Punching out sealing ring
3. Clean the crankshaft flange. The crankshaft flange must not be dirty or rusty. If necessary,
clean it with brake cleaner and sand off any rust with a metal-polishing pad (e.g. Never Dull).
→ Cleaning crankshaft flange

CAYENNE GTS) > INSTALLING CRANKSHAFT SEALING RING (ON TRANSMISSION
SIDE) > INSTALLATION INSTRUCTIONS FOR CRANKSHAFT SEALING RING AND
HALL-SENDER ROTOR
Fig 1: Identifying Crankshaft Sealing Ring Installation Position
1. Upper Part Of Crankcase
2. Crankshaft
3. Crankshaft Sealing Ring
4. Hall-Sender Rotor
Installation Dimensions For Shaft Sealing Ring And Hall-Sender Rotor [In Mm]
Installation Dimension Reference Point 1 Reference Point 2
2.9 mm Crankshaft Hall-sender rotor
7.5 mm Crankcase Crankshaft sealing ring
13.0 mm Crankshaft Crankshaft sealing ring

CAYENNE GTS) > INSTALLING CRANKSHAFT SEALING RING (ON TRANSMISSION
SIDE) > INSTALLING SEALING RING FOR CRANKSHAFT (ON TRANSMISSION SIDE)
Information
2. Crankcase
3. Crankshaft
1. Connect the sealing ring and sleeve to the tool Spacer 9609/2 . → Fitting sealing ring
Fig 2: Installing Sealing Ring Onto Tool
2. Position the centering device Spacer 9609/2 on the crankshaft flange. Pay attention to the
Centering tool
Fig 3: Identifying Centering Tool
from the tool.

1. Install hall-sender rotor. → 284419 REMOVING AND INSTALLING HALL-SENDER ROTOR
WM 137519 REMOVING AND INSTALLING CRANKSHAFT VIBRATION DAMPER

(CAYENNE TURBO & CAYENNE TURBO S) > TOOLS

Arm Bracket Special Tool 9679/1

(CAYENNE TURBO & CAYENNE TURBO S) > PRELIMINARY WORK
1. Remove radiator frame → REMOVING COOLING FAN HOUSING - section on "Removing".
2. Remove drive belt → REMOVING DRIVE BELT - section on "Removing".

(CAYENNE TURBO & CAYENNE TURBO S) > REMOVING VIBRATION DAMPER
(CRANKSHAFT PULLEY)
Information
1. Arm Bracket 9679/1 must be inserted into the vibration damper and turned until it locks. →
Arm bracket in vibration damper
Fig 1: Identifying Vibration Damper Arm Bracket
NOTE: Incorrect handling of tools
1. Risk of damage to the body
→ Only use tools approved by Porsche.
→ Always ensure that the tool is seated correctly.
→ Protect the body and interior of the vehicle from damage with protective covers.
→ Cover delicate components with cardboard or sheetmetal panels.
Information
Protect the radiator fins using cardboard or a sheetmetal panel to prevent damage.
Cover wing and peripheral parts to protect them.
2. Fit large torque wrench → Large torque wrench on the central screw or T-piece -2- (large
socket, width across flats 27) and loosen central screw for balancer. Do not use the screw
again. Use a tubular handle -1- , if necessary. Loosening torque is very high.
Fig 2: Installing Torque Wrench On Central Screw

Fig 3: Loosening Vibration Damper Bolt
3. Remove central screw and pull vibration damper down and forward. → Vibration damper
Fig 4: Removing Vibration Damper

(CAYENNE TURBO & CAYENNE TURBO S) > INSTALLING VIBRATION DAMPER
(CRANKSHAFT PULLEY)
Information
Information
Information
A feather key is inserted into the crankshaft. When fitting the vibration damper (crankshaft pulley),
ensure that the feather key slots into the groove .
The key must not fall into the engine .

Vibration damper (crankshaft pulley) and crankshaft stub must be cleaned .
1. Position vibration damper (crankshaft pulley) onto the crankshaft stub. Press the vibration
damper slightly towards the engine, while at the same time twisting it until it slips towards the
timing-case cover. When doing so, be careful of the feather key → Pulley on crankshaft stub .
Fig 1: Positioning Vibration Damper (Crankshaft Pulley) Onto Crankshaft Stub
2. New central screw must be fitted hand-tight. → Central screw in crankshaft

Fig 2: Locating Crankshaft Central Screw
Information
3. Arm Bracket 9679/1 must be inserted into the vibration damper and turned until it locks →
Arm bracket in the pulley . Get another worker to use the arm bracket.
Fig 3: Identifying Pulley Arm Bracket
4. Using a torque wrench and a suitable socket (width across flats 27), tighten the central screw
→ Large torque wrench at central screw and Only carry out step-by-step Torque Tightening
.
Fig 4: Installing Torque Wrench At Central Screw

Fig 5: Identifying Water Pump Pulley, Vibration Damper And Screws
1. Water Pump Pulley
2. M8 Screw
3. Vibration Damper
4. Screw M18; Use New Screws
6. M8 Screw
7. Tandem Pump Pulley
5. After tightening to the specified torque, mark the vibration damper and central screw for the
torque-angle tightening using a water-resistant marker. To do this, make an initial mark on the
vibration damper and central screw at the same position -1 and 2- . Make a final mark in
accordance with the specified torque angle only on the vibration damper -3- .
Fig 6: Identifying Vibration Damper And Central Screw Marks

Carry out the torque-angle tightening procedure so that the mark on the screw is turned from
the initial mark on the vibration damper step-by-step (repositioning the tools repeatedly) to the
final mark on the vibration damper -arrow- . This concludes the torque-angle tightening
procedure.
Fig 7: Tightening Vibration Damper Central Screw

Fig 8: Identifying Vibration Damper Tool

(CAYENNE TURBO & CAYENNE TURBO S) > SUBSEQUENT WORK
1. Install drive belt → INSTALLING DRIVE BELT - section on "Installing".
2. Install radiator frame → INSTALLING COOLING FAN HOUSING - section on "Installing".

WM 137619 REMOVING AND INSTALLING VIBRATION DAMPER (CRANKSHAFT
PULLEY) [CAYENNE S E-HYBRID & CAYENNE (3.0)] > TOOLS

PULLEY) [CAYENNE S E-HYBRID & CAYENNE (3.0)] > TECHNICAL VALUES

Value 1 2
Fastening Screw For Vibration Initial 20 Nm

Replace
Damper Tightening (15 ft. lb.)
Fastening Screw For Vibration Final

+90°
Damper Tightening
Tighten In Diagonally 9 Nm
Fastening Screw For Joint Tightening
Opposite Sequence (6.5 ft.
Flange On Pulley Side Torque
And In Steps lb.)
Fastening Screw Securing

Tightening 20 Nm
Poly-V-Belt Pulley For Coolant
Torque (15 ft. lb.)
Pump To Coolant Pump
9 Nm
Fastening Screw For Coolant Tightening
(6.5 ft.
Pump Torque
lb.)
Fastening Screw On
Tightening 40 Nm
Tensioning Element For
Torque (30 ft. lb.)
Poly-V-Belt Pulley
Fastening Screw For Vibration Initial 20 Nm

Replace
Damper tightening (15 ft. lb.)
Fastening Screw For Vibration Final

+90°
Damper Tightening
Fastening Screw Securing Tightening 20 Nm

Generator To Engine Torque (15 ft. lb.)
Tightening 40 Nm
Deflection Roller For
Torque (30 ft. lb.)
Poly-V-Belt
9 Nm
Fastening Screw For Joint Tightening
(6.5 ft.
Flange On Pulley Side Torque
lb.)

Tightening 20 Nm
Poly-V-Belt Pulley For Coolant
Torque (15 ft. lb.)
Pump To Coolant Pump
9 Nm
Fastening Screw For Coolant Tightening
(6.5 ft.
Pump Torque
lb.)
Fastening Screw On Tightening 40 Nm

Tensioner For Poly-V-Belt Torque (30 ft. lb.)
Fastening Nut Securing Cable Tightening 20 Nm

Shoe To Generator Torque (15 ft. lb.)

PULLEY) [CAYENNE S E-HYBRID & CAYENNE (3.0)] > PRELIMINARY WORK
1. Remove poly-V-belt for compressor and poly-V-belt. → 137819 REMOVING AND INSTALLING

PULLEY) [CAYENNE S E-HYBRID & CAYENNE (3.0)] > REMOVING VIBRATION
DAMPER > ASSEMBLY OVERVIEW - POLY-V-BELT DRIVE
1. Poly-V-Belt
3. Poly-V-Belt Pulley For Generator
4. Joint Flange On Pulley Side

Not Shown - Screw → Tightening Torque: 9 Nm (6.5 ft. lb.)
6. Poly-V-Belt Pulley For Coolant Pump
7. Coolant Pump
8. Screw → Tightening Torque: 9 Nm (6.5 ft. lb.)
9. Tensioning Element For Poly-V-Belt
Not Shown - Screw → Tightening Torque: 40 Nm (30 ft. lb.)

DAMPER > ASSEMBLY OVERVIEW - POLY-V-BELT DRIVE
1. Poly-V-Belt/Mark Rolling Direction
3. Generator

5. Cover For Deflection Roller
6. Deflection Roller For Poly-V-Belt → Tightening Torque: 40 Nm (30 ft. lb.)
9. Poly-V-Belt Pulley For Coolant Pump
11. Coolant Pump
12. Joint Flange On Pulley Side Replace
13. Screw
14. Holder For Vane Type Pump
15. Sliding Bush
16. Screw
17. Vane Type Pump
18. Pulley For Vane Type Pump
19. Screw
20. Tensioner For Poly-V-Belt → Tightening Torque: 40 Nm (30 ft. lb.)
21. Holder For Air-Conditioning Compressor
22. Screw
23. Air-Conditioning Compressor
24. Screw
25. Dowel Sleeve
26. Cover For Tensioner
27. Vibration Damper
Not Shown - Cable Shoe On Generator → Tightening Torque: 20 Nm (15 ft. lb.)

DAMPER > REMOVING VIBRATION DAMPER
NOTE: Incorrect handling of pulley
Risk of damage to pulley

→ The pulley is sensitive to impact. Do not pry off the pulley with a screwdriver.
→ Do not re-use a damaged pulley.
1. Remove screws -1- for vibration damper and counter using Counter-Hold Tool 3036 .
Fig 1: Identifying Counter-Hold Tool And Screws
2. Remove vibration damper.

PULLEY) [CAYENNE S E-HYBRID & CAYENNE (3.0)] > INSTALLING VIBRATION
DAMPER
Risk of damage to pulley

Information
Information
The offset bore holes mean that installation is only possible at one position.

PULLEY) [CAYENNE S E-HYBRID & CAYENNE (3.0)] > SUBSEQUENT WORK
1. Install poly-V-belt for compressor and poly-V-belt. → 137819 REMOVING AND INSTALLING
WM 137619 REMOVING AND INSTALLING PULLEY (CAYENNE S & CAYENNE GTS) >
TOOLS
Counter-Hold Tool Special Tool 9679/3
Holding Wrench Special Tool 9732
TECHNICAL VALUES

Value 1 2
Fastening Screw Securing Tightening 23 Nm
M8 x 16
Pulley To Coolant Pump Torque (17 ft. lb.)
M18 x 1.5 x 72; Step 1

Vibration Damper To Tightening 20 Nm
Counter Screw Torque At
Crankshaft Torque (15 ft. lb.)
Damper
M18 x 1.5 x 72 Step 2

Damper
M18 x 1.5 x 72; Step 3

Damper
M18 x 1.5 x 72; Step 4

Vibration Damper To Torque
Counter Screw Torque At 180°
Crankshaft Angle
Damper
Pulley To Power- Tightening 23 Nm

M8 x 16 (3 ea.)
Steering/Tandem Pump Torque (17 ft. lb.)
TECHNICAL VALUES > PULLEYS
Fig 1: Identifying Water Pump Pulley, Vibration Damper, Power-Steering Pump Pulley, Tandem Pump
Pulley And Screws
1. Water Pump Pulley
2. Screw, M8 x 16 → Tightening Torque: 23 Nm (17 ft. lb.)

3. Vibration Damper
4. Screw, M18 x 1.5 x 72; Use New Screw; → Tightening Torque: 20 Nm (15 ft. lb.) →
Tightening Torque: 50 Nm (37 ft. lb.) → Tightening Torque: 100 Nm (74 ft. lb.) → Torque
angle: 180°
7. Tandem Pump Pulley
REMOVING PULLEY (VIBRATION BALANCER)
1. Counter-Hold Tool 9679/3 with the rectangular tube from Holding Wrench 9732 must be
inserted into the vibration damper and turned until it locks. → see Fig 1
Fig 1: Identifying Vibration Damper Counter-Hold Tool
2. Fit the large torque wrench or T-piece -2- and use a tubular handle if necessary -1- .
1. 2.1. Undo the central screw of the damper. Do not use the screw again.
2. 2.2. Use a tubular handle -1- if necessary.

Fig 2: Identifying Vibration Damper Tool And Large Wrench
Information
3. 2.3. Loosening torque is very high
3. Remove central screw and pull vibration damper down and forward. → see Fig 3
Fig 3: Removing Vibration Damper
INSTALLING PULLEY (VIBRATION BALANCER)
1. Position vibration damper onto the crankshaft stub.
1. 1.1. Press the vibration damper slightly towards the engine, while at the same time
turning it until it slips towards the timing-case cover.
Information
1. A feather key is inserted into the crankshaft. When fitting the vibration damper
(crankshaft pulley), ensure that the feather key slots into the groove .
2. The key must not fall into the engine .
3. Vibration damper (crankshaft pulley) and crankshaft stub must be cleaned .
2. 1.2. When doing so, be careful of the feather key. → Pulley on crankshaft stub
Fig 1: Positioning Vibration Damper Onto Crankshaft Stub
2. Fit the New central screw -arrow- hand-tight.

Fig 2: Locating Crankshaft Central Screw
3. Counter-Hold Tool 9679/3 with the rectangular tube from Holding Wrench 9732 must be
inserted into the vibration damper and turned until it locks.
Information
1. 3.1. Get another worker to use the counter-hold tool

Fig 3: Identifying Vibration Damper Tool
4. Using a torque wrench and a suitable socket, tighten the central screw → see Fig 4 and only
carry out step-by-step Torque Tightening . Tightening Torque 20 Nm (15 ft. lb.) Tightening
Torque 50 Nm (37 ft. lb.) Tightening Torque 100 Nm (74 ft. lb.)
Fig 4: Installing Torque Wrench On Central Screw
5. Mark the vibration damper and central screw for torque-angle tightening using a water-
resistant marker -3- .
1. 5.1. Make an initial mark on the vibration damper and central screw at the same
position -1 and 2- .
2. 5.2. Make a final mark in accordance with the specified torque angle only on the
vibration damper -3- .

3. 5.3. Turn the torque-angle tightener step by step from the starting mark -1 and 2- on
the vibration damper to the end mark on the vibration damper -3- (-direction of
arrow- ). Torque angle 180°
Fig 5: Marking Vibration Damper And Central Screw
WM 137801 CHECKING DRIVE BELT (CAYENNE) > PRELIMINARY WORK
1. Remove intake pipe from air cleaner to engine. → REMOVING AIR BOX FOR THROTTLE
HOUSING (INTAKE PIPES UPSTREAM OF THROTTLE VALVE) - section on "Removing"
WM 137801 CHECKING DRIVE BELT (CAYENNE) > INFORMATION > DAMAGE
SYMPTOMS AND GENERAL INFORMATION
NOTE: Drive belt removed incorrectly
Risk of damage to drive belt
→ Only remove the drive belt when it is cold.
→ Replace damaged drive belt.
NOTE: Drive belt breaks and becomes jammed
Risk of damage to components (trim panels, electric cables, etc.)
Sealing ring on crankshaft vibration balancer can start to leak
Vibration balancer can overheat and lose its strength
→ Following belt breakage, check adjacent components and the interior of the engine compartment for
damage, and repair or replace damaged parts if necessary.
→ Find out why the belt broke. Check deflection rollers or crankshaft vibration balancer for prior
damage.
→ If the drive belt is jammed, replace vibration balancer.
→ Disconnect power supply to the drive motor of components or to the battery.
Information
The following table indicates damage which necessitates replacement .

Fig 1: Identifying Drive Belt Damage
Item Type Of Damage Explanation
-A- Slight Crack In A Rib Drive Belt Is OK
Hairline Crack That Runs Across The Entire

-B- Replace Drive Belt
Belt Width, Or The Butt Seam Is Damaged
Drive Belt Must Be Replaced If There Is More

-C- Crack Running Down To Half Of Rib Height Than One Crack Running Down To Half Of Rib
Height.
-D- Crack Running To Base Of Rib Replace Drive Belt
Crack Running To Traction Cord, Or Sides So

-E- Worn That The Traction Cord Becomes Replace Drive Belt
Visible
-F- Rib Detachment Replace Drive Belt
-G- Rib Fracture Replace Drive Belt
WM 137801 CHECKING DRIVE BELT (CAYENNE) > CHECKING DRIVE BELT
Information
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. → Marking the drive belt
Fig 1: Identifying Drive Belt Marking
2. Turn engine at the vibration balancer in the rolling direction using a socket wrench until the
chalk mark is at the same position again. While turning at the crankshaft, check the drive belt
at the deflection rollers for signs of damage.
3. When turning the engine, check deflection rollers for smooth operation, intact running track
and play. Replace noisy and damaged rollers.
WM 137801 CHECKING DRIVE BELT (CAYENNE) > SUBSEQUENT WORK
1. Install intake pipe. → INSTALLING AIR BOX FOR THROTTLE HOUSING (INTAKE PIPES
UPSTREAM OF THROTTLE VALVE) - section on "Installing"
WM 137819 REMOVING AND INSTALLING DRIVE BELT (CAYENNE S & CAYENNE

GTS) > REMOVING DRIVE BELT
NOTE: Drive belt removed incorrectly
Risk of damage to drive belt

→ Only remove the drive belt when it is cold.
→ Replace damaged drive belt.
NOTE: Drive belt breaks and becomes jammed
Risk of damage to components (trim panels, electric cables, etc.)
Sealing ring on crankshaft vibration balancer can start to leak
Vibration balancer can overheat and lose its strength
→ Following belt breakage, check adjacent components and the interior of the engine compartment for
damage, and repair or replace damaged parts if necessary.
→ Find out why the belt broke. Check deflection rollers or crankshaft vibration balancer for prior
damage.
→ If the drive belt is jammed, replace vibration balancer.
Fig 1: Identifying Drive Belt, Hydraulic Belt Tensioner And Screws

1. Deflection Roller 2
2. Hydraulic Belt Tensioner
3. Screw, M8 x 96
5. Dual Poly V-Belt
1. Mark the rolling direction of the drive belt with chalk.
2. Open coolant hose connecting clip. Lift coolant hose aside.
3. Relieve and remove drive belt. To do this, turn the belt tensioner clockwise at the hexagon →
Belt tensioner hexagon using a ring wrench (a/f 30) or change-over ratchet with socket →
Loosening the belt (relieve the drive belt) and remove the drive belt from the tensioning roller.
Then relieve the belt tensioner slowly.
Fig 2: Loosening Belt Tensioner

Fig 3: Removing Belt
4. Remove drive belt.
WM 137819 REMOVING AND INSTALLING DRIVE BELT (CAYENNE S & CAYENNE

GTS) > INSTALLING DRIVE BELT
1. Fit the drive belt as shown. At the end, only leave a loose loop of the drive belt on the belt
tensioner ready for fitting.
1. 1.1. Fit used drive belt in the rolling direction according to removal marking. Fit the
drive belt straight on all pulleys without tilting it (leave loop in front of tensioning
roller). Finally, turn the belt tensioner clockwise at the hexagon using a ring wrench
(a/f 30) or change-over ratchet with socket and place the drive belt around the
tensioning roller. Then relieve the belt tensioner slowly.
2. 1.2. Relieve the belt tensioner by turning it clockwise again at the hexagon and fit
drive belt loop. Tighten the belt tensioner.
2. Check that the drive belt is positioned correctly on the pulleys. → Belt drive
Fig 1: Identifying Drive Belt Routing
2. Hydraulic Belt Tensioner
3. Screw, M8 x 96
5. Dual Poly V-Belt
3. Turn engine clockwise at the vibration balancer and check that the drive belt is fitted correctly.
This work is much easier during a service because the spark plugs are removed.
4. Move coolant hose into the correct position and close the connecting clip on the coolant hose.
WM 138519 REMOVING AND INSTALLING BALANCE SHAFT (CAYENNE S HYBRID,

CAYENNE TIP (3.0), CAYENNE TIP & CAYENNE TIP (3.0) "PLATINUM EDITION") >
TOOLS

Locking Pin VW Tool T40069
Locating Pins VW Tool T40116

TECHNICAL VALUES

Value 1 2
Fastening Screw Securing Balance Tightening 60 Nm (44

Weight On Transmission Side Torque ft. lb.)
Fastening Screw For End Plate
Torque ft. lb.)
Fastening Screw Securing Balance Tightening 60 Nm (44

Weight On Pulley Side Torque ft. lb.)

PRELIMINARY WORK
1. Engine removed. → 100119 REMOVING AND INSTALLING ENGINE
2. Engine separated from transmission. → 100127 REMOVING ENGINE FROM

TRANSMISSION AND MOUNTING ENGINE ON TRANSMISSION
3. Remove joint flange on pulley side. → 137419 REMOVING AND INSTALLING SEALING RING
FOR VIBRATION BALANCER
4. Remove lower timing chain cover. → 153319 REMOVING AND INSTALLING TIMING-CASE
COVER
5. Remove drive chain for auxiliary drives. → 153319 REMOVING AND INSTALLING

REMOVING BALANCE SHAFT > ASSEMBLY OVERVIEW - BALANCE SHAFT
Fig 1: Overview Of Balance Shaft
1. Balance Shaft
3. Balance Weight On Transmission Side

4. End Plate
6. Balance Weight On Pulley Side

REMOVING BALANCE SHAFT > REMOVING BALANCE SHAFT
1. Lock the balance weight -1- at the rear of the engine with Locating Pins T40116 .
Unscrew screw -2- and remove balance weight from the balance shaft.
Fig 1: Identifying Balance Weight
2. Unscrew screw -2- while countering the balance weight with a mandrel and remove the
balance weight -1- at the front of the engine from the balance shaft.
Fig 2: Identifying Balance Weight And Screw
3. Unscrew screws -arrows- and remove end plate for the balance shaft at the rear of the
engine.
Pull the balance shaft to the rear and out of the cylinder block.
Fig 3: Locating Balance Shaft End Plate Screws

INSTALLING BALANCE SHAFT
Information
1. Crankshaft -1- secured in "TDC" position with Locking Pin T40069 .

Fig 1: Identifying Locking Pin (T40069)

SUBSEQUENT WORK
1. Install drive chain for auxiliary drives. → 153319 REMOVING AND INSTALLING
2. Install lower timing chain cover. → 153319 REMOVING AND INSTALLING TIMING-CASE
COVER
3. Install joint flange on pulley side. → 137419 REMOVING AND INSTALLING SEALING RING
FOR VIBRATION BALANCER
4. Mount engine on the transmission. → 100127 REMOVING ENGINE FROM TRANSMISSION

5. Install engine. → 100119 REMOVING AND INSTALLING ENGINE

Service Manual: 15 - ENGINE - CYLINDER HEAD, VALVE CONTROL -- 92A CAYENNE
WM 150502 CHECKING THE TIMING (CAYENNE (3.0) & CAYENNE S E-HYBRID) >
TOOLS
Adapter VW Tool T40058
Camshaft Clamps VW Tool T40133
TECHNICAL VALUES
Locking Pin T40069 Tightening Torque 25 Nm (19 ft. lb.)

PRELIMINARY WORK
1. Remove cylinder head covers at the left and right. → 158219 REMOVING AND INSTALLING
CYLINDER HEAD COVER (VALVE COVER)
CHECKING THE TIMING
1. Using Adapter T40058 and an angled ring wrench, turn the crankshaft to "TDC" in direction of
rotation of the engine.
Only Turn The Crankshaft In Direction Of Rotation Of The Engine -Arrow-!
Fig 1: Rotating Crankshaft
2. The notch -A- must be aligned with the joint -arrow- .

Fig 2: Locating Crankshaft Notch And Joint
Information
If you inadvertently turn the crankshaft beyond "TDC", turn it back approx. 30° and set it to
"TDC" again.
3. The threaded bores -arrows- in the camshafts must be facing upwards.

Fig 3: Locating Camshafts Threaded Bores
4. Unscrew screw plug -arrow- for the "TDC" mark on the crankshaft from the cylinder block.
Fig 4: Locating TDC Mark Screw Plug
5. Locking Pin T40069 must be screwed into the bore and tightened to → Tightening Torque:
25 Nm (19 ft. lb.) .
Locking pin T40069 must engage in the securing bore on the crankshaft -1- .
Fig 5: Identifying Pin (T40069)
6. You must be able to secure the camshaft for cylinder bank 1 in "TDC" position using Camshaft
Clamps T40133 .
Fig 6: Locating Camshaft Clamp (T40133/1)
7. You must be able to secure the camshaft for cylinder bank 2 in "TDC" position using Camshaft
Clamps T40133 .
8. If the camshafts cannot be secured, the valve timing must be set.
SUBSEQUENT WORK
1. Install cylinder head cover at the left and right. → 158219 REMOVING AND INSTALLING
WM 150516 SETTING THE TIMING (CAYENNE (3.0) & CAYENNE S E-HYBRID) >
TOOLS

Special Wrench VW Tool T10035

Camshaft Clamps VW Tool T40133
TECHNICAL VALUES
Tolerance Tolerance
1 2
Fastening Screw For Camshaft Initial 80 Nm (59 ft.

Replace
Controller Tightening lb.)
Fastening Screw For Camshaft Final

+90°
Controller Tightening

Replace
Sprocket tightening lb.)
+90°
Sprocket Tightening
Fastening Screw For Chain Tightening 9 Nm (6.5 ft.

Tensioner Torque lb.)
Fastening Screw Securing Bearing Initial 8 Nm (6 ft.

Plate For Drive Sprocket Tightening lb.)
Fastening Screw Securing Bearing Final

+45°
Plate For Drive Sprocket Tightening
Initial 5 Nm (3.5 ft.

Fastening Screw For Bearing Pin Replace
Tightening lb.)
Final +60 Nm (+44

Fastening Screw For Bearing Pin
Tightening ft. lb.)

Replace
Sprocket Tightening lb.)

+90°
Sprocket Tightening

Replace
Controller Tightening lb.)

+90°
Controller Tightening

Tightening lb.)
Final
Fastening Screw For Bearing Pin +90°
Tightening

Fastening Screw On Camshaft Tightening 25 Nm (19 ft.

Clamp Torque lb.)

Locking Pin T40069
Torque lb.)

Locking Pin T40069
Torque lb.)
Fastening Screw On Camshaft Tightening 25 Nm (19 ft.

Clamp Torque lb.)
PRELIMINARY WORK
1. Remove left and right timing chain covers. → 153319 REMOVING AND INSTALLING
TIMING-CASE COVER
2. Remove cylinder head cover at the left and right. → 158219 REMOVING AND INSTALLING
SETTING THE TIMING > ASSEMBLY OVERVIEW - TIMING CHAINS > LEFT TIMING
CHAIN
Fig 1: Identifying Left Timing Chain Components
3. Camshaft Sprocket, For Outlet Camshaft
4. Camshaft Controller, For Intake Camshaft
5. Left Timing Chain
1. For re-installation, mark rolling direction with paint/color marker
7. Slide
8. Chain Tensioner, For Left Timing Chain
9. Bearing Plate, For Drive Sprocket
11. Drive Sprocket, For Left Timing Chain
12. Bearing Pin, For Drive Sprocket For Left Timing Chain
13. Screws Replace → Initial Tightening: 5 Nm (3.5 ft. lb.) → Final Tightening: +60 Nm (+44 ft.
lb.)
SETTING THE TIMING > ASSEMBLY OVERVIEW - TIMING CHAINS > RIGHT TIMING
CHAIN
Fig 1: Identifying Right Timing Chain Components
2. Camshaft Sprocket, For Outlet Camshaft
4. Camshaft Controller, For Intake Camshaft

6. Bearing Pin, For Drive Sprocket For Right Timing Chain
7. Drive Sprocket, For Right Timing Chain
8. Right Timing Chain
9. Thrust Washer, For Drive Sprocket For Right Timing Chain
10. Chain Tensioner, For Right Timing Chain
11. Slide
SETTING THE TIMING > ASSEMBLY OVERVIEW - TIMING CHAINS > SETTING THE
TIMING
NOTE: Timing not set correctly
Risk of engine damage
Rough running engine
Loss of engine power
→ Do not use force when fitting the staking tool.
→ Make sure that the gap is equal on both sides.
→ When inserting the staking tools, do not use force to turn the camshafts against any resistance.
→ The engine must be exactly at top dead center.
→ The opposite cylinder must be at ignition TDC.
Information
1. Insert guide pin of Adapter T40058 as follows:

1. 1.1. The large diameter -arrow 1- is facing the engine.
2. 1.2. The small diameter -arrow 2- is facing the adapter.

Fig 1: Identifying Adapter (T40058)
2. Use adapter -T40058- and an angled ring wrench to counter the crankshaft.
Only Turn The Crankshaft In Direction Of Rotation Of Engine -Arrow-!


Information
Illustration shows cylinder head for cylinder bank 2 (left)
4. Camshaft Clamps T40133 must be fitted on both cylinder heads -arrows- and tightened to
→ Tightening Torque: 25 Nm (19 ft. lb.) .
Fig 4: Locating Camshaft Clamps
6. Locking pin T40069 must be screwed into the bore hole and tightened to → Tightening
Torque: 25 Nm (19 ft. lb.) . Turn the crankshaft -1- back and forth slightly if necessary in
order to center the locking pin fully.
Information
1. The chain tensioners for the timing chain are oil-damped. They can only be compressed
slowly with constant pressure.
7. Using a screwdriver -1- , press the guide rail for the chain tensioner for the left timing chain in
as far as it will go. Then lock the chain tensioner with the Locking Pin T40071 .
Fig 7: Pressing Guide Rail And Locking Chain Tensioner (Left)
Information
1. The chain tensioners for the timing chain are oil-damped. They can only be compressed
slowly with constant pressure.
8. Using a screwdriver -1- , press the guide rail for the chain tensioner for the right timing chain
in as far as it will go. Then lock the chain tensioner with the Locking Pin T40071 .
Fig 8: Pressing Guide Rail And Locking Chain Tensioner (Right)
9. Counter the relevant camshaft controller using Counter-Hold Tool 3036 and loosen the screw
using Special Wrench T10035 .
Fig 9: Loosening Camshaft Controller Bolt
Information
Disregard item 1 and arrow.
10. Counter the relevant camshaft sprocket using Pin Wrench 3212 and loosen the screw using
Special Wrench T10035 .
Fig 10: Loosening Camshaft Sprocket Bolt
11. For re-installation, mark installation position of camshaft controller and camshaft sprocket with
paint.
Unscrew screws -1- and -2- on the left cylinder head and remove camshaft controller and
camshaft sprocket.
Fig 11: Identifying Camshaft Controller And Sprocket
12. For re-installation, mark installation position of camshaft controller and camshaft sprocket with
paint.
Unscrew screws -1- and -2- on the right cylinder head and remove camshaft controller and
camshaft sprocket.
Fig 12: Identifying Camshaft Sprocket And Controller
13. Crankshaft -1- secured in "TDC" position with Locking Pin T40069 → Tightening Torque: 25
Nm (19 ft. lb.) .
Information
14. Camshafts on both cylinder heads secured in "TDC" position with Camshaft Clamps T40133
(-arrows- ).
15. Install camshaft sprockets according to the markings made during removal.
When installing camshaft sprockets, make sure that pins of the camshaft sprockets engage in
the bores on the camshafts -arrows- .
Fig 15: Installing Camshaft Sprocket
16. Turn the camshaft sprocket on the camshaft anti-clockwise as far as it will go -arrow- .
Fig 16: Turning Camshaft Sprocket
17. The marking point -1- must be opposite the setting window -2- .
Fig 17: Identifying Camshaft Sprocket Marking Point And Window
18. Re-install camshaft controller according to the markings made during removal.
1. 18.1. The groove -1- in the camshaft controller must be opposite the setting window
-2- .
Fig 18: Identifying Camshaft Controller Groove And Window
19. Fit the left timing chain on the drive sprocket, fit the camshaft controller and camshaft sprocket
and loosely screw in screws -1- and -2- .
It should still be possible to turn the camshaft controller and camshaft sprocket on the
camshaft without tilting.
Remove locking pin T40071.

20. Re-install the camshaft controller on the right cylinder head according to the markings made
during removal.
1. 20.1. Fit the right timing chain on the drive sprocket, fit the camshaft controller and
camshaft sprocket and loosely screw in screws -1- and -2- .
2. 20.2. It should still be possible to turn the camshaft controller and camshaft sprocket
on the camshaft without tilting.
3. 20.3. Remove locking pin T40071.

21. Fit pin wrench -3212- on the camshaft timing gear for the right outlet camshaft.
Get a second mechanic to keep the timing chain pretensioned by pressing on the camshaft
sprocket in -direction of arrow- .
Tighten screws as follows while still keeping the camshaft sprocket pretensioned:
Step Screw Tightening Torque
1. On Outlet Camshaft 80 Nm (59 ft. lb.)
1. 1 On Intake Camshaft 80 Nm (59 ft. lb.)

Fig 21: Tightening Camshaft Sprocket Bolt
22. Counter the relevant camshaft controller using Counter-Hold Tool -3036- and loosen the
screw using Special Wrench -T10035- .
Get a second mechanic to keep the timing chain pretensioned by pressing on the counter-hold
tool.
Tighten screws as follows while still keeping the camshaft controller pretensioned:
1. 1 On Outlet Camshaft 80 Nm (59 ft. lb.)
1. On Intake Camshaft 80 Nm (59 ft. lb.)

Fig 22: Tightening Camshaft Controller Bolt
23. Tighten screws for the camshaft controller and camshaft sprocket on the left cylinder head as
follows:
2. -1- On Outlet Camshaft, Final Tightening Torque
2. -2- On Intake Camshaft, Final Tightening Torque

24. Tighten screws for the camshaft controller and camshaft sprocket on the right cylinder head as
follows:
2. -1- On Outlet Camshaft, Final Tightening Torque
2. -2- On Intake Camshaft, Final Tightening Torque

Information
25. Remove Camshaft Clamps -T40133- from both cylinder heads -arrows- .
26. Remove Locking Pin -T40069- .

Information
If you inadvertently turn the crankshaft beyond "TDC", turn it back approx. 30° and set it to
"TDC" again.
27. Using Adapter -T40058- and an angled ring wrench, turn the crankshaft two turns in direction
of rotation of the engine -arrow- until the crankshaft is back at "TDC" position.
29. Fit Camshaft Clamps -T40133- on both cylinder heads and tightened to → Tightening
Torque: 25 Nm (19 ft. lb.) .
30. Screw Locking Pin -T40069- directly into the bore.
The locking pin must engage in the securing bore on the crankshaft -1- . If not, set the timing
again.
31. Remove camshaft clamps from both cylinder heads.
32. Remove locking pin T40069.
33. Install screw plug for "TDC" mark on crankshaft.
SUBSEQUENT WORK
COVER (VALVE COVER)
2. Install timing chain cover. → 153319 REMOVING AND INSTALLING TIMING-CASE COVER
WM 150516 SETTING TIMING FOR CAMSHAFTS (CAYENNE S & CAYENNE GTS) >
TOOLS

Special
Locating Pins 9595/1
Tool
Special
Auxiliary Chain Tensioner 9683/1
Tool
Staking Tool For Valve Special

9861
Timing Tool
TECHNICAL VALUES

Value 1 2
Central Screw Securing Camshaft Initial 30 Nm (22

Controller To Camshaft Tightening ft. lb.)
Central Screw Securing Camshaft Final

+40°
Controller To Camshaft Tightening
PRELIMINARY WORK
1. Remove cylinder head cover. → 158219 REMOVING AND INSTALLING CYLINDER HEAD
COVER
2. The spark plugs can be removed so that it will be easier to turn the crankshaft. → 287020
REMOVING AND INSTALLING SPARK PLUGS
SETTING TIMING FOR CAMSHAFTS
NOTE: Incorrect handling of crankshafts
Risk of damage to the timing system
→ Never turn the crankshaft against the rolling direction or when the chain tensioner is removed.
→ Proceed carefully with your work.
→ Only turn the engine at the crankshaft.
→ After working on the camshaft, re-set the valve timing.
→ Observe general warning notes and working regulations.
NOTE: Timing not set correctly
Rough running engine
Loss of engine power
→ Do not use force when fitting the staking tool.
→ Make sure that the gap is equal on both sides.
→ When inserting the staking tools, do not use force to turn the camshafts against any resistance.
→ The engine must be exactly at top dead center.
→ The opposite cylinder must be at ignition TDC.
Information
The adjustment of the oil pump with balance shaft with respect to the crankshaft must be correct .
Correct adjustment of the balance shaft with respect to the crankshaft is a prerequisite for the valve
timing of the camshafts .
If the engine has vibrations in the crank drive, also check that the balance shaft is set correctly. For
details of how to adjust the balance shaft , see → 172019 REMOVING AND INSTALLING OIL
PUMP
1. Turn the crankshaft at the vibration balancer so that the vibration balancer's staking bore -2- is
located approx. 45° degrees in front of the lower staking point on the timing-case cover -1- .
Fig 1: Identifying Vibration Balancer Staking Bore
2. Loosen central screws on the four camshaft controllers.
3. Remove chain tensioner. → 153519 REMOVING AND INSTALLING TIMING CHAINS ON V6

DFI ENGINES
4. Auxiliary Chain Tensioner 9683/1 must be screwed in hand-tight. Connect 1 bar of

compressed air and slowly increase to 5.0 up to 5.5 bar (prevents the assembly chain
tensioner from "crashing" against the timing chain).
5. Turn the camshafts at the hexagon until the flat surfaces are pointing upwards.
Fig 2: Turning Camshaft
6. Staking Tool For Valve Timing 9861 must be fitted on the camshafts.
1. 6.1. Tighten screws to 20 Nm (15 ft. lb.) so that the camshafts are moved over the
flat surfaces -arrows- into the exact position.
Fig 3: Locating Camshaft Flat Surfaces And Staking Tool For Valve Timing
7. Secure the crankshaft.
1. 7.1. Locating Pins 9595/1 must be inserted into the staking bore on the vibration
balancer -2- .
2. 7.2. Turn the crankshaft at the vibration balancer (approx. 45°) -3- so that the staking
pin in the vibration balancer slips into the lower staking point on the timing-case
cover -1- .
3. 7.3. At the same time, exert gentle pressure on the staking pin while turning.
Fig 4: Identifying Crankshaft Vibration Balancer Staking Bore
8. If You Accidentally Turn The Vibration Balancer Too Far, Do Not Try To Turn It Back
Again!
1. 8.1. The staking tools must be removed and the camshafts must be turned in such a
way that there is only the slightest pressure on the valve springs.
2. 8.2. Turn the crankshaft once and start the setting procedure again.
9. Camshafts and crankshaft are fixed correctly.
1. 9.1. Screwed-in assembly chain tensioner with approx. 5.0 to 5.5 bar pressure.
2. 9.2. Two fixed staking tools on the camshafts.
3. 9.3. Staking pin secures crankshaft in TDC of cylinder 1.
10. Tighten central screws on the four camshafts as instructed. To do this, counter at the hexagon
on the camshaft controllers and observe the specified sequence!
1. 10.1. Tightening Torque: Initial tightening 30 Nm (22 ft. lb.) Final tightening +40°
2. 10.2. Tightening sequence:
Tightening Sequence For Central Screw For Camshaft Controller (Item 2)

Result: Cylinder Bank: Camshaft:
1. Bank 1, Cylinders 1-3 Outlet
2. Bank 1, Cylinders 1-3 Intake
4. Bank 2, Cylinders 4-6 Outlet
11. Remove tools.
12. Install chain tensioner.
13. Check by turning the engine twice.
SUBSEQUENT WORK
1. Install spark plugs. → 287020 REMOVING AND INSTALLING SPARK PLUGS
COVER
WM 150516 CHECKING AND SETTING TIMING FOR CAMSHAFTS (CAYENNE TIP &
CAYENNE TIP "PLATINUM EDITION") > PRELIMINARY WORK
Information
Always check all components, such as timing chains, sprockets, locking pins and chamfers for
wear or damage. Always replace faulty components .
Always replace all fastening screws for the sprockets .
Before removing the timing chains, mark the running direction with a colored pen .
Maintain the same timing chain running direction during re-installation .
Never use a prick punch or file for marking .
Information
Fix camshaft in place
To loosen the fastening screws on the camshaft controller, counter the relevant camshaft with an
open-ended wrench (a/f 27) .
To prevent damage, remove the camshaft guide .
1. Remove all engine compartment covers. → REMOVING FRONT TRIM PANEL (ENGINE
COMPARTMENT) - section on "Removing"
2. Remove engine.
3. Remove transmission.
1. 3.1. For vehicles with manual transmission, see: → REMOVING TRANSMISSION -

1. 3.1.1. Remove flywheel.
2. 3.2. For vehicles with automatic transmission, see: → REMOVING AUTOMATIC

TRANSMISSION - section on "Removing"
1. 3.2.1. Remove drive plate for torque converter. → REMOVING DRIVE

PLATE FOR TORQUE CONVERTER - section on "Removing"

"Removing"
5. Remove cylinder head cover. → REMOVING CYLINDER HEAD COVER - section on

"Removing"
6. Remove the timing-case cover at the top and bottom. → REMOVING TIMING-CASE COVER
- section on "Removing"
7. Set crankshaft to compression TDC for cylinder 1. → 150502 CHECKING THE TIMING ON V6
DFI ENGINES - section on "Checking"
8. Remove camshaft controllers. → 158419 REMOVING AND INSTALLING CAMSHAFT

CONTROLLER ON V6 DFI ENGINES .
9. Remove timing chain -3- . → 153519 REMOVING AND INSTALLING TIMING CHAIN
(AUXILIARY DRIVE MECHANISM)
10. Remove drive chain -17- . → 153519 REMOVING AND INSTALLING TIMING CHAIN
(AUXILIARY DRIVE MECHANISM)
CAYENNE TIP "PLATINUM EDITION") > INFORMATION
Fig 1: Identifying Timing Chains Components
2. Fastening Screw
3. Timing Chain
4. Outlet Camshaft Controller
5. Sealing Ring
6. Oil Pump
7. Fastening Screw
8. Tensioning Rail
9. Chain Tensioner For Timing Chain
10. Sealing Ring
11. Bearing Pin
12. Sprocket For Drive Chain
14. Fastening Screw
16. Drive Wheel For Drive Chain
17. Drive Chain
19. Bolt
20. Fastening Screw For Timing-Chain Guide Rail
21. Fastening Screw For Timing-Chain Guide Rail
22. Fastening Screws For Camshaft Controllers
25. Intake Camshaft Controller
27. Valve for intake camshaft controller
28. Guide Rail
CAYENNE TIP "PLATINUM EDITION") > SETTING THE TIMING
1. Set the timing
1. 1.1. Position the oil pump shaft -1- with the flat side up so that it is horizontal to the
marking -2- .
Fig 1: Locating Oil Pump Shaft
2. Install sprocket for oil pump
3. Install drive chain. → 153519 REMOVING AND INSTALLING TIMING CHAIN (AUXILIARY
DRIVE MECHANISM)
4. Install drive wheel for timing chain.
5. Install timing chain. → 153519 REMOVING AND INSTALLING TIMING CHAIN (AUXILIARY
DRIVE MECHANISM)
6. After you have fitted the timing chain, turn the crankshaft twice and check the timing. →
150502 CHECKING THE TIMING ON V6 DFI ENGINES
CAYENNE TIP "PLATINUM EDITION") > SUBSEQUENT WORK
Information

1. Install the cylinder head cover. → INSTALLING CYLINDER HEAD COVER - section on
"Installing"
2. Install intake-air distributor. → INSTALLING INTAKE-AIR DISTRIBUTOR - section on

"Installing"
3. Install transmission.
1. 3.1. For vehicles with manual transmission, see: → INSTALLING TRANSMISSION -

1. 3.1.1. Install flywheel.
2. 3.2. For vehicles with automatic transmission, see: → INSTALLING AUTOMATIC

TRANSMISSION - section on "Installing"
1. 3.2.1. Remove drive plate for torque converter. → INSTALLING DRIVE

PLATE FOR TORQUE CONVERTER - section on "Installing"
4. Install engine.
5. Install all engine compartment covers. → INSTALLING FRONT TRIM PANEL (ENGINE
WM 150520 REMOVING AND INSTALLING CAMSHAFTS (CAYENNE S & CAYENNE


COVER
2. Remove camshaft controllers. → 158419 REMOVING AND INSTALLING ACTUATOR FOR

CAMSHAFT (CAMSHAFT CONTROLLER)
Also for cylinder bank 1 cyl. 1-3:
3. Remove vacuum pump. → 477619 REMOVING AND INSTALLING VACUUM PUMP

GTS) > REMOVING CAMSHAFTS
Information
During removal, note the installation position and allocation of the camshafts and bearing covers
on a sheet of paper in such a way that they cannot be mixed up .
Protect camshafts and bearing covers from dirt and place the components on a clean surface
according to installation position .
1. Remove camshafts.
1. 1.1. Loosen screws -11- and -15- slowly and evenly, one after the other from the
outside in.
2. 1.2. Remove mounting saddle -8- and bearing cover -10- .
3. 1.3. Remove camshafts and place them on a clean, soft surface.

Fig 1: Identifying Camshaft Components (Cylinders 1-3)

GTS) > INSTALLING CAMSHAFTS > MARKING ON BEARING COVER
Fig 1: Identifying Camshaft Bearing Cover Markings (Cylinders 1 To 3)
All markings can be read from the exhaust side/main diagram applies symmetrically for
both cylinder heads
arrow - Direction of travel

GTS) > INSTALLING CAMSHAFTS > INSTALLING CAMSHAFTS
1. Insert camshafts so that the minimum amount of pressure is exerted on the valve springs and
coat bearing locations with normal multipurpose grease or engine oil.
2. Perform further installation in reverse order, paying attention to the following:
1. 2.1. Tighten screws slowly and evenly.
2. 2.2. Tightening Torque Item 11:
Tightening Torque Item 15:

Fig 1: Identifying Camshaft Components (Cylinders 1-3)

1. Install vacuum pump. → 477619 REMOVING AND INSTALLING VACUUM PUMP
2. Install camshaft controllers. → 158419 REMOVING AND INSTALLING ACTUATOR FOR

3. Install cylinder head cover. → 158419 REMOVING AND INSTALLING ACTUATOR FOR
WM 150719 REMOVING AND INSTALLING CAMSHAFT TIMING GEAR (CAYENNE

TURBO & CAYENNE TURBO S) > PRELIMINARY WORK
1. Remove cylinder head cover (valve cover) on both cylinder banks. → 158219 REMOVING
AND INSTALLING CYLINDER HEAD COVER
2. The spark plugs should be removed to make the crankshaft easier to turn. → 287020
REMOVING AND FITTING SPARK PLUGS

TURBO & CAYENNE TURBO S) > REMOVING CAMSHAFT TIMING GEAR
NOTE: Small parts falling into the timing case
→ Do not let the diamond washer and other small parts fall into the timing case.
1. Turn the crankshaft at the vibration balancer so that the vibration balancer's staking bore -2- is
located approx. 45° degrees in front of the lower staking point on the timing-case cover -1- .
Fig 1: Identifying Vibration Balancer Staking Bore

DFI ENGINES
3. Loosen all four screws of the camshafts (sprockets and camshaft controllers) (undo one to two
turns). Counter at the respective hexagon. → Loosening camshafts (illustrated with
timing-case cover removed)
Fig 2: Loosening Camshafts
Information
1. Move the camshafts carefully. Do not force .
2. Turn in the other direction if necessary .
Information
4. Turn all four camshafts so that all the data matrix codings at the adjustment edges are pointing
upwards almost simultaneously (this enables the camshafts to exert the minimum amount of
pressure on the valve lifters) → Camshaft position for cylinders 1 to 4 → Camshaft position for
cylinders 5 to 8 . The camshafts are turned at their hexagon using an appropriate open-ended
wrench → Hexagon at camshaft . Observe identical information on assembling the camshafts.
Fig 3: Identifying Camshaft Position (Cylinders 1 To 4)


Fig 5: Identifying Camshaft Hexagon
5. Loosen timing chain.
6. Remove screw for the respective camshaft timing gear -3- and carefully take out camshaft
timing gear -2- with both hands under the timing chain. Carefully loosen camshaft timing gear
from behind using a rubber hammer if necessary.
1. Double-Chain Camshaft Drive
2. Camshaft Sprocket
3. Screw, M12 Tighten Fully After Setting Timing .
4. Deflector Rail
5. Screw, M8 x 35
6. Camshaft-To-Camshaft Guide Pad

TURBO & CAYENNE TURBO S) > INSTALLING CAMSHAFT TIMING GEAR
Information
3. Screw, M12 Tighten Completely After Setting Timing .
4. Deflector Rail
5. Screw, M8 x 35
1. Lift timing chain and place camshaft timing gear carefully on the camshaft. In order to have
sufficient play in the timing chain, turn the loosened camshaft controller back and forth if
necessary. Place timing chain on camshaft timing gear.
2. Fit screw for camshaft timing gear and screw it in loosely.
3. Screw in the four screws of the sprockets and camshaft controller as far as possible (it must
still be possible to turn the sprockets and camshaft controller to adjust the timing).
4. Set the timing. → 150516 SETTING TIMING FOR CAMSHAFTS Do not tighten the sprockets
and camshaft controllers to the final Tightening Torque until the timing has been set.

TURBO & CAYENNE TURBO S) > SUBSEQUENT WORK
1. Fit cylinder head cover (valve cover). → 158219 REMOVING AND INSTALLING CYLINDER
HEAD COVER
2. Fit spark plugs. → 287020 REMOVING AND FITTING SPARK PLUGS
WM 153319 REMOVING AND INSTALLING TIMING-CASE COVER (CAYENNE S &


Value 1 2
Tightening 60 Nm
Chain Tensioner
Torque (44 ft. lb.)
Fastening Screw Securing Joint

Aluminum Screw Initial 4 Nm (3
Flange To Timing-Case Cover,
Must Be Replaced Tightening ft. lb.)
Top

Final
Flange To Timing-Case Cover, +90°
Tightening
Top

Aluminum Screw Initial 4 Nm (3
Flange To Timing-Case Cover,
Must Be Replaced Tightening ft. lb.)
Bottom

Final
Flange To Timing-Case Cover, +90°
Tightening
Bottom
Fastening Screw For Replace Aluminum Initial 4 Nm (3

Timing-Case Cover Screw Tightening ft. lb.)
Fastening Screw For Final

+90°
Timing-Case Cover Tightening
10 Nm
Fastening Screw For Replace Aluminum Initial
(7.5 ft.
Timing-Case Cover Screw Tightening
lb.)

+90°
Fastening Screw Securing Crash Tightening 23 Nm

M8 x 20
Support To Oil Guide Housing Torque (17 ft. lb.)
Fastening Screw Securing Crash

Aluminum Screw, Initial 4 Nm (3
Support To Timing-Case
M6 x 30/Replace Tightening ft. lb.)
Cover/Oil Guide Housing
Fastening Screw Securing Crash

Final
Support To Timing-Case +90°
Tightening
Cover/Oil Guide Housing
Timing-Case Cover Length 0.1 mm

Fastening Screw For Replace Aluminum Initial 4 Nm (3
Timing-Case Cover Screw Tightening ft. lb.)

+90°
10 Nm
Fastening Screw For Replace Aluminum Initial
(7.5 ft.
Timing-Case Cover Screw Tightening
lb.)

+90°



SUPPORT (MOUNTING BRACKET)
3. Drain engine oil
4. Remove drive belt. → 137819 REMOVING AND INSTALLING DRIVE BELT .
5. Remove coolant hoses in front of the timing-case cover.

Fig 1: Identifying Coolant Return Hoses

6. Remove both valve covers. → 158219 REMOVING AND INSTALLING CYLINDER HEAD
COVER
7. Remove pulley. → 137619 REMOVING AND REINSTALLING PULLEY (VIBRATION

BALANCER)
8. Remove joint flange from crankshaft sealing ring for pulley. → 137419 REMOVING AND
INSTALLING CRANKSHAFT SEALING RING FOR PULLEY/VIBRATION BALANCER
9. Remove both turbochargers. → 213019 REMOVING AND INSTALLING TURBOCHARGER
10. Remove oil pan. → 175019 REMOVING AND INSTALLING OIL PAN
11. Remove oil guide housing. → 175019 REMOVING AND REINSTALLING OIL GUIDE
HOUSING
DFI ENGINES

CAYENNE GTS) > INFORMATION > TIMING-CASE COVER
Fig 1: Identifying Timing-Case Cover
1. Timing-Case Cover
2. Outer Seal, Right Replace
3. Inner Seal Replace
4. Seal, Rib Replace

5. Sealing Ring Replace
6. Chain Tensioner → Tightening Torque: 60 Nm (44 ft. lb.)
7. Dowel Sleeve
9. Aluminum Screw, M6/replace → Initial Tightening: 4 Nm (3 ft. lb.) → Final Tightening:

+90°
10. Aluminum Screw, M6/replace → Initial Tightening: 4 Nm (3 ft. lb.) → Final Tightening:
+90°
11. Joint Flange

CAYENNE GTS) > INFORMATION > APPLYING SEALANT ON TIMING-CASE COVER
Fig 1: Identifying Timing-Case Cover Sealant Application Area
1. Applying sealant on lower timing-case cover
2. Applying sealant on connection point between timing-case cover and cylinder head, top
3. Length of sealant: 20 mm

CAYENNE GTS) > INFORMATION > CLEANING TIMING-CASE COVER
Clean sealing faces on the timing-case cover -arrows- with Loctite 7515 before applying sealant.
Fig 1: Locating Timing-Case Cover Sealing Faces

CAYENNE GTS) > INFORMATION > TIGHTENING SPECIFICATIONS FOR
TIMING-CASE COVER
Fig 1: Timing-Case Cover Screw Tightening Sequence
1-30 - Tightening sequence
1-4 - Screw, M6 x 55
5 + 6 - Screw, M8 x 55
7-12 - Screw, M6 x 30
13 + 14 - Screw, M6 x 55
15-28 - Screw, M6 x 30
29 - Screw, M6 x 55
30 - Screw, M6 x 30
1-4 + 7-30 - Screw, M6 → Initial Tightening: 4 Nm (3 ft. lb.) → Final Tightening: +90°
5 + 6 - Screw, M8 → Initial Tightening: 10 Nm (7.5 ft. lb.) → Final Tightening: +90°

CAYENNE GTS) > INFORMATION > CRASH SUPPORT TO OIL GUIDE
HOUSING/TIMING-CASE COVER
Fig 1: Identifying Crash Support To Oil Guide Housing/Timing-Case Cover Screws
2. Aluminum Screw, M6 x 30/Replace → Initial Tightening: 4 Nm (3 ft. lb.) → Final

Tightening: +90°
3. Crash support

CAYENNE GTS) > REMOVING TIMING-CASE COVER
NOTE: Timing-case cover removed incorrectly
Risk of damage to seal between oil pan and crankcase
Risk of engine leaks
→ Always reseal the oil pan when removing the timing-case cover.
1. Remove deflection rollers -1, 4- and belt tensioner -2- .
1. 1.1. Lever off the deflection roller covers.
2. 1.2. Unscrew the belt tensioner screws -3- and the deflection roller screws.
3. 1.3. Remove belt tensioner and deflection rollers.

Fig 1: Identifying Belt Drive
2. Disconnect positive crankcase vent lines from the holders.
3. Disconnect cable duct -1- from the timing-case cover.
1. 3.1. Remove screw -2- .

Fig 2: Identifying Timing-Case Cover Cable Duct
4. Remove timing-case cover.
1. 4.1. Loosen screws in the sequence -30 - 1- .
2. 4.2. Remove screws -1 - 30- .
3. 4.3. Carefully lift off the timing-case cover. Lever off if necessary.
Fig 3: Identifying Timing-Case Cover Screws Tightening Sequence

CAYENNE GTS) > INSTALLING TIMING-CASE COVER
Information
Information
Acetone can be used to clean the sealing faces. Ventilate this for 5 minutes before applying more
sealant .
Information
The timing-case cover must be aligned using a dial gauge or steel gauge .
The timing-case cover must not project over the lower part of the crankcase. Even the slightest
projection must be corrected .
It must not be less than (-dimension A- )1/10 mm (-dimension A < 1/10 mm- ).
Information
Carefully apply Loctite 5900 sealant on the timing chain housing in such a way that sealant cannot get
into the screw holes when you fit the timing-case cover. Loctite 5900 can increase the friction coefficient
of the aluminum screw. The sealant must not overflow.
1. Clean dirt and grease off the sealing faces of the engine and timing-case cover.
1. 1.1. Also clean sealing faces -arrows- using Loctite 7515.
Fig 1: Locating Timing-Case Cover Sealing Faces
2. Fit the new metal seals -2, 3, 4- on the timing-case cover.

Fig 2: Identifying Timing-Case Cover
3. Fill the openings in the metal seals with sealant -1, 2- . Apply sealant at the specified markings
on the engine → see Fig 3→ see Fig 3. Apply the sealant in such a way that no excess sealant
can expand into the engine when the timing-case cover is fitted (blocked oil ducts).
Fig 3: Identifying Timing-Case Cover Sealant Application Area
1. Applying sealant on lower timing-case cover
2. Applying sealant on connection point between timing-case cover and cylinder head,
top
3. Length of sealant application 20 mm
4. When fitting the timing-case cover, press the tensioning rail away from the camshaft controller
(cylinder 1) towards the timing chain using a screwdriver (second worker required).
5. Fit timing-case cover straight on without letting it slip out of place.
6. Screw down all fastening screws by hand. At this stage, the screw heads should not be all the
way down.
1. 6.1. Replace all screws.
7. Press the timing-case cover upwards slightly and tighten the four fastening screws [approx. 1 -
2 Nm (0.5 - 1.5 ft. lb.)] so that the timing-case cover grips a little. Then align the timing-case
cover.
8. Align timing-case cover within 5 minutes and screw it on .

CAYENNE GTS) > INSTALLING TIMING-CASE COVER > ALIGNING TIMING-CASE
COVER USING A DIAL GAUGE
Information
The timing-case cover must not project over the crankcase. The maximum offset is → Length: 0.1 mm
.
1. Insert the dial gauge into the universal dial gauge bracket and position it so that the dial gauge
has a preload of about 1 mm. → see Fig 1
Fig 1: Adjusting Preload
2. Set dial gauge scale to 0. To do this, place the dial gauge bracket on a completely flat surface
(e.g. crankcase flange) and turn the dial gauge scale until the pointer is at 0. → see Fig 2
Fig 2: Adjusting Dial Gauge Scale To Zero
3. Measure offset. To do this, push with the bracket starting from the lower part of the crankcase
towards the timing-case cover (the base of the dial gauge bracket is not located on the same
component as the dial gauge probe) and measure the offset → see Fig 3. The timing-case
cover must not be set back by more than 0.1 mm. It must not project out.
Fig 3: Measuring Timing-Case Cover Offset
4. Align the timing-case covers by tapping lightly with a rubber hammer. → see Fig 4
Fig 4: Aligning Timing-Case Cover
5. Once you have aligned the timing-case cover, tighten two fastening screws on the left and right
of the timing-case cover base hand-tight. Then check the position of the timing-case cover
again using the dial gauge. → see Fig 5
Fig 5: Measuring Timing-Case Cover Offset

CAYENNE GTS) > SECURING TIMING-CASE COVER
1. Secure aligned timing-case cover.
1. 1.1. Tighten screws to the specified Tightening Torque in the sequence -1 - 30- .
Fig 1: Timing-Case Cover Tightening Sequence
1-30 - Tightening sequence
1-4 - Screw, M6 x 55
5 + 6 - Screw, M8 x 55
7-12 - Screw, M6 x 30
13 + 14 - Screw, M6 x 55
15-28 - Screw, M6 x 30
29 - Screw, M6 x 55
30 - Screw, M6 x 30
1-4 + 7-30 - Screw M6 → Initial tightening: 4 Nm (3 ft. lb.) → Final tightening:

+90°
5 + 6 - Screw M8 → Initial tightening: 10 Nm (7.5 ft. lb.) → Final tightening:

+90°

1. Install chain tensioner. → 153519 REMOVING AND INSTALLING TIMING CHAINS ON V6 DFI
ENGINES
2. Install oil guide housing. → 175019 REMOVING AND INSTALLING OIL GUIDE HOUSING
3. Install oil pan. → 175019 REMOVING AND INSTALLING OIL PAN
4. Install turbocharger. → 213019 REMOVING AND INSTALLING TURBOCHARGER
5. Install joint flange on crankshaft sealing ring for pulley. → 137419 REMOVING AND
INSTALLING CRANKSHAFT SEALING RING FOR PULLEY/VIBRATION BALANCER
6. Install coolant hoses in front of the timing-case cover.
7. Install drive belt. → 137819 REMOVING AND INSTALLING DRIVE BELT .
8. Fill in engine oil.
9. Install pulley. → 137619 REMOVING AND INSTALLING PULLEY (VIBRATION BALANCER)
10. Install both valve covers. → 158219 REMOVING AND INSTALLING CYLINDER HEAD
COVER
11. Install engine with transmission. → 100119 REMOVING AND INSTALLING ENGINE
WM 153519 REMOVING AND INSTALLING TIMING CHAIN (CAYENNE GTS, CAYENNE

1. Remove the engine. → 100119 REMOVING AND INSTALLING ENGINE
2. Remove timing-case cover. → 153319 REMOVING AND INSTALLING TIMING-CASE

COVER

S, CAYENNE TURBO & CAYENNE TURBO S) > REMOVING TIMING CHAIN
Information
The rolling direction of the timing chain must always be the same .
If the timing chain is to be reused, the rolling direction of the timing chain must be marked before it
is removed .
Information
If the timing chain has to be removed or replaced, check the guide and tensioning rails as well as the
chain pinions for wear and scoring and replace them if necessary.
1. Loosen the fastening screws on the camshaft timing gears and camshaft controllers (by one or
two turns). To do this, counter at the hexagon on the camshaft controller and camshaft timing
gear using a ring wrench. → Camshaft timing gears and camshaft controllers
Fig 1: Loosening Camshaft Timing Gears And Camshaft Controllers
2. Remove timing chain from all sprockets by pulling it forwards.

S, CAYENNE TURBO & CAYENNE TURBO S) > INSTALLING TIMING CHAIN
Information
is removed .
Information
Camshaft timing gears and camshaft controllers must be fitted and it must be possible to turn them
(without tilting).
1. Check that the guide and tensioning rails are installed at the correct position.
2. Place timing chain loosely on all sprockets. Ensure that the timing chain is positioned correctly
on the guide rails.

1. Install timing-case cover. → 153319 REMOVING AND INSTALLING TIMING-CASE COVER
2. Set the timing. → 150516 SETTING TIMING FOR CAMSHAFTS
3. Install the engine. → 100119 REMOVING AND INSTALLING ENGINE
WM 153519 REMOVING AND INSTALLING TIMING CHAIN (AUXILIARY DRIVE

MECHANISM) (CAYENNE (3.0) & CAYENNE S E-HYBRID) > TOOLS
Special Wrench VW Tool T40049

Locating Pin VW Tool T40116

MECHANISM) (CAYENNE (3.0) & CAYENNE S E-HYBRID) > TECHNICAL VALUES

Value 1 2
Fastening Screw Securing Drive Initial 30 Nm (22

Replace
Sprocket For Oil Pump Tightening ft. lb.)
Fastening Screw Securing Drive Final

+90°
Sprocket For Oil Pump Tightening
Fastening Screw Securing Initial 15 Nm (11

Replace
Sprocket For Balance Shaft Tightening ft. lb.)
Fastening Screw Securing Final

+90°
Sprocket For Balance Shaft Tightening
Fastening Screw For Chain Initial 10 Nm (7.5

Replace
Tensioner Tightening ft. lb.)
Fastening Screw For Chain Final

+45°
Tensioner Tightening
Locking Pin T40069
Torque ft. lb.)

MECHANISM) (CAYENNE (3.0) & CAYENNE S E-HYBRID) > PRELIMINARY WORK
1. Transmission removed.
COVER

MECHANISM) (CAYENNE (3.0) & CAYENNE S E-HYBRID) > REMOVING AND
INSTALLING DRIVE CHAIN FOR AUXILIARY DRIVES > ASSEMBLY OVERVIEW -
DRIVE CHAIN FOR AUXILIARY DRIVES
Fig 1: Identifying Drive Chain Components
1. Crankshaft
2. Drive Chain, For Auxiliary Drives
3. Drive Sprocket, For Oil Pump

5. Compression Spring
7. Sprocket for balance shaft
8. Chain Tensioner With Guide Rail
9. Screw Replace → Initial Tightening: 10 Nm (7.5 ft. lb.) → Final Tightening: +45°

INSTALLING DRIVE CHAIN FOR AUXILIARY DRIVES > REMOVING DRIVE CHAIN FOR
AUXILIARY DRIVES
NOTE: Timing chain running direction not maintained
Risk of damage to sprockets
→ Mark running direction of timing chains.
1. Fit Special Wrench T40049 at the rear of the crankshaft with two screws -arrows- .
1. 1.1. When screwing on the Special Wrench -T40049- , only use screws with a
thread length -a- of max. 22 mm .
Fig 1: Locating Special Wrench (T40049)

Fig 2: Identifying Special Wrench Screws (T40049)
Turn crankshaft to "TDC" in direction of rotation of the engine.

3. Using Adapter -T40058- and an angled ring wrench, turn the crankshaft to "TDC" in direction
of rotation of the engine.
Only Turn The Crankshaft In Direction Of Rotation Of The Engine -Arrow-!

4. The notch -A- must be aligned with the joint -arrow- .

Fig 5: Identifying Crankshaft Notch And Joint
5. Locking Pin T40069 must be screwed into the bore hole and tightened to → Tightening
Torque: 25 Nm (19 ft. lb.) . Turn the crankshaft -1- back and forth slightly if necessary in
order to center the locking pin fully.
6. Remove chain and chain tensioner.
1. 6.1. Press the guide rail for the chain tensioner in -direction of arrow- and lock the
chain tensioner in place with the Locking Pin -T40071- .
2. 6.2. Unscrew screws -3- and remove the balance shaft sprocket.
3. 6.3. Unscrew screws -1- and -2- and remove the chain tensioner and chain.
Fig 7: Pressing Guide Rail For Chain Tensioner And Locking In Place With Locking
Pin

INSTALLING DRIVE CHAIN FOR AUXILIARY DRIVES > INSTALLING DRIVE CHAIN
FOR AUXILIARY DRIVES
Information
1. Crankshaft -1- secured in "TDC" position with Locking Pin T40069 .

1. Risk of damage to sprockets
2. Fit chain tensioner with chain and balance shaft sprocket.
1. 2.1. Lock balance shaft in "TDC" position with Locating Pin T40116 .
2. 2.2. The slots in the balance shaft sprocket must be centered with respect to the
threaded bores on the balance shaft. Move the chain by one tooth if necessary.
3. 2.3. Tighten chain tensioner screws.
4. 2.4. Screw sprocket screws -1- in loosely.

Fig 2: Tightening Chain Tensioner
3. It should still be possible to turn the sprocket on the balance shaft without tilting.
4. Remove locking pin T40071 to release the chain tensioner.
5. Press against the guide rail for the chain tensioner using a screwdriver -arrow- and tighten the
screws for the sprocket at the same time.
Pull Locating Pin -T40116- out of the balance shaft.

Fig 3: Pressing Chain Tensioner
6. Fit screw plug for "TDC" mark on the crankshaft.

MECHANISM) (CAYENNE (3.0) & CAYENNE S E-HYBRID) > SUBSEQUENT WORK
COVER
WM 153519 REMOVING AND INSTALLING TIMING CHAIN (TIMING DRIVE

MECHANISM) [CAYENNE S E-HYBRID & CAYENNE (3.0)] > TOOLS


MECHANISM) [CAYENNE S E-HYBRID & CAYENNE (3.0)] > TECHNICAL VALUES
Tolerance Tolerance
1 2
Initial 10 Nm (7.5
Fastening Screw For Guide Rail Replace
Tightening ft. lb.)
Final
Fastening Screw For Guide Rail +90°
Tightening
Initial 5 Nm (3.5 ft.

Tightening lb.)
Final +60 Nm (+44

Fastening Screw For Bearing Pin
Tightening ft. lb.)
Initial 10 Nm (7.5
Tightening ft. lb.)
Final
Tightening
Initial 10 Nm (7.5
Tightening ft. lb.)
Final
Tightening
Fastening Screw Securing Bearing Initial 8 Nm (6 ft.

Plate For Drive Sprocket tightening lb.)
Fastening Screw Securing Bearing Final

+45°
Plate For Drive Sprocket Tightening

Tightening lb.)
Final
Fastening Screw For Bearing Pin +90°
Tightening

Initial 10 Nm (7.5
Tightening ft. lb.)
Final
Tightening

MECHANISM) [CAYENNE S E-HYBRID & CAYENNE (3.0)] > PRELIMINARY WORK

COVER
4. Remove camshaft controller. → 158419 REMOVING AND INSTALLING CAMSHAFT

CONTROLLER
5. Remove drive chain for auxiliary drives. → 153319 REMOVING AND INSTALLING

MECHANISM) [CAYENNE S E-HYBRID & CAYENNE (3.0)] > REMOVING DRIVE CHAIN
FOR TIMING DRIVE MECHANISM > ASSEMBLY OVERVIEW - DRIVE CHAIN FOR
TIMING DRIVE MECHANISM
Fig 1: Identifying Timing Drive Mechanism Components
1. Guide Rail
3. Screws Replace → Initial Tightening: 5 Nm (3.5 ft. lb.) → Final Tightening: +60 Nm (+44 ft.
lb.)

5. Drive Sprocket, For Left Timing Chain
7. Drive Chain, For Timing Drive Mechanism
9. Guide Rail
11. Bearing Plate, For Drive Sprocket
12. Drive Sprocket, For Right Timing Chain
13. Thrust Washer
14. Bearing Pin, For Drive Sprocket
16. Seal Replace
17. Chain Tensioner
19. Crankshaft

MECHANISM) [CAYENNE S E-HYBRID & CAYENNE (3.0)] > REMOVING DRIVE CHAIN
FOR TIMING DRIVE MECHANISM > REMOVING DRIVE CHAIN FOR TIMING DRIVE
MECHANISM
Risk of damage to sprockets
1. Remove drive chain for timing drive mechanism.
1. 1.1. Press guide rail for chain tensioner for the drive chain in -direction of arrow-
and lock chain tensioner by inserting the Locking Pin T40071 .
2. 1.2. Unscrew screws -1- and remove guide rail.
3. 1.3. Unscrew screws -2- and remove chain tensioner.
4. 1.4. Remove drive chain for timing drive mechanism.

Fig 1: Removing Chain Tensioner Guide Rail

MECHANISM) [CAYENNE S E-HYBRID & CAYENNE (3.0)] > INSTALLING DRIVE
CHAIN FOR TIMING DRIVE MECHANISM
Information
1. Install drive chain for timing drive mechanism.
1. 1.1. Fit drive chain for timing drive mechanism onto the drive chain sprockets
according to the markings applied during removal.
2. 1.2. Install guide rail and tighten screws -1- .
3. 1.3. Install chain tensioner and tighten screws -2- .
4. 1.4. Press guide rail for chain tensioner for the drive chain in -direction of arrow-
and pull Locking Pin T40071 out of the chain tensioner.
Fig 1: Installing Chain Tensioner Guide Rail

MECHANISM) [CAYENNE S E-HYBRID & CAYENNE (3.0)] > SUBSEQUENT WORK
1. Install drive chain for auxiliary drives. → 153319 REMOVING AND INSTALLING
2. Install camshaft controller. → 158419 REMOVING AND INSTALLING CAMSHAFT

CONTROLLER
WM 153519 REMOVING AND INSTALLING TIMING CHAINS (CAYENNE) > TOOLS
Camshaft Bar VW Tool T10068A
Counter-Hold Tool VW Tool T10069
Adjusting Tool VW Tool T10363
WM 153519 REMOVING AND INSTALLING TIMING CHAINS (CAYENNE) > TECHNICAL

VALUES
Fastening Screws Always Replace Tightening Torque 8 Nm (6 ft. lb.)

Camshaft Controller Fastening Screw Tightening Torque 60 Nm (44 ft. lb.)
Camshaft Controller Torque Angle 90°
Camshaft Controller Fastening Screw Tightening Torque 60 Nm (44 ft. lb.)
Bearing Pin Tightening Torque 10 Nm (7.5 ft. lb.)
Chain Tensioner Tightening Torque 40 Nm (30 ft. lb.)
WM 153519 REMOVING AND INSTALLING TIMING CHAINS (CAYENNE) >

PRELIMINARY WORK
1. Remove all engine compartment covers. → 700219 REMOVING AND INSTALLING FRONT
TRIM (ENGINE COMPARTMENT)
3. Remove transmission.
1. 3.1. For vehicles with manual transmission, see: → 343519 REMOVING AND
INSTALLING TRANSMISSION
1. 3.1.1. Remove flywheel.
2. 3.2. For vehicles with automatic transmission, see: → 373519 REMOVING AND
INSTALLING AUTOMATIC TRANSMISSION
1. 3.2.1. Remove drive plate for torque converter. → 136319 REMOVING

AND INSTALLING DRIVE PLATE FOR TORQUE CONVERTER

DISTRIBUTOR
COVER (VALVE COVER)
6. Remove upper and lower timing-case cover. → 153319 REMOVING AND INSTALLING
TIMING-CASE COVER
7. Position crankshaft on cylinder 1 to the compression TDC. → TDC marking → 150502

CHECKING THE TIMING
Fig 1: Locating Crankshaft TDC Marking

INFORMATION > COMPONENT OVERVIEW
Fig 1: Identifying Timing Chains, Oil Pump, Sealing Ring And Sprocket
2. Fastening Screw
3. Timing Chain
5. Sealing Ring
6. Oil Pump
7. Fastening Screw
8. Tensioning Rail
10. Sealing Ring
11. Bearing Pin
12. Sprocket
13. Sprocket
14. Fastening Screw
17. Drive Chain
19. Bolt
20. Fastening Screw On Guide Rail For Timing Chain
28. Guide Rail
WM 153519 REMOVING AND INSTALLING TIMING CHAINS (CAYENNE) > REMOVING

TIMING CHAINS
1. Relieve the timing chain.
1. 1.1. Unscrew the chain tensioner -9- . → 153519 REMOVING AND INSTALLING
TIMING CHAINS ON V6 DFI ENGINES
2. 1.2. Unscrew the bearing pin -11- .
3. 1.3. Pull the tensioning rail -8- for the chain tensioner down and out.
4. 1.4. Remove guide rail -23- by unscrewing the fastening screws -20 and 21- .
5. 1.5. Remove timing chain from the camshaft controllers -4 and 25- .
2. Remove camshaft controller.
Information
1. To loosen the fastening screws on the camshaft controller, counter the relevant camshaft
with an open-ended wrench (a/f 27) .
2. To prevent damage, remove the camshaft guide .
1. 2.1. Remove outlet camshaft controller -4- by unscrewing the fastening screw -22- .
Counter the camshaft at the hexagon → Camshaft hexagon with an open-ended
wrench when doing this.
Information
1. To loosen the fastening screws on the camshaft controller, counter the relevant
camshaft with an open-ended wrench (a/f 27) .
2. To prevent damage, remove the camshaft guide .
2. 2.2. Remove intake camshaft controller -25- by unscrewing the fastening screw -22-
. Counter the camshaft at the hexagon with an open-ended wrench when doing this.
Information
1. Always check all components, such as timing chains, sprockets, locking pins and
chamfers for wear or damage. Always replace faulty components .
2. Always replace all fastening screws for the sprockets .
3. Before removing the timing chains, mark the running direction with a colored pen .
4. Maintain the same timing chain running direction during re-installation .
5. Never use a prick punch or file for marking .

3. Remove timing chain -3- .
1. 3.1. Remove oil pump sprocket -13- by unscrewing the fastening screw -14- .
Block the crankshaft using Counter-Hold Tool T10069 .
4. Relieve the drive chain -17- .
1. 4.1. Remove chain tensioner and tensioning rail -15- . To do this, unscrew both
fastening screws -2- .
5. Remove the drive chain -17- .
1. 5.1. Remove the sprocket -12- from the oil pump shaft.
WM 153519 REMOVING AND INSTALLING TIMING CHAINS (CAYENNE) > INSTALLING

TIMING CHAINS
1. Install drive chain.
1. 1.1. Check crankshaft position (compression TDC for cylinder 1). → 150502
CHECKING THE TIMING

2. 1.2. Place the drive chain -17- on the crankshaft drive gear wheel -16- .
3. 1.3. Position the oil pump shaft -1- with the flat side up so that it is horizontal to the
marking -2- .
Fig 2: Locating Oil Pump Shaft
4. 1.4. The markings on the sprocket -12- and oil pump -2- must be perfectly aligned.
If they are not perfectly aligned, it will not be possible to set the timing correctly. →
150516 SETTING THE TIMING
5. 1.5. Place the drive chain -17- over the sprocket -12- for the oil pump.
Then place the sprocket on the oil pump shaft while ensuring that the drive chain is
correctly tensioned in the guide rail -18- .
6. 1.6. Release the chain tensioner -15- using a small screwdriver, then press it
together and install it.
The fastening screws -2- must always be replaced so that the chain tensioner is
fixed in place with new fastening screws.
Then tighten the fastening screws using a torque wrench. → Tightening Torque: 8
Nm (6 ft. lb.)
2. Install timing chain.
1. 2.1. Check the position of the camshafts.
The camshaft bar T10068A must fit into the grooves on the intake and outlet
camshafts → Camshaft bar at the same time.
Cylinder 1 must be set to compression TDC.
→ 150502 CHECKING THE TIMING ON V6 DFI ENGINES
Fig 3: Identifying Camshaft Bar
2. 2.2. Fix the drive gear wheel for the high-pressure pump in place using adjusting
tool T10363 . Make sure that the marking -1- on the drive cam for the high-pressure
pump is pointing straight up.
Fig 4: Identifying Drive Gear Wheel
3. 2.3. Guide the timing chain through the timing case from above.
Fig 5: Identifying Timing Chain
Information
Tips for fitting the camshaft controllers:
1. The two camshaft controllers (identified by "24E" on the intake side and "32A"
on the outlet side) can be screwed onto the camshaft mounting in one position
only because of a dowel pin .
2. Turn the sensor wheel 1 on the removed intake camshaft controller as far as it
will go to the right. Hold the controller at this position. It must be possible to fit
the controller easily on the intake camshaft with the camshaft roller chain set
"tightly" and then tighten it hand-tight .
3. The outlet camshaft controller is locked in »idle state«. As a result, the sensor
wheel will not turn when you set the timing. If the locking mechanism is not
engaged (locked) in "idle state", the controller must be turned in both directions
by hand until it locks. If this is not possible, replace the camshaft controller .
4. There must be exactly 16 rollers between the markings on the camshaft

controllers "24E" and "32A" and the markings must be flush with the FSI
marking. → 150502 CHECKING THE TIMING ON V6 DFI ENGINES
4. 2.4. Turn the sensor wheel -1- on the intake camshaft controller -25- as far as it will
go to the right.
Position the intake camshaft controller on the camshaft and fix in place with the
fastening screw. The fastening screw Must Always Be Replaced .
Then place the timing chain over the sprocket on the intake camshaft controller.
Make sure that the timing chain is tensioned correctly between the intake camshaft
controller -25- and the drive gear wheel for the high-pressure pump -24- .
Fig 6: Turning Intake Camshaft Controller Sensor Wheel
1. 2.4.1. Counter the camshaft at the hexagon with an open-ended wrench →

Camshaft hexagon .
Tighten the fastening screw -22- with a torque wrench → Tightening

Torque: 60 Nm (44 ft. lb.) and then tighten further to → Torque angle:
90° .
5. 2.5. Place the timing chain over the sprocket on the outlet camshaft controller -4- .
Fix the outlet camshaft controller in place with the fastening screw -22- . The
fastening screw Must Always Be Replaced .
1. 2.5.1. Counter the camshaft at the hexagon -arrows- using an open-ended

wrench (a/f 27).
Tighten the fastening screw -22- using a torque wrench → Tightening

Torque: 60 Nm (44 ft. lb.) and then tighten further to → Torque angle:
90° .
3. Tension the timing chain.
1. 3.1. Install tensioning rail -8- for chain tensioner -9- .
2. 3.2. Fix the tensioning rail in place with the bearing pin -11- and then tighten using a
torque wrench. → Tightening Torque: 10 Nm (7.5 ft. lb.)
3. 3.3. The sealing ring -10- on the chain tensioner -9- must always be replaced .
1. 3.3.1. Then tighten the chain tensioner using a torque wrench. →

Tightening Torque: 40 Nm (30 ft. lb.) .
4. 3.4. Remove the camshaft bar T10068A .
5. 3.5. Remove the adjusting tool T10363 from the drive gear wheel for the
high-pressure pump.
4. After you have fitted the timing chain, turn the crankshaft twice and check the timing → 150502
CHECKING THE TIMING ON V6 DFI ENGINES . Reset the timing if necessary → 150516
SETTING THE TIMING ON V6 DFI ENGINES

SUBSEQUENT WORK
TIMING-CASE COVER
COVER

DISTRIBUTOR .
4. Install transmission.
1. 4.1. For vehicles with manual transmission, see: → 343519 REMOVING AND
1. 4.1.1. Install the flywheel.
2. 4.2. For vehicles with automatic transmission, see: → 373519 REMOVING AND
1. 4.2.1. Remove drive plate for torque converter. → 136319 REMOVING

AND INSTALLING DRIVE PLATE FOR TORQUE CONVERTER
5. Install engine. → 100119 REMOVING AND INSTALLING ENGINE
6. Install all engine compartment covers. → 700219 REMOVING AND INSTALLING FRONT
WM 153619 REMOVING AND INSTALLING CHAIN TENSIONER (CAYENNE) >

TECHNICAL VALUES

PRELIMINARY WORK
1. Remove engine compartment trim panel at the right. → 700219 REMOVING AND
INSTALLING FRONT TRIM (ENGINE COMPARTMENT)

REMOVING CHAIN TENSIONER
NOTE: Danger of timing chain jumping out of position
→ Never turn the engine at the crankshaft without a chain tensioner.
→ Never turn the crankshaft against the direction of rotation.
→ Always counter the sprockets when performing assembly work on them.
→ Make sure that nobody starts the engine or pushes the vehicle while in gear when the chain tensioner
is removed. To prevent this, stick a warning note on the steering wheel or ignition lock.
1. Remove chain tensioner.
1. 1.1. The chain tensioner is on the right side of the upper timing-case cover -arrow- .
Fig 1: Locating Chain Tensioner Installation Position

INSTALLING CHAIN TENSIONER

Information
1. Replace sealing ring on chain tensioner .
1. 1.1. Always replace sealing ring on chain tensioner.
2. 1.2. Tighten the chain tensioner -arrow- by hand.
3. 1.3. Tighten the chain tensioner using a torque wrench. → Tightening Torque: 50
Nm (37 ft. lb.)
Fig 1: Locating Chain Tensioner

SUBSEQUENT WORK
1. Install engine compartment trim panel at the right → 700219 REMOVING AND INSTALLING
FRONT TRIM (ENGINE COMPARTMENT) .
WM 153719 REMOVING AND INSTALLING HYDRAULIC VALVE FOR CAMSHAFT

CONTROL (CAYENNE) > TOOLS
Relay Puller Special Tool 9235

CONTROL (CAYENNE) > TECHNICAL VALUES
Tolerance Tolerance
1 2
Fastening Screws For Hydraulic Tightening 4 Nm (3 ft.

Valve Torque lb.)

CONTROL (CAYENNE) > PRELIMINARY WORK

"Removing"
2. Remove bar ignition modules. → REMOVING BAR IGNITION MODULES - section on

"Removing"
3. Remove cylinder head cover. → REMOVING CYLINDER HEAD COVER - section on

"Removing"
4. Remove the timing-case cover at the top. → REMOVING TIMING-CASE COVER - section on
"Removing"

CONTROL (CAYENNE) > REMOVING SOLENOID/HYDRAULIC VALVE FOR
CAMSHAFT CONTROLLERS
Information
Have a mirror to hand for the following work .
Press a lint-free cloth into the timing chain housing so that the fastening screws cannot fall into the
timing chain housing .
If a fastening screw falls into the timing chain housing, the engine must be removed and the lower
timing-case cover must also be removed .
1. Unscrew fastening screws -arrows- on hydraulic valves for camshaft controllers using a
socket wrench.
Fig 1: Locating Camshaft Controller Hydraulic Valves
2. Carefully pull out the solenoid valves using special tool Relay Puller 9235 .

CONTROL (CAYENNE) > INSTALLING SOLENOID/HYDRAULIC VALVE FOR
CAMSHAFT CONTROLLERS
NOTE: Incorrect handling of sealing rings and covers
Leaks
→ Use clean tools without burrs.
→ Make sure not to leave any scores or scratches when cleaning.
CAUTION: Risk of damage to solenoid valves!
Sealing ring can be damaged.
Incorrect Tightening Torque.
→ Press in solenoid valve firmly with your hand.
1. Install solenoid valves.
1. 1.1. Coat sealing ring with clean engine oil.
2. 1.2. Carefully position solenoid valves vertically with respect to the valve axis and
press them as far as they will go into the housing with your hand.
3. 1.3. Tighten fastening screws arrows to → Tightening Torque: 4 Nm (3 ft. lb.) .

Fig 1: Locating Camshaft Controller Hydraulic Valves

CONTROL (CAYENNE) > SUBSEQUENT WORK
1. Install timing-case cover at the top. → INSTALLING TIMING-CASE COVER - section on

"Installing"
2. Install cylinder head cover. → INSTALLING CYLINDER HEAD COVER - section on "Installing"
3. Install bar ignition module. → INSTALLING BAR IGNITION MODULES - section on "Installing"

"Installing"
WM 154719 REMOVING AND INSTALLING GUIDE AND TENSIONING RAILS ON V6

DFI ENGINES (CAYENNE) > REMOVING AND INSTALLING GUIDE AND TENSIONING
RAILS
For information on how to do this, see → 153519 REMOVING AND INSTALLING TIMING CHAINS
WM 153719 REMOVING AND INSTALLING SOLENOID/HYDRAULIC VALVE FOR

CAMSHAFT ADJUSTER (CAYENNE GTS, CAYENNE S, CAYENNE TURBO &
CAYENNE TURBO S) > TOOLS
Relay Puller Special Tool 9235

1. Remove valve cover → REMOVING CYLINDER HEAD COVER - section on "Removing".

CAYENNE TURBO S) > REMOVING SOLENOID/HYDRAULIC VALVE FOR CAMSHAFT
ADJUSTER
1. Unscrew fastening screws for hydraulic valve -4- .
2. Carefully pull the hydraulic valve -3- up and out. To do this, use Relay Puller 9235 . Hold
hydraulic valve only at the metal insert.
Fig 1: Identifying Hydraulic Valve And Camshaft Adjuster
1. Screw, M12 Tighten Fully After Setting Timing .; Screw must be replaced.
2. Camshaft adjuster with integrated hexagon for countering
4. Screw, M5 x 12
3. Inspect strainer of hydraulic valve and clean with solvent naphtha if necessary. Replace
hydraulic valve if heavily soiled.

CAYENNE TURBO S) > INSTALLING SOLENOID/HYDRAULIC VALVE FOR CAMSHAFT
ADJUSTER
Information
1. Replace sealing ring on hydraulic valve. Do not insert sealing ring twisted when fitting it.
2. Coat sealing ring lightly with engine oil and insert the hydraulic valve into the cylinder head.
Any installation position is possible.
3. Fit and tighten fastening screws.

Fig 1: Identifying Hydraulic Valve And Camshaft Adjuster
1. Screw, M12 Tighten fully after setting timing .; Screw must be replaced.
2. Camshaft adjuster with integrated hexagon for countering
4. Screw, M5 x 12

CAYENNE TURBO S) > SUBSEQUENT WORK
1. Install valve cover → INSTALLING CYLINDER HEAD COVER - section on "Installing".
WM 154720 REMOVING AND INSTALLING TENSIONING RAILS (CAYENNE TURBO &

CAYENNE TURBO S) > INFORMATION
1. The procedure for removing and installing tensioning rails is also described in section →
154820 REMOVING AND INSTALLING GUIDE RAILS .
WM 154820 REMOVING AND INSTALLING GUIDE RAILS (CAYENNE TURBO &

1. Remove timing chain. → 153519 REMOVING AND INSTALLING TIMING CHAINS

CAYENNE TURBO S) > REMOVING GUIDE AND TENSIONING RAILS
Information
is removed .
Information
1. Remove top guide rails (guide pad) between the camshafts if you have not already done so
-6- .
4. Deflector Rail
5. Screw, M8 x 35
2. Pull tensioning rail off the threaded peg. -4-

1. Threaded Peg
2. Threaded Peg
3. Guide Rail
4. Tensioning Rail
5. Chain Tensioner With Sealing Ring
6. Pin (For Locking The Oil-Pump Tensioning Rail)
3. Carefully slacken the lower tensioning rail for the oil pump chain. Press the tensioning rail back
with a small screwdriver until both staking holes between the tensioning rail and guide rail are
aligned. → Oil pump tensioning rail
Fig 3: Pressing Oil Pump Tensioning Rail
4. Stake tensioning rail for oil pump chain through the hole in the guide rail using a suitable drill
bit, drift punch or nail. This slackens the oil pump chain. → Staking tensioning rail for oil pump
chain
Fig 4: Staking Tensioning Rail For Oil Pump Chain
5. Remove guide rail -3- . Guide rail for oil pump chain is locked with -6- .
Fig 5: Identifying Guide Rail
6. Remove deflector rail -4- by loosening the fastening screws -5- .


4. Deflector Rail
5. Screw, M8 x 35

CAYENNE TURBO S) > INSTALLING GUIDE AND TENSIONING RAILS
Information
1. Fit deflector rail -4- by fitting the fastening screws -5- .

4. Deflector Rail
5. Screw, M8 x 35

2. Fit the guide rail -3- . The small tensioning rail is locked on the guide rail with -6- . Slide the
guide rail onto the threaded peg and move it into the correct installation position with respect to
the fitted oil pump drive chain. Pull the locking pin (the tensioning rail becomes attached).
Fig 2: Identifying Guide Rail
3. Slide the tensioning rail onto the threaded peg. -4-


1. Threaded Peg
2. Threaded Peg
3. Guide Rail
4. Tensioning Rail
5. Chain Tensioner With Sealing Ring
6. Pin (For Locking The Oil-Pump Tensioning Rail)
4. Fit top guide rails (guide pad) between the camshafts if you have not already done so -6- .
4. Deflector Rail
5. Screw, M8 x 35

1. Install timing chain. → 153519 REMOVING AND INSTALLING TIMING CHAINS
2. Install timing-case cover. → 153319 REMOVING AND INSTALLING TIMING-CASE COVER
WM 155519 REMOVING AND INSTALLING HYDRAULIC VALVE FOR VALVE LIFT

SWITCHOVER (CAYENNE S & CAYENNE GTS) > PRELIMINARY WORK
Information
Guided Fault Finding using the PIWIS Tester as well as the DME short test "Valve lift" must be
performed before replacing the hydraulic valve. This is essential in order to avoid replacing the hydraulic
valve unnecessarily.
The hydraulic valves are on the rear side of the cylinder heads facing the plenum panel.
1. Cylinder bank 1 to 3:
Remove vacuum pump → REMOVING VACUUM PUMP - section on "Removing".
Disconnect coolant pipe.
1. 2.1. Loosen coolant pipe holder -1- . Two screws are fitted.
Fig 1: Identifying Valve Lift Switchover Hydraulic Valves

SWITCHOVER (CAYENNE S & CAYENNE GTS) > REMOVING HYDRAULIC VALVE FOR
VALVE LIFT SWITCHOVER
3. Pull hydraulic valve -3- out of the cylinder head.
1. 3.1. Make sure that the sealing ring is also removed.


SWITCHOVER (CAYENNE S & CAYENNE GTS) > INSTALLING HYDRAULIC VALVE
FOR VALVE LIFT SWITCHOVER
1. Install hydraulic valve -3- with new sealing ring at the correct position.
Sealing ring must not slip out of place.
2. Fit and tighten fastening screws -4- .
3. Connect electric plug connection -2- .


SWITCHOVER (CAYENNE S & CAYENNE GTS) > SUBSEQUENT WORK
Install vacuum pump → INSTALLING VACUUM PUMP - section on "Installing".

Secure coolant pipe.
1. 2.1. Secure coolant pipe holder.
WM 153619 REMOVING AND INSTALLING CHAIN TENSIONER (CAYENNE TIP &

CAYENNE TIP "PLATINUM EDITION") > TECHNICAL VALUES

1. Remove engine compartment trim panel at the right. → 700219 REMOVING AND

CAYENNE TIP "PLATINUM EDITION") > REMOVING CHAIN TENSIONER
1. Remove chain tensioner.
1. 1.1. The chain tensioner is on the right side of the upper timing-case cover -arrow- .
Fig 1: Locating Chain Tensioner Installation Position

CAYENNE TIP "PLATINUM EDITION") > INSTALLING CHAIN TENSIONER
Information
Replace sealing ring on chain tensioner .
1.1. Always replace sealing ring on chain tensioner.

1.2. Tighten the chain tensioner -arrow- by hand.
1.3. Tighten the chain tensioner using a torque wrench. → Tightening Torque: 50 Nm (37 ft.
lb.)
Fig 1: Locating Chain Tensioner

1. Install engine compartment trim panel at the right → 700219 REMOVING AND INSTALLING
FRONT TRIM (ENGINE COMPARTMENT) .
WM 154719 REMOVING AND INSTALLING GUIDE AND TENSIONING RAILS ON V6

DFI ENGINES (CAYENNE TIP & CAYENNE TIP "PLATINUM EDITION") > REMOVING
AND INSTALLING GUIDE AND TENSIONING RAILS
For information on how to do this, see → 153519 REMOVING AND INSTALLING TIMING CHAINS
WM 155901 CHECKING HYDRAULIC TAPPETS (CAYENNE S HYBRID, CAYENNE TIP

(3.0) & CAYENNE TIP (3.0) "PLATINUM EDITION") > TOOLS

(3.0) & CAYENNE TIP (3.0) "PLATINUM EDITION") > PRELIMINARY WORK
COVER (VALVE COVER)

(3.0) & CAYENNE TIP (3.0) "PLATINUM EDITION") > CHECKING HYDRAULIC
TAPPETS > TEST CONDITIONS
Engine must be at operating temperature.
The valve on the hydraulic tappet you are checking must be closed.
1. Use adapter T40058 and an angled ring wrench to turn the crankshaft in direction of rotation
of the engine -arrow- until the valve on the hydraulic tappet you are checking is closed.
2. Measure the amount of play between the cams and rocker arm.
1. 2.1.
2. 2.2. Press the rocker arm down -arrow- .
Information
Defective or worn hydraulic tappets cannot be repaired, but must be replaced.
3. 2.3. If you can slide a feeler gauge 0.20 mm between the cams and rocker arm,
replace the hydraulic tappet.
4. 2.4. Replace hydraulic tappet.

Fig 2: Checking Hydraulic Tappets Play

(3.0) & CAYENNE TIP (3.0) "PLATINUM EDITION") > SUBSEQUENT WORK
COVER (VALVE COVER)
WM 155919 REMOVING AND INSTALLING HYDRAULIC TAPPETS (CAYENNE TIP &

1. Remove the camshafts. → 150520 REMOVING AND INSTALLING CAMSHAFTS ON V6 DFI

ENGINES

CAYENNE TIP "PLATINUM EDITION") > INFORMATION > COMPONENT OVERVIEW
1. Intake Camshaft
2. Camshaft Bearing Cover
3. Outlet Camshaft
4. Hexagon Nut On Camshaft Bearing Cover

5. Sealing Rings (40 X 1.5)
7. Oval-Head Screw On Timing Chain Housing
10. Hexagon-Head Bolts On Camshaft Controllers
11. Cylinder Head Height (Min. Height a=139.9 mm)
13. Bearing Shaft
14. Valves
15. Dowel Sleeve
16. Cylinder Head
17. Pump Tappet
18. Hydraulic Tappet
19. Valve Stem Seal
20. Timing Chain
21. Safety Clip
22. Rocker Arm
23. Valve Spring
24. Valve-Spring Plate
25. Valve Collets

CAYENNE TIP "PLATINUM EDITION") > REMOVING HYDRAULIC TAPPETS
Information
Observe the most important working regulations and warning notes → The most important working
regulations and warning notes .
Information
Rocker arms are joined to the hydraulic tappets with a safety clip .
The safety clip must be handled carefully!
If the hydraulic tappets are to be re-used, they must be marked according to installation position
using a water-resistant felt-tip pen and set aside in such a way that they cannot be mixed up!
If the hydraulic tappets are to be re-used, they must be installed at the same position!
Rocker arms must be set aside in such a way that they cannot be mixed up .
1. Take rocker arms with hydraulic tappets out of cylinder head.
1. 1.1. Rocker arms, complete with safety clip and hydraulic tappet, must be pulled out
carefully → Installation position of rocker arm -1- and hydraulic tappet -2- without
tilting them.
Fig 1: Identifying Rocker Arm And Hydraulic Tappet Installation Position
2. Check component arrangement. Check that components are complete and intact.
Defective or damaged components must be replaced. The safety clip is hooked into the front of
the rocker arm -1- and into the support lever -2- .
Check the position of the valve pressure face with respect to the rocker arm during removal
-3- .
Fig 2: Identifying Hydraulic Tappet And Rocker Arm Position
3. Lay rocker arms, hydraulic tappets and safety clips aside in such a way that they cannot be
mixed up. Mark installation position according to cylinder and valve.

CAYENNE TIP "PLATINUM EDITION") > INSTALLING HYDRAULIC TAPPETS
Information
Information
When installing the camshafts, make sure that the rocker arms do not slip off the valve pressure
face .
1. Assemble hydraulic tappet, rocker arm and safety clip.
1. 1.1. Make sure that the hydraulic tappet and rocker arm are joined correctly with the
safety clips -1 and 2- .
Fig 1: Identifying Rocker Arm/Hydraulic Tappet Assembly
2. Oil the components. Install hydraulic tappet and rocker arm. Make sure that the safety clip
does not slip out of place during installation.
1. 2.1. The pressure face of the rocker arm -3- must be positioned on the valve
pressure face. This can slip out of place during subsequent installation of the
camshaft.
Fig 2: Identifying Rocker Arm And Hydraulic Tappet Installation Position

1. Install the camshafts. → 150520 REMOVING AND INSTALLING CAMSHAFTS ON V6 DFI

ENGINES
WM 156120 REMOVING AND INSTALLING VALVES (CAYENNE TURBO & CAYENNE

TURBO S) > TOOLS
Valve Stem Seal

VW Tool 3364
Puller
Assembly Driver Special Tool 9606/1
Tool For
Commercially Nr. 54
Fitting/Removing
Valve Keys
31mm Fastening Commercially Nr. 54

Screw Available Tool Pos. 1A
28mm Fastening Commercially Nr. 54

Screw Available Tool Pos. 1B

TURBO S) > PRELIMINARY WORK
1. Remove cylinder head. → 157019 REMOVING AND INSTALLING CYLINDER HEAD
2. Remove camshafts. → 150520 REMOVING AND INSTALLING CAMSHAFTS
3. Take hydraulic tappets out of the cylinder head and lay them on a clean surface, arranged
according to cylinders and valves. Do not interchange components.

TURBO S) > INFORMATION > COMPONENT OVERVIEW
In the Turbo, the exhaust valve is fitted with internal and external valve springs (set of valve
springs) and adapted concave washers. The exhaust valve in the turbo engine has the same
outer dimensions as the exhaust valve of the naturally aspirated engine. However, because of the
sodium filling, the exhaust valve in the turbo engine is lighter and the shank over the shank
entries is longer. For further details, please see Figures Fig 1 and TABLE entitled "Valve
dimensions" .
Fig 1: Identifying Valve Components
1. Intake Valve (Identical In The Naturally Aspirated And Turbo Engines)
2. Valve-Seat Ring Intake
3. Valve Guide
4. Lower Valve-Spring Plate Intake
5. Valve Stem Seal
6. Set Of Valve Springs, Intake (Identical In The Naturally Aspirated And Turbo Engines)
7. Upper Valve-Spring Plate Intake
8. Valve Collet
9. Upper Valve-Spring Plate Outlet (Different In The Naturally Aspirated And Turbo Engines)
10. Set Of Valve Springs (Turbo Outlet); Valve Spring (Naturally Aspirated Engine Outlet)
11. Lower Valve-Spring Plate Outlet (Different In The Naturally Aspirated And Turbo Engines)
12. Valve-Seat Ring Outlet
13. Exhaust Valve (Different In The Naturally Aspirated And Turbo Engines)
Distinguishing features of exhaust valve on naturally aspirated and turbo engine
1. Exhaust Valve - Naturally Aspirated Engine
2. Exhaust Valve - Turbo Engine
3. Difference In Shank Length Over Shank Entries

Fig 2: Identifying Difference Between Exhaust Valve On Naturally Aspirated And Turbo Engine

TURBO S) > INFORMATION > SPECIAL TOOLS
Fig 1: Identifying Valve Special Tools
1. Valve Stem Seal Puller 3364 → Only Used To Remove Valve Stem Seals.
2. Assembly Driver 9606/1 → Only Used To Remove Valve Stem Seals.
3. Universal Assembly Bar With Universal Assembly Driver Tool For Fitting/Removing Valve
Keys Nr. 54 Pos. 1
4. Hooking Piece (Fitting Hook) With Holder (Several Possible)
5. Plastic Guide For Inlet And Outlet Valve 31mm Fastening Screw Nr. 54 Pos. 1A and 28mm
Fastening Screw Nr. 54 Pos. 1B
6. Assembly Fixture For Valve Keys
7. Assembly Cartridge For Valve Keys
8. Assembly Bar (Hook) With Adjustable Lever

TURBO S) > INFORMATION > VALVE DIMENSIONS
Intake Valve (Naturally Exhaust Valve -

Exhaust Valve - Turbo
Dimension Aspirated And Turbo Naturally Aspirated
Engine
Engines) Engine
Valve Disc Diameter 38.30 mm 33.00 mm 33.00 mm
Valve Stem Diameter 5.92 mm 5.92 mm 5.92 mm
Overall Length (From

Valve Disc To Valve 107.70 mm 108.20 mm 108.20 mm
Pressure Area)
Angle At Valve Seat Area 45° 45° 45°
46.7 Gr. (Lighter Than In

Weight 56.8 gr. 48.8 gr. Naturally Aspirated Engine
Because Of Sodium Filling)

TURBO S) > REMOVING VALVES
Information
Secure the cylinder head on a level surface, which allows easy access to the valves from
underneath .
No valves should be hidden by the surface under the cylinder head .
The cylinder head fastening must not tip over when tools are used .
1. Before removing the valves, remove the spark plugs and screw in the valve lock → Screwing
in tool . The valve lock prevents the valves from opening when they are pressed down.
Alternatively, a rubber plate placed underneath helps on a level cylinder head surface -2- .
Fig 1: Installing Valve Lock

Fig 2: Identifying Valve Lock And Rubber Plate
2. Fit and set the tool on the cylinder head.
1. 2.1. Screw a holder -1- with a suitable thread into the matching thread on the
cylinder head. The hook -2- is pre-fitted in the holder.
Fig 3: Fitting Cylinder Head Hook
2. 2.2. Insert a suitable plastic guide -1- instead of the cam follower.
Fig 4: Inserting Plastic Guide
3. 2.3. Insert assembly cartridge -1- for the valve keys into the plastic guide.
Fig 5: Inserting Assembly Cartridge
4. 2.4. Engage a lever (assembly fork) -1- into the hook and position it correctly on the
assembly cartridge. Make sure that the tool and equipment can work straight.
Fig 6: Installing Valve Tool
3. Remove the valve keys.
1. 3.1. Press the assembly cartridge down against the valve spring force using a lever
(assembly fork) and keep it pressed → Pressing down tool . The knurled screw on
the assembly cartridge moves forward -1- .
Fig 7: Pressing Down Tool

Fig 8: Pressing Valve Tool Lever
Information
The mechanic must practise for use of the assembly cartridge to be effective. Some
repetitions must be made to ensure that the valve keys are correctly held in place.
2. 3.2. Turn the knurled screw back and forward -1- so that the valve keys engage and
are held in the assembly cartridge -2- . The knurled screw moves back again.
Fig 9: Turning Knurled Screw
3. 3.3. Remove the assembly cartridge and check that the two valve keys are
positioned correctly -1- .
Fig 10: Assembling Valve Keys
4. 3.4. Pull the knurled screw on the assembly cartridge -1- and disengage the valve
keys -2- .
Fig 11: Removing Valve Keys
4. Remove valve springs, spring plate and valve keys from the cylinder head.
5. Remove valve locks and push the valves to the side of the combustion chamber.

TURBO S) > INSTALLING VALVES
NOTE: Valve grinding paste not removed
Risk of damage to sealing face on intake valve
→ Remove all valve grinding paste fully after grinding.
Information
The valves cannot be touched up afterwards .
The valves can be ground using commercially available valve grinding paste .
1. Apply a small a fit of valve grinding paste to the valve seat.
2. Oil the valve stem of a new valve and insert it into the valve guide from the combustion
chamber. Push the valve in until it is seated securely in the valve seat of the cylinder head.
3. Grind down the valve with a commercially available valve grinder (with a rubber suction cup)
using rotating movements. To do this, grip the valve grinder between the palms of your hands
and press it against the valve seat in rotating movements → Grinding the valve seat .
Fig 1: Grinding Valve Seat
4. Carry out the grinding operation for each valve that is replaced. Check for leaks using some
fuel and installed spark plugs. The fuel must not escape through the valve seat. Carefully
remove valve grinding paste.
5. Fit valve lock → Locking valves

Fig 2: Identifying Valve Lock
6. Replace valve stem seals. For details, see → 156355 REPLACING VALVE STEM SEALS
7. Fit valve springs, concave washer and valve keys. To do this, place valve springs (there are
two in the exhaust valve in the turbo engine) on the bottom concave washer. Place top
concave washer in position.
Information
The mechanic must practise for use of the assembly cartridge to be effective. Some repetitions
must be made to ensure that the valve keys are correctly held in place.
8. Insert the valve keys into the assembly cartridge.
1. 8.1. Press the spring-tensioned washer of the assembly fixture down -1- and insert
the valve keys -2- with the narrow end down.
Fig 3: Pressing Valve Key In Assembly Fixture
2. 8.2. Ensure that the valve keys fit symmetrically and are inserted as far as they will
go in the tool. The spring-tensioned washer automatically locks the valve keys in
place.
3. 8.3. Position the assembly cartridge -2- so that it is centered on the assembly fixture.
Observe installation position of the valve keys -1- .
Fig 4: Identifying Assembly Cartridge
4. 8.4. Press the assembly cartridge against the spring force onto the assembly fixture.
The knurled screw moves forward. Turn the knurled screw back and forward until the
valve keys engage. Repeat this several times if necessary. → Assembly cartridge
grips the valve keys Fig 5
Fig 5: Assembling Cartridge Grips Valve Keys
5. 8.5. Check that the valve keys are held symmetrically in the assembly cartridge -1- .
Fig 6: Identifying Valve Keys
9. Place the valve key assembly cartridge onto the cylinder head (same as removal of valve) and
position it on the top spring plate.
10. Press the assembly cartridge down against the valve spring force using a lever (assembly fork)
and keep it pressed. The knurled screw moves forward. Turn the knurled screw back and
forward until the valve keys engage → Installing valve keysFig 7. Repeat this several times if
necessary.
Fig 7: Installing Valve Keys
11. When installing the valve keys, check that they are positioned correctly.

TURBO S) > SUBSEQUENT WORK
1. Install cylinder head. → 157019 REMOVING AND INSTALLING CYLINDER HEAD
2. Fit hydraulic tappets. Do not interchange components.
3. Install camshafts. → 150520 REMOVING AND INSTALLING CAMSHAFTS
WM 156355 REPLACING VALVE STEM SEALS (CAYENNE) > TOOLS

Lever tool VW Tool 2036
puller VW Tool 3364
Press-On Tool VW Tool 3365

Valve Lever VW Tool VW 541/1A
WM 156355 REPLACING VALVE STEM SEALS (CAYENNE) > PRELIMINARY WORK
1. Remove camshafts → 150520 REMOVING AND INSTALLING CAMSHAFTS
2. Take rocker arms out of the cylinder head and lay them on a clean surface, arranged according
to cylinders and valves. For details of parts, see → 155919 REMOVING AND INSTALLING
HYDRAULIC TAPPETS . Do not get components mixed up.
3. Remove spark plugs → WM 287020 REMOVING AND INSTALLING SPARK PLUGS

(CAYENNE) .
WM 156355 REPLACING VALVE STEM SEALS (CAYENNE) > INFORMATION >

COMPONENT OVERVIEW
1. Intake Camshaft
3. Outlet Camshaft

5. Sealing Rings (40 x 1.5)
11. Cylinder Head Height (min. Height a=139.9 mm)
13. Bearing Shaft
14. Valves
15. Dowel Sleeve
16. Cylinder Head
17. Pump Tappet
18. Support Element
19. Valve Stem Seal
20. Timing Chain
21. Safety Clip
22. Rocker Arm
23. Valve Spring
25. Valve Collets
WM 156355 REPLACING VALVE STEM SEALS (CAYENNE) > REPLACING VALVE

STEM SEALS
Information
Information
Position the pistons of the relevant cylinder at the bottom dead center .
Each piston is pressed downwards as pressure builds up in the cylinder .
1. Set piston for the corresponding cylinder to bottom dead center.

2. Lever Tool 2036 -1, 2 and 4- must be attached to the cylinder head and then adjusted. The
installation position of the tool must be adjusted for each valve.
Fig 1: Positioning Tool
3. Adapter T40012 -3- must be screwed into the relevant spark plug thread and while constantly
supplying compressed air (min. 6 bar overpressure). This builds up pressure in the cylinder so
that the valve does not fall into the cylinder while you are working.
4. Valve lever VW 541/1A -5- must be attached under the pipe of the lever tool 2036 . Then
press the concave washer on the valve down using the pressure piece. Keep pressing the
washer down.
5. Remove the two valve keys from the valve using pointed-nose pliers or a fine magnet.
6. Relax the concave washer and valve spring and remove loose components.
7. Remove the valve stem seals from the valve using a puller 3364 .
8. Push a plastic sleeve -A- on to the valve (protects the valve stem seal from the key grooves).
Oil a new valve stem seal -B- and insert it into the Press-On Tool 3365 -1- .
Fig 2: Identifying Plastic Sleeve, Valve Stem Seal And Tool
9. Fit the valve stem seal using the Press-On Tool 3365 -1- .
Fig 3: Installing Valve Stem Seal
10. Fit the valve springs, concave washers and valve keys using the Valve Lever VW 541/1A and
Lever Tool 2036 .
11. Remove the air connection and fit it to the next spark plug thread.
12. Replace the next valve stem seal using the procedure described above.
Information
1. Before switching to another cylinder, the cylinder must be positioned at the bottom dead
center and supplied with compressed air (see 1 ) .
WM 156355 REPLACING VALVE STEM SEALS (CAYENNE) > SUBSEQUENT WORK >
SUBSEQUENT WORK FOR REPLACING VALVE STEM SEALS
1. After all the valve stem seals have been replaced, fit rocker arms correctly.
2. Fit camshafts. → 150520 REMOVING AND INSTALLING CAMSHAFTS
WM 156355 REPLACING VALVE-STEM SEALS (CAYENNE GTS, CAYENNE S,

CAYENNE TURBO & CAYENNE TURBO S) > TOOLS
Puller VW Tool 3364
Assembly Driver Special Tool 9606/1
Valve Key
Commercially
Assembly/Disassembly Nr. 54-1
Available Tool
Tool For The Cayenne
Tool For
Commercially Nr. 54
Fitting/Removing Valve
Keys
Commercially Nr. 54
31mm Fastening Screw
Available Tool Pos. 1A
Commercially Nr. 54
28mm Fastening Screw
Available Tool Pos. 1B

CAYENNE TURBO & CAYENNE TURBO S) > PRELIMINARY WORK
Information
The valve-stem seals can be replaced when installed .
Depending on the tool setup, peripheral components at the sides, such as plenum panels or servo
oil reservoirs, may first have to be removed
The tool can be adjusted to all M6 or M8 studs or internal threads (tool details below) .
The angle of the assembly bar lever can be adjusted according to space requirements .

2. Take hydraulic tappets out of the cylinder head and lay them on a clean surface, arranged
according to cylinders and valves. Do not interchange components.

CAYENNE TURBO & CAYENNE TURBO S) > INFORMATION > COMPONENT
OVERVIEW
In the Turbo, the exhaust valve is fitted with internal and external valve springs (set of valve
springs) and adapted concave washers. The exhaust valve in the turbo engine has the same
outer dimensions as the exhaust valve of the naturally aspirated engine. However, because of the
sodium filling, the exhaust valve in the turbo engine is lighter and the shank over the shank
entries is longer. For further details, please see Figures Fig 1 and TABLE entitled "Valve
dimensions" .
Fig 1: Identifying Valve Components
1. Intake Valve (Identical In The Naturally Aspirated And Turbo Engines)
2. Valve-Seat Ring Intake
3. Valve Guide
4. Lower Valve-Spring Plate Intake
5. Valve Stem Seal
6. Set Of Valve Springs, Intake (Identical In The Naturally Aspirated And Turbo Engines)
7. Upper Valve-Spring Plate Intake
8. Valve Collet
9. Upper Valve-Spring Plate Outlet (Different In The Naturally Aspirated And Turbo Engines)
10. Set Of Valve Springs (Turbo Outlet); Valve Spring (Naturally Aspirated Engine Outlet)
11. Lower Valve-Spring Plate Outlet (Different In The Naturally Aspirated And Turbo Engines)
12. Valve-Seat Ring Outlet
13. Exhaust Valve (Different In The Naturally Aspirated And Turbo Engines)
Distinguishing Feature Of Exhaust Valve On Naturally Aspirated And Turbo Engine
1. Exhaust Valve - Naturally Aspirated Engine
2. Exhaust Valve - Turbo Engine
3. Difference In Shank Length Over Shank Entries

Fig 2: Identifying Difference Between Exhaust Valve On Naturally Aspirated And Turbo Engine

CAYENNE TURBO & CAYENNE TURBO S) > INFORMATION > SPECIAL TOOLS
Fig 1: Identifying Valve Special Tools
1. Puller 3364 → Only Used To Remove Valve-Stem Seals.
2. Assembly Driver 9606/1 → Only Used To Remove Valve-Stem Seals.
3. Universal Assembly Bar With Universal Assembly Driver Tool For Fitting/Removing Valve
Keys Nr. 54 Pos. 1
4. Hooking Piece (Fitting Hook) With Holder (Several Possible)
5. Plastic Guide For Inlet And Outlet Valve 31mm Fastening Screw Nr. 54 Pos. 1A and 28mm
Fastening Screw Nr. 54 Pos. 1B
6. Assembly Fixture For Valve Keys
7. Assembly Cartridge For Valve Keys
8. Assembly Bar (Hook) With Adjustable Lever

CAYENNE TURBO & CAYENNE TURBO S) > INFORMATION > VALVE DIMENSIONS
Intake Valve (Naturally Exhaust Valve -

Exhaust Valve - Turbo
Dimension Aspirated And Turbo Naturally Aspirated
Engine
Engines) Engine
Valve Disc Diameter 38.30 mm 33.00 mm 33.00 mm
Valve Stem Diameter 5.92 mm 5.92 mm 5.92 mm
Overall Length (From

Valve Disc To Valve 107.70 mm 108.20 mm 108.20 mm
Pressure Area)
Angle At Valve Seat Area 45° 45° 45°
46.7 Gr. (Lighter Than In

Weight 56.8 gr. 48.8 gr. Naturally Aspirated Engine
Because Of Sodium Filling)

CAYENNE TURBO & CAYENNE TURBO S) > REMOVING VALVE-STEM SEAL
Information
When required, all valve-stem seals on both cylinder rows must be replaced.
Information
1. Position the pistons of the relevant cylinder at the bottom dead center. To do this, guide the
timing chain carefully when turning the crankshaft.
2. Screw in compressed-air hose from the valve key assembly/disassembly tool for the
Cayenne Nr. 54-1 tool set (or similar) in the relevant spark plug bore so that it is tightly
sealed. Apply compressed air constantly to cylinder (at least 6 bar overpressure). This builds
up pressure in the cylinder so that the valve does not fall into the cylinder while you are
working . Replace all four valve-stem seals for a cylinder and refit valve keys. Only then fit
compressed-air hose on the next cylinder and apply compressed air constantly.
3. Fit and set the tool on the cylinder head
1. 3.1. Screw -1- a holder with the appropriate thread into its matching thread on the
cylinder head. The hooking piece -2- is pre-fitted in the holder.
Fig 1: Installing Hook
2. 3.2. Insert the appropriate plastic guide -1- in place of the tappet.
Fig 2: Inserting Plastic Guide
3. 3.3. Insert assembly cartridge -1- for the valve keys into the plastic guide.
Fig 3: Inserting Assembly Cartridge
4. 3.4. Hook the lever (assembly bar) -1- into the hook and place correctly onto the
assembly cartridge. Make sure that the tool and equipment can be effective directly.
Fig 4: Hooking Tool lever
4. Remove the valve keys
1. 4.1. Press the assembly cartridge with the lever (assembly bar) against the force of
the valve-spring and keep pressed → Press down the tool . The knurled screw of the
assembly cartridge pushes forward -1- .
Fig 5: Pressing Tool Lever

Fig 6: Pressing Tool Lever
Information
The mechanic must practise for use of the assembly cartridge to be effective. Some
repetitions must be made to ensure that the valve keys are correctly held in place.
2. 4.2. Turn the knurled screw back and forth -1- until the valve keys snap into place
and are held there -2- in the assembly cartridge. The knurled screw retracts.
Fig 7: Turning Knurled Screw
3. 4.3. Remove the assembly cartridge and check correct position of both valve keys
-1- .
Fig 8: Assembling Valve Keys Cartridge
4. 4.4. Pull out the knurled screw from the assembly cartridge -1- and knock out the
valve keys -2- .
Fig 9: Removing Valve Keys
5. Remove valve springs, spring plate and valve keys from the cylinder head.
6. Withdraw sliding sleeve of Puller 3364 . When positioning the Puller 3364 on the fitted
valve-stem seal, ensure that the metal edge of the valve-stem seal is positioned behind the
corresponding metal edge of the puller. -1- → Valve-stem seal in puller
Fig 10: Identifying Valve-Stem Seal And Puller

Fig 11: Identifying Valve-Stem Seal In Puller
7. When engaging the Puller 3364 , push sliding sleeve down and close tool. -arrow-
Fig 12: Engaging Puller
8. Remove valve-stem seal by activating the negative (slide) hammer. -arrow- . Repeat
procedure for valves on pressurised cylinder (reposition tool accordingly).
Fig 13: Removing Valve-Stem Seal
Information
Before switching to another cylinder, the cylinder must be positioned at the bottom dead center and
supplied with compressed air (see 1 ) .

CAYENNE TURBO & CAYENNE TURBO S) > INSTALLING VALVE-STEM SEALS
Information
Information
When required, all valve-stem seals on both cylinder rows must be replaced.
Information
Protective caps must be ordered as separate spare parts. They are reusable. They are used to protect
the valve-stem seal so that it is not damaged at the valve stem end.
1. Prepare valve-stem seal -1- , protective cap -3- and Assembly Driver 9606/1 -2- .
Fig 1: Identifying Valve-Stem Seal With Tool
2. Push protective cap onto valve stem end. → Protective cap

Fig 2: Identifying Valve-Stem Seals Protective Cap
3. Oil valve stem, protective cap and valve-stem seal. Push valve-stem seal with sealing lip
upwards -1- over the protective cap -2- onto the valve stem. Remove protective cap.
Fig 3: Locating Valve-Stem Seal Protective Cap And Valve-Stem Seal
4. Guide the Assembly Driver 9606/1 over the valve stem and fit the valve-stem seal by hand or
by tapping it lightly using the rubber hammer as far as it will go. -arrow-
Fig 4: Pushing Valve-Stem Seal
5. Fit valve springs, concave washer and valve keys. To do this, place valve springs (there are
two in the exhaust valve in the turbo engine) on the bottom concave washer. Place top
concave washer in position.
Information
The mechanic must practise for use of the assembly cartridge to be effective. Some repetitions
must be made to ensure that the valve keys are correctly held in place.
6. Insert valve keys into the assembly cartridge.
1. 6.1. Press the spring washer of the assembly fixture downwards -1- and insert the
valve key -2- with the narrow end pointing downwards.
Fig 5: Pressing Valve Key In Assembly Fixture
2. 6.2. Ensure that the valve keys fit symmetrically and are inserted as far as they will
go in the tool. The spring washer automatically locks the valve keys in place.
3. 6.3. Place the assembly cartridge -2- onto the center of the assembly fixture.
Observe installation position of the valve keys -1- .
Fig 6: Identifying Assembly Cartridge
4. 6.4. Press the assembly cartridge against the spring force onto the assembly fixture.
The knurled screw moves forward. When doing so, turn the knurled screw back and
forth until the valve keys snap into place. Repeat as required. → Assembly cartridge
accepts the valve keysFig 7
Fig 7: Assembling Valve Keys Cartridge
5. 6.5. Make sure the valve keys are held symmetrically in place in the assembly
cartridge -1- .
Fig 8: Identifying Valve Keys
7. Place the valve key assembly cartridge onto the cylinder head (same as removal of valve) and
position it on the top spring plate.
8. Press the assembly cartridge with the lever (assembly bar) against the force of the valve-
spring and keep pressed. The knurled screw moves forward. When doing so, turn the knurled
screw back and forth until the valve keys snap into place → Install valve keysFig 9. Repeat as
required.
Fig 9: Install Valve Keys
9. When installing the valve keys, check their correct positioning.
10. Replace all four valve-stem seals for a cylinder and refit valve keys. Only then fit
compressed-air hose on the next cylinder and apply compressed air constantly.
Information
Before switching to another cylinder, the cylinder must be positioned at the bottom dead center and
supplied with compressed air (see 1 ) .

CAYENNE TURBO & CAYENNE TURBO S) > SUBSEQUENT WORK
1. Fit hydraulic tappets. Do not interchange components.
WM 157019 REMOVING AND INSTALLING CYLINDER HEAD ON V6 DFI ENGINES


value 1 2
M9 x 1.25 x 141 (7 ea.,

15 Nm
Cylinder-Head Screws Center) and M9 x 1.25 x 111 Initial
(11 ft.
(Internal Serration) (13 ea., Outer), Always Tightening
lb.)
Replace
30 Nm
(22 ft.
lb.)
Cylinder-Head Screws
Torque angle 180°
(Internal Serration)
23 Nm
Timing-Case Cover To Tightening
M8 (17 ft.
Cylinder Head Torque
lb.)

M6 x 25
Hexagon-Head Bolts Tightening 8 Nm (6

M8 x 20
On Oil Pump Torque ft. lb.)
40 Nm
Tightening
Torque
lb.)
10 Nm
M8 x 11.5 (7.5 ft.
lb.)
Initial
Drive Wheel For Timing M10 x 40 (always Replace) (44 ft.
Tightening
Chain lb.)
Drive Wheel For Timing Torque Angle 90°
Chain
10 Nm
Tightening
Torque
lb.)
20 Nm
(15 ft.
Guide Rail Torque
lb.)
23 Nm
M8 x 45 (17 ft.
Guide Rail Torque
lb.)
Hexagon-Head Bolts 60 Nm
M12 X 1.5 X 85 (Always Initial
On Camshaft (44 ft.
Replace) Tightening
Controllers lb.)
Hexagon-Head Bolts
On Camshaft Torque Angle 90°
Controllers

1. Remove belt tensioner. → 137319 REMOVING AND INSTALLING BELT TENSIONER
Arrow - Cheese head bolts on belt tensioner
2. Release the engine wire harness around the cylinder head. → 975219 REMOVING AND
INSTALLING WIRE HARNESS FOR ENGINE
MODULES

DISTRIBUTOR
5. Remove cylinder head cover (valve cover). → 158219 REMOVING AND INSTALLING
6. Remove upper timing-case cover. → 153319 REMOVING AND INSTALLING TIMING-CASE
COVER
7. Position cylinder 1 to compression TDC. → 150502 CHECKING THE TIMING
8. Remove timing chain from the camshaft controllers and set it aside. To do this, remove both
camshaft controllers. → 158419 REMOVING AND INSTALLING CAMSHAFT CONTROLLER

(CAYENNE) > REMOVING CYLINDER HEAD
Risk of squashing
1. Remove screws used to secure the timing case to the cylinder head. -1-
Fig 1: Lower Timing-Case Cover Screws
Information
1. If more extensive work was carried out, e.g. if the cylinder head was replaced, the
exhaust manifolds, fuel injectors, fuel distributor pipe, combination valve, timing chain
housing and various small parts must also be modified .
2. Remove cylinder head. Loosen the screws one after the other in the Opposite Sequence to
the sequence shown, i.e. start at cylinder-head screw 20 and loosen cylinder-head screw 1
last.
20-1 - Loosening sequence for cylinder-head screws
Fig 2: Identifying Cylinder Head Tightening Sequence

(CAYENNE) > INSTALLING CYLINDER HEAD
Information
1. Install cylinder head.
Information
1. It is best to use only a spatula and acetone to clean the sealing faces. Ensure good
ventilation because of the acetone!
2. Use a cleaning cloth to wipe the sealing faces clean and remove any grease .
3. Replace the cylinder-head gasket .
4. Replace the cylinder-head screws with new ones .
2. 1.2. Cylinder head gasket Must Always Be Replaced .

3. 1.3. Always observe tightening sequence (1-20) for cylinder-head screws -1 to 20-
and tighten to the specified torque.

(11 ft. lb.).
3. 1.3.3. Then tighten all cylinder-head screws a Second Time to 30 Nm (22

ft. lb.).

180°.
Fig 1: Identifying Cylinder Head Tightening Sequence
1-20 - Tightening sequence for cylinder-head screws → Initial tightening: 15 Nm

(11 ft. lb.) → Tightening Torque: 30 Nm (22 ft. lb.) → Torque angle: 180°
2. Secure the timing case to the cylinder head. -1- Fit both M8 screws → Tightening Torque: 23
Nm (17 ft. lb.) .
Fig 2: Identifying Lower Timing-Case Cover Screws

1. Fit both camshaft controllers. → 158419 REMOVING AND INSTALLING CAMSHAFT

CONTROLLER ON V6 DFI ENGINES
2. Fit the timing chain on the camshaft controllers. → 153519 REMOVING AND INSTALLING
TIMING CHAIN (AUXILIARY DRIVE MECHANISM)

TENSIONER
2. Oval-Head Screw On Timing Chain Housing → Tightening Torque: 8 Nm

(6 ft. lb.)
3. Timing Chain
5. Sealing Ring
6. Oil Pump
8. Tensioning Rail
9. Chain Tensioner On Timing Chain → Tightening Torque: 40 Nm (30 ft.

lb.)
10. Sealing Ring (A22 x 27), Always Replace
12. Sprocket
14. Hexagon-Head Bolt → Initial Tightening: 60 Nm (44 ft. lb.) → Torque

Angle: 90°
17. Drive Chain
21. Hexagon-Head Bolt On Guide Rail → Tightening Torque: 23 Nm (17 ft.

lb.)
22. Hexagon-Head Bolts On Camshaft Controllers → Initial Tightening: 60

Nm (44 ft. lb.) → Torque Angle: 90°
28. Guide Rail
1. Risk of damage to the timing system
→ Never turn the crankshaft against the rolling direction or when the chain tensioner
is removed.

4. Fit Upper timing-case cover. → 153319 REMOVING AND INSTALLING TIMING-CASE

6. Install belt tensioner. → 137319 REMOVING AND INSTALLING BELT TENSIONER ON DFI
ENGINES
7. Fit and tension the drive belt.
→ 137819 REMOVING AND INSTALLING DRIVE BELT
Fig 2: Identifying Drive Belt Routing Diagram
1. Crankshaft vibration balancer
2. Coolant pump
3. Drive belt tensioning roller
5. Power-steering pump/tandem pump
6. Generator

"Installing"
9. Install bar ignition modules. → INSTALLING BAR IGNITION MODULES
10. Install engine wire harness. → WM 975219 REMOVING AND INSTALLING WIRE HARNESS
FOR ENGINE
WM 157019 REMOVING AND INSTALLING CYLINDER HEAD (CAYENNE TURBO &


Information
If more extensive work is planned, e.g. if the entire cylinder head is to be replaced, the exhaust
manifolds, fuel injectors, high-pressure pump or vacuum pump must also be removed .
2. Remove engine from transmission → 100127 REMOVING ENGINE FROM TRANSMISSION

AND MOUNTING ENGINE ON TRANSMISSION and fit on the assembly support → 1001IN
SECURING ENGINE ON ASSEMBLY SUPPORT .
3. Loosen the turbocharger on turbo engines. → 213019 REMOVING AND INSTALLING

TURBOCHARGER

DISTRIBUTOR
5. Remove the fuel distribution pipe. → 243019 REMOVING AND INSTALLING FUEL
DISTRIBUTION PIPE
6. Remove the timing-case cover. → 153319 REMOVING AND INSTALLING TIMING-CASE

COVER
7. Remove timing chain. → 153519 REMOVING AND INSTALLING TIMING CHAINS
8. Remove deflector rail. → 154719 REMOVING AND INSTALLING GUIDE AND TENSIONING
RAILS

CAYENNE TURBO S) > REMOVING CYLINDER HEAD
1. Remove vent line.

2. 1.2. Unclip vent line -2- from the cable duct and remove it -arrow- .
Fig 1: Locating Vent Line
2. Expose the engine wire harness close to the vacuum pump. → Engine wire harness close to
vacuum pump → Engine wire harness at the rear right
Fig 2: Locating Engine Wire Harness Close To Vacuum Pump

Fig 3: Locating Engine Wire Harness (Rear Right)
3. Unclip the engine wire harness close to the high-pressure pump.
1. 3.1. Unclip the engine wire harness at the retaining clips -arrows A- .
2. 3.2. Unscrew the screw socket -arrow B- .

Fig 4: Locating Engine Wire Harness Close To High-Pressure Pump
4. Lift the wire harness up and out at the cylinder heads -arrow-
Fig 5: Locating Engine Wire Harness
5. Remove mounting saddle at the front -8- (cylinder bank 1 to 4 shown). This hides the cylinder
head screws underneath.
1. Camshaft (Outlet)
2. Camshaft (Intake)
3. Hydraulic Valve For Variable Valve Lift Control
4. Screw, M5 x 12
5. Switching Tappet (Oil With Engine Oil)
6. Bucket Tappet (Oil With Engine Oil)
7. Stopper
8. Mounting Saddle 1 To 4
9. Stopper
10. Bearing Locations (Oil With Engine Oil)
6. Remove front M8 screw securing the cylinder head of cylinders 1 to 4 to the crankcase. -3-
Fig 7: Identifying Cylinder Head (1-4)
7. Remove cylinder head screws in the opposite order to the tightening sequence shown →
Tightening sequence for cylinder head . Remove cylinder head. If necessary, remove the
valve lifters now and lay them aside in the correct order.
Fig 8: Cylinder Head Bolt Tightening Sequence
8. Remove cylinder head gasket.

9. Remove cylinder head for cylinders 5 to 8 in the same way. → Cylinder head 5 to 8

CAYENNE TURBO S) > INSTALLING CYLINDER HEAD
Information
Information
All sealing surfaces must be clean and free of grease!
It is essential to work carefully!
Tightening sequences and Tightening Torques must be observed!
Information
1. Replace cylinder head gasket.
2. Place cylinder head gasket correctly, i.e. according to specifications, onto the straight pins on
the engine crank housing. This must be done in such a way that the marking 'Top' is legible
-see Fig 1-.
Fig 1: Identifying Cylinder Bank (1-4)

Fig 2: Identifying Cylinder Bank (5-8)
3. Fit cylinder head. Insert cylinder head screws (screws can be re-used). For tightening
specifications, see → 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES,
ASSEMBLY OVERVIEWS
1. Cylinder Head 1 To 4
2. Cylinder Head Gasket 1 To 4
3. M8 Screw
4. Lid
5. Stopper
6. Stopper
7. Restrictor For Valve Lift Adjustment
8. Cylinder Head Screws
9. Spark Plug
1. Cylinder Head 5 To 8
2. Screw Plug
3. Spark Plug
4. Cylinder Head Gasket 5 To 8
5. Stopper
6. Restrictor For Valve Lift Adjustment
7. Stopper
8. Lid
9. Cylinder Head Screws → For Tightening Specifications, See Tightening Sequence

For Cylinder Head, See Figure
4. Fit front M8 screw to secure the cylinder head of cylinders 1 to 4 to the crankcase. -3-
5. Fit the mounting saddle at the front -8- (cylinder bank 1 to 4 shown).
Fig 6: Identifying Camshafts, (Cylinder Bank 1-4)
1. Camshaft (Outlet)
2. Camshaft (Intake)

4. Screw, M5 x 12
5. Switching Tappet (Oil With Engine Oil)
6. Bucket Tappet (Oil With Engine Oil)
7. Stopper
8. Mounting Saddle 1 To 4
9. Stopper
10. Bearing Locations (Oil With Engine Oil)
6. Secure wire harness to the engine.
1. 6.1. Position and lay engine wire harness on the engine housing -arrow- .
2. 6.2. Tighten fastening screws.

Fig 7: Securing Engine Wire Harness On Engine Housing
7. Clip in engine wire harness at the rear right using the retaining clip -arrow- .
Fig 8: Locating Engine Wire Harness
8. Clip in engine wire harness close to the vacuum pump.
1. 8.1. Clip in engine wire harness using the retaining clip -arrow A- .
2. 8.2. Slide engine wire harness onto the holder -arrow B- .

Fig 9: Locating Engine Wire Harness Close To Vacuum Pump
9. Clip in engine wire harness close to the high-pressure pump.
1. 9.1. Screw in and tighten the screw socket -arrow A- .
2. 9.2. Clip in engine wire harness using the retaining clips -arrows B- .
Fig 10: Installing Engine Wire Harness
10. Install vent line.
1. 10.1. Position vent line -1- and clip it into the cable duct -arrow- .

Fig 11: Locating Vent Line

1. Fit deflector rail. → 154719 REMOVING AND INSTALLING GUIDE AND TENSIONING RAILS
3. Fit timing chain. → 153519 REMOVING AND INSTALLING TIMING CHAINS
4. Fit timing-case cover. → 153319 REMOVING AND INSTALLING TIMING-CASE COVER

6. Fit the fuel distributor pipe. → 243019 REMOVING AND INSTALLING FUEL DISTRIBUTOR
PIPE
7. Fit intake-air distributor. → 244619 REMOVING AND INSTALLING INTAKE-AIR

DISTRIBUTOR
8. Fit the turbocharger on V8 turbo engines. → 213019 REMOVING AND INSTALLING

TURBOCHARGER
9. Take the engine from the assembly support and connect it to the transmission. → 100127
TRANSMISSION .
10. Install the engine. → 100119 REMOVING AND INSTALLING ENGINE
WM 157501 CHECKING VALVE STEM GUIDE (VALVE TILT CLEARANCE) (CAYENNE)

> TOOLS
Universal Dial Gauge VW

VW 387
Bracket Tool

> PRELIMINARY WORK > PRELIMINARY WORK FOR CHECKING VALVE STEM
GUIDE (VALVE TILT CLEARANCE)
Remove valves → 156120 REMOVING AND INSTALLING VALVES .

> INFORMATION > COMPONENT OVERVIEW
1. Intake Camshaft
3. Outlet Camshaft

11. Cylinder Head Height (min. Height a=139.9 mm)
13. Bearing Shaft
14. Valves
15. Dowel Sleeve
16. Cylinder Head
17. Pump Tappet
18. Support Element
19. Valve Stem Seal
20. Timing Chain
21. Safety Clip
22. Rocker Arm
23. Valve Spring
25. Valve Collets

> CHECKING VALVE STEM GUIDE (VALVE TILT CLEARANCE)
1. Turn cylinder head around so that the compression chamber is visible.
NOTE: Dirt and contamination
1. Risk of damage to units or components
→ Protect components from dirt and contamination.
→ Clean or replace dirty components.
Information
2. Universal Dial Gauge Bracket VW 387 -1- must be secured to the cylinder head. Secure a
suitable dial gauge with a measuring tip in the Universal Dial Gauge Bracket VW 387 .
Fig 1: Checking Valve Stem Guide
Information
1. A new valve must be used for the test .
2. Intake valves and exhaust valves have different shank diameters. The fitting new valve
must be used for checking the respective valve guide .
3. Insert new valve into valve guide from the combustion chamber. Push it in until the valve stem
end is flush with the valve guide.
4. Engage measuring tip tightly on the side of the valve disc and tilt valve to and fro at the valve
guide -see arrow- .
5. If the tilt clearance is greater than 0.8 mm, the cylinder head must be replaced.

> SUBSEQUENT WORK > SUBSEQUENT WORK FOR CHECKING VALVE STEM
GUIDE (VALVE TILT CLEARANCE)
Install valves → 156120 REMOVING AND INSTALLING VALVES .
WM 157019 REMOVING AND INSTALLING CYLINDER HEADS (CAYENNE S HYBRID,

CAYENNE TIP (3.0) & CAYENNE TIP (3.0) "PLATINUM EDITION") > TOOLS

Camshaft Clamp VW Tool T40133

CAYENNE TIP (3.0) & CAYENNE TIP (3.0) "PLATINUM EDITION") > TECHNICAL
VALUES

value 1 2
Fastening Screw On Hall Tightening 9 Nm (6.5

Sender Torque ft. lb.)
Fastening Screw For Initial 40 Nm (30

Replace
Cylinder Head Tightening ft. lb.)

+90°
Fastening Screw On Final
+90°
Cylinder Head Tightening
Fastening Screw On Tightening 9 Nm (6.5

Cylinder Head Cover Torque ft. lb.)

Connector Strip Torque ft. lb.)
Fastening Screw For Tightening 5 Nm (3.5

Replace
Camshaft Control Torque ft. lb.)
Fastening Screws Securing Replace Aluminum

Chain Box To Cylinder Screws With Steel
Torque ft. lb.)
Head Screws

Cylinder Head Torque ft. lb.)


CAYENNE TIP (3.0) & CAYENNE TIP (3.0) "PLATINUM EDITION") > PRELIMINARY
WORK
1. Remove poly-V-belt. → 137819 REMOVING AND INSTALLING DRIVE BELT
2. Remove upper and front coolant pipe. → 196120 REMOVING AND INSTALLING COOLANT
PIPES
3. Remove catalytic converters. → 267319 REMOVING AND INSTALLING (MAIN) CATALYTIC

CONVERTER

CAYENNE TIP (3.0) & CAYENNE TIP (3.0) "PLATINUM EDITION") > REMOVING
CYLINDER HEADS > ASSEMBLY OVERVIEW - CYLINDER HEAD
Fig 1: Overview Of Cylinder Head Assembly
1. Cylinder-head gasket Replace
2. Cylinder Head
3. Screw
4. Vacuum Pump
5. O-ring Replace
6. Hall Sender
8. Screw Replace → Initial Tightening: 40 Nm (30 ft. lb.) → Tightening Torque: +90° → Final
Tightening: +90°
9. Ignition Coil
10. Cylinder Head Cover
11. Seal Replace If Damaged Or Leaking
12. Cover
13. Screw Replace If Seal Is Damaged → Tightening Torque: 9 Nm (6.5 ft. lb.)
15. Connector Strip For Ignition Coils
16. Cylinder head cover seal Replace If Seal Is Damaged
17. Solenoid Valve For Camshaft Control On Intake Side
18. Screw Replace → Tightening Torque: 5 Nm (3.5 ft. lb.)
19. O-Ring Replace

CYLINDER HEADS > THREADED JOINT SECURING CHAIN BOX TO CYLINDER HEAD
arrows - Screws, steel → Tightening Torque: 9 Nm (6.5 ft. lb.)

Fig 1: Locating Lower Timing Chain Cover

CYLINDER HEADS > CYLINDER HEAD COVER, LEFT - TIGHTENING TORQUE AND
TIGHTENING SEQUENCE
Tighten screws in the sequence -1... 12- to → Tightening Torque: 9 Nm (6.5 ft. lb.) until secure.

CYLINDER HEADS > CYLINDER HEAD COVER, RIGHT - TIGHTENING TORQUE AND
TIGHTENING SEQUENCE
Tighten screws in the sequence -1... 12- to → Tightening Torque: 9 Nm (6.5 ft. lb.) until secure

CYLINDER HEADS > CYLINDER HEAD TIGHTENING TORQUE AND TIGHTENING
SEQUENCE
2. Tighten to 40 Nm (30 ft. lb.) until secure
3. Turn 90° further


CYLINDER HEADS > REMOVING CYLINDER HEADS
Information
The following describes how both cylinder heads can be removed at the same time .
It is also possible to remove only one cylinder head. To do this, refer to the relevant work
instructions in the following description .
Information
Disregard item 4.
1. Disconnect electric plug connections at the left and right -1, 2, 3 - on the fuel injectors.
Fig 1: Identifying Fuel Injectors Plug Connections
2. Disconnect connections on the left cylinder head:
1. -1- . Hall sender 2
2. -2- . Positive crankcase ventilation hose
3. -3- . Camshaft control valve 2
-arrows- Fastening screws for wire harness

Fig 2: Locating Connections On Left Cylinder Head
3. Pull off connector -1- on air-conditioning compressor and unscrew screw -2- for ground cable.
Pull off all other connectors and set electric wire harness aside.
Fig 3: Identifying Air-Conditioning Compressor Connector
4. Disconnect connections on the right cylinder head:
Unscrew screw -1- for the ground strap.
Disconnect electric plug connection -2- .

Fig 4: Identifying Right Ground Strap Screw
1. -1- Camshaft control valve 1
2. -2- Hall sender
Move electric wire harness aside.

Fig 5: Locating Electric Plug Connections
6. Unscrew screw -arrow- and pull out guide tube for oil dipstick.
Fig 6: Locating Oil Dipstick Guide Tube
7. Remove vacuum hose from the vacuum pump by loosening the hose clamp -1- .
Remove vane type pump for power steering from the cylinder head. → 477619 REMOVING
AND INSTALLING VACUUM PUMP (HYBRID)
Fig 7: Locating Vacuum Pump
8. Remove camshaft controller and camshaft sprocket. → 158419 REMOVING AND

INSTALLING CAMSHAFT CONTROLLER
9. Locking Pin T40071 can now be removed from the left cylinder head.
Fig 8: Identifying Locking Pin
Information
The locking pin T40071 remains inserted.
10. Unscrew screws -1- and -2- and remove the right chain tensioner.
Fig 9: Removing Right Chain Tensioner
11. Unscrew screws -arrows- at the back of the cylinder head.
Left cylinder head: 3 screws
Right cylinder head: 4 screws

Fig 10: Locating Cylinder Head Screws
12. Loosen cylinder head screws in the sequence -1... 8- .
Unscrew screws, remove cylinder head and place it on a soft surface (plastic foam).
Fig 11: Identifying Cylinder Head Screws Loosening Sequence

CYLINDER HEADS > REMOVING CYLINDER HEADS
Information
The following describes how both cylinder heads can be removed at the same time .
It is also possible to remove only one cylinder head. To do this, refer to the relevant work
instructions in the following description .
Information
Disregard item 4.
Information
Information
Disregard item 4.
1. Disconnect electric plug connections at the left and right -1, 2, 3 - on the fuel injectors.
Fig 1: Identifying Fuel Injectors Plug Connections
2. Disconnect connections on the left cylinder head:
1. -1- . Hall sender 2
2. -2- . Positive crankcase ventilation hose
3. -3- . Camshaft control valve 2

Fig 2: Locating Connections On Left Cylinder Head
3. Disconnect connections on the right cylinder head:
Unscrew screw -1- for the ground strap.
Disconnect electric plug connection -2- .

Fig 3: Identifying Right Ground Strap Screw
4. -1- Camshaft control valve 1
-2- Hall sender
Move electric wire harness aside.

Fig 4: Locating Fastening Screws For Wire Harness
5. Unscrew screw -arrow- and pull out guide tube for oil dipstick.
Fig 5: Locating Oil Dipstick Guide Tube
6. Remove vacuum hose from the vacuum pump by loosening the hose clamp -1- .
Remove vane type pump for power steering from the cylinder head. → 477619 REMOVING
AND INSTALLING VACUUM PUMP (HYBRID)
Fig 6: Locating Vacuum Pump Clamp
7. Remove camshaft controller and camshaft sprocket. → 158419 REMOVING AND

8. Locking Pin T40071 can now be removed from the left cylinder head.
Fig 7: Removing Locking Pin
Information
9. Unscrew screws -1- and -2- and remove the right chain tensioner.
Fig 8: Removing Right Chain Tensioner
10. Unscrew screws -arrows- at the back of the cylinder head.

Fig 9: Identifying Cylinder Head Screws
11. Loosen cylinder head screws in the sequence -1... 8- .
Unscrew screws, remove cylinder head and place it on a soft surface (plastic foam).
Fig 10: Cylinder Head Screws Loosening Sequence

CAYENNE TIP (3.0) & CAYENNE TIP (3.0) "PLATINUM EDITION") > INSTALLING
CYLINDER HEADS
Information
Information
If you are installing a replacement cylinder head, the contact surfaces between the hydraulic
compensation elements, rocker arms and running surfaces of cams must be oiled before installing
the cylinder head cover .
If you are replacing the cylinder head or cylinder head gasket, change the coolant and engine oil .
Replace screws that are tightened to an additional torque angle .
Replace self-locking nuts as well as sealing rings, seals and O-rings .
Note the different sealants for sealing surfaces and cylinder head screws .
Secure all hose connections with standard hose clamps .
1. Secure the camshaft for cylinder bank 1 in "TDC" position using Camshaft Clamp T40133 .
2. Secure the camshaft for cylinder bank 2 in "TDC" position using Camshaft Clamp T40133 .
3. Secure the crankshaft -1- in "TDC" position with Locking Pin T40069 .
4. Fit new seals for the front coolant pipe.
1. 4.1. Fit cylinder-head gasket.
2. 4.2. Installation position: "top" marking or part number must be visible.
3. 4.3. Check dowel sleeves -arrows- in the cylinder block.
4. 4.4. Fit cylinder head.

Fig 4: Locating Dowel Sleeves
5. Tighten cylinder head screws.

6. Tighten screws for lower timing chain cover.

CAYENNE TIP (3.0) & CAYENNE TIP (3.0) "PLATINUM EDITION") > SUBSEQUENT
WORK
1. Install camshaft controller. → 158419 REMOVING AND INSTALLING CAMSHAFT

CONTROLLER
2. Install upper and front coolant pipe. → 196120 REMOVING AND INSTALLING COOLANT
PIPES
3. Install catalytic converter. → 267319 REMOVING AND INSTALLING CATALYTIC

CONVERTER
4. Install poly-V-belt. → 137819 REMOVING AND INSTALLING DRIVE BELT

5. Change engine oil. → 170117 CHANGING ENGINE OIL AND OIL FILTER
6. Fill in coolant. → 193817 DRAINING AND FILLING COOLANT (INCLUDES BLEEDING)

> TOOLS
Universal Dial Gauge VW

VW 387
Bracket Tool

> PRELIMINARY WORK
1. Remove valves. → REMOVING VALVES - section on "Removing"

> CHECKING VALVE-STEM GUIDE (VALVE TILT CLEARANCE) > CHECKING VALVE
STEM GUIDE
1. Turn the cylinder head so that the compression chamber is visible.
Information
Given the different valve-stem dimensions, only use the intake valve in the intake guide and
the outlet valve in the outlet guide.
2. Insert the valve into the valve stem guide.
1. The end of the valve stem must be flush with the end of the valve guide.
NOTE: Dirt and contamination
1. Risk of damage to units or components
→ Protect components from dirt and contamination.
→ Clean or replace dirty components.
3. Secure the Universal Dial Gauge Bracket VW 387 (-1- ) on the cylinder head. Secure a
suitable dial gauge with a measuring tip in the universal dial gauge bracket.
4. To measure the valve tilt clearance:
5. Position the measuring tip securely on the side of the valve disc and tilt the valve back and
forth in the valve guide -arrow- .
1. Wear limit: 1.0 mm.
Information
1. If the wear limit is exceeded, repeat the measurement with new valves. If the wear limit is
still exceeded, replace the cylinder head. The valve guides cannot be replaced .
2. If the valve is replaced during repairs, use a new valve for the measurement .

> SUBSEQUENT WORK
1. Install valves. → INSTALLING VALVES - section on "Installing"
WM 158055 REPLACING SEAL FOR CYLINDER HEAD COVER (CAYENNE) >

PRELIMINARY WORK
"Removing"

"Removing"

REPLACING VALVE COVER SEAL
1. Remove valve cover (cylinder head cover) and replace valve cover seal. Then re-fit valve
cover.
For details, see → REMOVING CYLINDER HEAD COVER - section on "Removing"

SUBSEQUENT WORK
1. Install bar ignition modules. → INSTALLING BAR IGNITION MODULES - section on

"Installing"

"Installing"
WM 158055 REPLACING CYLINDER HEAD COVER GASKET (CAYENNE GTS,

CAYENNE S, CAYENNE TURBO & CAYENNE TURBO S) > INFORMATION
For instructions, see → 158219 REMOVING AND INSTALLING CYLINDER-HEAD COVER .
WM 158219 REMOVING AND INSTALLING CYLINDER HEAD COVER (VALVE COVER)

(CAYENNE S HYBRID, CAYENNE TIP (3.0) & CAYENNE TIP "PLATINUM EDITION") >
TECHNICAL VALUES

value 1 2
Fastening Screw On Hall Tightening 9 Nm (6.5

Sender Torque ft. lb.)
Fastening Screw For Initial 40 Nm (30

Replace
Cylinder Head Tightening ft. lb.)

+90°
Fastening Screw On Final

+90°
Cylinder Head Tightening

Cylinder Head Cover Torque ft. lb.)

Connector Strip Torque ft. lb.)
Replace
Camshaft Control Torque ft. lb.)
Fastening Screws Securing Replace Aluminum

Chain Box To Cylinder Screws With Steel
Torque ft. lb.)
Head Screws



PRELIMINARY WORK
1. Remove ignition coils. → 282020 REMOVING AND INSTALLING BAR IGNITION MODULES

REMOVING CYLINDER HEAD COVER
Information
The procedure for removing the left and right cylinder head cover is the same. Illustration shows only the
left side.
RoW vehicles:
1. Remove hose for positive crankcase ventilation -arrow- by pressing the release buttons.
Unscrew screws for the left cylinder head cover in the sequence -1... 12 - and remove cylinder
head cover.
Fig 1: Left Cylinder Head Cover Screws Loosening Sequence
USA vehicles:
Information
Danger of violation of exhaust emission legislation on USA vehicles.
1. Do not open hose connection!
2. Unscrew screws for the left cylinder head cover in the sequence -1... 12 - and set cylinder
head cover together with the connected positive crankcase ventilation hose -arrow- aside.

REMOVING CYLINDER HEAD COVER > REMOVING CYLINDER HEAD COVER
Information
The procedure for removing the left and right cylinder head cover is the same. Illustration shows only the
left side.
1. Remove hose for positive crankcase ventilation -arrow- by pressing the release buttons.
Unscrew screws for the left cylinder head cover in the sequence -1... 12- and remove cylinder
head cover.

INSTALLING CYLINDER HEAD COVER > ASSEMBLY OVERVIEW - CYLINDER HEAD
Fig 1: Overview Of Cylinder Head Assembly
1. Cylinder-Head Gasket Replace
2. Cylinder Head
3. Screw
4. Vacuum Pump
5. O-Ring Replace
6. Hall Sender
8. Screw Replace → Initial Tightening: 40 Nm (30 ft. lb.) → Tightening Torque: +90° → Final
Tightening: +90°
9. Ignition Coil
11. Seal Replace If Damaged Or Leaking
12. Cover
13. Screw Replace If Seal Is Damaged → Tightening Torque: 9 Nm (6.5 ft. lb.)
15. Connector Strip For Ignition Coils
16. Cylinder Head Cover Seal Replace If Seal Is Damaged
17. Solenoid Valve For Camshaft Control On Intake Side
18. Screw Replace → Tightening Torque: 5 Nm (3.5 ft. lb.)
19. O-Ring Replace

INSTALLING CYLINDER HEAD COVER > THREADED JOINT SECURING CHAIN BOX
TO CYLINDER HEAD
arrows - Screws, steel → Tightening Torque: 9 Nm (6.5 ft. lb.)

Fig 1: Locating Lower Timing Chain Cover Screws

INSTALLING CYLINDER HEAD COVER > CYLINDER HEAD COVER, LEFT -
TIGHTENING TORQUE AND TIGHTENING SEQUENCE
Tighten screws in the sequence -1... 12- to → Tightening Torque: 9 Nm (6.5 ft. lb.) until secure.

INSTALLING CYLINDER HEAD COVER > CYLINDER HEAD COVER, RIGHT -
TIGHTENING TORQUE AND TIGHTENING SEQUENCE
Tighten screws in the sequence -1... 12- to → Tightening Torque: 9 Nm (6.5 ft. lb.) until secure

INSTALLING CYLINDER HEAD COVER > CYLINDER HEAD TIGHTENING TORQUE
AND TIGHTENING SEQUENCE
2. Tighten to 40 Nm (30 ft. lb.) until secure


INSTALLING CYLINDER HEAD COVER > INSTALLING CYLINDER HEAD COVER
Information
1. 1.1. Replace damaged cylinder head cover seals.
2. 1.2. Replace screws for cylinder head cover with damaged seal.
3. 1.3. Clean sealing faces to remove any oil and grease.

SUBSEQUENT WORK
1. Install ignition coils. → 282020 REMOVING AND INSTALLING BAR IGNITION MODULES

Tolerance Tolerance
1 2
Fastening Screws And Tightening 10 Nm (7.5 ft.

M6
Nuts Torque lb.)


"Removing"

"Removing"

Fig 1: Overview Of Cylinder Head
1. Oil Cap

3. Fastening Screws
4. Cylinder Head Cover Gasket

(CAYENNE) > REMOVING CYLINDER HEAD COVER
1. Remove cylinder head cover.
1. 1.1. Unscrew oil cap.
2. 1.2. Unscrew all fastening screws -3- .
3. 1.3. Lift off cylinder head cover (valve cover) and set it down on a clean surface.
Fig 1: Identifying Cylinder Head Cover (V6 DFI Engine)

(CAYENNE) > INSTALLING CYLINDER HEAD COVER
1. Before fitting the cylinder head cover, apply sealant 000 043 207 54 (status 02/09) as shown
→ Applying sealant on upper timing-case cover .
Fig 1: Locating Upper Timing-Case Cover Sealant Application Area
2. Install cylinder head cover (valve cover)
Information
1. The seals on the ignition coil slots have a twist lock. These must be inserted into the
corresponding cut-out on the cylinder head cover .
1. 2.1. Replace cylinder head cover gasket and shank seals.
2. 2.2. Tighten fastening screws -3- hand-tight.
Information
1. The cylinder head cover must be tightened evenly in a clockwise direction!
2. The sealing rings of the M6 fastening screws with distance sleeve must be
checked for damage and replaced if necessary!
3. 2.3. Tighten fastening screws as shown → Tightening sequence for cylinder head
cover ;. → Tightening Torque: 10 Nm (7.5 ft. lb.)
Fig 2: Cylinder Head Cover Screws Tightening Sequence
4. 2.4. Screw on oil cap.

Fig 3: Identifying Cylinder Head Cover (V6 DFI Engine)

1. Install bar ignition modules. → INSTALLING BAR IGNITION MODULES - section on

"Installing"

"Installing"
WM 158219 REMOVING AND INSTALLING CYLINDER HEAD COVER (CAYENNE GTS

& CAYENNE S) > TOOLS

Support Special Tool 9866
Open-Jawed Commercially Nr. 95

Wrench Insert Available Tool Pos. 2
Commercially Nr. 98-1

Adapter

& CAYENNE S) > TECHNICAL VALUES

value 1 2
Fastening Screw For Positive Replace Aluminum Initial 4 Nm (3

Crankcase Ventilation Line Screw Tightening ft. lb.)
Fastening Screw For Positive Final

+90°
Crankcase Ventilation Line Tightening
Fastening Screw Securing 10 Nm

Tightening
Positive Crankcase Ventilation M6 x 30 (7.5 ft.
Torque
Valve To Cylinder Head Cover lb.)
10 Nm
Fastening Screw For Tightening
(7.5 ft.
High-Pressure Line Torque
lb.)
Coat Ball/Conical
Union Nuts On High-Pressure Initial 20 Nm
Joint With Microgleit
Lines Tightening (15 ft. lb.)
977S.
10 Nm
(7.5 ft.
High-Pressure Line Torque
lb.)
+35 Nm
Union Nuts For High-Pressure Final
(+26 ft.
Lines Tightening
lb.)
Fastening Screw Securing Valve Aluminum Screw, Initial 4 Nm (3

Cover To Cylinder Head M6 x 30/Replace Tightening ft. lb.)
Fastening Screw Securing Valve Steel Screw, M8 x Tightening 23 Nm

Cover To Cylinder Head 35 Torque (17 ft. lb.)
10 Nm
Fastening Screw Securing Valve Aluminum Screw, Initial
(7.5 ft.
Cover To Cylinder Head M8 x 35/Replace Tightening
lb.)
Fastening Screw Securing Valve Final

+90°
Cover To Cylinder Head tightening
Fastening screw securing valve Aluminum screw, M6 Initial 4 Nm (3

cover to cylinder head x 30/replace tightening ft. lb.)
Fastening screw securing valve Final

+90°
cover to cylinder head tightening
Fastening screw securing valve Torque

-180°
cover to cylinder head angle

Fastening screw securing valve Final

+90°
cover to cylinder head tightening

Fastening Screw Securing Valve Tightening 23 Nm

Steel screw, M8 x 44
Cover To Cylinder Head Torque (17 ft. lb.)
10 Nm
Fastening Screw Securing Valve Aluminum Screw, Initial
(7.5 ft.
Cover To Cylinder Head M8 x 35/Replace Tightening
lb.)

+90°
Cover To Cylinder Head Tightening

+90°
Fastening Screw Securing Valve Torque

-180°
Cover To Cylinder Head Angle


+90°

& CAYENNE S) > PRELIMINARY WORK > PRELIMINARY WORK FOR CYLINDERS 1 -
3
1. Remove torque support. → 103719 REMOVING AND INSTALLING TORQUE SUPPORT
2. Remove positive crankcase ventilation valve. → 105119 POSITIVE CRANKCASE

VENTILATION VALVE
3. Remove high-pressure pump. → 246319 REMOVING AND INSTALLING HIGH-PRESSURE

PUMP
4. Remove ignition coils. → 282020 REMOVING AND INSTALLING IGNITION COILS
5. Remove solenoid/hydraulic valve for camshaft controller. → 153719 REMOVING AND

INSTALLING SOLENOID/HYDRAULIC VALVE FOR CAMSHAFT CONTROLLER

& CAYENNE S) > PRELIMINARY WORK > PRELIMINARY WORK FOR CYLINDERS 4 -
6
2. Remove positive crankcase ventilation valve. → 105119 POSITIVE CRANKCASE

VENTILATION VALVE
3. Remove high-pressure pump. → 246319 REMOVING AND INSTALLING HIGH-PRESSURE

PUMP
4. Remove ignition coils. → 282020 REMOVING AND INSTALLING IGNITION COILS
5. Remove solenoid/hydraulic valve for camshaft controller. → 153719 REMOVING AND


& CAYENNE S) > TECHNICAL VALUES > POSITIVE CRANKCASE VENTILATION
Fig 1: Positive Crankcase Ventilation Valve And O-Ring
1. Positive Crankcase Ventilation Valve
2. O-Rings
3. Positive Crankcase Ventilation Line
4. Aluminum Screw, M6 x 16/Replace → Initial Tightening: 4 Nm (3 ft. lb.) → Final

Tightening: +90°
5. Holder
6. Screw, M6 x 30 → Tightening Torque: 10 Nm (7.5 ft. lb.)

& CAYENNE S) > TECHNICAL VALUES > VALVE COVER
Fig 1: Identifying Valve Cover (Cylinders 1-3)
1. Engine Cover Mounting
2. Valve Cover
3. O-Rings
Top - O-ring, 22.5 x 2.5 FPM
Bottom - O-ring, 22.5 x 2.5 HNBR
4. Oil Cap
5. Centering Pin
6. Oil Mist Separator
7. Cylinder-Head Cover Gasket, Inner
8. Cylinder-Head Cover Gasket

& CAYENNE S) > TECHNICAL VALUES > HIGH-PRESSURE PUMP WITH
HIGH-PRESSURE LINES
Fig 1: Identifying High-Pressure Pump And Lines
1. Coat High-Pressure Line For Cylinders 1-3 Ball/Conical Joint With Microgleit 977S Grease
2. Screw, M6 x 16 → Tightening Torque: 10 Nm (7.5 ft. lb.)
3. Clamp
4. Coat high-pressure connecting line Ball/Conical Joint With Microgleit 977S Grease
5. Coat high-pressure line for cylinders 4-6 Ball/Conical Joint With Microgleit 977S Grease
Tightening Specifications For Fuel Lines To High-Pressure Pump And Fuel Gallery:
1. Fit Union Nuts Hand-Tight.
2. Screw In And Align Holder/Clamp.
3. Tighten Union Nuts To → Initial Tightening: 20 Nm (15 ft. lb.)
4. Tighten Holder/Clamp To → Tightening Torque: 10 Nm (7.5 ft. lb.)
5. Tighten Union Nuts To → Final Tightening: +35 Nm (+26 ft. lb.) .

& CAYENNE S) > TECHNICAL VALUES > TIGHTENING SPECIFICATIONS FOR
DIE-CAST VALVE COVERS
Fig 1: Valve Cover Tightening Sequence (Cylinders 1-3)
1-14 - Always observe the specified tightening sequence!
1+2 - Aluminum screw, M6 x 30 → Initial tightening: 4 Nm (3 ft. lb.)
13+14 - Screw, M8 x 35 → Tightening Torque: 23 Nm (17 ft. lb.)
9-12 - Aluminum screw, M8 x 35 → Initial tightening: 10 Nm (7.5 ft. lb.) → Final tightening: +90°
3-8 - Aluminum screw, M6 x 30 → Initial tightening: 4 Nm (3 ft. lb.) → Final tightening: +90°
1+2 - Loosen → Torque angle: -180°
1+2 - Aluminum screw, M6 x 30 → Initial tightening: 4 Nm (3 ft. lb.) → Final tightening: +90°
Fig 2: Valve Cover Tightening Sequence (Cylinders 4-6)
1-14 - Always observe the specified tightening sequence!
1+2 - Aluminum screw, M6 x 30 → Initial tightening: 4 Nm (3 ft. lb.)
13+14 - Screw, M8 x 44 → Tightening Torque: 23 Nm (17 ft. lb.)
10-12 - Aluminum screw, M8 x 35 → Initial tightening: 10 Nm (7.5 ft. lb.) → Final tightening: +90°
3-9 - Aluminum screw, M6 x 30 → Initial tightening: 4 Nm (3 ft. lb.) → Final tightening: +90°
1+2 - Loosen → Torque angle: -180°
1+2 - Aluminum screw, M6 x 30 → Initial tightening: 4 Nm (3 ft. lb.) → Final tightening: +90°

& CAYENNE S) > REMOVING CYLINDER HEAD COVER > REMOVING CYLINDER
HEAD COVER FOR CYLINDERS 1 - 3
Information
Replace sealing rings, seals and O-rings.
Information
Attach all tie-wraps at the same places during installation.
Information
For better access in the engine compartment, use Support 9866 .

Fit support -1- instead of torque support .
The engine can be moved by turning the hexagon (a/f 17) to the left or right -arrows- .
Fig 1: Moving Engine Using Tool (9866)
1. Loosen fastening screws -1 and 2 - .

Information
1. Fuel lines must not be bent .
2. Bent fuel lines must be replaced .
2. Disconnect high-pressure line -1- and swivel it aside.

3. Unscrew fastening screws -1 to 14 - .
Replace Aluminum Screws .

Fig 4: Valve Cover Screws Tightening Sequence (Cylinders 1-3)
1. 4.1. Remove cam follower -6- from the cylinder head cover.
Fig 5: Identifying Cam Follower (High-Pressure Pump)

& CAYENNE S) > REMOVING CYLINDER HEAD COVER > REMOVING CYLINDER
Information
Information
For better access in the engine compartment, use Support 9866 .
Fig 1: Moving Engine With Special Tool (9866)
1. Unscrew fastening screws -1- and -2- .
2. Swivel wiring harness -3- aside.

Fig 2: Identifying High-Pressure Line
3. Loosen union nut securing high-pressure line -5- to fuel collection pipe.
Information
4. Swivel high-pressure line -5- aside.

5. Unscrew fastening screws -1 to 14 - .
Replace Aluminum Screws .

Fig 4: Valve Cover Screws Loosening Sequence (Cylinders 4-6)
1. 6.1. Remove cam follower -6- from the cylinder head cover.
Fig 5: Identifying Cam Follower For High-Pressure Pump

& CAYENNE S) > INSTALLING CYLINDER HEAD COVER > INSTALLING CYLINDER
Information
Information
Information
For better access in the engine compartment, use support 9866 .
1. Install cylinder head cover.
1. 1.1. Insert cam follower -6- for high-pressure pump into the cylinder head cover.
Information
1. Replace aluminum screws .
2. Always observe specified tightening sequence .
2. Tighten fastening screws -1 to 14 - on the cylinder head cover one after the other (depending
on version: see TECHNICAL VALUES ).

Information
3. Position high-pressure line -1- .
4. Tighten union nut for high-pressure line -1- using a suitable torque wrench, Adapter Nr. 98-1
Pos. 2 and Open-Jawed Wrench Insert Nr. 95 Pos. 2 . Initial Tightening 20 Nm (15 ft. lb.)
Final Tightening +35 Nm (+26 ft. lb.)
5. Tighten fastening screws -1 and 2 - .


& CAYENNE S) > INSTALLING CYLINDER HEAD COVER > INSTALLING CYLINDER
Information
Information
Information
1. Install cylinder head cover.
1. 1.1. Insert cam follower -6- for high-pressure pump into the cylinder head cover.
Information
1. Replace aluminum screws .
2. Always observe specified tightening sequence .
2. Tighten fastening screws -1 to 14 - on the cylinder head cover one after the other (depending
on version: see TECHNICAL VALUES ).

Information
3. Position high-pressure line -5- .
4. Tighten union nut securing high-pressure line -5- to fuel collection pipe. Initial Tightening 20
Nm (15 ft. lb.) Final Tightening +35 Nm (+26 ft. lb.)
5. Position B+ wiring harness -3- .

6. Tighten fastening screws -1- and -2- . Tightening Torque 10 Nm (7.5 ft. lb.)
Fig 5: Identifying High-Pressure Line

& CAYENNE S) > SUBSEQUENT WORK > SUBSEQUENT WORK FOR CYLINDERS 1 -
3
1. Install solenoid/hydraulic valve for camshaft controller. → 153719 REMOVING AND

2. Install ignition coils. → 282020 REMOVING AND INSTALLING IGNITION COILS
3. Install high-pressure pump. → 246319 REMOVING AND INSTALLING HIGH-PRESSURE

PUMP
4. Install positive crankcase ventilation valve. → 105119 POSITIVE CRANKCASE VENTILATION

VALVE
5. Fit engine in its original position using special tool 9866.
For better access to the fastening screws on the cylinder head cover .
6. Install torque support. → 103719 REMOVING AND INSTALLING TORQUE SUPPORT

& CAYENNE S) > SUBSEQUENT WORK > SUBSEQUENT WORK FOR CYLINDERS 4 -
6
1. Install solenoid/hydraulic valve for camshaft controller. → 153719 REMOVING AND

2. Install ignition coils. → 282020 REMOVING AND INSTALLING IGNITION COILS
3. Install high-pressure pump. → 246319 REMOVING AND INSTALLING HIGH-PRESSURE

PUMP
4. Install positive crankcase ventilation valve. → 105119 POSITIVE CRANKCASE VENTILATION

VALVE
5. Pull engine aside using special tool 9866. Support 9866
For better access to the fastening screws on the cylinder head cover .
WM 158419 REMOVING AND INSTALLING ACTUATOR FOR CAMSHAFT (CAYENNE

GTS & CAYENNE S) > TOOLS
Socket Wrench Special Tool 9863

For Camshaft
Ring Wrench Special Tool 9863/1

Insert

GTS & CAYENNE S) > TECHNICAL VALUES

GTS & CAYENNE S) > PRELIMINARY WORK
COVER

DFI ENGINES

GTS & CAYENNE S) > REMOVING ACTUATOR FOR CAMSHAFT
1. Loosen and unscrew central sensor.
1. 1.1. Loosen central screw -2- using Socket Wrench For Camshaft 9863 and
counter using a Ring Wrench Insert 9863/1 at the camshaft controller -3- while
doing this.
Fig 1: Identifying Camshaft Controllers
2. Pull both camshaft controllers off the camshaft and remove them one by one.

GTS & CAYENNE S) > INSTALLING ACTUATOR FOR CAMSHAFT
Information

Tightening Sequence For Central Screw For Camshaft Controller
Result: Cylinder Bank: Camshaft:
1. Bank 1, Cylinders 1-3 Exhaust
4. Bank 2, Cylinders 4-6 Exhaust
Fig 1: Identifying Camshaft Controllers

GTS & CAYENNE S) > SUBSEQUENT WORK
1. Set valve timing. → 150516 SETTING TIMING FOR CAMSHAFTS
2. Install chain tensioner. → 153519 REMOVING AND INSTALLING TIMING CHAINS ON V6 DFI
ENGINES
COVER
WM 158419 REMOVING AND INSTALLING CAMSHAFT CONTROLLER (CAYENNE) >
TOOLS
Camshaft Bar VW Tool T10068A
Adjusting Tool VW Tool T10363

TECHNICAL VALUES
Tolerance Tolerance
1 2
Fastening Tightening 60 Nm (44 ft.

Camshaft Controller
Screw Torque lb.)
Fastening Tightening 60 Nm (44 ft.

Camshaft Controller
Screw Torque lb.)
Guide Rail To Cylinder Tightening 23 Nm (17 ft.

Head Torque lb.)

Chain Tensioner
Torque lb.)
PRELIMINARY WORK
1. Remove the timing-case cover at the top. → REMOVING TIMING-CASE COVER - section on
"Removing"
2. Set crankshaft to compression TDC for cylinder 1 → TDC for cylinder 1 . → 150502
CHECKING THE TIMING ON V6 DFI ENGINES - section on "Checking"
Fig 1: Identifying TDC For Cylinder 1

REMOVING CAMSHAFT CONTROLLER
Information
Always check all components, such as timing chains, sprockets, locking pins and chamfers for
wear or damage. Always replace faulty components .
Before removing the timing chains, mark the running direction with a colored pen .
Maintain the same timing chain running direction during re-installation .

Never use a prick punch or file for marking .
Information


2. Fastening Screw
3. Timing Chain
5. Sealing Ring
6. Oil Pump
7. Fastening Screw
8. Tensioning Rail
10. Sealing Ring
11. Bearing Pin
12. Sprocket
13. Sprocket
14. Fastening Screw
17. Drive Chain
19. Bolt
28. Guide Rail
1. Relieve the timing chain.
1. 1.1. Unscrew the chain tensioner -9- . → REMOVING CHAIN TENSIONER -

section on "Removing".
2. 1.2. Detach upper guide rail -23- by unscrewing the fastening screw -21- . Do not
remove the guide rail.
3. 1.3. Lift up the timing chain at the camshaft controllers and remove it from the
camshaft controllers -4 and 25- .
2. Remove camshaft controllers.

Fig 2: Identifying Camshaft Hexagons
1. 2.1. Remove outlet camshaft controller -4- by unscrewing the fastening screw -22- .
Counter the camshaft at the hexagon → Camshaft hexagon with an open-ended
2. 2.2. Remove intake camshaft controller -25- by unscrewing the fastening screw -22-
. Counter the camshaft at the hexagon → Camshaft hexagon with an open-ended

NOTE: Incorrect handling of camshaft controllers

→ Do not turn the engine without camshaft controllers.
→ Counter the camshafts at the hexagon when tightening the camshaft controllers.
Information
Pay attention to marking and allocation of camshaft controllers to camshafts!
Do not interchange camshaft controllers!
1. Install camshaft controllers. Guide the timing chain around the components at the same time.
1. 1.1. Check the position of the camshafts.
Camshaft bar T10068A must fit into the grooves on the intake and outlet camshafts
→ Camshaft bar at the same time.
Cylinder 1 must be set to compression TDC.
→ 150502 CHECKING THE TIMING ON V6 DFI ENGINES
Fig 1: Identifying Camshaft Bar

2. 1.2. Secure drive gear wheel for high-pressure pump using Adjusting Tool T10363 .
-3- . Make sure that the marking -1- on the drive cam for the high-pressure pump is
pointing straight up. Fit adjusting tool with a fastening screw and tighten hand-tight
-2- .
Fig 2: Securing Drive Gear Wheel For DFI High-Pressure Pump
3. 1.3. From now on, read and follow the details and instructions for setting the timing.
→ 150516 SETTING THE TIMING ON V6 DFI ENGINES and → 150502
CHECKING THE TIMING ON V6 DFI ENGINES .
Information
Tips For Fitting The Camshaft Controllers:
1. The two camshaft controllers (identified by "24E" on the intake side and "32A"
on the outlet side) can be screwed onto the camshaft mounting in one position
only because of a dowel pin .
2. Turn the sensor wheel 1 on the removed intake camshaft controller as far as it
will go to the right. Hold the controller at this position. It must be possible to fit
the controller easily on the intake camshaft with the camshaft roller chain set
"tightly" and then tighten it hand-tight .
3. The outlet camshaft controller is locked in »idle state«. As a result, the sensor
wheel will not turn when you set the timing. If the locking mechanism is not
engaged (locked) in "idle state", the controller must be turned in both directions
by hand until it locks. If this is not possible, replace the camshaft controller .
4. There must be exactly 16 rollers between the markings on the camshaft
controllers "24E" and "32A" and the markings must be flush with the FSI
marking. → 150502 CHECKING THE TIMING ON V6 DFI ENGINES
4. 1.4. Turn sensor wheel -1- on the intake camshaft controller as far as it will go to the
right. Then position intake camshaft controller on the camshaft and fix in place with
the fastening screw. The fastening screw Must Always Be Replaced .
Fig 3: Turning Sensor Wheel

1. 1.4.1. Counter the camshaft at the hexagon with an open-ended wrench →

Camshaft hexagon .
Tighten fastening screw -22- with a torque wrench → Tightening Torque:

60 Nm (44 ft. lb.) and then tighten further to → Torque angle: 90° .
Fig 5: Tightening Camshaft Screws
5. 1.5. Place outlet camshaft controller on the camshaft. Place timing chain over the
sprocket on the outlet camshaft controller -4- . Fix the outlet camshaft controller in
place with the fastening screw -22- . The fastening screw must always be
replaced .
1. 1.5.1. Counter the camshaft at the hexagon -arrows- with an open-ended

wrench (a/f 27).
Tighten the fastening screw with a torque wrench → Tightening Torque:

60 Nm (44 ft. lb.) and then tighten further to → Torque angle: 90° .
2. Tension the timing chain.
1. 2.1. Fit tensioning rail -8- for the chain tensioner on the timing chain.
2. 2.2. Fit guide rail -23- on the timing chain and fit the screw -21- . → Tightening
Torque: 23 Nm (17 ft. lb.) .
3. 2.3. Sealing ring -10- on the chain tensioner -9- must always be replaced .
1. 2.3.1. Then tighten the chain tensioner with a torque wrench. →

Tightening Torque: 40 Nm (30 ft. lb.) .
4. 2.4. Camshaft bar T10068A must now be removed.
5. 2.5. Adjusting tool T10363 must be removed from the drive gear wheel for the
high-pressure pump.
3. After you have fitted the timing chain, turn the crankshaft twice and check the timing. →
150502 CHECKING THE TIMING ON V6 DFI ENGINES . Adjust the timing if necessary. →
150516 SETTING THE TIMING ON V6 DFI ENGINES

SUBSEQUENT WORK
1. Install the timing-case cover at the top. → INSTALLING TIMING-CASE COVER - section on
"Installing"

"Installing"
WM 158419 REMOVING AND INSTALLING CAMSHAFT ADJUSTERS (CAYENNE

TURBO & CAYENNE TURBO S) > TOOLS
Socket-Wrench Special Tool 9714

Insert

1. Remove cylinder head cover (valve cover) on both cylinder banks. → 158219 REMOVING
AND INSTALLING CYLINDER HEAD COVER
2. The spark plugs should be removed to make the crankshaft easier to turn. → 287020
REMOVING AND FITTING SPARK PLUGS

TURBO & CAYENNE TURBO S) > REMOVING ACTUATOR FOR CAMSHAFT
(CAMSHAFT CONTROLLER)

Fig 1: Identifying Camshaft Actuator
1. Screw, M12 Tighten Fully After Setting Timing . Always use a new screw.
4. Screw, M5 x 12
1. Turn the crankshaft at the vibration balancer using Socket-Wrench Insert 9714 so that the
staking bore of the vibration balancer -2- is approx. 45 degrees in front of the lower staking
point on the timing-case cover -1- .
Fig 2: Identifying Crankshaft Staking Bore Angle

DFI ENGINES
3. Loosen all four screws on the camshafts (sprockets and camshaft controllers) by one to two
turns. Counter at the respective hexagon.
Fig 3: Loosening Camshafts Bolts
Information
1. Move the camshafts carefully. Do not force .
2. Turn in the other direction if necessary .
Information
4. Turn all four camshafts so that all the data matrix codings at the adjustment edges are pointing
upwards almost simultaneously (this enables the camshafts to exert the minimum amount of
pressure on the valve lifters) → Camshaft position for cylinders 1 to 4 → Camshaft position for
cylinders 5 to 8 . The camshafts are turned at their hexagon using an appropriate open-ended
wrench → Hexagon at camshaft . Observe identical information on assembling the camshafts.


Fig 6: Turning Camshaft
5. Loosen timing chain.
NOTE: Small parts falling into the timing case
1. Risk of engine damage
→ Make sure that no small parts fall into the timing case.
6. Remove screw for the respective camshaft controller -1- (counter at the hexagon) and
carefully take out the camshaft controller with both hands under the timing chain → Removing
camshaft controller from chain . Carefully loosen the camshaft controller from behind using a
rubber hammer if necessary → Loosening camshaft controller .
Fig 7: Identifying Camshaft Controller Screw
1. Screw, M12 Tighten Fully After Setting Timing . Always Use A New Screw.
2. Camshaft Adjuster With Integrated Hexagon For Countering
3. Hydraulic Valve For Camshaft Control
4. Screw, M5 x 12
Fig 8: Loosening Camshaft Controller

Fig 9: Removing Camshaft Controller From Chain

TURBO & CAYENNE TURBO S) > INSTALLING ACTUATOR FOR CAMSHAFT
(CAMSHAFT CONTROLLER)
Information
1. Lift timing chain and place camshaft controller carefully on the camshaft → Camshaft controller
on camshaft . In order to have sufficient play in the timing chain, turn camshaft timing gear
back and forth as required → Turning camshaft timing gear . Place timing chain on the
camshaft controller.
Fig 1: Installing Camshaft Controller On Camshaft

Fig 2: Turning Camshaft Timing Gear
2. Position fastening screw and hexagon on the camshaft controller and screw in loosely (it must
still be possible to turn the camshaft controller) → Camshaft adjustment .
Fig 3: Identifying Camshaft Controller Screw
1. Screw, M12 Tighten Fully After Setting Timing . Always Use A New Screw.
2. Camshaft Adjuster With Integrated Hexagon For Countering
3. Hydraulic Valve For Camshaft Control
4. Screw, M5 x 12
3. Screw in the four screws of the sprockets and camshaft controller as far as possible (it must
still be possible to turn the sprockets and camshaft controller to adjust the timing).
4. Set the timing. → 150516 SETTING TIMING FOR CAMSHAFTS . Do not tighten the sprockets
and camshaft controller to the final Tightening Torque until the timing has been set.

1. Fit cylinder head cover (valve cover). → 158219 REMOVING AND INSTALLING CYLINDER
HEAD COVER
2. Fit spark plugs. → 287020 REMOVING AND FITTING SPARK PLUGS

Service Manual: 17 - ENGINE - LUBRICATION -- 92A CAYENNE
WM 170101 CHECKING ENGINE-OIL LEVEL (CAYENNE) > CHECKING ENGINE-OIL
LEVEL
WARNING: Hot fluid
Danger of scalding
NOTE: Incorrect oil level
Risk of damage to engine or catalytic converter
→ Check the oil level regularly.
→ The oil level must not fall below the Minimum marking or rise above the Maximum marking.
→ Only use engine oil approved by Porsche.
Information
It is sufficient to read off the engine-oil level in the instrument cluster as described in the Driver's Manual
when the specified conditions are met.
Test conditions:
Engine oil temperature is at least 60 °C
Vehicle is parked horizontally.
Wait a few minutes after stopping the engine to allow the oil to flow back into the oil pan.
The oil dipstick on the Cayenne, model year 2008-2009, is also suitable as an alternative method of
checking the engine-oil level.
Part No.: 955 107 068 00
Test procedure:
1. Pull out oil dipstick and wipe it off with a clean, lint-free cloth. Push dipstick back in fully, pull it
out again and read off the oil level → Markings on the oil dipstick . Correct engine-oil level if
necessary.
1. 1 - Max. marking
2. 2 - Min. marking
3. a - Above cross-hatched area up to Max. marking: no more oil needs to be added.
4. b - Oil level within cross-hatched area: additional engine oil can be added.
5. c - Area from Min. marking to cross-hatched area: refill engine oil up to the cross-hatched
area.
Fig 1: Locating Oil Dipstick Markings
WM 170101 CHECKING ENGINE-OIL LEVEL (CAYENNE) > CHECKING ENGINE-OIL

LEVEL > OIL FILLING QUANTITIES
Oil filling quantity with change of filter
MIN 5.4 liters
MAX 6.9 liters
MIN - MAX difference 1.5 liters
First fill 8.0 liters
WM 170101 CHECKING ENGINE-OIL LEVEL ON THE INSTRUMENT CLUSTER

(CAYENNE TIP, CAYENNE MAN, CAYENNE GTS, CAYENNE S HYBRID, CAYENNE
TURBO S, CAYENNE DIESEL, CAYENNE S DIESEL, CAYENNE TIP (3.0)) > CHECKING
ENGINE-OIL LEVEL
Information
Requirements for oil level measurement using the instrument cluster:
Vehicle must be standing horizontally
Oil temperature 80°... 100°
Engine off
Ignition on
Wait two minutes after opening the engine compartment lid
1. Select the Oil level function in the multi-function display.
1. 1.1. Select Vehicle in the main menu, then select Oil level and confirm your
selection.
2. Check the engine-oil level on the segment display and top up engine oil if necessary.
1. 2.1. The segment display is green if the engine-oil level is between the Min and Max
markings.
1. Maximum engine-oil level → Maximum engine-oil level , segments are green .

Fig 1: Identifying Engine-Oil Level (Maximum)
2. Minimum engine-oil level → Minimum engine-oil level , lowest segment is

yellow .
Fig 2: Identifying Engine-Oil Level (Minimum)
3. Engine-oil level too low → Engine-oil level too low , lowest segment is red .
Fig 3: Identifying Engine-Oil Level (Low)
4. Engine-oil level too high → Engine-oil level too high , all segments are yellow
.
Fig 4: Identifying Engine-Oil Level (High)
3. Refill quantity:
1. The difference between the Min and Max markings is approx. 1 liter
2. One segment of the display corresponds to approx. 0.25 liters
WM 170101 CHECKING ENGINE-OIL LEVEL USING THE PIWIS TESTER (CAYENNE,

CAYENNE GTS, CAYENNE S HYBRID, CAYENNE S E, CAYENNE TURBO, CAYENNE
(3.0)) > TOOLS

II
WM 170101 CHECKING ENGINE-OIL LEVEL USING THE PIWIS TESTER (CAYENNE,
CAYENNE GTS, CAYENNE S HYBRID, CAYENNE S E, CAYENNE TURBO, CAYENNE
(3.0)) > CHECKING ENGINE-OIL LEVEL
Information
1. PIWIS Tester II 9818 must be connected and ignition switched on.
2. Start the diagnostic program and select the required vehicle.
3. Select the DME control unit in the control unit overview. Press [F12] to continue.
4. Select the Maintenance/repairs menu. Press [F12] to continue.
5. Select the Oil filling function. Press [F12] to continue.
Information
Requirements for oil level measurement using the PIWIS Tester:
1. Engine running at idle speed
2. The engine oil temperature (T030) is 90 °C
3. The vehicle is horizontal on a level surface
6. Start the engine and let it run until an engine oil temperature of 90° C is reached.
Rev the engine if necessary to heat the engine oil to the specified temperature.
7. The oil level measurement process starts automatically as soon as the engine oil temperature
of 90° C is reached.
8. Switch off engine.
1. Risk of damage to engine or catalytic converter
9. Add the quantity of oil displayed on the PIWIS Tester II 9818 .
10. Disconnect the PIWIS Tester.
WM 170117 CHANGING ENGINE OIL AND OIL FILTER (CAYENNE) > TECHNICAL
VALUES
Lid for oil/water Tightening 25 Nm (19

heat exchanger torque ftlb.)
(banjo bolt)
Oil pressure Tightening 20 Nm (15

switch torque ftlb.)
Oil filter cover Tightening 25 Nm (19

torque ftlb.)
Oil drain plug Tightening 10 Nm (7.5

for oil filter torque ftlb.)
cover
Oil-filter Tightening 23 Nm (17

console to torque ftlb.)
engine support
arm
Fastening Tightening 8 Nm (6 ftlb.) +/-10 %

oil cooler to
oil-filter housing


torque ftlb.)

for oil filter torque ftlb.)
cover
Oil-filter Tightening 23 Nm (17

console to torque ftlb.)
engine support
arm
Fastening Tightening 23 Nm (17 +/-10 %

bracket
Oil drain plug Tightening 30 Nm (22

torque ftlb.)
Oil filling Filling capacity 6.0 Liter

capacity without
oil filter

capacity with oil
filter

torque ftlb.)
capacity without
oil filter

capacity with oil
filter

on oil filter torque ftlb.)
cover

torque ftlb.)
Oil filling Filling capacity 0.9 liters

capacity after
oil filter is
removed
WM 170117 CHANGING ENGINE OIL AND OIL FILTER (CAYENNE) > PRELIMINARY
WORK
1. Jack up the vehicle at the points provided.
2. Remove engine underbody panel. → REMOVING ENGINE GUARD
WM 170117 CHANGING ENGINE OIL AND OIL FILTER (CAYENNE) > INFORMATION >
COMPONENT OVERVIEW
1. Oil-filter housing/engine support arm
2. Sealing ring; replace when removing and oil lightly
4. Oil/water heat exchanger; note installation position
5. Lid for oil/water heat exchanger (banjo bolt) → Tightening torque: 25 Nm (19 ftlb.)
8. Oil filter cover with short-circuiting valve (2.5 bar opening pressure) → Tightening torque: 25
Nm (19 ftlb.)
9. Oil drain plug for oil filter cover → Tightening torque: 10 Nm (7.5 ftlb.)
10. Fastening screws → Tightening torque: 23 Nm (17 ftlb.)

Fig 1: Identifying Oil Filter Housing
WM 170117 CHANGING ENGINE OIL AND OIL FILTER (CAYENNE) > INFORMATION >
COMPONENT OVERVIEW
1. Oil-filter housing/engine support arm
4. Oil cooler
5. Screw → Tightening torque: 8 Nm (6 ftlb.)+/-10 %

8. Oil filter cover with short-circuiting valve (2.5 bar opening pressure) → Tightening torque: 25
Nm (19 ftlb.)
9. Oil drain plug for oil filter cover → Tightening torque: 10 Nm (7.5 ftlb.)
10. Fastening screws → Tightening torque: 23 Nm (17 ftlb.)
11. Fastening screws for bracket → Tightening torque: 23 Nm (17 ftlb.)+/-10 %
12. Holder
13. Holder
14. Water hose for crankcase
15. Water hose for thermostat housing
16. Hose clamp, 23 x 12
17. Hose clamp, 19 x 12

Fig 1: Overview - Oil Filter And Oil Cooler
WM 170117 CHANGING ENGINE OIL AND OIL FILTER (CAYENNE) > DRAINING AND
FILLING ENGINE OIL
WARNING: Hot fluid
Danger of scalding
→ Avoid contact with hot fluid.

Information
When changing engine oil, drain the oil when it is hot because hot oil is more fluid than cold oil and all
dirt particles and suspended matter can be cleaned out. Position the collecting container as close as
possible to the drain outlet of the oil pan.
Information
Engine oil should not be removed by suction as particles of dirt may remain in the oil pan .
1. Remove oil drain plug -arrow- and collect the engine oil in a collecting container (allow to
drain for approx. 5 minutes). Dispose of waste oil in accordance with legal requirements.
Fig 1: Locating Oil Drain Plug
2. Replace and fit oil drain plug. → Tightening torque: 30 Nm (22 ftlb.)
3. Fill in engine oil of the stipulated viscosity and quality.
Oil filter Filling capacity
without filter → Filling capacity: 6.0 Liter

with filter → Filling capacity: 6.9 Liter
WM 170117 CHANGING ENGINE OIL AND OIL FILTER (CAYENNE) > DRAINING AND
FILLING ENGINE OIL > DRAINING AND FILLING ENGINE OIL
WARNING: Hot fluid
Danger of scalding
Information
When changing engine oil, drain the oil when it is hot because hot oil is more fluid than cold oil and all
dirt particles and suspended matter can be cleaned out. Position the collecting container as close as
possible to the drain outlet of the oil pan.
Information
Engine oil should not be removed by suction as particles of dirt may remain in the oil pan .
1. Remove the oil drain plug -arrow- and collect the engine oil in a collecting container (allow to
drain for approx. 5 minutes). Dispose of waste oil in accordance with legal requirements.
2. Replace and fit oil drain plug. → Tightening torque: 30 Nm (22 ftlb.)
3. Fill in engine oil of the stipulated viscosity and quality.
Oil filter Filling capacity
without filter → Filling capacity: 5.8 Liter
with filter → Filling capacity: 6.7 Liter
WM 170117 CHANGING ENGINE OIL AND OIL FILTER (CAYENNE) > REMOVING AND
INSTALLING OIL FILTER
WARNING: Hot fluid
Danger of scalding

1. Unclip power-steering hose on front-axle final drive and lift it to one side. → Power-steering
hose
Fig 1: Locating Power-Steering Hose
2. Cover components with cloths and cardboard to keep the body of the axle and the front-axle
final drive clean. Remove oil drain plug on oil filter cover and drain the oil filter. -arrow- Fit new
sealing ring on the oil drain plug on the oil filter cover. → Tightening torque: 10 Nm (7.5 ftlb.)
3. Loosen the oil filter cover with a socket (a/f 36). -arrow-
Fig 3: Locating Oil Filter Cover
4. Remove oil filter cover. To do this, remove oil filter cover with filter element in direction of
travel. Remove filter element separately if necessary. Drain the remaining oil into a disposal
container.
5. Remove filter element and dispose of it in accordance with legal requirements. → Oil filter
element and oil filter cover
Fig 4: Removing Oil Filter Element And Oil Filter Cover
6. Clean the oil filter cover thoroughly inside and outside and replace the sealing ring. Carefully
lever off the sealing ring → Removing sealing ring . Do not damage the oil filter cover while
doing so.
Fig 5: Removing Sealing Ring
7. Insert filter element into the oil filter cover. → Oil filter element and oil filter cover
Fig 6: Inserting Oil Filter Element And Oil Filter Cover
8. Lightly oil the O-ring for the oil filter cover. Install oil filter cover. → Tightening torque: 25 Nm
(19 ftlb.)
9. Clip in power-steering hose on the front-axle final drive. → Power-steering hose

Fig 7: Locating Power-Steering Hose
10. Clean dirty components with a cloth.
11. Check and fill in engine oil. The oil filling capacity after removing the oil filter is → Filling
capacity: 0.9 liters .
WM 170117 CHANGING ENGINE OIL AND OIL FILTER (CAYENNE) > SUBSEQUENT
WORK
1. Fit underbody panelling.
Information
After changing the oil or checking the engine-oil level (e.g. during the sales check), the oil level
must be topped up to the MAX marking when the oil is still warm.
2. Start the engine and check the oil level. See below.
WM 170117 CHANGING ENGINE OIL AND OIL FILTER (CAYENNE) > CHECKING
ENGINE-OIL LEVEL (MARKINGS ON OIL DIPSTICK)
The vehicle must stand horizontally.

The engine must be switched off and at operating temperature.
Before measuring, allow engine oil to flow back into the oil pan for approximately 3 minutes.
1. Pull out oil dipstick and wipe it off with a clean, lint-free cloth. Push dipstick back in fully, pull it
out again and read off the oil level → Markings on the oil dipstick . Correct the engine-oil level
if necessary.
Information
1. After changing the oil, the oil level must be checked on the dipstick .
2. The engine must have reached its operating temperature .

Fig 1: Locating Oil Dipstick Markings
3. 1 - Max. marking
4. 2 - Min. marking
5. a - Above cross-hatched area up to Max. marking: no more oil needs to be added.
6. b - Oil level within cross-hatched area: additional engine oil can be added.
7. c - Area from Min. marking to cross-hatched area: refill engine oil up to the cross-hatched
area.
WM 170301 CHECKING OIL PRESSURE (CAYENNE) > TECHNICAL VALUES

Oil-pressure Tightening 20 Nm (15

sender torque ftlb.)
WM 170301 CHECKING OIL PRESSURE (CAYENNE) > TOOLS AND MATERIALS
Fig 1: Identifying Oil Pressure Tester
-A- Oil pressure tester "OP Used to measure engine oil pressure; use
85" WE1276 adapter insert 4 and screw in with suitable
sealing ring instead of the oil-pressure sender
-B- Test hose (included in

set)
WM 170301 CHECKING OIL PRESSURE (CAYENNE) > PRELIMINARY WORK
1. Remove engine guard. → REMOVING ENGINE GUARD
WM 170301 CHECKING OIL PRESSURE (CAYENNE) > CHECKING OIL PRESSURE

Danger of burns to the eyes and skin
→ Do not smoke, eat or drink in the work area.
WARNING: Hot fluid
Danger of scalding
Information
Oil pressure may be too low for a number of reasons:
Oil is diluted .
Oil pump is faulty .
Bearing clearance is too large (e.g. crankshaft bearing) .
Oil level is too low .
Oil pressure-regulating valve is faulty .
Incorrect oil has been used. Only use oil that has been approved by Porsche for the measurement
.
Information
The oil-pressure sender is located on the oil-filter console to the left under the generator .
Information
When the oil-pressure sender is unscrewed, approx. 0.3 liters of engine oil will escape .
Collect emerging engine oil and dispose of it in accordance with the applicable national laws .
1. Loosen and unscrew oil-pressure sender. → Removing Oil-Pressure Sender

Fig 1: Locating Oil-Pressure Sender
2. Use adapter insert 4 with a suitable sealing ring instead of the oil-pressure sender and tighten
hand-tight.
3. Connect the test hose to the adapter insert.
4. Connect oil pressure tester "OP 85" to the test hose.

Fig 2: Identifying Oil Pressure Tester
Information
1. The oil temperature must be between 80 and 100 °C when measuring oil pressure .
2. Check the oil temperature using a special thermometer or PST II tester .
5. Start the engine and rev to the required test speed. Read off the oil pressure on the oil
pressure tester "OP 85".
Engine speed [RPM] Oil pressure [bar]
1, 500 1.7
2, 000 3.0 to 5.5
more than 2, 000 7.0
Information
1. When the oil pressure tester "OP 85" is unscrewed, approx. 0.3 liters of engine oil will
escape .
Collect emerging engine oil and dispose of it in accordance with the applicable national
laws .
6. Remove oil pressure tester "OP 85" and test hose.
7. Screw in oil-pressure sender with a new sealing ring and tighten it. → Installing Oil-Pressure
Sender → Tightening torque: 20 Nm (15 ftlb.)
WM 170301 CHECKING OIL PRESSURE (CAYENNE) > SUBSEQUENT WORK
1. Install engine guard. → INSTALLING ENGINE GUARD
2. Check oil level and correct it if necessary. → 170101 CHECKING ENGINE-OIL LEVEL
WM 170419 REMOVING AND INSTALLING OIL-PRESSURE SENDER (CAYENNE) >

TECHNICAL VALUES


COMPONENT OVERVIEW
Fig 1: Overview - Oil Filter And Oil-Filter Console
-1- Oil-filter console 1
-2- Sealing ring 1 Replace when

removing, oil lightly
-3- Sealing ring 3 Replace when
-4- Oil cooler 1 Note installation

position
-5- Cover for oil cooler 1
-6- Oil-pressure sender 1
-7- Oil filter element 1
-8- Oil filter cover 1 Drain after removal Replace sealing

ring when
-9- Oil drain plug for oil 1

filter cover
-10- Fastening screws 5

PRELIMINARY WORK

REMOVING OIL-PRESSURE SENDER
WARNING: Hot fluid
Danger of scalding

Information
Oil is diluted .
Bearing clearance is too large (e.g. crankshaft bearing)
Oil pressure regulating valve is faulty .
.
Information
The oil-pressure sender is located on the oil-filter console to the left under the generator .
1. Release and pull off connector on oil-pressure sender -arrow- .

Fig 1: Locating Connector On Oil-Pressure Sender
Information
1. When the oil-pressure sender is unscrewed, approx. 0.3 liters of engine oil will escape .
Collect emerging oil and dispose of it in accordance with the applicable national laws .
2. Loosen and unscrew oil-pressure sender -arrow- .


INSTALLING OIL-PRESSURE SENDER
1. Screw in oil pressure switch with a new sealing ring and tighten it. → Tightening torque: 20
Nm (15 ftlb.)
2. Slide on and engage connector on oil-pressure sender -arrow- .


SUBSEQUENT WORK
2. Check the oil level and correct it if necessary. → 170101 CHECKING ENGINE-OIL LEVEL
WM 170419 REMOVING AND INSTALLING OIL-PRESSURE SENDER (CAYENNE S,

CAYENNE TURBO, CAYENNE GTS, CAYENNE S HYBRID, CAYENNE DIESEL,
CAYENNE S DIESEL, CAYENNE TIP (3.0)) > PRELIMINARY WORK
Information
If vehicles have fault entries relating to oil pressure, oil pump activation, oil pressure monitoring, etc. in
the DME control unit (and a warning light comes "on" on the instrument cluster), proceed as follows:
Check the oil level .
Delete related faults .
Do not replace components, such as the oil pump, oil pressure sensor or oil pressure control valve
if you suspect that they are faulty .
If the vehicle has not been driven for a long time (months), the control mechanism in the oil pump can
become stiff ("stick").
Very short trips and a lot of loading/maneuvering can cause t↓he oil to become very diluted => Oil
pressure very low. For example, 20 cold starts in quick succession can reduce the viscosity of the
engine oil by 30%.
Change the engine oil. Test-drive the vehicle .
If error messages/warnings are displayed again, proceed in accordance with the instructions
under Guided Fault Finding in the PIWIS Tester .

CAYENNE S DIESEL, CAYENNE TIP (3.0)) > REMOVING OIL-PRESSURE SENDER
WARNING: Hot fluid
Danger of scalding

Information
Oil is diluted .
Bearing clearance is too large (e.g. crankshaft bearing)
Oil pressure regulating valve is faulty .
.
Information
When the oil-pressure sender is unscrewed, approx. 0.3 liters of engine oil will escape .
Collect emerging oil and dispose of it in accordance with the applicable national laws .
Component overview of oil-pressure sender
2. Sealing ring
4. Screw, M6 x 40
5. Stopper
6. Sealing ring
Fig 1: Overview - Oil Pressure Sender
1. Release and pull off connector on oil-pressure sender.
2. Unscrew fastening screws -4- and remove oil-pressure sender -3- . The adapter is removed
as well.

CAYENNE S DIESEL, CAYENNE TIP (3.0)) > INSTALLING OIL-PRESSURE SENDER
Information
Component overview of oil-pressure sender
2. Sealing ring
4. Screw, M6 x 40
5. Stopper
6. Sealing ring
Fig 1: Overview - Oil Pressure Sender
1. Replace sealing rings for adapter and oil-pressure sender.
2. Slide oil-pressure sender -3- into the adapter -1- .
3. Fit the fastening screws -4- .
4. Plug in connector for oil-pressure sender.

CAYENNE S DIESEL, CAYENNE TIP (3.0)) > SUBSEQUENT WORK
2. Check the oil level and top up if necessary.
WM 170519 REMOVING AND INSTALLING OIL PRESSURE SWITCH (CAYENNE TIP

(3.0) "PLATINUM EDITION", CAYENNE S HYBRID, CAYENNE TIP (3.0)) > TOOLS

used oil Workshop WE 1385
collection and equipment
extraction unit
V.A.G 1782
articulated VW tool T40175

wrench

(3.0) "PLATINUM EDITION", CAYENNE S HYBRID, CAYENNE TIP (3.0)) > TECHNICAL
VALUES
Fastening Tightening 13 Nm
screw on torque
oil-filter
housing
Oil pressure Tightening 20 Nm

switch torque
Fastening nut On double screw Tightening 13 Nm (9.5

on oil-filter torque ftlb.)
housing

screw on torque
oil-filter
housing
Lid on oil-filter Tightening 35 Nm

housing torque
Double screw Tightening 16 Nm

securing torque
oil-filter
housing

switch for torque
reduced oil
pressure

(3.0) "PLATINUM EDITION", CAYENNE S HYBRID, CAYENNE TIP (3.0)) > ASSEMBLY
OVERVIEW - OIL-FILTER HOUSING, OIL PRESSURE SWITCH
torque: 20 Nm
6. Sleeve
7. Rubber sleeve
2. With oil non-return valve, cannot be replaced
9. O-ring/replace

14. Seal/replace
Fig 1: Overview - Oil Filter Housing And Oil Pressure Switch

(3.0) "PLATINUM EDITION", CAYENNE S HYBRID, CAYENNE TIP (3.0)) > OIL
PRESSURE SWITCH FOR REDUCED OIL PRESSURE
Grey insulator


(3.0) "PLATINUM EDITION", CAYENNE S HYBRID, CAYENNE TIP (3.0)) > REMOVING
OIL PRESSURE SWITCH > REMOVING OIL PRESSURE SWITCH FOR REDUCED OIL
PRESSURE
1. Remove engine cover. → REMOVING ENGINE COVER (DESIGN COVER) .
Information
For the sake of clarity, illustration shows removed compressor.

2. Disconnect electric plug connection -2- using assembly tool T10118 .
3. Unscrew oil pressure switch for reduced oil pressure -1- using articulated wrench T40175 .

(3.0) "PLATINUM EDITION", CAYENNE S HYBRID, CAYENNE TIP (3.0)) > REMOVING
OIL PRESSURE SWITCH > REMOVING OIL PRESSURE SWITCH
1. Remove engine cover. → REMOVING ENGINE COVER (DESIGN COVER) .
2. Expose electric lines running along the oil-filter housing.
3. Disconnect electric plug connection -arrow- .

Fig 1: Locating Oil Pressure Switch
4. Unscrew oil pressure switch using articulated wrench T40175 .

(3.0) "PLATINUM EDITION", CAYENNE S HYBRID, CAYENNE TIP (3.0)) > INSTALLING
OIL PRESSURE SWITCH > INSTALLING OIL PRESSURE SWITCH FOR REDUCED OIL
PRESSURE
Information
1. 1.1. Replace sealing ring.
2. 1.2. Insert new oil pressure switch into the bore immediately to prevent oil loss.

(3.0) "PLATINUM EDITION", CAYENNE S HYBRID, CAYENNE TIP (3.0)) > INSTALLING
OIL PRESSURE SWITCH > INSTALLING OIL PRESSURE SWITCH
Information
1. 1.1. Replace sealing ring. Not available individually
2. 1.2. Replace oil pressure switch with sealing ring.
3. 1.3. Insert new oil pressure switch into the bore immediately to prevent oil loss.
2. Check the oil level. → 170101 CHECKING ENGINE-OIL LEVEL
WM 171119 REMOVING AND INSTALLING OIL LEVEL SENSOR AND OIL

TEMPERATURE SENSOR (CAYENNE S E, CAYENNE (3.0)) > TECHNICAL VALUES
Fastening nut for Tightening 9 Nm (6.5

oil level and oil torque ftlb.)
temperature
sensor

for baffle plate torque ftlb.)
Fastening screw Fit with securing Tightening 9 Nm (6.5

liquid torque ftlb.)
Fastening screw Replace Initial 3 Nm (2 ftlb.)

for engine oil tightening
cooler
Fastening screw Final tightening +90°

for engine oil
cooler

for engine oil torque ftlb.)
cooler (bottom)

saddle
Fastening screw Replace Initial 30 Nm (22

for sprocket tightening ftlb.)

for sprocket

for oil pump torque ftlb.)
torque ftlb.)

TEMPERATURE SENSOR (CAYENNE S E, CAYENNE (3.0)) > REMOVING OIL LEVEL
SENSOR AND OIL TEMPERATURE SENSOR > ASSEMBLY OVERVIEW - OIL PAN, OIL
PUMP, ENGINE OIL COOLER
7. Screw/replace
9. Dowel sleeve
10. O-ring/replace
13. Seal/replace
14. Seal/replace
20. Sleeve
21. Mounting saddle
25. O-ring/replace
26. Seal/replace
27. O-ring/replace
28. Oil pump
30. Screw/replace

Fig 1: Overview - Oil Pan, Oil Pump And Engine Oil Cooler

Fig 2: Identifying Oil Pan Lower Part

Fig 3: Identifying Oil Pan Upper Part

TEMPERATURE SENSOR (CAYENNE S E, CAYENNE (3.0)) > REMOVING OIL LEVEL
SENSOR AND OIL TEMPERATURE SENSOR > REMOVING OIL LEVEL SENSOR AND
OIL TEMPERATURE SENSOR
1. Drain engine oil. → 170117 CHANGING ENGINE OIL AND OIL FILTER
Unscrew nuts -1- and remove oil level sensor and oil temperature sensor -4- .
Fig 1: Identifying Oil Level Sensor And Oil Temperature Sensor

TEMPERATURE SENSOR (CAYENNE S E, CAYENNE (3.0)) > INSTALLING OIL LEVEL
SENSOR AND OIL TEMPERATURE SENSOR
Information
1. 1.1. Replace sealing ring 2 .
2. 1.2. Check the oil level. → 170101 CHECKING ENGINE-OIL LEVEL
WM 171119 REMOVING AND INSTALLING OIL LEVEL SENSOR (CAYENNE (3.0)) >
TECHNICAL VALUES
Oil drain plug M14 x 1.5 Tightening 30 Nm (22

torque ftlb.)
Fastening M6 x 25 Tightening 10 Nm (7.5

screw for oil torque ftlb.)
level sensor
PRELIMINARY WORK
1. Remove engine guard → REMOVING ENGINE GUARD
REMOVING OIL LEVEL SENSOR

WARNING: Hot fluid
Danger of scalding
1. Loosen oil drain plug -arrow- and collect engine oil in a container.
Dispose of waste oil in accordance with legal requirements .
2. Replace and tighten oil drain plug -arrow- . → Tightening torque: 30 Nm (22 ftlb.)
3. Release connector on oil level sensor -a- and pull it off.

Fig 3: Locating Oil Level Sensor
4. Loosen fastening screws -arrows- and pull the oil level sensor out of the oil pan.
Fig 4: Locating Oil Level Sensor Screws
INSTALLING OIL LEVEL SENSOR
1. Fit oil level sensor with a new seal. Tighten fastening screws -arrows- . → Tightening
Fig 1: Locating Oil Level Sensor Screws
2. Slide on and engage connector.
3. Fill in engine oil and check engine-oil level → 170101 CHECKING ENGINE-OIL LEVEL .
SUBSEQUENT WORK
1. Mount engine guard → INSTALLING ENGINE GUARD
WM 171719 REMOVING AND INSTALLING GUIDE FOR OIL DIPSTICK (CAYENNE

(3.0)) > TECHNICAL VALUES

for oil dipstick torque
Fastening screw M8 x 26 Tightening 20 Nm (15

torque ftlb.)
Fastening screw M6 Tightening 10 Nm (7.5
torque ftlb.)
Carefully loosen M6 Tightening 10 Nm (7.5

fastening screw torque ftlb.)
for thrust
washer
Fastening screw M8 x 28 Tightening 23 Nm (17

torque ftlb.)
Fastening screw M6 x 13 Tightening 8 Nm (6 ftlb.)

for oil pipe torque
Oil drain plug M14 x 21 Tightening 30 Nm (22

torque ftlb.)

for oil pan torque
Fastening M8 x 116 M8 x 63 Tightening 20 Nm (15


Fit bolt Tightening 25 Nm (19

torque ftlb.)
Fastening screw Initial tightening 100 Nm (74

for torsional ftlb.)
vibration
damper
Fastening screw Final tightening 90°

for torsional
vibration
damper
Fastening screw M6 Tightening 8 Nm (6 ftlb.)

for guide tube torque
Fastening screw M6 Tightening 8 Nm (6 ftlb.)

for sheetmetal torque
holder

(3.0)) > PRELIMINARY WORK
1. Remove design cover. → REMOVING ENGINE COVER (DESIGN COVER)

Fig 1: Removing Engine Cover

(3.0)) > INFORMATION > COMPONENT OVERVIEW
-1- - → Tightening torque: 8 Nm (6 ftlb.)
-2- - Oil dipstick guide
-3- - Oil dipstick
-4- - Oil check valve, pay attention to direction of installation
-5- - Knock sensor; right with and left without cable
-7- - → Tightening torque: 10 Nm (7.5 ftlb.)
-8- - Cover for oil pump drive
-9- - O-ring; replace
-10- - Oil pump drive

-11- - Crankcase
-12- - Intermediate shaft
-13- - Thrust plate
-14- - → Tightening torque: 10 Nm (7.5 ftlb.) , use impact bolter if necessary; insert screws
with screw locking agent
-15- - Drive shaft for oil pump; pay attention to the assembly of plastic washer
-16- - Crankshaft reference mark sender
-17- - Oil pump, observe tightening sequence
-20- - → Tightening torque: 30 Nm (22 ftlb.) ; replace
-21- - Oil pan
-22- - Oil-level sender
-23- - Sealing ring; replace
-26- - Engine support arm/oil filter housing
-28- - To thermostat; replace O-ring
-31- - Secondary unit holder
-32- - Coolant pipe; replace O-ring
-33- - Knock sensor (without cable)
-34- - Torsional vibration damper
-35- - → Initial tightening: 100 Nm (74 ftlb.) → Final tightening: 90° ; replace screw
Fig 1: Overview Of Oil Pan

(3.0)) > REMOVING GUIDE FOR OIL DIPSTICK > REMOVING GUIDE FOR OIL
DIPSTICK
Information
Measure the oil level before removing any parts and draw a diagram of the oil level on the oil
dipstick as a reference .
1. Screw off fastening nuts -arrows- on sheetmetal holder. Press sheetmetal holder aside.
Fig 1: Locating Sheetmetal Holder Nuts
2. Unscrew fastening screw -1- on the guide.

Fig 2: Identifying Guide Screws
3. Remove connector for crankshaft pulse sender on the guide -arrow- .

Fig 3: Removing Crankshaft Pulse Sender Connector
4. Carefully pull the guide and oil dipstick out of the cylinder block. Turn it back and forth as
required.
5. Check that the sealing ring is on the guide. Pull the sealing ring out of the bore if necessary
using an angled piece of wire.

(3.0)) > INSTALLING GUIDE FOR OIL DIPSTICK > INSTALLING GUIDE FOR OIL
DIPSTICK
Information
The sealing ring on the guide must be replaced .
1. Replace sealing ring, apply a little grease to the ring and push it as far as it will go onto the
guide -arrow- . Remove the oil dipstick from the guide to facilitate installation.
Fig 1: Locating Guide Sealing Ring
Information
1. Illuminate the installation position well for fitting the guide .
2. Insert the guide into the bore on the cylinder block and align it. Fit and tighten fastening screw
-1- for the guide. → Tightening torque: 8 Nm (6 ftlb.)
Fig 2: Identifying Guide Screw
3. Check the oil level using the oil dipstick and compare it with the diagram you drew (serves as a
reference for checking that the guide was fitted correctly in the cylinder block).
4. Fit connector for crankshaft pulse sender on the guide.

Fig 3: Installing Crankshaft Pulse Sender Connector
5. Move sheetmetal holder into installation position and tighten it -arrows- . → Tightening
Fig 4: Locating Sheetmetal Holder Screws

(3.0)) > SUBSEQUENT WORK
1. Fit design cover. → INSTALLING ENGINE COVER (DESIGN COVER)

Fig 1: Pressing Engine Cover
WM 172019 REMOVING AND INSTALLING OIL PUMP (CAYENNE) > TECHNICAL

VALUES

screw torque ftlb.)
Oil pump cover Opening 5.5 bar +/-0.2 bar

with pressure pressure
valve regulator
Fastening M6 x 18 Tightening 8 Nm (6 ftlb.)

screw torque
Fastening M6 Tightening 8 Nm (6 ftlb.)

screw torque

screw for oil torque
pipe
screw for oil torque ftlb.)
pump
WM 172019 REMOVING AND INSTALLING OIL PUMP (CAYENNE) > INFORMATION >
COMPONENT OVERVIEW
-1- - Drive shaft for oil pump drive; component is symmetrical, thus it is not possible to install
incorrectly
-2- - Oil pump
-4- - Gear wheels; tooth flank play: 0.20 mm; axial flank play: 0.10 mm
-5- - → Opening pressure: 5.5 bar+/-0.2 bar ; clean intake strainer
-6- - → Tightening torque: 8 Nm (6 ftlb.) ; fit medium-tight with screw locking agent
-7- - Oil pressure pipe; insert with sealant
-9- - Sealing ring; replace if damaged

Fig 1: Overview - Oil Pump
WM 172019 REMOVING AND INSTALLING OIL PUMP (CAYENNE) > PRELIMINARY

WORK
Remove oil pan. → Removing Oil Pan
WM 172019 REMOVING AND INSTALLING OIL PUMP (CAYENNE) > REMOVING OIL
PUMP
1. Loosen fastening screws -1- on oil pressure pipe.
2. Loosen fastening screws -2- on oil pump.


Fig 1: Locating Oil Pump Screws
3. Remove oil pump.
4. Remove drive shaft.

Fig 2: Removing Drive Shaft
WM 172019 REMOVING AND INSTALLING OIL PUMP (CAYENNE) > INSTALLING OIL
PUMP
Information
Seals must always be replaced .
1. Insert drive shaft for oil pump into the cylinder block.
Check that the two plastic washers are in place .

Fig 1: Inserting Drive Shaft
2. Position oil pump on cylinder block. Fastening screws -2- must then be screwed in .
3. Insert fastening screws -1- for oil pressure pipe with screw locking agent and tighten them. →
4. Tighten fastening screws -2- on oil pump. → Tightening torque: 23 Nm (17 ftlb.)
Fig 2: Locating Oil Pump Fastening Screws
WM 172019 REMOVING AND INSTALLING OIL PUMP (CAYENNE) > SUBSEQUENT

WORK
Install oil pan. → Installing Oil Pan
WM 172619 REMOVING AND INSTALLING OIL PRESSURE CONTROL VALVE

(CAYENNE, CAYENNE S E, CAYENNE (3.0)) > PRELIMINARY WORK
1. Remove air-conditioning compressor. → REMOVING ELECTRIC AIR-CONDITIONING

COMPRESSOR
2. Remove left engine mounting. → REMOVING ENGINE MOUNTING


(CAYENNE, CAYENNE S E, CAYENNE (3.0)) > REMOVING OIL PRESSURE CONTROL
VALVE
Unscrew screw -3- and pull off oil pressure control valve -4- .
Fig 1: Identifying Oil Pressure Control Valve

(CAYENNE, CAYENNE S E, CAYENNE (3.0)) > INSTALLING OIL PRESSURE CONTROL
VALVE
Information
1. 1.1. Replace O-ring -2- .

Fig 1: Identifying Oil Pressure Control Valve

(CAYENNE, CAYENNE S E, CAYENNE (3.0)) > SUBSEQUENT WORK
1. Install air-conditioning compressor. → INSTALLING COMPRESSOR
Information
1. Install left engine support and tighten the screws -arrows- to the specified torque.
2. Install left engine mounting. → INSTALLING ENGINE MOUNTING
WM 172619 REMOVING AND INSTALLING PRESSURE-REGULATING VALVE

(CAYENNE S, CAYENNE TURBO, CAYENNE GTS, CAYENNE TURBO S) > TOOLS

relay puller Special tool 9235
socket-wrench Special tool 9753

insert

(CAYENNE S, CAYENNE TURBO, CAYENNE GTS, CAYENNE TURBO S) > TECHNICAL
VALUES
Oil pressure Cap screw, M36 Tightening 40 Nm (30

control valve to torque ftlb.)
oil pump
Joint flange to M6 Tightening 10 Nm (7.5

oil guide torque ftlb.)
housing

PRELIMINARY WORK
Information
If vehicles have fault entries relating to oil pressure, oil pump activation, oil pressure monitoring, etc. in
the DME control unit (and a warning light comes "on" on the instrument cluster), proceed as follows:
Check the oil level .
Delete related faults .

Do not replace components, such as the oil pump, oil pressure sensor or oil pressure control valve
if you suspect that they are faulty .
If the vehicle has not been driven for a long time (months), the control mechanism in the oil pump can
become stiff ("stick").
Very short trips and a lot of loading/maneuvering can cause the oil to become very diluted => Oil
pressure very low. For example, 20 cold starts in quick succession can reduce the viscosity of the
engine oil by 30%.
Change the engine oil. Test-drive the vehicle .
If error messages/warnings are displayed again, proceed in accordance with the instructions
under Guided Fault Finding in the PIWIS Tester .
1. Jack up the vehicle at the points provided.
2. Remove engine underbody panelling. → REMOVING ENGINE GUARD
3. Drain engine oil. For details, see → 170117 CHANGING ENGINE OIL AND OIL FILTER ON
DFI ENGINES

1. Guide tube
2. O-ring
3. Screw, M6 x 16
4. Oil dipstick
5. O-ring
6. Screw, M6 x 25
7. Oil-level sensor
8. O-ring
9. Joint flange for solenoid valve
10. Screw, M6 x 20
11. Screw, M6 x 16
1. Oil pump with suction stage (Turbo shown)
2. Screw, M8 x 22
4. Cap screw, M36 x 1.5 x 12
5. Solenoid valve
7. Dowel sleeve
8. Screw, M6 x 45
9. Sprocket cover
10. Screw, M6 x 16
11. Drive chain
12. Connection for intake manifold joining socket

Fig 2: Locating Oil Pump, Sprocket And Screws
1. Screw, M6 x 20
2. Joint flange with sealing ring
3. Cap screw, M36
4. Oil sealing ring with engine oil
5. Solenoid valve/oil pressure control valve
6. Special socket socket-wrench insert 9753
7. Puller relay puller 9235

Fig 3: Identifying Oil Pressure Control Valve And Tool

OIL PRESSURE CONTROL VALVE (SOLENOID VALVE) ON 4.8-LITER DFI ENGINES
Information
The oil pressure control valve is fitted in the oil guide housing under the generator between the engine
carrier -1- and oil filter -2- .
Fig 1: Identifying Pressure Control Valve Installation Position
1. Carefully grip the cable plug on the oil pressure control valve with a pointed-nose pliers and
release it. Pull off cable plug.
2. Expose cable and set it aside. -cable-

Fig 2: Identifying Oil Pressure Control Valve Cable
3. Remove screws on joint flange. -1-
4. Carefully lever off the joint flange with a screwdriver → Levering off joint flange . Overcome
the resistance of the two sealing rings on the oil pressure control valve while doing this.
Fig 3: Removing Pressure-Regulating Valve Joint Flange
5. Fit special socket socket-wrench insert 9753 on a ratchet through the opening in the oil
guide housing and loosen cap screw on oil pressure control valve. → Using special socket
Fig 4: Installing Socket-Wrench (9753)
6. Grip oil pressure control valve with a relay puller 9235 and turn carefully to remove it. →
Removing/fitting oil pressure control valve
Fig 5: Removing Oil Pressure Control Valve

OIL PRESSURE CONTROL VALVE (SOLENOID VALVE) ON 4.8-LITER DFI ENGINES
1. Screw, M6 x 20
2. Joint flange with sealing ring
3. Cap screw, M36
4. Oil sealing ring with engine oil
5. Solenoid valve/oil pressure control valve
6. Special socket socket-wrench insert 9753
7. Puller relay puller 9235

Fig 1: Identifying Oil Pressure Control Valve And Tool
1. Replace two sealing rings on the oil pressure control valve -4- . Replace sealing ring on joint
flange -2- .
2. Coat the two sealing rings on the oil pressure control valve lightly with Vaseline or engine oil.
3. Fit the oil pressure control valve as far as it will go into the oil pump → Removing/fitting oil
pressure control valve so that the cable plug on the wire harness can be clipped in later
without turning it.
Fig 2: Removing Oil Pressure Control Valve
4. Insert cap screw into the special socket socket-wrench insert 9753 and slide it on over the
oil pressure control valve. Tighten cap screw hand-tight. When everything is fitted correctly,
tighten the cap screw → Using special socket . → Tightening torque: 40 Nm (30 ftlb.)
Fig 3: Identifying Socket-Wrench (9753)
5. Slide on joint flange with new sealing ring. Screw in and tighten screws -1- . → Tightening
Fig 4: Identifying Oil Pressure Control Valve Cable
6. Route cable, clip it in and connect cable plug.

SUBSEQUENT WORK
1. Fill in engine oil and check oil level. For details, see → 170117 CHANGING ENGINE OIL AND
OIL FILTER ON DFI ENGINES
2. Fit engine underbody panelling. → INSTALLING ENGINE GUARD
WM 172919 REMOVING AND INSTALLING OIL-FILTER HOUSING (CAYENNE S E,


used oil Workshop WE 1385
collection and equipment
extraction unit
VAS 6622

Fastening Tightening 13 Nm
screw on torque
oil-filter
housing

switch torque
Fastening nut On double screw Tightening 13 Nm (9.5

on oil-filter torque ftlb.)
housing

screw on torque
oil-filter
housing
Lid on oil-filter Tightening 35 Nm

housing torque
Double screw Tightening 16 Nm

securing torque
oil-filter
housing

switch for torque
reduced oil
pressure
1. Remove compressor. → REMOVING COMPRESSOR
2. Remove positive crankcase ventilation pipes.

CAYENNE (3.0)) > REMOVING OIL-FILTER HOUSING > ASSEMBLY OVERVIEW -
OIL-FILTER HOUSING, OIL PRESSURE SWITCH
torque: 20 Nm
6. Sleeve
7. Rubber sleeve
2. With oil non-return valve, cannot be replaced
9. O-ring/replace
14. Seal/replace
Fig 1: Overview Of Oil-Filter Housing And Oil Pressure Switch
Oil pressure switch for reduced oil pressure
Grey insulator


CAYENNE (3.0)) > REMOVING OIL-FILTER HOUSING > REMOVING OIL-FILTER
HOUSING
NOTE: Oil will leak out when changing oil filter
Contamination of adjacent components
→ Cover adjacent components
1. Remove oil filter element and drain engine oil. → 170117 CHANGING ENGINE OIL AND OIL
FILTER
2. Extract engine oil from the oil-filter housing using used oil collection and extraction unit
VAS 6622 WE 1385 .
3. Expose electric lines. Unscrew screws -3- and move holder with electric plug connections
aside.
Fig 1: Identifying Electric Plug Connection
4. Unscrew screws -3- and push hose for secondary air to the rear.
Fig 2: Identifying Secondary-Air Line
5. Remove hose -arrow- for positive crankcase ventilation by pressing the release buttons.
Fig 3: Locating Positive Crankcase Ventilation Hose
6. Disconnect electric plug connection -arrow- on the oil pressure switch.

Fig 4: Locating Oil Pressure Switch Electric Plug Connection
Information
Place a cloth underneath the oil-filter housing to catch emerging engine oil.
7. Unscrew screws -arrows- . Screw off nut -1- and remove oil-filter housing.
Fig 5: Locating Oil-Filter Housing Screws

CAYENNE (3.0)) > INSTALLING OIL-FILTER HOUSING
Information
1. 1.1. Replace sealing rings, seals and O-rings.

1. Install oil filter element and fill in engine oil. → 170117 CHANGING ENGINE OIL AND OIL
FILTER
WM 173019 REMOVING AND INSTALLING OIL FILTER (CAYENNE) > PRELIMINARY

WORK
1. For instructions, see → 170117 CHANGING ENGINE OIL AND OIL FILTER ON DFI
ENGINES
WM 173055 CHANGING OIL FILTER (CAYENNE S HYBRID, CAYENNE TURBO) >

PRELIMINARY WORK
2. Drain engine oil. → Draining And Filling Engine Oil

REMOVING AND INSTALLING OIL FILTER > CHANGING OIL FILTER
WARNING: Hot fluid
Danger of scalding
Information
Do not remove the sealing ring with a sharp object .
The oil filter cover contains a cut-out through which the O-ring can be removed .
Position collecting container as close as possible to the oil filter so that no hot oil sprays out at the
side!
Have sufficient cleaning cloths ready .
Cover chassis hoses with cleaning cloths .
Information

1. Loosen oil filter cover -1- using a suitable hexagon socket or ring wrench -2- and unscrew
and remove it.
Fig 1: Loosening Oil Filter Cover
2. Slowly open the oil filter cover. Drain the remaining oil into a container.
3. Remove filter element. Dispose of the filter in accordance with legal requirements.
4. Clean the oil filter cover thoroughly inside and outside and replace the sealing ring. Carefully
lever off the sealing ring → see Fig 2. Do not damage the oil filter cover while doing so.
Fig 2: Replacing Sealing Ring
5. First fit the filter element into the oil guide housing.
6. Lightly coat the sealing ring on the oil filter cover with engine oil. Screw in the oil filter cover
and tighten it hand-tight using a suitable ring wrench.

SUBSEQUENT WORK
2. Fill in engine oil. → Draining And Filling Engine Oil
WM 174019 REMOVING AND INSTALLING OIL/WATER HEAT EXCHANGER (OIL

COOLER) ON DFI ENGINES (CAYENNE TIP "PLATINUM EDITION", CAYENNE TIP,
CAYENNE MAN) > TECHNICAL VALUES
Oil cooler cover Tightening 25 Nm (19

torque ftlb.)
Fastening nut M6 Tightening 8 Nm (6 ftlb.)
for sheetmetal torque
holder

CAYENNE MAN) > PRELIMINARY WORK
1. Pull the design cover vertically upwards and off.

Fig 1: Pulling Engine Cover
2. Remove engine compartment cover at the left → 700219 REMOVING AND INSTALLING
3. Remove air cleaner housing lid and air-cleaner element → REMOVING AIR CLEANER
HOUSING .
4. Remove engine guard → REMOVING ENGINE GUARD
5. Drain coolant → 193817 DRAINING AND TOPPING UP WITH COOLANT (INCLUDES

BLEEDING) .

CAYENNE MAN) > REMOVING OIL/WATER HEAT EXCHANGER (OIL COOLER) ON DFI
ENGINES
WARNING: Danger of burns from hot engine oil!
→ Allow engine to cool down.
→ Wear personal protective gear (e.g. safety goggles, gloves).
1. Remove two fastening nuts for the hose holder and press the holder aside -arrows- .
Fig 1: Locating Hose Holder Nuts
Information
1. When opening the oil/water heat exchanger, collect emerging fuel (engine oil and
coolant) with a pan and cloth .
2. Remove the two coolant hoses from the oil/water heat exchanger -arrow- .
Fig 2: Locating Coolant Hoses On Oil/Water Heat Exchanger
3. Grip the oil cooler cover at the hexagon with a suitable tool and loosen carefully. Take oil cooler
cover (banjo bolt) out of the oil/water heat exchanger and remove together with the oil/water
heat exchanger.
4. Observe installation position of both sealing rings. Sealing rings must be replaced.
5. Clean sealing faces.

CAYENNE MAN) > INSTALLING OIL/WATER HEAT EXCHANGER (OIL COOLER)
Information
Sealing rings must be replaced .
1. Place the two sealing rings in installation position.
2. Position the oil/water heat exchanger on the oil-filter housing/assembly mount and insert the oil
cooler cover through. Screw the oil cooler cover (banjo bolt) on hand-tight.
3. Tighten the oil cooler cover (banjo bolt). → Tightening torque: 25 Nm (19 ftlb.) .
4. Fit the two coolant hoses on the oil/water heat exchanger -arrow- .
5. Move holder into installation position. Fit fastening nuts for the hose holder -arrows- . →
Tightening torque: 8 Nm (6 ftlb.) .
Fig 2: Identifying Sheetmetal Holder Nuts

CAYENNE MAN) > SUBSEQUENT WORK
1. Install left engine support. → WM 1001IN SUPPORTING THE ENGINE ON THE BODY
(CAYENNE GTS, CAYENNE TURBO S, CAYENNE S HYBRID, CAYENNE S E, CAYENNE
TURBO, CAYENNE (3.0))
WM 174019 REMOVING AND INSTALLING OIL COOLER (CAYENNE TURBO S,

CAYENNE S HYBRID, CAYENNE S E, CAYENNE TURBO) > TOOLS


CAYENNE S HYBRID, CAYENNE S E, CAYENNE TURBO) > TECHNICAL VALUES
Oil-filter cover Special wrench a/f Tightening 25 Nm (19

to oil guide 94/36 (1 ea.) torque ftlb.)
housing
Oil cooler to oil M6 x 20 (6 ea.) Tightening 10 Nm (7.5

Fastening M6 x 16 Tightening 10 Nm (7.5

holder to oil
guide housing

CAYENNE S HYBRID, CAYENNE S E, CAYENNE TURBO) > TECHNICAL VALUES >
OIL COOLER, OIL FILTER AND OIL GUIDE HOUSING
1. Oil guide housing (upper part of oil pan)
2. Oil-filter cover → Tightening torque: 25 Nm (19 ftlb.)
3. Oil filter
4. Sealing ring on oil filter/oil or grease before fitting/replace

7. Oil cooler
9. Holder
11. Aluminum screw, M6 x 30 Al9/replace
12. Screw, M6 x 25
Fig 1: Identifying Oil Cooler, Oil Filter And Oil Guide Housing

CAYENNE S HYBRID, CAYENNE S E, CAYENNE TURBO) > PRELIMINARY WORK
1. Drain engine oil. → Draining And Filling Engine Oil
2. Drain coolant. → 193817 DRAINING AND FILLING COOLANT

CAYENNE S HYBRID, CAYENNE S E, CAYENNE TURBO) > REMOVING OIL COOLER
1. Disconnect coolant hoses.
1. 1.1. Loosen the clips -1- on the coolant hoses at the oil cooler and slide them onto
the hoses -A- .
2. 1.2. Clamp the hoses using hose clamp 3093 or hose clamp 3094 .
3. 1.3. Unclip the coolant hose assembly -3- on the oil cooler from the holder -2- (-B-
).
4. 1.4. Pull off hoses -C- .

Fig 1: Removing Coolant Hoses
2. Remove oil cooler.
1. 2.1. Unscrew and remove fastening screws -1- .
2. 2.2. Tilt oil cooler at the top in direction of travel -A- .
3. 2.3. Remove oil cooler.
4. 2.4. Soak up emerging oil with a cloth.

Fig 2: Removing Oil Cooler

CAYENNE S HYBRID, CAYENNE S E, CAYENNE TURBO) > INSTALLING OIL COOLER
1. 1.1. Clean sealing faces and replace seals.

CAYENNE S HYBRID, CAYENNE S E, CAYENNE TURBO) > SUBSEQUENT WORK
1. Fill in coolant. → 193817 DRAINING AND FILLING COOLANT
2. Fill in engine oil. → Draining And Filling Engine Oil

COOLER) (CAYENNE S E, CAYENNE (3.0)) > TOOLS


COOLER) (CAYENNE S E, CAYENNE (3.0)) > TECHNICAL VALUES

temperature
sensor



cooler

for engine oil
cooler

cooler (bottom)

saddle


for sprocket


torque ftlb.)
COOLER) (CAYENNE S E, CAYENNE (3.0)) > PRELIMINARY WORK
1. Remove sound insulation. → 108019 REMOVING AND INSTALLING ENGINE GUARD

COOLER) (CAYENNE S E, CAYENNE (3.0)) > REMOVING ENGINE OIL COOLER >
ASSEMBLY OVERVIEW - OIL PAN, OIL PUMP, ENGINE OIL COOLER
7. Screw/replace
9. Dowel sleeve
10. O-ring/replace
13. Seal/replace
14. Seal/replace
20. Sleeve
21. Mounting saddle

25. O-ring/replace
26. Seal/replace
27. O-ring/replace
28. Oil pump
30. Screw/replace

Fig 1: Overview Of Oil Pan, Oil Pump And Engine Oil Cooler



COOLER) (CAYENNE S E, CAYENNE (3.0)) > REMOVING ENGINE OIL COOLER >
REMOVING ENGINE OIL COOLER
1. Clamp coolant hoses as shown using hose clamp 3094 .

WARNING: Hot fluid
Disconnect coolant hoses from the engine oil cooler.
Fig 1: Identifying Engine Oil Cooler Coolant Hoses
2. Unscrew fastening screw used to secure the oil pan to the engine oil cooler -arrow- .
Place a waste oil container under the engine.

Fig 2: Locating Engine Oil Cooler Screw
NOTE: Mixing fluids
1. Risk of damage to components
→ Close off all openings immediately after exposing them (with adhesive tape, suitable
stoppers).
3. Unscrew fastening screws -1... 4- and remove engine oil cooler.

Fig 3: Identifying Engine Oil Cooler Screw

COOLER) (CAYENNE S E, CAYENNE (3.0)) > INSTALLING ENGINE OIL COOLER
Information
1. 1.1. Check coolant level. → 190101 CHECKING COOLING SYSTEM
2. 1.2. Check the oil level. → 170101 CHECKING ENGINE-OIL LEVEL

COOLER) (CAYENNE S E, CAYENNE (3.0)) > SUBSEQUENT WORK
1. Install sound insulation. → 108019 REMOVING AND INSTALLING ENGINE GUARD
WM 175019 REMOVING AND INSTALLING OIL PAN (LOWER PART) (CAYENNE S E,


temperature
sensor



cooler

for engine oil
cooler

cooler (bottom)

saddle


for sprocket


torque ftlb.)

1. Drain engine oil. → 170117 CHANGING ENGINE OIL AND OIL FILTER
2. Unscrew engine oil cooler from the engine and tie it at the side. The coolant hoses can remain
connected. → 174019 REMOVING AND INSTALLING OIL COOLER

CAYENNE (3.0)) > REMOVING OIL PAN > ASSEMBLY OVERVIEW - OIL PAN, OIL

7. Screw/replace
9. Dowel sleeve
10. O-ring/replace
13. Seal/replace
14. Seal/replace
20. Sleeve
21. Mounting saddle
25. O-ring/replace
26. Seal/replace
27. O-ring/replace
28. Oil pump
30. Screw/replace

Fig 1: Overview - Oil Pan, Oil Pump, Engine Oil Cooler



CAYENNE (3.0)) > REMOVING OIL PAN > REMOVING OIL PAN
1. Remove screws -1... 3- .

Fig 1: Identifying Low-Temperature Coolant Pipes Screws
2. Unscrew screw -arrow- for ATF lines.

Fig 2: Locating ATF Lines
3. Remove lower part of oil pan.
1. 3.1. Disconnect electric plug connection -2- at the oil level and oil temperature
sensor and expose electric wiring.
2. 3.2. Unscrew screws for lower part of oil pan -1- .
3. 3.3. Slowly release lower part of oil pan from the adhesive, but do not bend lower
part of oil pan while doing this.

CAYENNE (3.0)) > INSTALLING OIL PAN
Information
WARNING: Risk of damage or injury from foreign bodies flying around during grinding,
drilling and milling
Oil bores blocked

→ Ensure that they are cleaned thoroughly and that any remaining sealant is removed completely.
1. Remove sealant residue from upper and lower parts of oil pan using a rotating plastic brush.
1. 1.1. Sealing surfaces must be free of oil and grease.

Fig 1: Cleaning Oil Pan
Fig 2: Cutting Nozzle On Sealant Tube
3. Apply a bead of sealant -arrow- to the clean sealing surface on the lower part of the oil pan as
shown.
Information
The component must be installed and secured within five minutes of applying sealant.
Sealant bead thickness: approx. 1.5 mm .
Check use-by date of sealant .

Fig 3: Locating Sealant Bead Of Oil Pan
4. Fit lower part of oil pan and tighten screws.


1. Install engine oil cooler. → 174019 REMOVING AND INSTALLING OIL COOLER
2. Install ATF lines.
3. Fill in engine oil and check the oil level. → 170101 CHECKING ENGINE-OIL LEVEL
WM 175019 REMOVING AND INSTALLING OIL PAN (UPPER PART) (CAYENNE S E,


temperature
sensor


cooler

for engine oil
cooler

cooler (bottom)

saddle


for sprocket


torque ftlb.)

1. Engine secured on engine and gearbox support. → 1001IN SUPPORTING ENGINE ON

MOUNTING BRACKET
2. Remove lower timing chain cover.→ 153319 REMOVING AND INSTALLING TIMING-CASE
COVER
3. Remove the oil pump. → 172019 REMOVING AND INSTALLING OIL PUMP

CAYENNE (3.0)) > REMOVING OIL PAN > ASSEMBLY OVERVIEW - OIL PAN, OIL

7. Screw/replace
9. Dowel sleeve
10. O-ring/replace
13. Seal/replace
14. Seal/replace
20. Sleeve
21. Mounting saddle
25. O-ring/replace
26. Seal/replace
27. O-ring/replace
28. Oil pump
30. Screw/replace

Fig 1: Overview - Oil Pan, Oil Pump And Engine Oil Cooler



CAYENNE (3.0)) > REMOVING OIL PAN > REMOVING OIL PAN
1. Unscrew screws -arrows- and remove the lower baffle plate.

Fig 1: Locating Baffle Plate Screws
2. Loosen and unscrew screws -1... 6- for upper part of oil pan in diagonally opposite sequence.
Carefully detach upper part of oil pan from the adhesive and push it off the dowel sleeves on
the cylinder block.

CAYENNE (3.0)) > INSTALLING OIL PAN
Information
The component must be installed and secured within five minutes of applying sealant.
Information
Oil bores blocked
→ Ensure that they are cleaned thoroughly and that any remaining sealant is removed completely.
1. Remove old sealant from the grooves on the upper part of the oil pan and from the sealing
surfaces.
WARNING: Risk of damage or injury from foreign bodies flying around during
grinding, drilling and milling
1. 1.1. Remove sealant residue from the upper part of the oil pan and cylinder block
using a rotating plastic brush.
2. 1.2. Sealing surfaces must be free of oil and grease.

Fig 1: Cleaning Oil Pan Upper Part
2. Cut off the nozzle on the tube at the front marking (nozzle diameter is approx. 1.5 mm).
Fig 2: Cutting Sealant Tube Nozzle
3. Apply a bead of sealant -arrow- to the clean sealing surface on the upper part of the oil pan
as shown.
1. 3.1. The grooves on the sealing surfaces must be filled completely with sealant.
2. 3.2. Sealant bead thickness: approx. 1.5... 2.0 mm .
Check use-by date of sealant .

Fig 3: Locating Sealant Bead Of Oil Pan
4. Insert seal -1- and O-ring -2- into the guide frame.
Fig 4: Identifying Seal And O-Ring
5. Position upper part of oil pan (check position of dowel sleeves) and tighten screws.

1. Install the oil pump. → 172019 REMOVING AND INSTALLING OIL PUMP
COVER
WM 175019 REMOVING AND INSTALLING OIL GUIDE HOUSING (CAYENNE S,


CAYENNE TURBO, CAYENNE GTS, CAYENNE TURBO S) > TECHNICAL VALUES

CAYENNE TURBO, CAYENNE GTS, CAYENNE TURBO S) > PRELIMINARY WORK
1. Remove vibration balancer. → 137619 REMOVING AND INSTALLING VIBRATION DAMPER

(CRANKSHAFT PULLEY)
2. Support the engine in the vehicle. → 1001IN SUPPORTING THE ENGINE ON THE BODY
3. Remove engine carrier. To do this, remove the screws from the hydraulic mounts from below
and remove them from the longitudinal member. → 103019 REMOVING AND INSTALLING
ENGINE CARRIER
Fig 1: Locating Engine Carrier Screws
1. Front-axle final drive
2. Front axle
3. Steering gear
Fig 2: Identifying Front Axle Final Drive
4. Remove oil pan. → 175019 REMOVING AND INSTALLING OIL PAN
5. Unclip coolant hoses from the clip on the oil/water heat exchanger. → Coolant return on
oil/water heat exchanger
Fig 3: Identifying Oil/Water Heat Exchanger Coolant Return Hose
6. Remove oil-pressure sender.

Fig 4: Identifying Oil Pressure Sensor
1. 6.1. Release and pull off connector on oil-pressure sender.
2. 6.2. Unscrew fastening screws -4- and remove oil-pressure sender -3- . The
adapter -1- is removed as well.
7. Unscrew five screws -arrows- between the timing-case cover and oil guide housing. (Four
screws can be seen in the illustration, the fifth screw is behind the oil-pressure sender.)
Fig 5: Locating Timing-Case Cover And Oil Guide Housing Screws
8. Disconnect coolant supply to the oil/water heat exchanger. To do this, clamp the coolant hoses
for the oil/water heat exchanger with hose clamps. For example, use hose clamp 3093 or
hose clamp 3094 . Pull the coolant hoses off the oil/water heat exchanger. Coolant will run
out.
9. Drain engine oil. → 170117 CHANGING ENGINE OIL AND OIL FILTER .
10. For PDCC: Remove fastening nuts -1- on front wire assembly -2- from the oil pan.
Fig 6: Removing PDCC Lines Bracket
11. On turbo engines, remove the two side oil extraction lines -5- and (bottom illustration) -8- from
the oil guide housing.
1. 4 - Sealing ring
2. 5 - Oil extraction line
3. 6 - Screw, M6 x 12
4. 7 - Screw, M6 x 16
5. 8 - Seal for turbocharger, cylinders 1 to 4

Fig 7: Identifying Oil Extraction Line, Sealing Ring And Screws (Cylinders 1 To 4)
1. 7 - Screw, M6 x 16
2. 8 - Oil extraction line
3. 9 - Seal for turbocharger, cylinders 5 to 8
4. 10 - Sealing ring
Fig 8: Identifying Oil Extraction Line, Sealing Ring And Screws (Cylinders 5 To 8)
12. Release electric plug connection on the oil level sensor -a- and expose the cable. Remove oil
level sensor.
Fig 9: Locating Oil Level Sensor
13. Remove cable plug and joint flange -1, 2, 3- on the oil pressure control valve.
1. Screws, M6 x 20
2. Sealing flange
3. O-ring
4. M6 screw; oil level sensor to oil guide housing
5. Oil level sensor
6. M6 screw; oil guide housing to lower part of crankcase

14. Loosen ATF lines at the oil guide housing and lay them aside. → REMOVING LINES FOR ATF
COOLING

CAYENNE TURBO, CAYENNE GTS, CAYENNE TURBO S) > INFORMATION >
COMPONENT INFORMATION
1. Oil guide housing
3. Oil filter
4. Oil-filter sealing ring
7. Oil/coolant heat exchanger
8. Screw, M6 x 20; self-tapping screws ex-works; metric screws can also be used
Fig 1: Identifying Oil/Coolant Heat Exchanger Components
2. Doboseal sealing compound
1. Screws, M6 x 20
2. Sealing flange
3. O-ring
5. Oil level sensor


CAYENNE TURBO, CAYENNE GTS, CAYENNE TURBO S) > REMOVING OIL GUIDE
HOUSING
Information
The description only applies when installed .
If the oil guide housing is removed when the transmission is disconnected, the oil guide housing
must be aligned with the aid of a dial gauge .
To remove the oil guide housing, it is not necessary to remove the timing case cover. If the timing
case cover is removed while carrying out work later, the oil guide housing must also be removed .
Information
1. Remove the bottom two screws between the transmission and oil guide housing.
Fig 1: Locating Oil Guide Housing And Transmission Screws
2. After removing the oil guide housing, the connecting tubes (oil lines and oil pipes) between the
oil pump and oil guide housing must be removed. Do not forget the side oil suction pipes on
the turbo engine. See illustrations below.
3. Intake pipe on oil pump
4. O-ring
6. O-ring
7. O-ring, 22 x 3
9. O-ring
10. O-ring
11. Screw, M6 x 16; oil pressure pipe to oil pump and oil guide housing; oil regulating line
to oil pump and oil guide housing; turbocharger extraction line to oil pump
12. Screw, M6 x 20
Fig 2: Identifying Oil Lines - Turbo Engine
A. For arrangement of oil lines, see other illustrations below
2. O-ring
4. O-ring
5. O-ring
7. O-ring
8. O-ring
9. Screw, M6 x 16; oil pressure pipe to oil pump and oil guide housing; oil regulating line
to oil pump and oil guide housing
10. Screw, M6 x 20
1. 1 - Mounting for oil extraction line for turbocharger, cylinders 1 to 4
3. 3 - Mounting for oil separator vent line, cylinders 5 to 8
4. 4 - Mounting for oil pump intake pipe
5. 6 - Mounting for oil pressure pipe
6. 9 - Mounting for oil regulating line
Fig 4: Identifying Oil Lines And Intake Pipe - Turbo Engine
1. Mounting for oil pump intake pipe
2. Mounting for oil separator vent line, cylinders 5 to 8
3. Mounting for oil pressure pipe
4. Mounting for oil regulating line

3. Loosen the oil guide housing. To do this, unscrew the screws -4- for the lower part of the
crankcase.
1. Screws, M6 x 20
2. Sealing flange
3. O-ring
5. Oil level sensor

4. Remove bonding (sealant) between the oil guide housing and crankcase. Carefully prise off the
cast lugs using a screwdriver or a soft rubber hammer if necessary.
5. Guide the oil guide housing carefully around the oil pump and remove it.
6. Remove sealing ring for the lower part of the crankcase.
7. Clean sealing faces. Brush off remaining sealant with a plastic brush and then degrease the
sealing face.

CAYENNE TURBO, CAYENNE GTS, CAYENNE TURBO S) > INSTALLING OIL GUIDE
HOUSING
Information
Information
1. Clean sealing surfaces on the oil guide housing and crankcase. The sealing surfaces must be
dry and free of grease.
2. Apply liquid sealant to the oil guide housing. Apply Doboseal 224N sealant using the hand-held
cartridge. The contour of the bead of sealant must be as shown in the figure shown below. The
sealing bead should be approx. 1.0 mm wide and high. Ensure that the bead of sealant is
continuous and that there are no gaps. → Applying sealant to oil guide housing
1. Seal application (geometry, 1-mm bead of sealant)
2. Doboseal 224N sealing compound
3. Insert a new sealing ring into the ring groove on the lower part of the crankcase and bond it
with a very small amount of grease.
Information
When installing the oil guide housing, make sure that it is perfectly aligned and that there is no
dirt or dust between the components. Fit the oil guide housing straight. The maximum offset
must be less than 0.1 mm and it must not project over the crankcase. Otherwise, leaks can
occur while driving.
4. Place the oil guide housing on the crankcase and push evenly against the transmission bell
housing.
5. Screw in a fastening screw on each corner of the oil guide housing and tighten screws by
hand.
Information
1. If the transmission or engine is removed, the oil guide housing must be aligned using a
dial gauge .
6. Then screw in all screws by hand. While doing this, push the oil guide housing towards the
transmission. Also fit the two transmission screws and tighten hand-tight.
7. Starting at the transmission flange and proceeding forwards, tighten the screws evenly and in
diagonally opposite sequence. Don't forget the five screws from the top to the timing-case
cover. (Four screws can be seen in the illustration, the fifth screw is behind the oil-pressure
sender.) → Screws between timing-case cover and oil guide housing Observe the different
tightening torques .
Fig 2: Locating Timing-Case Cover And Oil Guide Housing Screws
8. Install oil-pressure sender.

1. 8.1. Replace sealing rings for adapter and oil-pressure sender.
2. 8.2. Slide oil-pressure sender -3- into the adapter -1- .
4. 8.4. Plug in connector for oil-pressure sender.

Fig 3: Identifying Oil Pressure Sensor
1. Screws, M6 x 20
2. Sealing flange
3. O-ring
4. Screw, M6 x 30; oil guide housing to lower part of crankcase
5. Oil level sensor
6. Screw, M6 x 25; oil level sensor to oil guide housing

9. Tighten the bottom two screws between the transmission and oil guide housing → Screws
between oil guide housing and transmission . For details, see → 373527 REMOVING AND
Fig 5: Locating Oil Guide Housing And Transmission Screws
10. After fitting the oil guide housing, the connecting tubes (oil lines and oil pipes) between the oil
pump and oil guide housing must be fitted. On the Turbo, fit the side oil suction pipes. See
illustrations below.
4. O-ring
6. O-ring
7. O-ring, 22 x 3
9. O-ring
10. O-ring
11. Screw, M6 x 16; oil pressure pipe to oil pump and oil guide housing
12. Screw, M6 x 20
Fig 6: Identifying Oil Lines, Oil Pressure Pipe And Screws - Turbo Engine
A. For arrangement of oil lines, see other illustrations below
2. O-ring
4. O-ring
5. O-ring
7. O-ring
8. O-ring
9. Screw, M6 x 16; oil pressure pipe to oil pump and oil guide housing
10. Screw, M6 x 20
Fig 7: Identifying Oil Lines, Oil Pressure Pipe And Screws - Naturally Aspirated
Engine
3. 3 - Mounting for oil separator vent line, cylinders 5 to 8
4. 4 - Mounting for oil pump intake pipe
5. 6 - Mounting for oil pressure pipe
6. 9 - Mounting for oil regulating line
Fig 8: Identifying Oil Lines And Intake Pipe - Turbo Engine
1. Mounting for oil pump intake pipe
2. Mounting for oil separator vent line, cylinders 5 to 8
3. Mounting for oil pressure pipe
4. Mounting for oil regulating line


CAYENNE TURBO, CAYENNE GTS, CAYENNE TURBO S) > FITTING OIL GUIDE
HOUSING USING A DIAL GAUGE
Information
When installing the oil guide housing, make sure that it is perfectly aligned and that there is no dirt or
dust between the components. Fit the oil guide housing straight. The maximum offset must be less than
0.1 mm and it must not project over the crankcase. Otherwise, leaks can occur while driving.
Information
The following work steps are only necessary if the transmission is disconnected at the time the oil
guide housing is being installed .
Place the oil guide housing on the crankcase and fit a fastening screw on each corner.
1. Insert the dial gauge into the universal dial gauge bracket and position it so that the dial gauge
has a preload of about 1 mm.
Fig 1: Inserting Dial Gauge Into Universal Dial Gauge Bracket
2. Set dial gauge scale to 0. To do this, place the dial gauge bracket on a completely flat surface
(e.g. crankcase flange) and turn the dial gauge scale until the pointer is at 0.
Fig 2: Adjusting Dial Gauge
3. Measure the offset. In order to do this, push with the bracket starting from the crankcase flange
towards the oil guide housing flange (the foot of the dial gauge bracket is located on the other
component like the dial gauge probe) and measure the offset. The oil guide housing must not
be set back any more than 0.1 mm. Even the slightest projection must be corrected.
Fig 3: Measuring Oil Guide Housing Offset
4. Align the oil guide housing by tapping lightly with a rubber hammer.
5. Once the oil guide housing is aligned, tighten the four fastening screws. Then check the
position of the oil guide housing again with the dial gauge.
Fig 4: Checking Oil Guide Housing
6. Tighten the remaining fastening screws. For details of tightening torques, see Installing Oil
Guide Housing .

CAYENNE TURBO, CAYENNE GTS, CAYENNE TURBO S) > SUBSEQUENT WORK
1. Fit joint flange and cable plug for oil pressure control valve.
2. Fit ATF lines on the oil guide housing. → 386219 REMOVING AND INSTALLING LINE FOR
ATF COOLING
3. Fit the oil pan. → 175019 REMOVING AND INSTALLING OIL PAN
4. Fit the oil level sensor, plug in electric plug connection for the oil level sensor and route the
cable.
5. On turbo engines, fit the two side oil extraction lines -5- and (bottom illustration) -8- on the oil
guide housing.
1. Vent line for turbocharger, cylinders 1 to 4; vent line to oil extraction line for
turbocharger
2. Oil feed line for turbocharger, cylinders 1 to 4; oil feed line for turbocharger to
connection piece
3. Connection piece
4. Sealing ring
6. Screw, M6 x 12
7. Screw, M6 x 16

Fig 1: Identifying Vent Line, Connection Pipe And Sealing Ring (Cylinders 1 To 4)
1. Oil feed line for turbocharger, cylinders 5 to 8
2. M6 nut
3. Holding clamp
4. Vent line for turbocharger, cylinders 5 to 8
5. Holding clamp
6. Screw, M6 x 12; holder for turbocharger oil feed line to lower part of crankcase;
holding clamp for oil feed line to holder
7. Screw, M6 x 16
10. Sealing ring

12. Clamp
13. Holder for oil feed line

Fig 2: Identifying Vent Line, Connection Pipe And Sealing Ring (Cylinders 5 To 8)
6. Install engine carrier. → INSTALLING ENGINE CARRIER

Fig 3: Locating Engine Carrier Bolt
1. Front-axle final drive
2. Front axle
3. Steering gear
Fig 4: Identifying Front Axle Final Drive And Steering Gear
7. For PDCC: Fit fastening nuts -1- securing front wire assembly -2- to the oil pan.
Fig 5: Locating PDCC Line Bracket

8. Connect coolant supply line to the oil/water heat exchanger. Connect the coolant hoses to the
oil/water heat exchanger at the same time. Remove hose clamps.
9. Clip in coolant hoses on the oil/water heat exchanger. → Coolant return line
Fig 6: Identifying Coolant Return Line
10. Fit vibration balancer. → INSTALLING VIBRATION DAMPER
12. Fill in engine oil. For details, see → 170117 CHANGING ENGINE OIL AND OIL FILTER .
13. Bleed and fill the cooling system. → 193817 DRAINING AND FILLING COOLANT (INCLUDES
BLEEDING)
14. Align the front axle and bleed all open systems.
15. Carry out a check. After test-driving the vehicle, check the engine for leaks. Then check the oil
level.
WM 175019 REMOVING AND INSTALLING OIL PAN (CAYENNE) > TOOLS

sealant Commercially 000.043.300.39
available tool
WM 175019 REMOVING AND INSTALLING OIL PAN (CAYENNE) > TECHNICAL

VALUES
Oil pan Oil drain plug, M14 Tightening 30 Nm (22

x 21 torque ftlb.)

dipstick

screw torque ftlb.)
Fastening M6 Tightening 10 Nm (7.5

screw torque ftlb.)
Carefully M6 Tightening 10 Nm (7.5

loosen torque ftlb.)
fastening screw
for thrust
washer

screw torque ftlb.)

pipe
Oil drain plug M14 x 21 Tightening 30 Nm (22

torque ftlb.)

pan
Fastening M8 x 116 M8 x 63 Tightening 20 Nm (15


Fit bolt Tightening 25 Nm (19
torque ftlb.)

screw for ftlb.)
torsional
vibration
damper
Fastening Final tightening 90°

screw for
torsional
vibration
damper
Sealing Diameter 3 mm
compound
bead
Oil pan screws M6 x 20 Tightening 12 Nm (9 ftlb.)

torque
WM 175019 REMOVING AND INSTALLING OIL PAN (CAYENNE) > PRELIMINARY

WORK

Fig 1: Identifying Engine Guard
2. Support the engine on the body. → WM 1001IN SUPPORTING THE ENGINE ON THE BODY
3. Remove the front-axle carrier. → REMOVING FRONT-AXLE CARRIER
4. Remove engine carrier. → REMOVING ENGINE CARRIER
Information
1. Collect oil in a clean container so that it can be re-used .
5. Loosen oil drain plug -arrow- and collect engine oil in a container.
Dispose of waste oil in accordance with legal requirements .

6. Replace oil drain plug -arrow- . → Tightening torque: 30 Nm (22 ftlb.)

WM 175019 REMOVING AND INSTALLING OIL PAN (CAYENNE) > INFORMATION >
COMPONENT OVERVIEW
-2- - Oil dipstick guide
-3- - Oil dipstick
-4- - Oil check valve, pay attention to direction of installation
-5- - Knock sensor; right with and left without cable
-7- - → Tightening torque: 10 Nm (7.5 ftlb.)
-8- - Cover for oil pump drive
-9- - O-ring; replace
-10- - Oil pump drive

-11- - Crankcase
-12- - Intermediate shaft
-13- - Thrust plate
-14- - → Tightening torque: 10 Nm (7.5 ftlb.) , use impact bolter if necessary; insert screws
with screw locking agent
-15- - Drive shaft for oil pump; pay attention to the assembly of plastic washer
-16- - Crankshaft reference mark sender
-17- - Oil pump, observe tightening sequence
-20- - → Tightening torque: 30 Nm (22 ftlb.) ; replace
-21- - Oil pan
-22- - Oil-level sender
-26- - Engine support arm/oil filter housing
-28- - To thermostat; replace O-ring
-31- - Secondary unit holder
-32- - Coolant pipe; replace O-ring
-33- - Knock sensor (without cable)
-34- - Torsional vibration damper
-35- - → Initial tightening: 100 Nm (74 ftlb.) → Final tightening: 90° ; replace screw
Fig 1: Overview Of Oil Pan
WM 175019 REMOVING AND INSTALLING OIL PAN (CAYENNE) > REMOVING OIL
PAN

WARNING: Hot fluid
Danger of scalding
1. Release connector on oil level sensor -a- and pull it off -arrow- .
Fig 1: Removing Oil Level Sensor Connector
2. Loosen fastening screws on oil pan in reverse numerical order (25... 1).
Fig 2: Oil Pan Screws Loosening Sequence
3. Remove the oil pan.
Loosen the oil pan by tapping it lightly with a rubber hammer if necessary.
4. Remove sealant from the crankcase with a plastic wedge.

Fig 3: Removing Sealant Crankcase Using Plastic Wedge
5. Clean the oil pan thoroughly.
Use a special plastic brush for drills if necessary.

Fig 4: Cleaning Oil Pan Using Plastic Brush
WM 175019 REMOVING AND INSTALLING OIL PAN (CAYENNE) > INSTALLING OIL
PAN
1. Apply a bead of sealant sealant 000.043.300.39 to the oil pan.
Sealing surfaces must be clean and free of grease .
NOTE: Oil pump suction line blocked
1. Risk of engine damage
→ The bead of sealing compound must not be thicker than → Diameter: 3 mm .
Guide the bead of sealant past the inside of the screw holes -arrows- .
Fig 1: Locating Oil Pan Sealant Applying Area
2. Fit oil pan on the crankcase and tighten fastening screws in numerical order (1... 25). →
Fig 2: Oil Pan Screws Tightening Sequence
Information
1. After fitting the oil pan, the sealant must be allowed to dry for approx. 30 minutes .
2. Then fill in engine oil .
3. Fill in engine oil of the stipulated viscosity and quality and check the oil level.→ 170117
CHANGING ENGINE OIL AND OIL FILTER
Fig 3: Locating Oil Dipstick Mark
WM 175019 REMOVING AND INSTALLING OIL PAN (CAYENNE) > SUBSEQUENT

WORK
1. Install engine carrier. → INSTALLING ENGINE CARRIER
2. Install the front-axle carrier. → INSTALLING FRONT-AXLE CARRIER
3. Remove engine safety device. → WM 1001IN SUPPORTING THE ENGINE ON THE BODY

Service Manual: 19 - ENGINE - COOLING -- 92A CAYENNE
WM 190101 CHECKING COOLING SYSTEM (ALL MODELS) > TOOLS
Antifreeze And Battery

Workshop
Acid Tester WE 1036
Equipment
SUN-Duo-Check
Antifreeze And Battery Workshop

WE 1037
Acid Tester FT 2030 Equipment
Workshop
Cooling System Tester WE 1069
Equipment
Filling device Special tool 9696
WM 190101 CHECKING COOLING SYSTEM (ALL MODELS) > TOOLS AND

MATERIALS
Fig 1: Identifying Cooling System Leak Tester
A. Cooling system leak tester (pump), see Cooling system tester WE 1069
B. Hose Extension FZ 100
C. K22 Cap Adapter (For Sports Cars)
D. K60 cap adapter (included in scope of delivery Filling Device 9696 )
Antifreeze tester => Antifreeze And Battery Acid Tester FT 2030 WE 1037 or Antifreeze And
Battery Acid Tester SUN-Duo-Check WE 1036
WM 190101 CHECKING COOLING SYSTEM (ALL MODELS) > CHECKING COOLING

SYSTEM > COOLANT: CHECKING THE LEVEL AND ANTIFREEZE CONTENT

WARNING: Hot fluid
Danger of scalding
NOTE: Cooling circuit not filled correctly
Risk of damage to vehicle components
→ Do not start the engine after relieving the system pressure.
→ Fill the cooling system correctly and bleed it before starting the engine.
Information
The coolant filled in at the factory is intended to suffice for the entire service life. As long as the
coolant is not contaminated by foreign bodies or other fluids it need not be changed .
Different coolant additives must not be mixed and doing so may damage the cooling system. Only
use original Porsche coolant additives .
The coolant must be set to antifreeze protection of -37 °C. This corresponds to a mixing ratio of 50:
50 (coolant additive: water). This mixing ratio provides optimum corrosion and antifreeze
protection .
Coolant additives, coolants and cleaning agents must be disposed of according to the respective,
applicable national laws .
Seals in the cooling system must be replaced by new ones following disassembly .
Information
Test conditions for checking engine coolant level =>
Engine cold
Vehicle parked horizontally on level ground
1. Open the maintenance cover -1- .

Fig 1: Opening Engine Maintenance Cover
2. Carefully open the cap on the coolant reservoir. Unscrew the cap in an anti-clockwise direction.
Fig 2: Turning Coolant Reservoir Cap
3. Check antifreeze content with a commercially available antifreeze tester. If it is lower than -37
°C, it must be adjusted accordingly. The coolant level must not drop below the minimum mark.
Fig 3: Checking Antifreeze Content
Information
1. The following table specifies how much coolant must be replaced by pure antifreeze in
order to adjust the freezing point to -37 °C .
Measured antifreeze protection in °C Antifreeze quantity to be added (in liters)
-5 9
- 10 8.5
- 15 7.5
- 20 7
- 25 5
- 30 3.5
- 35 1.5
Checking engine coolant level

5. Check the engine coolant level. If necessary, fill the coolant reservoir with coolant to the
maximum marking. If there is considerable coolant loss, the cause must be investigated.
Fig 5: Identifying Coolant Reservoir
6. Carefully open the cap on the coolant reservoir if necessary. Unscrew the cap in an
anti-clockwise direction.
7. Screw cap back on the coolant reservoir.

8. Close the maintenance flap.

SYSTEM > CHECKING THE ANTIFREEZE CONTENT OF THE COOLANT USING A
REFRACTOMETER
Information
The following diagram shows the scale used by Leitenberger . Antifreeze and battery acid tester
FT 2030 WE 1037
The scale can vary slightly, depending on the manufacturer .
The ETHYLENE scale must be used for Porsche antifreeze .
Other commercially available testers can also be used provided correct results are guaranteed .
Fig 1: Checking Coolant Antifreeze Content Using Refractometer
Designation of the
Item Explanation
display
Scale for
-A- Do not use for engine type M48.
propylene-based coolant
Scale for ethylene-based

-B- Coolant such as elf GLACELF SUPRA. Use for engine type M48.
coolant
The charge state of a battery can be checked here. The values on the
-C- Scale for battery acid left side indicate the specific gravity of the electrolyte. The battery must
be recharged once the charge drops below 1.20.
Scale for alcohol-based

-D- The freezing point of the windscreen cleaner can be read off here.
windscreen cleaner
In conjunction with the points of intersection of the relevant scales, it

-E- Light/dark limit
specifies the value to be established.
The light/dark limit must be located here when sprinkled with distilled
-F- Waterline
water.
1. Using a pipette, take a sample from the coolant reservoir.

Fig 2: Checking Coolant Reservoir Sample
2. Deposit a few drops on the test surface.

Fig 3: Checking Test Surface Drops
3. Close the light-diffusing lens. A closed film must form.

Fig 4: Identifying Light-Diffusing Lens
4. Using the refractometer, view against a very bright light source. A very clear light/dark limit
emerges. The point of intersection between this line and the display scale marks the freezing
point of the coolant.
5. A freezing point that is too low must be adjusted accordingly.
Information
1. The following table specifies how much coolant must be replaced by pure antifreeze in
order to adjust the freezing point to -37 °C .
Measured antifreeze protection in °C Antifreeze quantity to be added (in liters)
-5 9
- 10 8.5
- 15 7.5
- 20 7
- 25 5
- 30 3.5
- 35 1.5

SYSTEM > CHECKING COOLING SYSTEM FOR LEAKS/CHECKING FILL QUALITY
(PARTICULARLY ON SYSTEMS WITH THERMAL MANAGEMENT)
Information
If the coolant level drops significantly during the test and there is a danger that the reservoir will be
emptied, the cooling system is not filled correctly (air bubbles in the system or vacuum filling not
carried out sufficiently, for example) .
If the coolant level drops only slightly during the test, the system is filled correctly .
Information
Possible symptoms of an incorrectly filled cooling system include (air bubbles in siphons) =>
Little or no heat output .
Noises from the dashboard/switch panel close to the heat exchanger ("gurgling, glugging") .
Sporadic low coolant level indicator .
Implausible engine temperatures (jumps, fast fluctuations in the instrument cluster) .
1. Check the cooling system for leaks. To do this, apply a test pressure of approx. 1.5 bar using
the cooling system test device and check hose connections for leakage. The pressure must
not drop.
Fig 1: Identifying Cooling System Test Device
2. Check the engine coolant level. If necessary, fill the coolant reservoir with coolant to the
maximum marking. If there is considerable coolant loss, the cause must be investigated.
3. Screw on the cap of the coolant reservoir again until it locks with an audible click.
4. Close the maintenance flap.
5. Check radiator for external dirt. The radiators should not be excessively dirty. If necessary, they
can be cleaned using a vacuum cleaner with a brush attachment.
WM 1901IN ASSEMBLY OVERVIEW - COOLING SYSTEM (CAYENNE) > TECHNICAL

VALUES
Tolerance Tolerance
1 2
Fastening screws for radiator Tightening 25 Nm (19 ft.

mounting Torque lb.)
Fastening screw for top radiator Tightening 5 Nm (3.5 ft.

mounting Torque lb.)
WM 1901IN ASSEMBLY OVERVIEW - COOLING SYSTEM (CAYENNE) > INFORMATION

> CONNECTION DIAGRAM FOR COOLANT HOSES
Fig 1: Coolant Hoses Connection Diagram
1. Coolant Reservoir
2. Circulating Pump
3. Shut-Off Valve For ATF Preheater
4. ATF Preheater
5. Heat Exchanger For Heater
6. Shut-Off Valve For Heat Exchanger For Heater
7. Engine Oil Cooler
8. Cylinder Block
9. Coolant Pump
10. Radiator With ATF Cooler And Condenser
11. Coolant Regulator
12. Cylinder Head

> ASSEMBLY OVERVIEW PART 1 - COOLING SYSTEM
Fig 1: Overview Of Cooling System
2. Circulating Pump
3. ATF Preheater
4. Coolant Temperature Sensor

5. Temperature Sensor For Engine Temperature Control
6. Coolant Pump
7. Coolant Control Valve
Pull the plug-in couplings to check that they are seated securely
Tightening Torques:
M6 screws: 10 Nm (7.5 ft. lb.)
M8 screws: 20 Nm (15 ft. lb.)

1. ATF Preheater
4. Circulating Pump
5. Shut-Off Valve For ATF Preheater
Tightening Torques:

2. Circulating Pump
4. Hoses For Heat Exchanger For Heater

5. Engine Oil Cooler
6. Housing For Coolant Regulator
7. Adapter, For Top Cooler
8. Check Valve, In Coolant Hose
9. Adapter, For Bottom Cooler
Tightening Torques:

> ASSEMBLY OVERVIEW - RADIATOR AND RADIATOR FAN
Fig 1: Overview Of Radiator And Radiator Fan
1. Radiator Module With Condenser And ATF Cooler
2. Fan Frame
3. Radiator Fan
4. Rubber Mounting For Radiator Mounting

5. Bottom Radiator Mounting
6. Screws → Tightening Torque: 25 Nm (19 ft. lb.)
7. Top Radiator Mounting
8. Rubber Mounting For Radiator Mounting
10. Locking Pin
WM 192019 REMOVING AND INSTALLING COOLING FAN HOUSING (RADIATOR

FRAME) (CAYENNE S & CAYENNE GTS) > PRELIMINARY WORK
1. Remove cover for front lock support. → REMOVING COVER FOR FRONT LOCK SUPPORT -
2. Remove molded hoses. → 213919 REMOVING AND INSTALLING PRESSURE PIPE .
3. Remove air box for throttle housing (Y-shaped pipe). → REMOVING AIR BOX FOR

FRAME) (CAYENNE S & CAYENNE GTS) > REMOVING COOLING FAN HOUSING >
REMOVING
1. Unclip electric wire harness -2- from the brackets on the cooling fan housing -3- .
2. Release and disconnect electric plug connection -1- for fan at the cooling fan housing -3- .
3. Unscrew screws -arrows- and set the coolant pipe -4- with connected coolant hoses aside.
Fig 1: Locating Radiator Frame Wire Harness And Plug Connection
4. Release locking springs -9- at the left and right of the cooling fan housing.
Fig 2: Identifying Locking Springs
5. Pull cooling fan housing out of the brackets at the side and at the bottom and swivel it to the
right slightly (in direction of travel) -arrow A- .
Fig 3: Pulling Cooling Fan Housing
6. Carefully remove the cooling fan housing by pulling it up -arrow B- .

FRAME) (CAYENNE S & CAYENNE GTS) > INSTALLING COOLING FAN HOUSING >
INSTALLING
1. Carefully press the coolant hose aside and fit the cooling fan housing carefully into the engine
compartment along the radiator from top to bottom.
2. Check that it is fitted correctly. To do this, check that the locking springs on the left and right
have engaged properly and that the three fastening lugs on the underside have engaged in the
plastic clips.

FRAME) (CAYENNE S & CAYENNE GTS) > SUBSEQUENT WORK
1. Install air box for throttle housing (Y-shaped pipe) with charge-air hoses. → INSTALLING AIR
BOX FOR THROTTLE HOUSING - section on "Installing"
2. Install molded hoses. → 213919 REMOVING AND INSTALLING PRESSURE PIPE .
3. Install cover for front lock support. → INSTALLING COVER FOR FRONT LOCK SUPPORT -
WM 192419 REMOVING AND INSTALLING CENTRE AIR GUIDE (ALL MODELS) >
TECHNICAL VALUES
Basic Tolerance
value 2

Tightening 5 Nm (3.5 +/-0.5 Nm (+/-
Center Air Guide To Radiator
Torque ft. lb.) 0.5 ft. lb.)
Module
Fastening Screw On Radiator Tightening 3.5 Nm +/-0.5 Nm (+/-

Holder Torque (2.5 ft. lb.) 0.5 ft. lb.)
PRELIMINARY WORK
1. Remove front bumper. → REMOVING FRONT BUMPER - section on "Removing"
REMOVING CENTRE AIR GUIDE
1. Unclip temperature sensor.
2. Unscrew fastening screws on center air guide at the radiator module -1- .
Fig 1: Removing Centre Air Guide Screws
3. Unclip three expansion rivets at the top -2- .

Fig 2: Removing Centre Air Guide Rivets
4. Release top of holder from the radiator.
1. 4.1. Unscrew fastening screws on radiator holder at the left and right.
Fig 3: Removing Holder From Radiator
5. Unclip air guide at the side of the radiator.

Fig 4: Unclipping Air Guide
6. Press the radiator to the rear.

Fig 5: Pressing Radiator
7. Remove the air guide -3- in a downward direction.

INSTALLING CENTRE AIR GUIDE
1. The center air guide is installed in reverse order to removal.
2. Tighten fastening screws used to secure the center air guide to the radiator module to →
Tightening Torque: 5 Nm (3.5 ft. lb.) +/- 0.5 Nm (+/- 0.5 ft. lb.) .
3. Tighten fastening screws on radiator holder to → Tightening Torque: 3.5 Nm (2.5 ft. lb.) +/-
0.5 Nm (+/- 0.5 ft. lb.) .
SUBSEQUENT WORK
1. Install front bumper. → INSTALLING FRONT BUMPER - section on "Installing"
WM 193519 REMOVING AND INSTALLING COOLING-AIR FLAPS (CAYENNE S &

1. Remove front apron. → 631537 DISASSEMBLING AND ASSEMBLING FRONT APRON

2. Remove center air guide. → 192419 REMOVING AND INSTALLING CENTRE AIR GUIDE
3. Remove front retaining strip. → 631719 REMOVING AND INSTALLING FRONT RETAINING
STRIP

CAYENNE GTS) > REMOVING COOLING-AIR FLAPS
1. Unscrew Screws -6- .
4. Disconnect electric plug connection at the cooling-air flaps -1- .
5. Remove cooling-air flaps -1- by pulling them up and press the bracket -4- forward slightly.
Fig 1: Identifying Cooling-Air Flaps And Bracket

CAYENNE GTS) > INSTALLING COOLING-AIR FLAPS

1. Install front retaining strip. → 631719 REMOVING AND INSTALLING FRONT RETAINING
STRIP
2. Install center air guide. → 192419 REMOVING AND INSTALLING CENTRE AIR GUIDE
3. Install front apron. → 631537 DISASSEMBLING AND ASSEMBLING FRONT APRON
WM 193817 DRAINING AND FILLING COOLANT (INCLUDES BLEEDING) (CAYENNE S

E-HYBRID) > TOOLS
Cooling System Workshop

WE 1069
Tester Equipment
Filling Device Special Tool 9696

Assembly Tools For

Commercially
Spring Band Nr. 72
Available Tool
Clamps
Flexible Screwdriver Commercially

Nr. 73-1
a/f 7 Available Tool

E-HYBRID) > TOOLS
Fig 1: Identifying Special Tools
-A- - Flexible screwdriver a/f 7 (for loosening or tightening screw-type hose clamps) Flexible
Screwdriver a/f 7 Nr. 73-1
-B- - Antifreeze testing device (for checking the antifreeze content in the cooling system. The
design may be different from that shown here.)
-C- - Spring band clamp pliers (for opening and closing spring band clamps) Assembly Tools
For Spring Band Clamps Nr. 72
-1- - Canister (canister with lifting tube, capacity of approx. 30 l, with volume scale)
-2- - Hose extension
-3- - Adapter K 22 (supplied with radiator vacuum-filling device) Not used for the Cayenne!
-4- - Venturi nozzle (supplied with radiator vacuum-filling device)
-5- - Adapter K 65 (supplied with radiator vacuum-filling device) For the Cayenne! => (Fitted
instead of the cap on the coolant expansion tank.)
-6- - Pressure gauge (supplied with radiator vacuum-filling device)

E-HYBRID) > COOLANT FOR HIGH-TEMPERATURE COOLING SYSTEM > DRAINING
COOLANT (HIGH-TEMPERATURE COOLING SYSTEM)

Information
If larger components (e.g. engine, radiator, etc.) are to be removed/installed, it is absolutely essential to
drain the cooling system. Otherwise, hidden air bubbles can prevent the system from filling properly.
This results in temperature problems in the cooling and heating systems.
2. Place a drip tray under the engine.
3. Open the cap on the coolant reservoir.
WARNING: Hot fluid
4. Drain coolant at the radiator.
1. 4.1. Pull off quick-connecting lock -arrow- at the bottom right of the radiator.
2. 4.2. Pull coolant hose off the radiator.

Fig 1: Locating Coolant Hose
5. Disconnect coolant hose -arrow- from the engine oil cooler and drain coolant.
Fig 2: Locating Engine Oil Cooler Coolant Hose

E-HYBRID) > COOLANT FOR HIGH-TEMPERATURE COOLING SYSTEM > FILLING
COOLANT (HIGH-TEMPERATURE COOLING SYSTEM)
1. If you have not already done so, screw cap adapter K65 for the coolant reservoir onto the
reservoir.
2. Connect the flexible extension (FZ 100) to the cap.
3. Connect the vacuum pressure gauge of the bleeder tool to the flexible extension. When doing
so, ensure that both shut-off valves are closed (positioned at 90° with respect to flow direction).
4. Connect the Venturi nozzle to the vacuum gauge. -arrow-
Fig 1: Connecting Venturi Nozzle To Vacuum Gauge
Information
1. The amount of coolant available must be approx. 2 liters more than the amount to be
filled in .
2. Because different quantities of coolant can drain away during different types of repairs,
the filling capacity can vary greatly. Recommendation: To be on the safe side, fill the
canister to 30 l, then bleed the cooling system. The difference after bleeding is the
coolant quantity that is sucked in. Check the volume scale on the canister .
3. An antifreeze content of -35 °C corresponds to a mixture of 50: 50 (antifreeze: water) .
5. Place a canister with a sufficient amount of coolant and with an antifreeze content of -35 °C
beside the vehicle close to the reservoir.
Information
1. The filling process is completed more quickly if the canister is positioned at roughly the
same height as the coolant reservoir .
6. Push the filler hose -5- of the vacuum gauge onto the canister connection. Route the return
line -6- from the Venturi nozzle to a second container (bucket).
Fig 2: Identifying Vacuum Filling Device Components
Information
1. A hissing sound after connecting the compressed air supply is usual .
7. Connect the compressed air supply.

Fig 3: Connecting Compressed Air Supply
8. Open both shut-off valves on the vacuum gauge → see Fig 4 until the transparent filler hose is
completely filled with coolant.
Fig 4: Identifying Shut-Off Valves
9. Close the left shut-off valve (V1) -arrow- on the vacuum gauge and allow a vacuum to build
up in the cooling system.
Fig 5: Locating Left Shut-Off Valve
Information
1. If no vacuum is generated (the pointer does not move to the green area), there is a leak
in the cooling system .
2. If a vacuum is still not established, there is a blockage in the tool. Clean the device, use
clean compressed air .
3. Deformation of the rubber hoses of the cooling system is normal .
4. Pressure of between 6 and 10 bar must be present. The higher the pressure, the better
the vacuum in the vehicle cooling system .
5. When the pressure gauge pointer is in the green area of the display scale, a sufficient
vacuum has been built up .
6. After both shutoff valves on the vacuum pressure gauge have been closed and the
compressed air supply has been disconnected, the vacuum must not drop. If the vacuum
drops within approx. 30 seconds, there is a leak in the coolant circuit .
10. When there is a sufficient vacuum in the cooling system (pointer is in the green area), close the
right shut-off valve (V2) and then disconnect the compressed air supply.
Fig 6: Identifying Right Shut-Off Valve
11. Open the left shut-off valve (V1) on the vacuum gauge again. The cooling system is then filled.
12. When there is no trace of vacuum present or the coolant is no longer drawn from the canister,
open the right shut-off valve (V2).
→ see Fig 7
13. Then remove the complete filling tool (including the adapter K65).
14. Check the coolant level in the reservoir. Top up or drain coolant as required until the coolant is
at the "MAX" marking.
Fig 8: Identifying Coolant Reservoir Marking

E-HYBRID) > COOLANT FOR HIGH-TEMPERATURE COOLING SYSTEM > CHECKING
COOLANT QUALITY (HIGH-TEMPERATURE COOLING SYSTEM)
WARNING: Hot fluid
Danger of scalding

Information
The coolant quality must be checked to ensure that there is no air in the cooling system.
2. Connect the cooling system tester:
1. 2.1. Cooling system tester WE 1069 must be attached to the coolant reservoir.
2. 2.2. Build up overpressure of approx. 1.0 bar using the hand pump on the cooling
system tester.
Information
If there are no leaks in the cooling system, the coolant level may drop by a maximum
of 25 mm. A considerably larger drop in the coolant level or evaporation of the
coolant from the expansion tank indicates that there is an air bubble in the cooling
system.
3. 2.3. Check the coolant level in the reservoir.
Coolant level OK:
Perform a test drive until the engine reaches its operating temperature.
Check the coolant level again.
Coolant level drops significantly:
Drain the cooling system
Repeat the filling process for the cooling system
Check the coolant quality

E-HYBRID) > COOLANT FOR HIGH-TEMPERATURE COOLING SYSTEM > CHECKING
COOLING SYSTEM FOR LEAKS (HIGH-TEMPERATURE COOLING SYSTEM)
WARNING: Hot fluid
Danger of scalding
1. Open the cap on the reservoir.

2. Cooling system tester WE 1069 must be attached to the coolant reservoir.
3. Build up overpressure of approx. 1.0 bar using the hand pump on the cooling system tester.
4. If this pressure is not maintained, find the leak and correct the problem.
5. Check pressure relief valve in the cap .
1. 5.1. Cooling system tester WE 1069 must be attached to the cap.
2. 5.2. Build up overpressure using the hand vacuum pump on the cooling system
tester.
3. 5.3. The pressure relief valve should open at an overpressure of 1.4... 1.6 bar .
6. Replace the cap if the pressure relief valve does not open as described.

E-HYBRID) > COOLANT FOR LOW-TEMPERATURE COOLING SYSTEM > DRAINING
COOLANT FOR LOW-TEMPERATURE COOLING SYSTEM 1
WARNING: Hot fluid
Danger of scalding
3. Disconnect coolant hose -1- at the electric coolant pump -2- .
1. 3.1. Loosen the clamp -arrow- and pull off coolant hose -1- .

Fig 1: Locating Coolant Hose And Electric Coolant Pump
4. Drain cooling system using pressure.
1. 4.1. Close off coolant hose -1- securely using a suitable stopper -3- .
(Example: stopper and hose clamp)
2. 4.2. Slide a piece of hose -4- onto the electric coolant pump -2- and insert the end
of the hose into a collection container.
3. 4.3. Hold the end of the hose tightly or secure it.
4. 4.4. Screw adapter K 65 from Filling Device 9696 onto the reservoir.
5. 4.5. Connect compressed air hose to the adapter K65 and apply max. 1.5 bar
pressure to the cooling system.
6. 4.6. Pull off piece of hose -4- and close off connection for electric coolant pump
securely using a stopper.
7. 4.7. Insert coolant hose -1- into a collection container.
Hold the end of the hose tightly or secure it.
8. 4.8. Repeat Steps 4 -- 5.

Fig 2: Identifying Coolant Low-Temperature System

E-HYBRID) > COOLANT FOR LOW-TEMPERATURE COOLING SYSTEM > DRAINING
COOLANT FOR LOW-TEMPERATURE COOLING SYSTEM 2

WARNING: Hot fluid
Danger of scalding
2. Disconnect coolant hose -1- from coolant pipe -2- .
1. 2.1. Loosen the clamp -arrow- and pull off coolant hose -1- .

Fig 1: Locating Coolant Hose And Coolant Pipe
3. Drain cooling system using pressure.

1. 3.1. Close off coolant hose -1- securely using a suitable stopper -3- .
(Example: stopper and hose clamp)
2. 3.2. Slide a piece of hose -4- onto the coolant pipe -2- and insert end of hose into a
collection container.
3. 3.3. Hold the end of the hose tightly or secure it.
4. 3.4. Screw adapter K 65 from Filling Device 9696 onto the reservoir.
5. 3.5. Connect compressed air hose to the adapter K65 and apply max. 1.5 bar
pressure to the cooling system.
6. 3.6. Pull off piece of hose -4- and close off coolant pipe -2- securely using a stopper.
7. 3.7. Insert coolant hose -1- into a collection container.
Hold the end of the hose tightly or secure it.
8. 3.8. Repeat Steps 3.4 through 3.5.

Fig 2: Identifying Coolant Low-Temperature System And Hoses

E-HYBRID) > COOLANT FOR LOW-TEMPERATURE COOLING SYSTEM > FILLING
COOLANT FOR LOW-TEMPERATURE COOLING SYSTEM

Information
The filling process is completed more quickly if the canister is positioned at roughly the same
height as the coolant reservoir .
Information
A hissing sound after connecting the compressed air supply is usual .
Information
If no vacuum is generated (the pointer does not move to the green area), there is a leak in the
cooling system .
If a vacuum is still not established, there is a blockage in the tool. Clean the device, use clean
compressed air .
Deformation of the rubber hoses of the cooling system is normal .
Pressure of between 6 and 10 bar must be present. The higher the pressure, the better the
vacuum in the vehicle cooling system .
When the pressure gauge pointer is in the green area of the display scale, a sufficient vacuum has
been built up .
After both shutoff valves on the vacuum pressure gauge have been closed and the compressed air
supply has been disconnected, the vacuum must not drop. If the vacuum drops within approx. 30
seconds, there is a leak in the coolant circuit .
1. Ignition switched off .
1. 1.1. If valves are at zero setting, open both cooling systems.
2. If you have not already done so, screw the cap adapter for the coolant reservoir onto the
reservoir.
4. Connect the vacuum gauge of the bleeder tool to the flexible extension. When doing so,
ensure that both shut-off valves are closed (positioned at 90° with respect to flow direction).
5. Connect the Venturi nozzle to the vacuum gauge. -arrow-

Fig 1: Connecting Venturi Nozzle To Vacuum Gauge
Information
1. The amount of coolant available must be approx. 2 liters more than the amount to be
filled in .
2. Because different quantities of coolant can drain away during different types of repairs,
the filling capacity can vary greatly. Recommendation: To be on the safe side, fill the
canister to 30 l, then bleed the cooling system. The difference after bleeding is the
coolant quantity that is sucked in. Check the volume scale on the canister .
3. An antifreeze content of -35 °C corresponds to a mixture of 50: 50 (antifreeze: water) .
Information
1. The filling process is completed more quickly if the canister is positioned at roughly the
same height as the coolant reservoir .
7. Push the filler hose -5- of the vacuum gauge onto the canister connection. Route the return
line -6- from the Venturi nozzle to a second container (bucket).
Fig 2: Identifying Vacuum-Filling Device Components
Information
1. A hissing sound after connecting the compressed air supply is usual .

9. Open both shut-off valves on the vacuum gauge → see Fig 4 until the transparent filler hose is
completely filled with coolant.
10. Close the left shut-off valve (V1) -arrow- on the vacuum gauge and allow a vacuum to build
up in the cooling system.
Fig 5: Locating Left Shut-Off Valve
Information
1. If no vacuum is generated (the pointer does not move to the green area), there is a leak
in the cooling system .
2. If a vacuum is still not established, there is a blockage in the tool. Clean the device, use
clean compressed air .
3. Deformation of the rubber hoses of the cooling system is normal .
4. Pressure of between 6 and 10 bar must be present. The higher the pressure, the better
the vacuum in the vehicle cooling system .
5. When the pressure gauge pointer is in the green area of the display scale, a sufficient
vacuum has been built up .
6. After both shutoff valves on the vacuum pressure gauge have been closed and the
compressed air supply has been disconnected, the vacuum must not drop. If the vacuum
drops within approx. 30 seconds, there is a leak in the coolant circuit .
11. When there is a sufficient vacuum in the cooling system (pointer is in the green area), close the
right shut-off valve (V2) and then disconnect the compressed air supply.
Fig 6: Identifying Right Shut-Off Valve
12. Open the left shut-off valve (V1) on the vacuum gauge again. The cooling system is then filled.
1. 12.1. The filling process is complete when no more coolant is being sucked out of the
canister.
13. To ensure that coolant can run on during the bleeding process using the PIWIS Tester, the
vacuum gauge remains in this mode.
14. Bleed the low-temperature system using the PIWIS Tester.

E-HYBRID) > COOLANT FOR LOW-TEMPERATURE COOLING SYSTEM > BLEEDING
THE LOW-TEMPERATURE COOLING SYSTEM USING THE PIWIS TESTER
Information
Information
The coolant low-temperature system must be bled using the PIWIS Tester in the following situations:
Components of the low-temperature system are removed or replaced .
The reservoir for the low-temperature system is empty .
1. Bleed the coolant low-temperature system using PIWIS Tester II 9818 .
1. 1.1. Switch on ignition.
2. 1.2. In the [Additional menu/F7], select menu item [Veh. functions/F7] and confirm
your selection.
3. 1.3. Select the [Bleed low-temperature cooling system] test.
4. 1.4. Start the bleeding process by pressing [F8].
5. 1.5. If the coolant level is dropping, correct it by adding coolant.
Do this using the connected filling tool.
6. 1.6. The bleeding process ends automatically.
2. Remove coolant filling tool.
3. Check the coolant level of the low-temperature system in the coolant reservoir.
1. 3.1. Fill in coolant until the engine coolant level in the reservoir is slightly above the
Max display.
4. Test-drive the vehicle and then check the engine coolant level in the reservoir.

E-HYBRID) > COOLANT FOR LOW-TEMPERATURE COOLING SYSTEM > CHECKING
COOLING SYSTEM FOR LEAKS (LOW-TEMPERATURE COOLING SYSTEM)
WARNING: Hot fluid
Danger of scalding
1. Open the cap on the reservoir.
2. Cooling system tester WE 1069 must be attached to the coolant reservoir.
3. Build up overpressure of approx. 1.0 bar using the hand pump on the cooling system tester.
4. If this pressure is not maintained, find the leak and correct the problem.
5. Check pressure relief valve in the cap .
1. 5.1. Cooling system tester WE 1069 must be attached to the cap.
2. 5.2. Build up overpressure using the hand vacuum pump on the cooling system
tester.
3. 5.3. The pressure relief valve must open at an overpressure of 1.4... 1.6 bar .
6. Replace the cap if the pressure relief valve does not open as described.
WM 193817 DRAINING AND FILLING COOLANT (CAYENNE GTS, CAYENNE S,

CAYENNE TURBO & CAYENNE TURBO S) > TOOLS
Filling device Special tool 9696
Assembly tools for Commercially

Nr. 72
spring band clamps available tool
Commercially
Flexible screwdriver Nr. 73-1
available tool

CAYENNE TURBO & CAYENNE TURBO S) > PRELIMINARY WORK
Information
Cooling systems with thermal management (controlled thermostats or coolant valves for controlling
engine temperature) must be vacuum-filled .
The thermostat must not be activated or electric current must not be applied to the thermostat
since this can cause irreparable damage to the thermoelectric couple .
Filling with a watering can only does not always guarantee a complete fill (trapped air -
overheating) .
Clamps on cooling system components should be examined carefully following refilling (check the
coolant level while cold and top up several times as required) .
Clamps on cooling system components must also be vacuum-filled if significant amounts of coolant
are drained. Drain at least two liters of coolant for vacuum-filling because otherwise the correct
vacuum cannot be built up .
1. Open the bonnet.

CAYENNE TURBO & CAYENNE TURBO S) > TOOLS AND MATERIALS > SPECIAL
TOOLS
-A- - Flexible screwdriver a/f 7 (for loosening and tightening screw-type hose clamps) Flexible
Screwdriver Nr. 73-1
-B- - Antifreeze tester (for checking the antifreeze content in the cooling system. The design
can deviate from that shown in the picture.)
-C- - Spring band clamp pliers (for opening and closing spring band clamps) Assembly Tools
For Spring Band Clamps Nr. 72

CAYENNE TURBO & CAYENNE TURBO S) > TOOLS AND MATERIALS > FILLING
DEVICE - OVERVIEW AND SETUP
Information
Note special features in the corresponding information for vehicles with auxiliary heater .
-1- - Adapter K 65 (Installed instead of the cap on the coolant reservoir.) Not shown!
2 - Hose Extension FZ 100 (Fitted between K65 and KVB 01.)
3 - KVB 01 (vacuum pressure gauge with two shut-off valves)
V1 - Shut-Off Valve V1 (shutoff valve for the filler hose.)
V2 - Shut-Off Valve V2 (Shutoff valve for the filler hose - outlet to Venturi nozzle.)
4 - Venturi Nozzle (A vacuum is produced in this component by means of compressed air.

vacuum in the vehicle cooling system.)
5 - Filler Hose (the cooling system is refilled via this hose.)
6 - Return Lines (the compressed air and extracted coolant are drawn off via this hose.)
1. Return Lines
2. Overflow Container (Bucket Or Canister)
3. Compressed Air Connection
4. Compressed Air Connection (Pressure Of Between 6 And 10 Bar Must Be Present.

The Higher The Pressure, The Better The Vacuum In The Vehicle Cooling System.)
5. Filling Canister With Coolant (It Is Best To Position The Canister Higher Than The
Reservoir).
6. Adapter K 65 (Fitted Instead Of The Cap On The Coolant Reservoir). General

Illustration Provided Here. Use An Intermediate Cable/Extension (FZ 100).
7. KVB 01 (vacuum Pressure Gauge With Two Shut-Off Valves V1 And V2)
V1 - Shut-Off Valve V1 (Shutoff Valve For The Filler Hose.)
V2 - Shut-Off Valve V2 (Shutoff Valve For The Filler Hose - Outlet To Venturi Nozzle.)
Fig 2: Overview Of Vacuum-Filling Device

CAYENNE TURBO & CAYENNE TURBO S) > DRAINING COOLANT
WARNING: Hot fluid
Danger of scalding
Information
protection .

3. Remove cap.
4. Move service clip on bleeder valve assembly -3- into service position. The bleeder valve
assembly is located next to the filler neck for the coolant reservoir -4- .
Fig 3: Moving Clip On Bleeder Valve Assembly
5. Drain the cooling system.
1. 5.1. Drain the cooling system. Open the coolant hose -2- on the bottom right radiator
(in direction of travel), drain coolant into a container and dispose of it according to the
applicable national laws if no longer required.
Fig 4: Identifying Coolant Hose
6. Secure the coolant hose -2- on the radiator again.
7. Proceed as follows if the cooling system needs to be bled again (in order to clean the cooling
system for example):
1. 7.1. Disconnect the coolant hose -6- for the coolant reservoir and collect emerging
coolant in a suitable container.
Fig 5: Identifying Coolant Reservoir Hose

CAYENNE TURBO & CAYENNE TURBO S) > DRAINING COOLANT
WARNING: Hot fluid
Danger of scalding
Information
protection .

3. Remove cap.
4. Move service clip on bleeder valve assembly -3- into service position. The bleeder valve
assembly is located next to the filler neck for the coolant reservoir -4- .
Fig 3: Moving Clip On Bleeder Valve Assembly
5. Drain the cooling system.
1. 5.1. Drain the cooling system. Open the coolant hose -2- on the bottom right radiator
(in direction of travel), drain coolant into a container and dispose of it according to the
applicable national laws if no longer required.
Fig 4: Identifying Coolant Hose
6. Secure the coolant hose -2- on the radiator again.
7. Proceed as follows if the cooling system needs to be bled again (in order to clean the cooling
system for example):
1. 7.1. Disconnect coolant hoses -5- from the oil/water heat exchanger and collect
emerging coolant.
Fig 5: Identifying Oil/Water Heat Exchanger
2. 7.2. Disconnect the coolant hose -6- for the coolant reservoir and collect emerging
coolant in a suitable container.
Fig 6: Identifying Coolant Reservoir Hose

CAYENNE TURBO & CAYENNE TURBO S) > FILLING THE COOLING SYSTEM
(INCLUDES BLEEDING)
Information
The amount of coolant available must be approx. 2 liters more than the amount to be filled in .
Because different quantities of coolant can drain away during different types of repairs, the filling
capacity can vary greatly. Recommendation: To be on the safe side, fill the canister to 30 l, then
bleed the cooling system. The difference after bleeding is the coolant quantity that is sucked in.
Check the volume scale on the canister .
An antifreeze content of -35 °C corresponds to a mixture of 50: 50 (antifreeze: water) .
Information
The filling process is completed more quickly if the canister is positioned at roughly the same
height as the coolant reservoir .
Information
A hissing sound after connecting the compressed air supply is usual .
Information
If no vacuum is generated (the pointer does not move to the green area), there is a leak in the
cooling system .
If a vacuum is still not established, there is a blockage in the tool. Clean the device, use clean
compressed air .
Deformation of the rubber hoses of the cooling system is normal .
vacuum in the vehicle cooling system .
When the pressure gauge pointer is in the green area of the display scale, a sufficient vacuum has
been built up .
After both shutoff valves on the vacuum pressure gauge have been closed and the compressed air
supply has been disconnected, the vacuum must not drop. If the vacuum drops within approx. 30
seconds, there is a leak in the coolant circuit .
1. Return Lines
2. Overflow Container (Bucket Or Canister)
3. Compressed Air Connection
4. Compressed Air Connection (Pressure Of Between 6 And 10 Bar Must Be Present. The Higher
The Pressure, The Better The Vacuum In The Vehicle Cooling System.)
5. Filling Canister With Coolant (It Is Best To Position The Canister Higher Than The Reservoir).
6. Adapter K 65 (Fitted Instead Of The Cap On The Coolant Reservoir.). General Illustration
Provided Here. Use An Intermediate Cable/Extension (FZ 100).
7. KVB 01 (Vacuum Pressure Gauge With Two Shut-Off Valves V1 And V2)
V1 - Shut-off valve V1 (shutoff valve for the filler hose.)
V2 - Shut-off valve V2 (Shutoff valve for the filler hose - outlet to Venturi nozzle.)
Fig 1: Overview Of Vacuum-Filling Device
1. If you have not already done so, screw cap adapter K65 for coolant reservoir onto the
reservoir.
3. Connect the vacuum pressure gauge of the bleeder tool to the flexible extension. When doing
so, ensure that both shutoff valves are closed (positioned at 90° with respect to flow direction).
4. Connect the Venturi nozzle to the vacuum pressure gauge.
→ Connecting Venturi nozzle to vacuum pressure gauge
Fig 2: Connecting Venturi Nozzle To Vacuum Pressure Gauge
6. Push the filler hose -5- of the vacuum pressure gauge onto the canister connection. Route the
return line -6- from the Venturi nozzle to a second container (bucket).

8. Open both shut-off valves on the vacuum pressure gauge
→ Shutoff valves on vacuum pressure gauge until the transparent filler hose has completely
filled with coolant.
Fig 5: Identifying Vacuum Pressure Gauge Shutoff Valves
9. Close the left shutoff valve (V1) -arrow- on the vacuum pressure gauge and allow a vacuum
to build up in the coolant circuit.
Fig 6: Locating Left Shutoff Valve (V1)
10. When there is a sufficient vacuum in the cooling system (indicator is in the green area), close
the right shutoff valve (V2) and then disconnect the compressed air supply.
Fig 7: Identifying Right Shutoff Valve (V2)
11. Re-open the left shut-off valve (V1) on the vacuum pressure gauge. The cooling system is then
filled.
12. When there is no trace of vacuum present or the coolant is no longer drawn from the canister,
open the right shutoff valve (V2).
→ Opening right shutoff valve

Fig 8: Identifying Right Shutoff Valve
13. Then remove the complete filling tool (including the adapter K65).
14. If necessary, fill the coolant reservoir with coolant to the maximum marking.
15. Start the engine and leave it running at idle speed. Move the selector lever to position "P" and
allow the engine to warm up.
16. Switch on passenger compartment heating. Blower setting: one bar.
17. Press the "Sport button". Activate "Sport" mode during ventilation.
18. Check the following while the vehicle is warming up.
1. 18.1. Coolant temperature -2- and engine oil temperature -1- in the instrument
cluster. Figure shows normal, acceptable values.
Fig 10: Identifying Instrument Cluster
2. 18.2. Feel the supply and return coolant hoses for the radiator and the peripheral
engine cooling hoses to check that they are heating up uniformly.
3. 18.3. It should be possible to force any suspected air bubbles through the cooling
system by pressing the accelerator pedal from idle speed to approx. 3500 RPM -3-
during the warm-up phase. Never supply power to the map-controlled thermostat
using the workshop tester.
Fig 11: Identifying Instrument Cluster
4. 18.4. The cooling system has been filled and bled correctly if =>
1. All coolant hoses are uniformly warm.
2. The temperature display in the instrument cluster is in the normal range.
3. The passenger compartment heater is warm.
4. The electric fan for engine cooling comes on.
19. Fit lid on the coolant reservoir.
20. Close the service clip on the bleeder valve assembly.
21. Close the maintenance cover.

CAYENNE TURBO & CAYENNE TURBO S) > SUBSEQUENT WORK
2. Conduct a test drive with the vehicle, check the fluid level in the reservoir after the cooling
system has cooled again and, if necessary, fill up to the max marking on the coolant reservoir
with coolant.
3. Check the cooling system if necessary.

WM 194019 REMOVING AND INSTALLING COOLANT RESERVOIR (ALL MODELS) >
TECHNICAL VALUES
Tolerance Tolerance
1 2
Fastening screw on coolant Tightening 9 Nm (6.5 ft.

reservoir Torque lb.)

PRELIMINARY WORK
1. Remove front trim panel (engine compartment) at the right. → REMOVING FRONT TRIM
PANEL (ENGINE COMPARTMENT) - section on "Removing"

REMOVING COOLANT RESERVOIR
WARNING: Hot fluid
Danger of scalding
Information
After pulling off the hoses, close off all openings immediately using commercially available rubber
stoppers.
When fitting parts, do not remove stoppers until shortly before installation.
Fig 1: Overview Of Coolant Reservoir (Petrol Engine)
2. Connector For Water Level Sensor
3. Fastening Screw For Coolant Reservoir
4. Breather Hose
5. Coolant Hose
6. Bleeder Valve Bracket
1. Remove fuel filter housing at the holder. → (includes draining water from fuel filter)
1. 1.1. Only on diesel engines.
Do Not Disconnect Fuel Lines .
2. Remove holder for fuel filter housing.
1. 2.1. Only on diesel engines.
3. Drain the coolant reservoir -1- using suction.
4. Unclip bleeder valve bracket -6- from the coolant reservoir -1- .
1. 4.1. Only for petrol engines.
5. Slide the hose clamp back and pull the breather hose -4- off the coolant reservoir.

7. Remove coolant reservoir -1- from the guides -7- by pulling it towards the center -arrow- .
Fig 2: Removing Coolant Reservoir
8. Release and disconnect electric plug connection -2- from the water level sensor.
9. Release locking mechanism on the coolant hose -5- and pull the coolant hose -5- off the
coolant reservoir.

INSTALLING COOLANT RESERVOIR
1. The coolant reservoir is installed in reverse order to removal.
2. Insert the coolant reservoir into the brackets on the floor and tighten fastening screw to →

SUBSEQUENT WORK
1. Top up coolant in the coolant reservoir. → 193817 DRAINING AND FILLING COOLANT
(INCLUDES BLEEDING)
2. Install front trim panel (engine compartment) at the right. → INSTALLING FRONT TRIM
PANEL (ENGINE COMPARTMENT) - section on "Installing"
WM 194519 REMOVING AND INSTALLING ADDITIONAL COOLANT PUMP (CAYENNE)

> TECHNICAL VALUES

value 1 2
Additional coolant pump holder to Tightening 1.5 Nm (1 ft.

3.5 x 20
additional coolant pump Torque lb.)
Fastening screws for additional Tightening 10 Nm (7.5

M6 x 12
coolant pump holder Torque ft. lb.)
Fastening nut for cable holder M6
Torque ft. lb.)
Fastening screws for engine wire Tightening 10 Nm (7.5

M6 x 12
harness holder Torque ft. lb.)

> PRELIMINARY WORK
1. Drain coolant → 193817 DRAINING AND FILLING COOLANT (INCLUDES BLEEDING) -

section on "Draining".
2. Remove engine compartment trim panels → REMOVING FRONT TRIM PANEL (ENGINE
3. Loosen tank vent valve and set it aside. → 202319 REMOVING AND INSTALLING TANK
VENT VALVE

> REMOVING ADDITIONAL COOLANT PUMP
Information
Cover the engine .
For this work, the worker must lie on the engine .
The additional coolant pump is difficult to reach .
1. Cover the intake-air distributor with covers.
2. Expose the engine wire harness.
1. 2.1. Cut tie-wrap -1- and open the clip -2- .
2. 2.2. Unscrew fastening screws -3- and remove engine wire harness holder -4- .
Fig 1: Identifying Engine Wire Harness Screws And Holder
3. Disconnect additional coolant pump.
1. 3.1. Unclip hose holder -1- .
2. 3.2. Loosen fastening nut -2- and remove cable holder -3- .

Fig 2: Identifying Coolant Pump Holder And Fasteners
WARNING: Hot fluid
4. Disconnect coolant hoses and cable plug.
1. 4.1. Loosen clamps -1- and pull off coolant hoses.
2. 4.2. Pull off cable plugs -2- .
3. 4.3. Remove additional coolant pump with holder -3- .

Fig 3: Identifying Coolant Hoses And Cable Plug

> REPLACING ADDITIONAL COOLANT PUMP
1. Replace additional coolant pump.
2. 1.2. Fit holder -2- on new additional coolant pump.
3. 1.3. Screw in and tighten fastening screws -1- . → Tightening Torque: 1.5 Nm (1 ft.
lb.)
Fig 1: Identifying Coolant Pump Holder And Screws

> INSTALLING ADDITIONAL COOLANT PUMP
1. Secure coolant hoses and cable plug.
1. 1.1. Place additional coolant pump with holder -3- in installation position.
2. 1.2. Plug in cable plug -2- .
3. 1.3. Attach coolant hoses and fasten clamps -1- .

Fig 1: Identifying Coolant Hoses And Cable Plug
2. Secure additional coolant pump.
1. 2.1. Screw in and tighten fastening screws -4- . → Tightening Torque: 10 Nm (7.5
ft. lb.)
2. 2.2. Position cable holder -3- and tighten fastening nut -2- . → Tightening Torque:
10 Nm (7.5 ft. lb.)
3. 2.3. Clip in hose holder -1- .

Fig 2: Identifying Coolant Pump Holder And Fasteners
3. Secure engine wire harness.
1. 3.1. Position engine wire harness holder -4- and tighten fastening screws -3- . →
Tightening Torque: 10 Nm (7.5 ft. lb.)
2. 3.2. Secure engine wire harness with a clip -2- and tie-wrap -1- .
Fig 3: Identifying Engine Wire Harness

> SUBSEQUENT WORK
1. Fit tank vent valve. → 202319 REMOVING AND INSTALLING TANK VENT VALVE
2. Add coolant and bleed the system → 193817 DRAINING AND FILLING COOLANT
(INCLUDES BLEEDING) - section on "Filling".
3. Fit engine compartment trim panels → 700219 REMOVING AND INSTALLING FRONT TRIM
PANEL (ENGINE COMPARTMENT) .
WM 194519 REMOVING AND INSTALLING ADDITIONAL COOLANT PUMP

(LOW-TEMPERATURE SYSTEM) (CAYENNE (3.0) & CAYENNE S E-HYBRID) >
REMOVING COOLANT PUMP FOR LOW-TEMPERATURE SYSTEM
WARNING: Hot fluid
Danger of scalding

1. Drain coolant for low-temperature cooling system. → 193817 DRAINING AND FILLING
COOLANT (INCLUDES BLEEDING)
2. Disconnect electric plug connection -1- and pull off coolant hoses -2- . Unscrew screws
-arrows- and remove fastening clip.
Fig 1: Locating Coolant Pump Low-Temperature System
WM 194519 REMOVING AND INSTALLING ADDITIONAL COOLANT PUMP

(LOW-TEMPERATURE SYSTEM) (CAYENNE (3.0) & CAYENNE S E-HYBRID) >
INSTALLING COOLANT PUMP FOR LOW-TEMPERATURE SYSTEM
Information
For Tightening Torques, tightening sequence and assembly overview, see → 1001IN Tightening
TorqueS, TIGHTENING SEQUENCES, ASSEMBLY OVERVIEWS
Fill in coolant for low-temperature system. → 193817 DRAINING AND FILLING COOLANT
(INCLUDES BLEEDING)
WM 195019 REMOVING AND INSTALLING COOLANT PUMP (CAYENNE) >
TECHNICAL VALUES
Tolerance Tolerance
1 2
Fastening screw, M6 x Tightening

Coolant pump 8 Nm (6 ft. lb.)
18 Torque
Pulley to coolant Tightening 20 Nm (15 ft.

Fastening screw, M8
pump Torque lb.)

PRELIMINARY WORK
1. Drain the cooling system. → 193817 DRAINING AND FILLING COOLANT (INCLUDES
BLEEDING)
2. Remove air box for throttle housing. → 243519 REMOVING AND INSTALLING AIR BOX FOR
THROTTLE HOUSING (INTAKE PIPES UPSTREAM OF THROTTLE VALVE)
WM 195019 REMOVING AND INSTALLING COOLANT PUMP (CAYENNE) > REMOVING

COOLANT PUMP
1. Release drive belt. → 137819 REMOVING AND INSTALLING DRIVE BELT
2. If the pulley has to be removed in order to replace the water pump, counter the pulley using a
commercially available mandrel or screwdriver and loosen the screws on the pulley.
3. Turn the drive wheel for the coolant pump in such a way that the fastening screws can be
reached through the holes in the pulley -arrows- .
4. Pull coolant pump out of the crankcase.

Fig 2: Identifying Coolant Pump

INSTALLING COOLANT PUMP
1. Clean sealing faces and check the condition of the seal that is stuck to the coolant pump for
signs of damage → O-ring for coolant pump . If the seal is leaking or damaged, replace the
coolant pump.
Fig 1: Locating Coolant Pump O-Ring
2. Move coolant pump into installation position.
3. Screw in and tighten the three fastening screws. → Tightening Torque: 8 Nm (6 ft. lb.)
Fig 2: Locating Water Pump Mounting
4. Fit the pulley if necessary. → Tightening Torque: 20 Nm (15 ft. lb.)

SUBSEQUENT WORK
1. Fit drive belt. → 137819 REMOVING AND INSTALLING DRIVE BELT
2. Fit air box for throttle housing. → 243519 REMOVING AND INSTALLING AIR BOX FOR
THROTTLE HOUSING (INTAKE PIPES UPSTREAM OF THROTTLE VALVE)
3. Fill and bleed the cooling system according to instructions. → 193817 DRAINING AND
FILLING COOLANT (INCLUDES BLEEDING)
WM 195019 REMOVING AND INSTALLING COOLANT PUMP (CAYENNE S HYBRID,

CAYENNE TIP (3.0), CAYENNE TIP "PLATINUM EDITION" & CAYENNE TIP (3.0)
"PLATINUM EDITION") > TOOLS

pin wrench VW tool 3212

"PLATINUM EDITION") > TECHNICAL VALUES

value 1 2
Fastening screw for coolant pump
Torque ft. lb.)
Fastening screw securing poly-V-belt

pulley for coolant pump to coolant
Torque ft. lb.)
pump
Initial 8 Nm (6 ft.
tightening lb.)
Torque
angle
Deflection roller for poly-V-belt
Torque ft. lb.)
Fastening screw for coolant regulator
Torque ft. lb.)

"PLATINUM EDITION") > PRELIMINARY WORK
1. Drain coolant. → 193817 DRAINING AND FILLING COOLANT (INCLUDES BLEEDING)
2. Disconnect front left coolant pipes and move them aside. The coolant hoses can remain
connected.
→ 196120 REMOVING AND INSTALLING COOLANT HOSES
3. Remove poly-V-belt for compressor. → 137819 REMOVING AND INSTALLING POLY-V-BELT

FOR COMPRESSOR
4. Remove poly-V-belt. → 137819 REMOVING AND INSTALLING POLY-V-BELT

"PLATINUM EDITION") > REMOVING COOLANT PUMP > ASSEMBLY OVERVIEW -
COOLANT PUMP, COOLANT REGULATOR, ADAPTERS

5. Screw → Initial Tightening: 8 Nm (6 ft. lb.) → Torque Angle: 90°
7. Washer
9. Adapter
10. Seal Replace
11. Seal Replace

"PLATINUM EDITION") > REMOVING COOLANT PUMP > REMOVING COOLANT
PUMP
WARNING: Hot fluid
Danger of scalding
1. Unscrew screws for poly-V-belt pulley for the coolant pump and counter using Pin Wrench
3212 .
1. Risk of damage to pulley
Remove poly-V-belt pulley.

Fig 1: Identifying Coolant Pump Poly-V-Belt Pulley
2. Pull off hose -A- , unscrew screws -arrows- and remove coolant pump.

"PLATINUM EDITION") > INSTALLING COOLANT PUMP
Information
Information
If you intend to re-install the previously used coolant pump, a bead of sealant measuring about 1.5 mm
thick must be applied to the cleaned sealing face in addition to the vulcanized seal.
Clean sealing faces to remove any oil and grease.

"PLATINUM EDITION") > SUBSEQUENT WORK
1. Install poly-V-belt. → 137819 REMOVING AND INSTALLING POLY-V-BELT
2. Install poly-V-belt for compressor. → 137819 REMOVING AND INSTALLING POLY-V-BELT

FOR COMPRESSOR
3. Secure front left coolant pipes. → 196120 REMOVING AND INSTALLING FRONT LEFT
COOLANT PIPES
4. Fill in coolant and bleed the system. → 193817 DRAINING AND FILLING COOLANT
(INCLUDES BLEEDING)
WM 195519 REMOVING AND INSTALLING COOLANT REGULATOR HOUSING (V8)

1. Remove intake-air distributor → REMOVING INTAKE-AIR DISTRIBUTOR - section on

"Removing".
2. Remove fuel distributor pipe → REMOVING FUEL DISTRIBUTOR PIPE (FUEL RAIL) - section
on "Removing".
3. Remove water pump → REMOVING COOLANT PUMP - section on "Removing".
4. Remove thermostat insert. → REMOVING COOLANT REGULATOR - section on "Removing".

(ALL MODELS) > REMOVING HOUSING FOR COOLANT REGULATOR > REMOVING
COOLANT REGULATOR HOUSING
1. Disconnect the front coolant hoses from the two thermostat housing pipes. → Coolant hoses to
radiator (illustration as example)
Fig 1: Identifying Radiator Coolant Hoses

2. Disconnect small coolant pipe at the side -4- , pull it forward and set it aside. To do this,
remove the screw -3- and pull off the pipe.
1. Connection Piece On Generator
2. Connection Piece Screw
3. Screw, M6 x 20
4. Coolant Return Line
5. Coolant Return Hose Assembly
6. Holder
7. Screw, M6 (Aluminum Screw)
8. Clip
3. Detach vent line at the cylinder heads. → Vent line

Fig 3: Detaching Vent Line

Fig 4: Overview Of Ventilation
1. Vent Line
2. Screw, M6 x 16
2. 3.2. Remove vent line -2- .
4. Remove screws for the wiring harness at the cylinder heads and at the water guide and loosen
the wiring harness. → Wire harness for engine
Fig 5: Removing Engine Wiring Harness
5. Remove screws for thermostat housing -2- and loosen thermostat housing -1- in an upward
direction. The coolant pipe -1- (Fig 7) remains fitted in the thermostat housing.
1. Thermostat Housing
2. Screw, M6 x 25
3. Screw, M6 x 25; Screwed To Fuel High-Pressure Distribution Pipe
4. Seal For Thermostat Housing; Replace
5. Thermostat Insert (Map-Controlled Thermostat); Including Electric Heating Element

Fig 7: Identifying Heater Coolant Pipe, Sealing Ring And Screws
1. Heater Coolant Pipe
2. M6 Screw
3. Sealing ring
4. Screw Plug, M16 x 1.5
5. M6 Screw
6. Coolant Guide Tube (Collection Pipe)
7. Sheetmetal Seal
8. Plug
6. Remove both coolant hoses from the coolant pipe behind the cable duct (illustration shows a
number of coolant hoses).
→ Coolant hoses Remove thermostat housing with coolant pipe.

7. Disconnect thermostat housing and coolant pipe if necessary. Replace sealing rings.

(ALL MODELS) > INSTALLING HOUSING FOR COOLANT REGULATOR
Information
The tightening specifications for the basic engine are stored centrally (→ 1001IN Tightening TorqueS,
TIGHTENING SEQUENCES, ASSEMBLY OVERVIEWS ).
1. The components are installed in reverse order to removal.
2. Sealing rings must be replaced.
3. Insert coolant pipe with new sealing rings into the thermostat housing following disassembly.
Insert sealing rings with grease 000.043.204.68.
4. Insert thermostat housing together with coolant pipe and screw down in the tightening
sequence.
→ Tightening sequence for thermostat housing
Fig 1: Thermostat Housing Screw Tightening Sequence

1. Fit thermostat insert (coolant regulator). For details, see → 195819 REMOVING AND
INSTALLING COOLANT REGULATOR (THERMOSTAT INSERT)
2. Fit water pump. → 195019 REMOVING AND INSTALLING COOLANT PUMP
PIPE

DISTRIBUTOR

(CAYENNE GTS & CAYENNE S) > PRELIMINARY WORK

DISTRIBUTOR
2. Remove vacuum reservoir. → 245419 REMOVING AND INSTALLING VACUUM RESERVOIR
3. Remove coolant pump. → 195019 REMOVING AND INSTALLING COOLANT PUMP
4. Remove coolant regulator. → 195819 REMOVING AND INSTALLING COOLANT

REGULATOR (THERMOSTAT INSERT)

(CAYENNE GTS & CAYENNE S) > REMOVING COOLANT REGULATOR HOUSING
1. Loosen clamps -arrows- and pull off coolant hoses -1 - and -2- .
1. 1.1. Soak up emerging coolant with a cloth.

Fig 1: Locating Coolant Regulator Housing
2. Loosen the vent line on the cylinder heads.

Fig 2: Loosening Cylinder Heads Vent Line

Fig 3: Removing Vent Line
1. 2.1. Unscrew and remove fastening screws -1- .
3. Remove wiring harness screws on the cylinder heads and at the water guide and loosen the
wiring harness. → see Fig 4
Fig 4: Removing Engine Wire Harness
4. Disconnect coolant pipe -4- , pull it forward and set it aside.
1. 4.1. Unscrew screw -3- and pull off coolant pipe -4- .
2. 4.2. Soak up emerging coolant with a cloth.

5. Unscrew the screws on the coolant regulator housing -2- and loosen coolant regulator housing
-1- by pulling it upwards. The coolant pipe -1- (bottom figure) remains fitted in the coolant
regulator housing.
Fig 6: Identifying Coolant Regulator Housing

Fig 7: Identifying Coolant Guide
6. Remove the two coolant hoses from the coolant pipe behind the cable duct (figure shows
several coolant hoses). → Coolant line Remove coolant regulator housing with coolant pipe.
Fig 8: Identifying Coolant Line
7. Disconnect coolant regulator housing and coolant pipe if necessary. Replace sealing rings.

(CAYENNE GTS & CAYENNE S) > INSTALLING COOLANT REGULATOR HOUSING
Information
1. The components are essentially installed in reverse order to removal.
3. Insert coolant pipe with new sealing rings into the coolant regulator housing following
disassembly. Insert sealing rings with grease 000.043.204.68.
4. Insert coolant regulator housing with coolant pipe and secure according to the specified
tightening sequence. → Tightening sequence for coolant regulator housing
Fig 1: Coolant Regulator Housing Screws Tightening Sequence

(CAYENNE GTS & CAYENNE S) > SUBSEQUENT WORK
1. Install coolant regulator. → 195819 REMOVING AND INSTALLING COOLANT REGULATOR

(THERMOSTAT INSERT)
2. Install coolant pump. → 195019 REMOVING AND INSTALLING COOLANT PUMP

DISTRIBUTOR
WM 195519 REMOVING AND INSTALLING HOUSING FOR COOLANT REGULATOR

(V8) (CAYENNE GTS, CAYENNE S, CAYENNE TURBO & CAYENNE TURBO S) >
PRELIMINARY WORK

"Removing".
2. Remove fuel distributor pipe → REMOVING FUEL DISTRIBUTOR PIPE - section on

"Removing".
3. Remove water pump → REMOVING COOLANT PUMP - section on "Removing".
4. Remove thermostat insert. → REMOVING - section on "Removing".

REMOVING HOUSING FOR COOLANT REGULATOR > REMOVING COOLANT
REGULATOR HOUSING
1. Disconnect the front coolant hoses from the two thermostat housing pipes. → Coolant hoses to
radiator (illustration as example)
Fig 1: Identifying Radiator Coolant Hoses
2. Disconnect small coolant pipe at the side -4- , pull it forward and set it aside. To do this,
remove the screw -3- and pull off the pipe.
3. Screw, M6 x 20
6. Holder
7. Screw, M6 (aluminum screw)
8. Clip
3. Detach vent line at the cylinder heads. → Vent line

Fig 3: Overview Of Ventilation

Fig 4: Detaching Vent Line
1. Vent line
2. Screw, M6 x 16
4. Remove screws for the wiring harness at the cylinder heads and at the water guide and loosen
the wiring harness. → Wire harness for engine
Fig 5: Removing Engine Wire Harness
5. Remove screws for thermostat housing -2- and loosen thermostat housing -1- in an upward
direction. The coolant pipe -1- (Fig 6) remains fitted in the thermostat housing.
2. Screw, M6 x 25
4. Seal For Thermostat Housing; replace
5. Thermostat Insert (map-controlled thermostat); including electric heating element

Fig 7: Identifying Heater Coolant Pipe, Sealing Ring And Screws
1. Heater Coolant Pipe
2. M6 screw
3. Sealing Ring
4. Screw Plug, M16 x 1.5
5. M6 screw
6. Coolant Guide Tube (Collection Pipe)
7. Sheetmetal Seal
8. Plug
6. Remove both coolant hoses from the coolant pipe behind the cable duct (illustration shows a
number of coolant hoses).
→ Coolant hoses Remove thermostat housing with coolant pipe.

7. Disconnect thermostat housing and coolant pipe if necessary. Replace sealing rings.

INSTALLING HOUSING FOR COOLANT REGULATOR
Information
1. The components are installed in reverse order to removal.
3. Insert coolant pipe with new sealing rings into the thermostat housing following disassembly.
Insert sealing rings with grease 000.043.204.68.
4. Insert thermostat housing together with coolant pipe and screw down in the tightening
sequence.
→ Tightening sequence for thermostat housing
Fig 1: Thermostat Housing Screw Tightening Sequence

SUBSEQUENT WORK
1. Fit thermostat insert (coolant regulator). For details, see → 195819 REMOVING AND
INSTALLING COOLANT REGULATOR (THERMOSTAT INSERT)
2. Fit water pump. → 195019 REMOVING AND INSTALLING COOLANT PUMP
PIPE

DISTRIBUTOR
WM 195819 REMOVING AND INSTALLING COOLANT REGULATOR (V8) (ALL

1. Drain the cooling system. → 193817 DRAINING AND FILLING IN COOLANT
2. Remove the throttle housing. → 244219 REMOVING AND INSTALLING THROTTLE

HOUSING
3. Remove the coolant pump. → 195019 REMOVING AND INSTALLING COOLANT PUMP
MODELS) > INFORMATION > COMPONENT OVERVIEW
2. Screw, M6 x 25
4. Seal For Thermostat Housing; replace
5. Thermostat Insert; including electric heating element

MODELS) > REMOVING COOLANT REGULATOR
Removed water pump -1- and thermostat insert -2- →

Fig 1: Identifying Thermostat And Water Pump
1. Release cable plug for thermostat insert using angled pointed-nose pliers between the
crankcase and thermostat housing and pull it off. → Cable plug for thermostat -1-
Fig 2: Identifying Thermostat Cable Plug

Fig 3: Releasing Thermostat Cable Plug
2. Remove thermostat insert using shop-made tool.
1. 2.1. Use pointed-nose pliers to wrap a piece of wire or stiff electric cable through
several spokes of the thermostat insert. Figure showing screwdriver → Secured
electric cable .
Fig 4: Securing Electric Cable
2. 2.2. Tie a knot in the wire or electric cable to prevent it from being pulled out.
3. 2.3. Insert an assembly lever or a large screwdriver through the cable. → Secured
electric cable
4. 2.4. Pull the thermostat insert out of the crankcase completely using an inserted
assembly lever or a large screwdriver. Support the assembly lever under the
vibration balancer if necessary.
→ Secured electric cable Figure shows removed thermostat insert → Removed

coolant regulator .

MODELS) > INSTALLING COOLANT REGULATOR
Information
Damaged coolant regulators must be replaced.
Use water-soluble assembly gel "Kluberplus S06-100" with the number 000 043 205 93 (status 06/08)
for the sealing rings on the thermostat insert. Dilute it 50:50 with water.
1. Replace the sealing rings on the thermostat insert and coat them lightly with "Kluberplus
S06-100". Figure shows thermostat insert with disassembly cable. -1- Check that the sealing
rings are fitted at the correct position (sealing rings must not be installed the wrong way
round).
Fig 1: Identifying Thermostat Insert
2. Push the thermostat insert through the opening in the crankcase and into the thermostat
housing. When doing this, make sure that the cable connection is facing upwards.
2. Screw, M6 x 25
3. Check that the coolant regulator was fitted as far as it will go. You must not be able to feel any
overhang or underhang between the coolant regulator and crankcase. The coolant regulator
must be seated flush in the crankcase.
Fig 3: Checking Coolant Regulator
4. Connect cable plug to the thermostat insert.

1. Fit the coolant pump. → 195019 REMOVING AND INSTALLING COOLANT PUMP
2. Fit the throttle housing. → 244219 REMOVING AND INSTALLING THROTTLE HOUSING
3. Bleed and fill the cooling system. → 193817 DRAINING AND FILLING COOLANT
4. After replacing the coolant regulator, the fault memory for engine control must be erased
(Erase adaptation values). The adaptation adapts to the new thermostat insert.
WM 195819 REMOVING AND INSTALLING COOLANT REGULATOR (V6) (CAYENNE

GTS & CAYENNE S) > PRELIMINARY WORK
BLEEDING)
2. Remove throttle housing. → 244219 REMOVING AND INSTALLING THROTTLE HOUSING

3. Remove coolant pump. → 195019 REMOVING AND INSTALLING COOLANT PUMP

GTS & CAYENNE S) > REMOVING COOLANT REGULATOR
Removed water pump -1- and coolant regulator -2- . →
1. Release cable plug -1- for the coolant regulator by inserting an angled pointed-nose pliers
between the crankcase and coolant regulator housing and disconnect it.
Fig 2: Identifying Coolant Regulator Cable Plug

Fig 3: Removing Coolant Regulator Cable Plug
2. Remove coolant regulator using shop-made tool.
1. 2.1. Use pointed-nose pliers to wrap a piece of wire or stiff electric cable through
several spokes of the coolant regulator. Figure showing screwdriver → Secured
electric cable .
Fig 4: Securing Electric Cable
2. 2.2. Tie a knot in the wire or electric cable to prevent it from being pulled out -2- .
3. 2.3. Insert an assembly lever or a large screwdriver through the cable. → Secured
electric cable
4. 2.4. Pull coolant regulator completely out of the crankcase or coolant regulator
housing. Support the assembly lever under the vibration balancer if necessary. →
Secured electric cable Figure shows removed coolant regulator → Removed coolant
regulator .
Fig 5: Removing Coolant Regulator

GTS & CAYENNE S) > INSTALLING COOLANT REGULATOR
Information
Damaged coolant regulators must be replaced.
Use water-soluble assembly gel "Kluberplus S06-100" with the number 000 043 205 93 (status 06/08)
for the sealing rings on the coolant regulator. Dilute it 50:50 with water.
1. Replace sealing rings on the coolant regulator and coat them lightly with "Kluberplus S06-100".
Figure shows coolant regulator with disassembly cable. Check that the sealing rings -1- are
fitted at the correct position (sealing rings must not be installed the wrong way round).
Fig 1: Identifying Coolant Regulator Sealing Rings
2. Push coolant regulator through the opening in the crankcase and in the coolant regulator
housing. When doing this, make sure that the cable connection is facing upwards.
3. Check that the coolant regulator was fitted as far as it will go. You must not be able to feel any
overhang or underhang between the coolant regulator and crankcase. The coolant regulator
must be seated flush in the crankcase.
Fig 2: Checking Fit Of Coolant Regulator
4. Connect cable plug on coolant regulator.

GTS & CAYENNE S) > SUBSEQUENT WORK
1. Fit the coolant pump. → 195019 REMOVING AND INSTALLING COOLANT PUMP
2. Fit the throttle housing. → 244219 REMOVING AND INSTALLING THROTTLE HOUSING
3. Fill and bleed the cooling system. → 195019 REMOVING AND INSTALLING COOLANT
PUMP
4. After replacing the coolant regulator, the engine control fault memory must be erased (Deleting
adaptation values). The adaptation adapts to the new thermostat insert.
WM 195819 REMOVING AND INSTALLING COOLANT REGULATOR (THERMOSTAT)

Fastening screw Tightening Torque 10 Nm (7.5 ft. lb.)

Fastening screw Tightening Torque 7 Nm (5 ft. lb.)
Fastening screw Tightening Torque 10 Nm (7.5 ft. lb.)

BLEEDING)
2. Disconnect the two coolant hoses at the sides and set them aside. → Coolant hoses
Fig 1: Disconnecting Coolant Hoses

(CAYENNE) > REMOVING > REMOVING COOLANT REGULATOR
1. Unscrew hexagon-head bolts. -20-
2. Remove cover on thermostat insert. -19-

3. Sealing ring Must Always Be Replaced . -9-
4. Replace the thermostat insert. -21-

Fig 1: Overview Of Coolant Regulator (3.6-Liter DFI Engine)
1. Fastening Screw → Tightening Torque: 10 Nm (7.5 ft. lb.)
2. Connecting Piece For Reservoir
3. Adapter
4. Seal
5. Coolant Pipe
6. Coolant Pipe
7. Fastening Screw → Tightening Torque: 7 Nm (5 ft. lb.)
8. Coolant Pipe
9. Sealing Ring
11. O-Ring Must Always Be Replaced
12. Check That Retaining Clip Is Seated Securely
13. Fastening Screw → Tightening Torque: 10 Nm (7.5 ft. lb.)
14. Retaining Clip
15. Coolant Pipe
16. Coolant Pipe
17. Coolant Pipe
18. Coolant Pipe
19. Cover On Thermostat Insert
21. Coolant Regulator
22. Coolant Pipe
23. Check Spray-On Seal On Coolant Pump
25. Coolant Pump Pulley
26. Fastening Screw For Coolant Pump

(CAYENNE) > INSTALLING
1. Replace sealing ring.
2. Assemble in reverse order.

1. Carry out the remaining work.
2. Fill the cooling system. → 193817 DRAINING AND FILLING COOLANT (INCLUDES
BLEEDING)
WM 196119 REMOVING AND INSTALLING COOLANT PIPES (CAYENNE (3.0) &
CAYENNE S E-HYBRID) > TOOLS
Hose Clamp VW Tool 3094

CAYENNE S E-HYBRID) > TECHNICAL VALUES

value 1 2
Fastening Screw For Front Left Tightening 9 Nm (6.5

Coolant Pipes Torque ft. lb.)


Fastening Screw Securing Holder For Tightening 22 Nm (16

Front Left Coolant Pipes To Engine Torque ft. lb.)
Fastening Screw For Front Coolant Tightening 9 Nm (6.5

Pipe Torque ft. lb.)

Fastening Screw Securing Lower Tightening 9 Nm (6.5
Coolant Pipe To Compressor Torque ft. lb.)
Fastening Screw Securing Lower Tightening 9 Nm (6.5

Fastening Screw Securing Upper Tightening 9 Nm (6.5

Fastening Screw Securing Upper Tightening 9 Nm (6.5

Fastening Screw For Upper Coolant Tightening 9 Nm (6.5


Fastening Screw For Engine Oil Tightening 9 Nm (6.5

Cooler Pipes Torque ft. lb.)
Fastening Screw For Engine Oil Tightening 9 Nm (6.5

Cooler Pipes Torque ft. lb.)

CAYENNE S E-HYBRID) > ASSEMBLY OVERVIEW - COOLANT PIPES
2. Coolant Pipes, Front Left

5. Holder
9. Front Coolant Pipe
10. Seal Replace
11. O-ring Replace
14. Lower Coolant Pipe On Compressor
16. Dowel Sleeve
17. Seal Replace
19. Seal Replace
20. Upper Coolant Pipe On Compressor
21. Dowel Sleeve
23. Seal Replace
24. Seal Replace
25. O-Ring/Replace
26. Upper Coolant Pipe
28. Seal Replace
32. Engine oil cooler pipes
33. O-ring Replace
34. Retaining Clip

CAYENNE S E-HYBRID) > REMOVING AND INSTALLING PIPES FOR ENGINE OIL
COOLER > REMOVING PIPES FOR ENGINE OIL COOLER
WARNING: Hot fluid
Danger of scalding
Remove return pipe for engine oil cooler:
2. Remove air-conditioning compressor. → 873419 REMOVING AND INSTALLING

Fig 1: Locating Engine Oil Cooler Coolant Hose
5. Remove coolant pipe.
1. 5.1. Unscrew screws -1- and -2- for the coolant pipes. Loosen hose clamp -3- .
2. 5.2. Swivel the coolant pipe slightly to the left -arrow- and pull it off the upper
coolant pipe.
Fig 2: Locating Coolant Pipe
Remove Supply Pipe For Engine Oil Cooler:
6. Unscrew screws -arrows- and remove holder for air-conditioning compressor.

Fig 3: Locating Air-Conditioning Compressor Holder
7. Pull the coolant hose off the engine oil cooler, unscrew fastening screws -2- and remove the
coolant pipe.
Fig 4: Identifying Engine Oil Cooler Coolant Hose

CAYENNE S E-HYBRID) > REMOVING AND INSTALLING PIPES FOR ENGINE OIL
COOLER > INSTALLING PIPES FOR ENGINE OIL COOLER
Information
2. 1.2. Secure all hose connections with standard hose clamps.
3. 1.3. Before installation, clean or smoothen the sealing face for the O-ring.
4. 1.4. Moisten the O-ring with coolant and slide it onto the coolant pipe.
2. Install air-conditioning compressor. → 873419 REMOVING AND INSTALLING


CAYENNE S E-HYBRID) > REMOVING AND INSTALLING FRONT LEFT COOLANT
PIPES > REMOVING FRONT LEFT COOLANT PIPES
WARNING: Hot fluid
Danger of scalding
1. Remove front engine cover.
Fig 1: Locating Upper Coolant Hose Brackets
5. Unscrew screws -1... 3- for the coolant pipes.

Fig 2: Identifying Coolant Pipes Screws
6. Release vacuum pipe -1- from the holder. Unscrew screw -2- and pull off coolant hoses
-arrow- .
Remove coolant pipes and hoses in a downward direction.

Fig 3: Locating Front Left Coolant Hoses Screws

CAYENNE S E-HYBRID) > REMOVING AND INSTALLING FRONT LEFT COOLANT
PIPES > INSTALLING FRONT LEFT COOLANT PIPES
Information
2. Fill in coolant for low-temperature cooling system. → 193817 DRAINING AND FILLING

CAYENNE S E-HYBRID) > REMOVING AND INSTALLING FRONT COOLANT PIPE >
REMOVING FRONT COOLANT PIPE
WARNING: Hot fluid
Danger of scalding
1. Drain off coolant for high-temperature cooling system. → 193817 DRAINING AND FILLING
2. Remove poly-V-belt for compressor and poly-V-belt. → 137819 REMOVING AND INSTALLING
DRIVE BELT
3. Remove front left coolant pipes. → 196120 REMOVING AND INSTALLING COOLANT PIPES
4. Loosen screws for poly-V-belt pulley for the coolant pump using PIN WRENCH 3212 as a
counter-hold tool.
Unscrew screws and remove poly-V-belt pulley.

Fig 1: Identifying Coolant Pump Poly-V-Belt Pulley
5. Remove front coolant pipe.
1. 5.1. Disconnect electric plug connection -3- on the coolant temperature sensor.
2. 5.2. Remove coolant hoses -1, 4- by lifting up the retaining clips.
3. 5.3. Remove upper coolant hose by loosening the hose clamp -2- .
4. 5.4. Loosen hose clamp -5- .
5. 5.5. Unscrew screws -arrows- and remove the front coolant pipe.
Fig 2: Locating Front Coolant Pipe Screws

CAYENNE S E-HYBRID) > REMOVING AND INSTALLING FRONT COOLANT PIPE >
INSTALLING FRONT COOLANT PIPE
2. Install front left coolant pipe. → 196120 REMOVING AND INSTALLING COOLANT PIPES
3. Install poly-V-belt for compressor and poly-V-belt. → 137819 REMOVING AND INSTALLING
DRIVE BELT
4. Fill in coolant for high-temperature cooling system. → 193817 DRAINING AND FILLING
CAYENNE S E-HYBRID) > REMOVING AND INSTALLING UPPER COOLANT PIPE >
REMOVING UPPER COOLANT PIPE
WARNING: Hot fluid
Danger of scalding
NOTE: Dirt on injection system components
Material damage
Rough-running engine
Bad exhaust emissions
→ Thoroughly clean connection points and adjacent areas before loosening them. If the engine is very
dirty, wash it before starting disassembly work.
→ Lay removed parts on a clean surface and cover them. Do not use fibre-shedding cloths.
→ Carefully cover components or seal them if repair work will not be carried out immediately. Place
rubber caps on connections. Seal intake openings with film or adhesive tape.
→ Only install clean parts. Do not take spare parts out of the packaging until just before installation.
→ Never use compressed air when the system is open. Do not move the vehicle.
Information
Do not bend high-pressure lines. Always remove the high-pressure distributor pipe and other
fuel-supply components in the high-pressure area completely. Check that the connection points are
not damaged and are perfectly clean and make sure there is no thread damage. Fit union nuts on
all connection points by hand before screwing in screws or bolts. Remove dirt on the conical/ball
joints. Check connection points for leaks following fitting .
Information
Absorb any escaping fuel using a suitable binding material or a cloth .
Cloths which have absorbed fuel must be disposed of according to the applicable national laws .
The fuel system must be depressurized before starting work on it .
Only work on the fuel system in well-ventilated rooms .
Any seals which have been removed must always be replaced .
Do not use any sealant containing silicone or silicone spray when the injection system is open.
Traces of silicone drawn in by the engine are not combusted and damage the oxygen sensors .
2. Remove compressor. → 211419 REMOVING AND INSTALLING COMPRESSOR
3. Unclip line -1- . Screw off nuts -arrows- and remove protective plate -2- .
Fig 1: Locating Protective Plate
4. Remove lower part of intake manifold at the right. → 244719 REMOVING AND INSTALLING
INTAKE MANIFOLD
5. Move hose -arrow- for secondary air forward out of the holder and disconnect it by pressing
the release buttons. Release hose for secondary air and vacuum hoses and press them aside.
Fig 2: Locating Secondary Air Hose
6. Unscrew threaded connection -1- and union nuts -2- and -3- . Unscrew screws -arrows- on
the retaining clips and remove high-pressure line.
Fig 3: Locating High-Pressure Line Screws And Nut
7. Remove coolant hose -2- from the coolant pipe. Unscrew screw -1- and pull coolant pipe to
the rear and out of the cylinder block -arrow- .
Fig 4: Removing Coolant Hose

CAYENNE S E-HYBRID) > REMOVING AND INSTALLING UPPER COOLANT PIPE >
INSTALLING UPPER COOLANT PIPE
WARNING: Leaking fuel supply lines
Emerging fuel
Risk of fire
→ Perform leak test.
Information

2. Install lower part of intake manifold at the right. → 244719 REMOVING AND INSTALLING
INTAKE MANIFOLD
3. Install compressor. → 211419 REMOVING AND INSTALLING COMPRESSOR

CAYENNE S E-HYBRID) > REMOVING AND INSTALLING COOLANT PIPES ON
COMPRESSOR > REMOVING COOLANT PIPES FROM COMPRESSOR
2. Remove front sound insulation. → 108019 REMOVING AND INSTALLING ENGINE GUARD
WARNING: Hot fluid
5. Clamp off coolant hose using Hose Clamp 3094 and remove it from the coolant pipes on the
compressor by releasing the hose clips -arrows- .
Fig 1: Locating Compressor Coolant Hoses
6. Unscrew screws -1- and -2- and remove coolant pipes.

Fig 2: Identifying Compressor Coolant Pipes

CAYENNE S E-HYBRID) > REMOVING AND INSTALLING COOLANT PIPES ON
COMPRESSOR > INSTALLING COOLANT PIPES ON COMPRESSOR
Information
2. Check the coolant level. → 193817 DRAINING AND FILLING COOLANT (INCLUDES
BLEEDING)
3. Install front sound insulation. → 108019 REMOVING AND INSTALLING ENGINE GUARD

CAYENNE S E-HYBRID) > REMOVING AND INSTALLING REAR LEFT COOLANT
PIPES ON TRANSMISSION > REMOVING REAR LEFT COOLANT PIPES ON
TRANSMISSION
WARNING: Hot fluid
Danger of scalding
2. Remove left catalytic converter. → 267319 REMOVING AND INSTALLING MAIN CATALYTIC
CONVERTER
3. Remove rear left coolant pipe.
1. 3.1. Unscrew screws -arrows- .
2. 3.2. Remove coolant hoses -1- and -3- by loosening the hose clamps.
3. 3.3. Remove rear left coolant pipes.

Fig 1: Locating Rear Coolant Pipes On Transmission

CAYENNE S E-HYBRID) > REMOVING AND INSTALLING REAR LEFT COOLANT
PIPES ON TRANSMISSION > INSTALLING REAR LEFT COOLANT PIPES ON
TRANSMISSION
Information

2. Install left catalytic converter. → 267319 REMOVING AND INSTALLING MAIN CATALYTIC
CONVERTER
WM 196120 REMOVING AND INSTALLING COOLANT PIPES (CAYENNE S E-HYBRID)

> TOOLS

> ASSEMBLY OVERVIEW - COOLANT PIPES
Pull plug-in couplings to make sure they are seated securely.
Tightening Torques for M6 screws: 10 Nm (7.5 ft. lb.)
Tightening Torques for M8 screws: 20 Nm (15 ft. lb.)

1. Upper Coolant Pipe On Compressor
2. Upper Coolant Pipe
3. Coolant Regulator With Housing
6. Retaining Clip
7. T-Piece For Power And Control Electronics For Electric Drive
8. Return Pipe For Engine Oil Cooler
9. Supply Pipe For Engine Oil Cooler
10. Hose For Charge-Air Cooling Pump
12. Lower Coolant Pipe On Compressor

> REMOVING AND INSTALLING PIPES FOR ENGINE OIL COOLER > REMOVING
PIPES FOR ENGINE OIL COOLER
Remove return pipe for engine oil cooler:
2. Remove electric air-conditioning compressor. → 873419 REMOVING AND INSTALLING

WARNING: Hot fluid
Fig 1: Locating Return Pipe For Engine Oil Cooler
5. Remove coolant pipe.
1. 5.1. Unscrew screws -1- and -2- for the coolant pipes. Loosen hose clamp -3- .
2. 5.2. Swivel the coolant pipe slightly to the left -arrow- and pull it off the upper
coolant pipe.
Fig 2: Locating Engine Oil Cooler Return Pipe Mounting
Remove supply pipe for engine oil cooler:
6. Support the engine.
7. Unscrew fastening screw on the engine mounting and lift the engine slightly.

WARNING: Hot fluid
9. Pull the coolant hose off the engine oil cooler, unscrew fastening screws -2- and remove the
coolant pipe.
Fig 4: Identifying Engine Oil Cooler Supply Pipe

> REMOVING AND INSTALLING PIPES FOR ENGINE OIL COOLER > INSTALLING
PIPES FOR ENGINE OIL COOLER
Information
2. Install left engine support.
3. Install electric air-conditioning compressor. → 873419 REMOVING AND INSTALLING


> REMOVING AND INSTALLING FRONT LEFT COOLANT PIPES > REMOVING FRONT
LEFT COOLANT PIPES
Fig 1: Locating Low-Temperature Cooling System Hose
5. Unscrew screws -1... 3- for the coolant pipes.

Fig 2: Identifying Low-Temperature Coolant Pipes Screws
6. Unscrew screws -1- and -2- and remove crash panel -A- .
WARNING: Hot fluid
7. Open the locks on the two rapid-action couplings -arrows- and pull off the coolant lines.
Fig 4: Pulling Coolant Lines
WARNING: Hot fluid
8. Release vacuum pipe -1- from the holder. Unscrew screw -2- and pull off coolant hoses
-arrow- .
Remove coolant pipes and hoses in a downward direction.

Fig 5: Locating Front Left Coolant Hoses Clamps

> REMOVING AND INSTALLING FRONT LEFT COOLANT PIPES > INSTALLING
FRONT LEFT COOLANT PIPES
Information
2. Fill in coolant for low-temperature cooling system. → 193817 DRAINING AND FILLING

> REMOVING AND INSTALLING FRONT COOLANT PIPE > REMOVING FRONT
COOLANT PIPE

FOR COMPRESSOR
3. Remove front left coolant pipes. → REMOVING FRONT LEFT COOLANT PIPES - section on
"Removing"
WARNING: Hot fluid
4. Remove coolant hose from the front coolant pipe by lifting up the retaining clip -arrow- .
Fig 1: Locating Coolant Hose Clip
5. Press the locking mechanism -arrows- together and pull off valve for coolant pump -1- .
Fig 2: Pulling Coolant Pump Valve
WARNING: Hot fluid
6. Disconnect secondary-air hose -1- and coolant hose -arrow- .

Fig 3: Locating Secondary-Air Hose
7. Loosen hose clamp -1- and disconnect electric plug connection -2- at the coolant temperature
sensor.
Unscrew screw -3- and fastening screws -arrows- .
Swivel coolant pipe forward and lift it up off the engine.

Fig 4: Pulling Coolant Pipe

> REMOVING AND INSTALLING FRONT COOLANT PIPE > INSTALLING FRONT
COOLANT PIPE
Information
2. Install front left coolant pipes. → INSTALLING FRONT LEFT COOLANT PIPES - section on
"Installing"
FOR COMPRESSOR

> REMOVING AND INSTALLING UPPER COOLANT PIPE > REMOVING UPPER
COOLANT PIPE
3. Unclip line -1- . Screw off nuts -arrows- and remove protective plate -2- .
Fig 1: Locating High-Pressure Pump Protective Plate
4. Remove lower part of intake manifold at the right. → 244719 REMOVING AND INSTALLING
INTAKE MANIFOLD
the release buttons. Release hose for secondary air and vacuum hoses and press them aside.
1. Material damage
2. Rough-running engine
3. Bad exhaust emissions
→ Thoroughly clean connection points and adjacent areas before loosening them. If the
engine is very dirty, wash it before starting disassembly work.
→ Carefully cover components or seal them if repair work will not be carried out immediately.
Place rubber caps on connections. Seal intake openings with film or adhesive tape.
→ Only install clean parts. Do not take spare parts out of the packaging until just before
installation.
1. Danger of fire or explosion
Information
1. Do not bend high-pressure lines. Always remove the high-pressure distributor pipe and
other fuel-supply components in the high-pressure area completely. Check that the
connection points are not damaged and are perfectly clean and make sure there is no
thread damage. Fit union nuts on all connection points by hand before screwing in
screws or bolts. Remove dirt on the conical/ball joints. Check connection points for leaks
following fitting .
Information
1. Absorb any escaping fuel using a suitable binding material or a cloth .
2. Cloths which have absorbed fuel must be disposed of according to the applicable
national laws .
3. The fuel system must be depressurized before starting work on it .
4. Only work on the fuel system in well-ventilated rooms .
5. Any seals which have been removed must always be replaced .
6. Do not use any sealant containing silicone or silicone spray when the injection system is
open. Traces of silicone drawn in by the engine are not combusted and damage the
oxygen sensors .
6. Unscrew threaded connection -1- and union nut -3- . Unscrew screws -arrows- on the
retaining clips and remove high-pressure line.
Fig 3: Locating High-Pressure Line Plug Connection
WARNING: Hot fluid
7. Remove coolant hose from the coolant pipe. Unscrew screw and pull coolant pipe to the rear
and out of the cylinder block.
Fig 4: Removing Coolant Hose From Coolant Pipe

> REMOVING AND INSTALLING UPPER COOLANT PIPE > INSTALLING UPPER
COOLANT PIPE
Emerging fuel
Risk of fire
Information

2. Install lower part of intake manifold at the right. → 244719 REMOVING AND INSTALLING
INTAKE MANIFOLD

> REMOVING AND INSTALLING COOLANT PIPES ON COMPRESSOR > REMOVING
COOLANT PIPES FROM COMPRESSOR
2. Remove front sound insulation. → 108019 REMOVING AND INSTALLING ENGINE GUARD
WARNING: Hot fluid
5. Clamp off coolant hose using Hose Clamp 3094 and remove it from the coolant pipes on the
compressor by releasing the hose clips -arrows- .
Fig 1: Locating Coolant Hose Clamps
6. Unscrew screws -1- and -2- and remove coolant pipes.

Fig 2: Identifying Coolant Pipes

> REMOVING AND INSTALLING COOLANT PIPES ON COMPRESSOR > INSTALLING
COOLANT PIPES ON COMPRESSOR
Information
2. Check the coolant level. → 193817 DRAINING AND FILLING COOLANT (INCLUDES
BLEEDING)
3. Install front sound insulation. → 108019 REMOVING AND INSTALLING ENGINE GUARD
WM 197019 REMOVING AND INSTALLING RADIATOR (V6) (CAYENNE GTS &

Tolerance Tolerance
1 2
Fastening Screws For Lower Tightening 25 Nm (19 ft.

Radiator Mounting Torque lb.)
Fastening Screws For Upper Tightening 5 Nm (3.5 ft.

Radiator Mounting Torque lb.)

1. Remove engine cover (design cover). → 108319 REMOVING AND INSTALLING ENGINE
3. Remove cooling fan housing (radiator frame). → 192019 REMOVING AND INSTALLING
COOLING FAN HOUSING (RADIATOR FRAME)
4. Drain refrigerant from the air conditioning system using suction. → 870317 DRAINING AND
FILLING REFRIGERANT
6. Remove cooling-air flap. → 193519 REMOVING AND INSTALLING COOLING-AIR FLAP
7. Remove left charge-air cooler. → 214319 REMOVING AND INSTALLING CHARGE-AIR

COOLER

CAYENNE S) > REMOVING RADIATOR
Do not open the air conditioning system if at all possible when removing the radiator module . Do not
bend the lines.
Do not bend the lines when installing the radiator module .
Information
The retaining clips should be mounted again immediately so that they are not confused .
1. Remove coolant hose -1- from the radiator by pulling out the safety clip on the coolant
connection piece and pulling off the hose. Then fit the safety clip again so that it does not get
mixed up.
Fig 1: Identifying Radiator Coolant Hose
2. Loosen the spring band clamp and pull off the breather hose -2- at the top right of the radiator.
Fig 2: Identifying Breather Hose On Radiator
3. Loosen coolant line holder -arrow - .

Fig 3: Locating Coolant Line Holder
4. Unscrew fastening screw -1- and press holder -2- with connected ATF lines -3- aside.
Fig 4: Removing ATF Lines
5. Remove refrigerant lines -A- from the radiator.
1. 5.1. Disconnect refrigerant lines on the radiator.

Fig 5: Identifying Refrigerant Line On Radiator
6. Unscrew fastening screw -5- used to secure the line holder for the power-steering cooler. Pull
the holder out and remove it.
Fig 6: Identifying Power-Steering Cooler Holder Screw
7. Loosen clips -arrows - over the radiator.

Fig 7: Locating Radiator Clips
8. Release safety clip -1- and remove coolant hose -2- from the radiator.
Fig 8: Identifying Lower Right Coolant Hose
9. Unscrew fastening screws -6 and 7- . Only loosen fastening screw -8- .
10. Remove both holders -arrows- at the left and right of the radiator.
Fig 9: Removing Radiator Screws
11. Turn the supports -arrows- at the left and right sides and pull them out of the rubber sleeve.
Fig 10: Locating Radiator Supports
12. Unclip power-steering cooler. To do this, unclip lines by pulling them forward out of the holder
-1- and then push them to the left out of the holder -2- . Secure the cooler at a suitable
position to prevent it from falling down.
Fig 11: Removing Power-Steering Cooler
13. Unscrew fastening screws -1- and remove lower air guide. → REMOVING CENTRE AIR
GUIDE - section on "Removing"
Fig 12: Removing Lower Air Guide
14. Unclip ATF cooler -5- on the radiator bracket and secure with ATF lines connected at a
suitable position to prevent it from falling down.
Fig 13: Removing ATF Cooler
Information
A second person is required for removing and installing the radiator.
15. Lift up the radiator and remove it carefully from the vehicle in an upward direction. Be careful of
all connecting lines when doing this.
Fig 14: Removing Radiator

CAYENNE S) > INSTALLING RADIATOR
Information
Do not open the air conditioning system if at all possible when Removing The Radiator Module . Do
not bend the lines.
Do not bend the lines when Installing The Radiator Module .
Information
A second person is required for removing and installing the radiator.
1. Carefully push in the radiator from above.

Fig 1: Installing Radiator
2. Secure the power-steering cooler. To do this, push the power-steering cooler from left to right
into the holder -1- and then clip the lines into the holder -2- .
3. Clip ATF cooler -5- into the radiator bracket.

Fig 2: Installing ATF Cooler
4. Secure air guide → Unscrewing fastening screws . → INSTALLING CENTRE AIR GUIDE -
Fig 3: Installing Air Guide Screws

Fig 4: Locating Power-Steering Cooler Line Holders
5. Slide the holders into the rubber sleeve for the radiator at the left and right sides -arrows- .
Fig 5: Locating Radiator Supports
6. Install both holders -arrows- at the left and right of the radiator.
7. Tighten fastening screws -6- . Tightening Torque 5 Nm (3.5 ft. lb.)
8. Tighten fastening screws -7 and 8 - . Tightening Torque 25 Nm (19 ft. lb.)

Fig 6: Installing Radiator Screws
9. Position the holder and tighten the fastening screw -5- used to secure the holder for the
power-steering cooler lines.
10. Fit coolant hose -2- on the radiator -3- and lock safety clip -1- .
Fig 7: Identifying Lower Right Coolant Hose

Fig 8: Identifying Power-Steering Cooler Holder Screw
11. Fit refrigerant lines -A- on the radiator.

Fig 9: Identifying Refrigerant Line On Radiator
12. Fit holder -2- with ATF lines connected -3- and tighten screw -1- .
Fig 10: Installing ATF Lines
13. Secure coolant line holder -arrow - .

Fig 11: Locating Coolant Line Holder
14. Slide breather hose -2- onto the right side of the radiator and fit hose clamp.
Fig 12: Identifying Breather Hose On Radiator
15. Push on coolant hose -1- and then slide on the safety clip for the adapter. The safety clip must
lock with an audible click.
Fig 13: Identifying Coolant Hose On Radiator

1. Install cooling-air flaps. → 193519 REMOVING AND INSTALLING COOLING-AIR FLAP
3. Fill air conditioning system with refrigerant. → 870317 DRAINING AND FILLING
REFRIGERANT
4. Install cooling fan housing (radiator frame). → 192019 REMOVING AND INSTALLING
COOLING FAN HOUSING (RADIATOR FRAME)
6. Install engine cover (design cover). → 108319 REMOVING AND INSTALLING ENGINE
WM 197819 REMOVING AND INSTALLING COOLANT TEMPERATURE SENSOR FOR

CONTROLLING ENGINE TEMPERATURE (CAYENNE) > PRELIMINARY WORK

2. Press tensioning arm of tensioning roller in -direction of arrow- . In non-tensioned position,
screw one M8 x 59 screw into the threaded bore -A- .
Fig 1: Loosening Tensioning Roller Tensioning Arm
3. Remove tensioning roller for poly-V-belt.
1. 3.1. Unscrew screws -arrows- and remove tensioning roller.

Fig 2: Locating Tensioning Roller Screws

CONTROLLING ENGINE TEMPERATURE (CAYENNE) > REMOVING COOLANT
TEMPERATURE SENSOR FOR CONTROLLING ENGINE TEMPERATURE >
ASSEMBLY OVERVIEW PART 1 - COOLING SYSTEM
2. Circulation Pump
3. ATF Preheater

5. Temperature Sensor For Controlling Engine Temperature
6. Coolant Pump
7. Coolant Control Valve
1. Replace O-rings and seals.
2. Pull plug-in couplings to check that they are seated securely
3. M6 screws: 10 Nm (7.5 ft. lb.)
4. M8 screws: 20 Nm (15 ft. lb.)

CONTROLLING ENGINE TEMPERATURE (CAYENNE) > REMOVING COOLANT
TEMPERATURE SENSOR FOR CONTROLLING ENGINE TEMPERATURE >
REMOVING COOLANT TEMPERATURE SENSOR FOR CONTROLLING ENGINE
TEMPERATURE
1. Disconnect connector for temperature sensor and expose the cable.
2. Unscrew fastening screw for temperature sensor using Allen Key T10058.
Fig 1: Removing Coolant Temperature Sensor

NOTE: Cooling system blocked
1. Engine overheating
→ Remove small parts
WARNING: Hot fluid
3. Pull temperature sensor out of the cylinder head and remove it by pulling it forward.
Information
1. If the O-ring and support washer are still in the cylinder head, they must be removed
using a piece of wire .
The following components must be on the temperature sensor.
1. -1- - Support washer
2. -2- - O-ring
Fig 2: Identifying Temperature Sensor Support Washer And O-Ring

CONTROLLING ENGINE TEMPERATURE (CAYENNE) > INSTALLING COOLANT
TEMPERATURE SENSOR FOR CONTROLLING ENGINE TEMPERATURE
1. Coat O-ring with coolant.
2. Move temperature sensor into installation position and press it into the cylinder head using a
suitable tool.
3. Perform further installation in reverse order, paying attention to the following:
Tightening Torque for temperature sensor: 5 Nm (3.5 ft. lb.)

CONTROLLING ENGINE TEMPERATURE (CAYENNE) > SUBSEQUENT WORK
WM 197819 REMOVING AND INSTALLING COOLANT TEMPERATURE SENSOR

2. Remove plenum panel wall behind the coolant expansion tank.

3. Remove vacuum pump. → 477619 REMOVING AND INSTALLING VACUUM PUMP

(CAYENNE TURBO & CAYENNE TURBO S) > REMOVING COOLANT TEMPERATURE
SENSOR
1. Expose access to temperature sensor -3- .
1. 1.1. Unclip oxygen sensor cable. Loosen the holder.

Fig 1: Identifying Temperature Sensor And Sleeve
1. Temperature sensor for engine compartment (installation position of

cylinder 8)
2. Sleeve
3. Temperature sensor (installation position of cylinder 4)
2. Pull off cable plug.
3. Remove coolant temperature sensor from the cylinder head.

(CAYENNE TURBO & CAYENNE TURBO S) > INSTALLING COOLANT TEMPERATURE
SENSOR
Information
1. Fit coolant temperature sensor -3- in the cylinder head. Tighten coolant temperature sensor.
Fig 1: Identifying Temperature Sensor And Sleeve
1. Temperature sensor for engine compartment (installation position of cylinder 8)
2. Sleeve
3. Temperature sensor (installation position of cylinder 4)
2. Peripheral equipment is installed in reverse order to removal.

1. Fit vacuum pump. → 477619 REMOVING AND INSTALLING VACUUM PUMP
2. Fit plenum panel wall behind the coolant expansion tank.

Service Manual: 20 - FUEL SUPPLY, CONTROL -- 92A CAYENNE
WM 2001IN INFORMATION ON WORKING ON THE PRESSURE TANK (CAYENNE S
E-HYBRID) > INFORMATION > RELIEVING PRESSURE IN THE TANK
WARNING: Pressurized components
Risk of bruising
→ Secure components to prevent them from falling off suddenly.
1. Before starting to work on the pressure tank, the following steps must be carried out:
1. 1.1. Press release button for the filler flap in the door panel on the driver's side.
2. 1.2. The message Tank readiness established appears after about 90 seconds
on the multi-function display in the instrument panel .
Release button for filler flap
2. Once tank readiness is established, the tank is depressurized and work can be done on the
fuel system/fuel tank.
WM 2001IN RULES RELATING TO CLEANLINESS AND INSTRUCTIONS FOR

WORKING ON THE FUEL SYSTEM (ALL MODELS) > INFORMATION > RULES
RELATING TO CLEANLINESS AND INSTRUCTIONS FOR WORKING ON THE FUEL
SYSTEM

necessary.
WARNING: Hot fuel and hot fuel lines.
Danger of scalding
→ Allow the fuel to cool down before opening line connections.
→ Wear protective gloves.
The work area and tools must be cleaned before working on the injection system.
Thoroughly clean connection points and adjacent areas before loosening them using engine or
brake cleaner and dry the cleaned area thoroughly.
During disassembly work, close off all open connections immediately using suitable clean
protection caps.
Do not remove the protection caps from any components until immediately before installation.
Pack components to be used again in new, sealable plastic bags.
Check the injection units and installation positions before installation by performing a visual
inspection for damage and soiling. Check that the injection unit stem is clean. If necessary, clean
the stem using a clean cloth, making sure not to damage it (no sharp tools!).
If the high-pressure lines will not be replaced, always mark the high-pressure lines during removal.
The high-pressure lines must only be re-fitted on the same cylinder.
Make sure not to damage the injection unit when removing the old sealing ring.
Check all new O-rings for signs of damage before fitting them. Coat O-rings with assembly oil or
engine oil before fitting them.
Align high-pressure lines without tension. Tighten all connections hand-tight at first and then
High-pressure lines must never be re-bent.
A tool can only be used to loosen and tighten lines on the entire high-pressure system. All other
assembly and disassembly processes must be carried out by hand and without tools.
Press fuel return hoses onto the injection units from above using your hand until they lock on each
injection unit with an audible click (do not press in the release pin while doing this). Then press the
release pin down. Check that the fuel return hoses are seated securely by pulling them upwards
with your hand and check for leaks.
Individual common rail components cannot be disassembled. All the components must be replaced
in the event of a fault.
No assembly work must be carried out on the common rail system when the engine is running.
The common rail system must not be bled by loosening high-pressure components after starting
the engine.
Fit all tie-wraps, which you removed or cut during removal, back at the same position during
installation.
When the fuel system is open: Never use compressed air if at all possible. Do not move the vehicle
if possible.
Also make sure that no diesel gets onto the coolant hoses. The hoses must be cleaned
immediately if necessary. Always replace worn hoses.
To avoid letting the high-pressure pump run dry and to start the engine quickly after replacing parts, the
following points must always be observed:
CAUTION: Danger of irreparable damage to the high-pressure pump if it runs dry
To avoid letting the fuel high-pressure pump run dry and to start the engine quickly after replacing
If parts/components of the fuel system between the fuel tank and fuel high-pressure pump are
removed or replaced, the basic setting must be performed in order to bleed the fuel system.
Perform initial fuel fill procedure after installing the high-pressure pump.
WM 200101 CHECKING FUEL SYSTEM (HIGH-PRESSURE SIDE) FOR LEAKS

(CAYENNE S & CAYENNE GTS) > TOOLS

Air-spring strut filling Workshop
WE 1282
Adapter Special tool 9759

(CAYENNE S & CAYENNE GTS) > TECHNICAL VALUES
High-pressure pump Pressure 10 bar
Fuel supply line Thread M16 x 1.5 Tightening torque 35 Nm (26 ft. lb.)

(CAYENNE S & CAYENNE GTS) > PRELIMINARY WORK

Material damage
Emerging fuel
Risk of fire
Information
Information
The ignition must be switched off when working on the fuel system .
After disassembly work on the high-pressure injection system, fit the components to the prescribed
torques.
Visible threaded joints must be inspected for leaks with the engine idling after a test drive.
For the check to be performed correctly, the components to be checked must not contain any fuel.
When dismantling, remove fuel from the lines.
1. Remove rear engine-compartment cover. → Removing front trim panel (engine compartment) -
2. Pull out fuse for the fuel pump in the central electrical system or disconnect the battery. This
ensures that the fuel pump does not start up when a door is opened.

(CAYENNE S & CAYENNE GTS) > TOOLS AND MATERIALS
Fig 1: Identifying Leak Test Tools
1. The required pressure is set on the compressed gas bottle using the commercially available
pressure gauge unit (pressure reducer). The commercially available compressed gas bottle
must be filled only with approved leak-locating gases.
2. Air-spring strut filling unit VAS 6231 WE 1282 with air-spring filling unit; the connection is
positioned between the pressure reducer and the adapter. Perform the leak test using
individual bursts of pressure.
3. Adapter 9759 for screwing into the low-pressure fuel line for the high-pressure pump.
4. Commercially available leak-locating spray for detecting gas leaks.
GAS SPECIFICATION
Leak-locating gas (test medium) Designation Composition/purity
4.6 (minimum
Helium He (gaseous, quality) 99.996 volume % (4.6) He
compressed)
5.0, etc. 99.999 volume % (5.0) He
not balloon gas!
95% nitrogen N2 and 5% hydrogen

Forming gas Forming gas 5
H2

(CAYENNE S & CAYENNE GTS) > CHECKING FUEL SYSTEM FOR LEAKS
Emerging fuel
Risk of fire
1. Place a cloth under the fuel supply line (low-pressure) and open the cap screw -1- using two
open-ended wrenches.
Fig 1: Identifying Fuel Supply Line (Low-Pressure)
Information
1. Check that the tool fittings are clean before starting the leak test .
2. Blow out the tool fittings before assembly using gentle bursts of pressure to prevent dust
and foreign bodies from getting into the high-pressure system during the leak test .
3. Ensure that the tools for the leak test remain clean and free of dirt when stored .
2. Adapter 9759 → Adapter 9759 with sealing ring must be screwed hand-tight and fully sealed
onto the fuel low-pressure line.
Fig 2: Identifying Adapter 9759 With Sealing Ring

Fig 3: Identifying Fuel Low-Pressure Line Adapter 9759
NOTE: Test pressure is exceeded
1. Risk of damage to high-pressure pump
→ The test gas test pressure must be set to less than → Pressure: 10 bar on the pressure
reducer on the test gas bottle.
WARNING: Working with compressed air
2. Risk of damaging and dirtying components
→ Wear protective goggles with side eye protection.
→ Protect the point at which the compressed air emerges with suitable material.
→ Place the point at which the compressed air emerges on suitable surfaces.
Information
The use of unapproved test gases results in incorrect test results. Only approved test gases
guarantee comparability with fuel high-pressure systems at pressures of up to 10 bar .
3. Fit test gas bottle with pressure reducer and air-spring strut filling unit VAS 6231 WE 1282
securely so that no gas can escape → Test equipment setup . Set pressure reducer to max.
10 bar pressure → Adjusting pressure reducer to between 7 and 9 bar of test gas pressure .
Fig 4: Identifying Filling Unit VAS 6231

Fig 5: Identifying Test Equipment Setup

Fig 6: Adjusting Pressure Reducer
4. Air-spring strut filling unit VAS 6231 WE 1282 must then be connected to the Adapter 9759
(-1- ). Tighten the connection if necessary.
Fig 7: Connecting Adapter
5. Depending on the high-pressure connections that were loosened (removed fuel distributor pipe
or removed high-pressure pump), complete the following steps →
If the fuel distributor pipe (high-pressure rail) was removed →
6. Before screwing the fuel distributor pipe (high-pressure rail) to the engine, quickly blow out
residual fuel from the high-pressure pump and high-pressure line (intake) to the high-pressure
rail.
1. 6.1. Apply a quick burst of pressure using the filling unit and blow the residual fuel
through the line into a cloth or receptacle. → Blowing out high-pressure line
Fig 8: Applying Quick Burst Of Pressure
2. 6.2. Drain residual fuel from the high-pressure distributor pipe before fitting it. Shake
the high-pressure distributor pipe over a cloth to do this.
7. Fit high-pressure distributor pipe (high-pressure rail) and tighten it to the correct tightening
torques. → Installing fuel distributor pipe (fuel rail) - section on "Installing"

8. Use air-spring strut filling device VAS 6231 WE 1282 to apply test gas pressure of between 7
and just under 10 bar to the completely fitted high-pressure system -2- . The pressure is
distributed slowly in the system and can increase slightly on the pressure gauge. If there is a
constant drop in pressure, there is a leak in the system.
Fig 9: Applying Pressure
9. Spray all connection points in the high-pressure system with commercially available
leak-locating spray. If the pressure drops even though the threaded joints are perfectly sealed,
also spray the soldered joints and connecting pipes as well as the high-pressure pump and
test equipment with leak-locating spray.
10. If there is a leak, Gently Sashaying , Moving And Growing air bubbles → Leaks will
emerge. These could be caused by a damaged seal, loose connections or incorrectly fitted
union nuts, for example. The cause must be determined and corrected.
Fig 10: Locating Fuel System Leaks
If the high-pressure pump was removed →
11. Before screwing the high-pressure line (intake) to the high-pressure pump, residual fuel must
be blown out of the high-pressure pump.
through the connection piece into a cloth.
→ Blowing out high-pressure pump

Fig 11: Applying Quick Burst Of Pressure
12. Screw high-pressure line correctly to the high-pressure pump. → Installing high-pressure pump
13. Use air-spring strut filling device VAS 6231 WE 1282 to apply test gas pressure of between 7
and just under 10 bar to the fitted high-pressure pump. The pressure is distributed slowly in the
system and can increase slightly on the pressure gauge. If there is a constant drop in
pressure, there is a leak in the system.
Fig 12: Applying Test Gas Pressure
14. Spray all connection points for the high-pressure pump with commercially available
also spray other connection points as well as the high-pressure pump and test equipment with
leak-locating spray.
15. If there is a leak, Gently Sashaying , Moving And Growing air bubbles will emerge (union
nut on injector is shown) → Leaks . These could be caused by a damaged seal, loose
connections or incorrectly fitted union nuts, for example. The cause must be determined and
corrected.
Fig 13: Locating Fuel System Leaks

(CAYENNE S & CAYENNE GTS) > SUBSEQUENT WORK
1. Remove tool setup.
2. Fit the fuel line. To do this, fit the fuel supply line (low pressure) at the marking correctly.
Counter while fitting. → Tightening torque: 35 Nm (26 ft. lb.)
3. Fit engine cover. For details, see → Installing front trim panel (engine compartment) - section
on "Installing"
4. Fit the fuse or connect the battery.
5. Bleed the fuel high-pressure system. → 2430B1 FILLING AND BLEEDING THE FUEL
HIGH-PRESSURE SYSTEM (INCLUDES BLEEDING FUEL DISTRIBUTOR PIPE)
WM 200201 CHECKING FUEL PRESSURE (CAYENNE S, CAYENNE TURBO,


K-Jetronic Tester Workshop
WE 1291
VAG 1318 equipment
Measuring adapter Special tool 9705
connection line Special tool 9705/3


CAYENNE GTS & CAYENNE TURBO S) > TECHNICAL VALUES
Tolerance Tolerance
1 2
Fastening nuts for sheetmetal Tightening 10 Nm (7.5 ft.

lid torque lb.)

CAYENNE GTS & CAYENNE TURBO S) > CHECKING FUEL PRESSURE (LOW
PRESSURE) USING THE PIWIS TESTER (QUICK TEST)
Information
Faults in the fuel high-pressure injection system can also be caused by defects in the pre-delivery
system (fuel low pressure) .
In the event of problems in the fuel high-pressure injection system, the pre-delivery system should
be checked first .
Information
A leak in the fuel high-pressure pump supplying the engine (mechanical drive) dilutes the oil. Check the
engine oil and initiate appropriate remedial action if necessary.
Information
The fuel system contains a fuel pump, which is controlled according to demand by a control unit, and a
supply-driven sucking jet pump.
Information
If you suspect that a pump in the fuel tank is defective (particularly if symptoms include a very low fuel
level), always check the sucking jet pump for dirt or blockages.
Information
Checking the low-pressure area with the high-pressure sensor cannot be used as the sole
reference .
The high-pressure sensor has a certain percent inaccuracy in the low-pressure area .
It is best to check the low-pressure area using both test methods (Tester and pressure gauge) .
General information on converting pressure →
10000 hPa = 10 bar = 10000 mbar
1000 kPa = 10 bar = 10000 mbar
1 MPa = 10 bar = 10000 mbar
1. Connect the Tester and get it ready. PIWIS Tester II 9818
1. 1.1. Connect a charger to the vehicle battery. The voltage should be approx. 12.5 V
(no rapid charging allowed because the voltage is too high!).
2. 1.2. The fuel pump can be activated and deactivated as follows:
3. 1.3. [Diagnostics] => [Cayenne] => [DME] => [Drive link test/Tests] => [Drive links] =>
[Fuel pump 1]
4. 1.4. 100% is displayed. The fuel pump starts to deliver fuel when you press [Start].
5. 1.5. The fuel pump stops when the percentage value changes to 0%. Press [Start]
again.
2. Call up the test value [B070 Fuel high-pressure actual value].
1. 2.1. [Diagnostics] → [Cayenne] → [DME] → [Actual values/input signals] → [B070

Fuel high-pressure actual value]
Fuel pressure is about 5800.0 hPa to 6100.0 hPa when the pump is running .
Fig 1: PIWIS Tester Values Screen Display
1. Drive links/tests
2. Fuel pump status (0% when pump is off - 100% when pump is running).
Always confirm by pressing [Start].
3. Fuel pressure in hPa (figure shows holding pressure shortly after switching
pump off).
Information
The fuel holding pressure must only drop by max. 1 bar (1000 mbar) in one hour.
3. Step 2: Check the fuel system for leaks (check holding pressure) →
1. 3.1. Read out the fuel high-pressure actual value in the DME control unit using the
PIWIS Tester.
1. Switch on ignition, activate fuel pump briefly, then switch off the fuel pump.
2. Nominal pressure is approx. 5000 to 5500.0 hPa. Monitor the fuel pressure for
about 5 to 10 minutes.
3. The pressure is not maintained. In other words: the fuel high-pressure actual
value has dropped considerably. There is an internal or external leak in the
fuel system.
4. The pressure is maintained. In other words: the fuel high-pressure actual
value has only dropped slightly.

CAYENNE GTS & CAYENNE TURBO S) > PRELIMINARY WORK
Information
1. Relieve the fuel pressure →
2. 1.2. Pull out the fuse for the fuel pump.
3. 1.3. Start the engine and wait until the engine starts up automatically.
2. Remove rear seat. → REMOVING 1/3-SPLIT FOLDING REAR SEAT or REMOVING
2/3-SPLIT FOLDING REAR SEAT - section on "Removing"
3. Remove the right cap (figure shows both caps) -arrows- . To do this, remove the carpeted
floor. Then loosen the four fastening nuts and remove the cap.
Fig 1: Locating Caps
4. Carefully pull off the fuel supply line -arrow- at the right connection unit (place several cloths
underneath to absorb the fuel that squirts out).
Fig 2: Locating Fuel Supply And Connection Points At Right Connection Unit
5. After opening the fuel line, connect the measuring tool immediately and re-insert the fuse for
the fuel pump.

CAYENNE GTS & CAYENNE TURBO S) > TOOLS AND MATERIALS > TEST TOOL
SETUP
Fig 1: Identifying Fuel Pressure And Fuel Delivery Rate Testing Tools
1. Measuring Adapter 9705 ; with rapid-action coupling → used for checking the fuel delivery
rate. Generates the required counter-pressure of 2.5 bar.
2. Pressure gauge with stopcock tester K-Jetronic Tester VAG 1318 WE 1291
3. Connecting line Connection Line 9705/3 ("female" rapid-action coupling)
4. Adapter 1318/7 from K-Jetronic Tester VAG 1318 WE 1291

5. Adapter 1318/15 (one-piece connecting piece); accessory for K-Jetronic Tester VAG 1318
WE 1291 ; → used for checking the fuel delivery pressure.
6. Connecting line Connection Line 9705/3 ("male" rapid-action coupling) → used for checking
the fuel delivery pressure.
7. Adapter 1318/17 (A) from K-Jetronic Tester VAG 1318 WE 1291 ; connection to Measuring
Adapter 9705 → used for checking the fuel delivery rate.

CAYENNE GTS & CAYENNE TURBO S) > CHECKING FUEL PRESSURE (LOW
PRESSURE)
1. Checking Fuel Supply Pressure (Low Pressure) →
1. 1.1. Connect pressure gauge with stopcock tester K-Jetronic Tester VAG 1318 WE
1291 using adapter 1318/7 and connecting line Connection Line 9705/3 ("female"
rapid-action coupling) on the side of the stopcock. On the other side of the stopcock,
connect adapter 1318/15 (one-piece connecting piece) and connecting line
Connection Line 9705/3 ("male" rapid-action coupling). The tool setup must be
fitted with sealing rings (copper, aluminum, or plastic, etc.) between the individual
components. The setup must be fully sealed. → Measuring tool for fuel delivery
pressure
Fig 1: Measuring Fuel Delivery Pressure
1. Connecting line Connection Line 9705/3 ("male" rapid-action coupling) →

used for checking the fuel delivery pressure.
2. Adapter 1318/15 (one-piece connecting piece); accessory for K-Jetronic

Tester VAG 1318 WE 1291 ; → used for checking the fuel delivery
pressure.
3. Pressure gauge with stopcock tester K-Jetronic Tester VAG 1318 WE

1291

5. Connecting line Connection Line 9705/3 ("female" rapid-action coupling)
2. 1.2. Connect measuring tool -2- between the connection unit output -3- and the fuel
supply line -1- . The stopcock is set to flow.
Fig 2: Connecting Measuring Tool
3. 1.3. Start the engine and leave it running at idle speed. Read off the fuel pressure on
the pressure gauge. The pressure gauge pointer can oscillate slightly at idle speed.
With increased idle speed (accelerator pressed slightly), the pointer deflection calms
down. The fuel low-pressure system operates at a constant pressure of 5.5 to 6.0
bar . The pointer oscillates at around this value. A measurement performed while
driving by a second worker can also generate values of below 5 bar (4.5 bar) briefly
at full throttle (with turbo in particular). This is not a sign of a defect.
2. Checking Fuel Retaining Pressure (Low Pressure) →
1. Engine cold
2. Workshop air-conditioned to normal temperature
3. Fluctuations may occur if the engine is warm or the outside temperature is high
4. Fully sealed measuring tool setup
1. 2.1. Same tool setup and connection as for measuring the fuel delivery pressure (see
Fig 1).
2. 2.2. Allow engine to run for a few minutes. Switch off engine. Check the pressure
drop. Drop in fuel pressure after "ignition is switched off" must not exceed 1 bar after
1 hour. Make sure that the tool setup itself does not have any leaks (even the
slightest leak). The fuel retaining pressure will decrease extremely rapidly and falsify
the measured result with even the tiniest leak.

CAYENNE GTS & CAYENNE TURBO S) > SUBSEQUENT WORK
1. Disconnect tool and reconnect vehicle connections. Absorb and wipe off residual fuel with a
cloth.
2. Fit the fuel supply line -arrow- at the right connection unit.
Fig 1: Locating Fuel Supply And Connection Points At Right Connection Unit
3. Fit the right cap (figure shows both caps). Then tighten the four fastening nuts. → Tightening
torque: 10 Nm (7.5 ft. lb.) Refit the carpeted floor and fix in place with double-sided adhesive
tape.
4. Install rear seat. → INSTALLING 1/3-SPLIT FOLDING REAR SEAT or INSTALLING 2/3-SPLIT
FOLDING REAR BACKREST - section on "Installing"
5. Air the vehicle with the windows open.
WM 200301 CHECKING FUEL QUALITY (ALL MODELS) > TOOLS
Fuel Identification Unit Workshop Equipment WE 1494
WM 200301 CHECKING FUEL QUALITY (ALL MODELS) > TOOLS AND MATERIALS
Overview of individual components of Fuel Identification Unit WE 1494

Fig 1: Fuel Identification Unit VAS 6774
1. VAS 6774/1: Spindle (density gauge)
2. VAS 6774/2: Measuring cylinder
3. VAS 6774/3: Fuel detector (for measuring diesel)
4. VAS 6774/4: Cleaning brush
5. VAS 6774/5: Adapter with clamps for connecting a 12-volt battery
6. VAS 6774/6: Filter pads for fuel detector
7. Case
WM 200301 CHECKING FUEL QUALITY (ALL MODELS) > CHECKING FUEL QUALITY
> CHECKING FUEL QUALITY - PETROL

Information
Only carry out the analysis in well-ventilated rooms and at room temperature (20° Celsius) .
Before starting the analysis, have a good look at the information on the CD and read the leaflet
(supplied in the case) carefully .
This analysis can only determine a reference value; a laboratory test is required for an exact
analysis .
The analysis does not constitute a legal basis; it is the starting point for further steps .
1. Push the measuring cylinder -1- into the fixing clip -2- in the case -arrow- .
Fig 1: Pushing Cylinder Into Fixing Clip
2. Place the spindle sleeve -1- under the lid of the case -arrow- so that the measuring cylinder
is horizontal.
Fig 2: Locating Spindle Sleeve Under Lid Of Case
3. Pour 500 milliliters (ml) -arrow- of petrol into the measuring cylinder.
Fig 3: Pouring Fuel Into Measuring Cylinder
4. Carefully immerse the measuring spindle into the liquid and let it go.
Do not drop the measuring spindle!

Fig 4: Caution - Do Not Drop Measuring Spindle
1. 4.1. The spindle must be floating in the middle in order to read off the scale value.
Fig 5: Positioning Spindle For Reading Value
2. 4.2. Read off the scale value.

Fig 6: Reading Measuring Spindle Scale Value
5. Assign the scale value using the table below.
Scale value (at 20°

Assessment Comment
Celsius)
Case for fuel laboratory (neither petrol nor Laboratory test

below 0
diesel) required
0... 5.5 Petrol EN 228
4.5... 6.5 E 85
approx. 7 E 100 (pure ethanol)
Laboratory test
7... 9 No evaluation possible (neither petrol nor diesel)
required
9... 11 Diesel in Asia (Russia/India)
10... 13 Diesel in accordance with EN 590 (Europe)
Laboratory test
13... 15 No evaluation possible, "wild mix"
required
Laboratory test
15... 17 Biodiesel
required
Measuring spindle does not stay in the fuel Laboratory test
above 17
(water-like density) required
Information
1. Dispose of fuel, fuel mixes and cleaning mixes according to the applicable national
regulations!
6. After testing the fuel, wash out and wash off measuring equipment thoroughly using the
cleaning brush, washing-up liquid and hot water.
Fig 7: Cleaning Measuring Equipment
7. After analyzing the fuel quality, carry out the required measures.
WM 200317 DRAINING AND FILLING FUEL (ALL MODELS) > TOOLS
Fuel transfer unit Tank Workshop

WE 1262
Primus 100/100S equipment
key VW tool T10202
WM 200317 DRAINING AND FILLING FUEL (ALL MODELS) > TECHNICAL VALUES
Tolerance
2
Sheetmetal ring on Tightening 145 Nm (107 +/-5 Nm (+/- 3.5

connection unit torque ft. lb.) ft. lb.)
Fastening nuts for Tightening 10 Nm (7.5 ft.

sheetmetal lid torque lb.)
WM 200317 DRAINING AND FILLING FUEL (ALL MODELS) > TOOLS AND
MATERIALS
Fig 1: Identifying Special Tool Tank Primus 100/100S WE 1262
A. Fuel transfer unit (This tool has been tested and approved by PORSCHE.); see Fig 1 Fuel
transfer unit Tank Primus 100/100S WE 1262 Please note: Use a second unit for diesel or
petrol if necessary.
B. Fuel nozzle special accessory (This can be used to refuel the vehicle. The fuel nozzle switches
off automatically as soon as the fuel tank is full.)
C. not required
D. not required
E. Suction line with venting device
WM 200317 DRAINING AND FILLING FUEL (ALL MODELS) > INFORMATION > USING
EQUIPMENT
Fig 1: Overview Of Fuel Transfer System
1. Air connection (connection for unlubricated/oil-free compressed air)
2. Fuel tank (capacity: 110 liters), (Tank can be changed. The scale at the side starts at approx.
10 liters. Other markings are shown in 5-liter steps.)
3. Pump reversal (This allows you to change the direction of the pump from the fuel feed
direction.)
4. Operating pressure display (Displays the set operating pressure of the pump. The value
cannot be more than 6.5 bar.)
5. On/Off switch (For switching the pump on and off.)
1. Connect the fuel hose -1- to the changeover tank. Connect the venting device (transparent
hose) to the changeover tank. Then attach the pneumatic stop switch -3- to the tank and
tighten the two knurled nuts.
Fig 2: Identifying Fuel Transfer System Connections
2. Connect the suction hose (or fuel nozzle) to the connection -1- and then connect the venting
device -2- .
3. When using the pump, always make sure that the earth cable is attached to the relevant
vehicle. Use an unpainted metal part (e.g. the catch bar) for this.
Fig 3: Locating Earth Cable
Information
1. Fuel can be removed directly through the fuel filler neck on older vehicles or vehicles
from other manufacturers by removing the connecting piece .
Fig 4: Identifying Connecting Piece
WM 200317 DRAINING AND FILLING FUEL (ALL MODELS) > PRELIMINARY WORK

NOTE: Incorrect handling of fuel tank
Risk of damage to fuel tank
→ Only use fuel pumps designed specifically for the vehicle for draining the fuel tank.
Information
All windows should be opened for better ventilation in the passenger compartment .

BATTERY

3. Remove the left and right lid -arrows- . To do this, remove the carpeted floor. Then loosen the
four fastening nuts and remove the lid.
Fig 1: Locating Lids

Fig 2: Identifying Left And Right Connection Units
1. Right connection unit with pressure regulator
2. Left connection unit with fuel filter
4. Disconnect all connections on the right connection unit. Disconnect electric plug connections.
Fig 3: Identifying Fuel Supply And Connection Points At Right Connection Unit
5. Disconnect electric plug connection from the left connection unit.

Fig 4: Identifying Left Connection Unit Connector
6. Open the right and left lock using Key T10202 and lift up the connection units. → Special tool
on lid
Fig 5: Identifying Special Tool On Lid
WM 200317 DRAINING AND FILLING FUEL (ALL MODELS) > DRAINING FUEL
Information
If the fuel-level indicator in the instrument cluster is above the half-full line, it is absolutely essential to
drain the fuel from the fuel tank. If not, the fuel does not need to be drained.
1. Drain the fuel, fuel level sender and fuel pump installed:
1. 1.1. Disconnect connecting piece from suction hose.

Fig 1: Disconnecting Connecting Piece From Suction Hose
2. 1.2. Insert the section hose first into the left half of the fuel tank and then into the
right half of the fuel tank in order to drain fuel.
3. 1.3. Drain the fuel.
1. 1.3.1. Set changeover lever to "Drain".
2. 1.3.2. Switch on the transfer unit and drain the required amount of fuel.
WM 200317 DRAINING AND FILLING FUEL (ALL MODELS) > SUBSEQUENT WORK
1. Replace seals when refitting the flanges. → Seals on flanges

Fig 1: Replacing Seals On Flanges
2. Close the tank. To do this, fit the sheetmetal ring on the left and right connection unit and
tighten using Key T10202 . → Cap → Tightening torque: 145 Nm (107 ft. lb.) +/-5 Nm
(+/-3.5 ft. lb.)
Fig 2: Inserting Key T10202
3. Fit all connections of the right connection unit (fuel lines, ventilation tubes and electric
connectors).
4. Plug in electric plug connection for the left connection unit.

Fig 4: Identifying Left Connection Unit Connector
5. Fit left and right lid. Then tighten the four fastening nuts. → Fastening nuts on caps →
Tightening torque: 10 Nm (7.5 ft. lb.) Refit the carpeted floor and fix with double-sided
adhesive tape.
FOLDING REAR SEAT - section on "Installing"
WM 200317 DRAINING AND FILLING FUEL (ALL MODELS) > FILLING WITH FUEL
(FILLING FUEL TANK)
1. Connect the filling device in accordance with operating instructions, fit the fuel nozzle and set
to fuel delivery mode. Refuel the vehicle just as you would at a service station. Fuel nozzle
switches off automatically.
WM 201019 REMOVING AND INSTALLING FUEL TANK (CAYENNE S, CAYENNE


Master Gear unit Workshop
WE 1206
elevating platform equipment

TURBO, CAYENNE GTS & CAYENNE TURBO S) > TECHNICAL VALUES
Tolerance Tolerance
1 2

Restraining straps on fuel tank M8 x 25
torque lb.)

Restraining straps on fuel tank M8 x 25
torque lb.)
Tightening 9 Nm (6.5 ft.

Filler neck To body
torque lb.)

Stone guard to body M6 nut
torque lb.)
Fastening nuts for sheetmetal Tightening 9 Nm (6.5 ft.

cover torque lb.)

Filler neck To body
torque lb.)

TURBO, CAYENNE GTS & CAYENNE TURBO S) > PRELIMINARY WORK FOR FUEL
TANK
BATTERY
4. Remove the rear axle carrier. → Removing rear axle - section on "Removing"
5. Remove rear wheel housing liner at the right. → 536919 REMOVING AND INSTALLING REAR
WHEEL HOUSING LINER
6. Remove underbody cover at the left and right. → 519319 REMOVING AND INSTALLING
COVER FOR CENTRE UNDERBODY


TURBO, CAYENNE GTS & CAYENNE TURBO S) > PRELIMINARY WORK FOR FUEL
TANK > PRELIMINARY WORK FOR FUEL TANK

BATTERY
2. Remove the rear axle carrier. → Removing rear axle - section on "Removing"
WHEEL HOUSING LINER
4. Remove underbody cover at the left and right. → 519319 REMOVING AND INSTALLING


TURBO, CAYENNE GTS & CAYENNE TURBO S) > REMOVING FUEL TANK

CAUTION: Risk of damaging fuel lines!
Lines can become kinked or can crack.
→ Never leave the carbon canister hanging freely on the lines.
→ A second person must hold the carbon canister during removal.
Information
Information
For safety reasons, the fuel tank should only be removed and installed when empty. → 200317
DRAINING AND FILLING FUEL
Fig 1: Overview Of Degassing Tank And Fuel Tank

Fig 2: Overview Of Fuel Tank (Diesel - Single-Pump System)
1. Fuel filler neck
2. Fuel tank
3. Left cap
4. Locking ring
5. Left fuel level sensor
6. Sucking jet pump, left
7. Protective cover
8. Restraining strap
9. Fastening screw
10. Protective cover
11. Left sucking jet pump (on tank floor)
12. Fuel pump (delivery unit)
13. Right fuel level sensor
14. Protective cover
15. Right cap
1. Open the filler flap and unscrew the fastening screw on the hook.
2. Loosen and remove the filler flap. To do this, insert a thin screwdriver through the four indents
-illustration- and release the filler flap.
Fig 3: Releasing Filler Flap
3. Remove the rubber sleeve around the fuel filler neck, unscrew the two fastening screws and
remove the ground cable.
Fig 4: Removing Rubber Sleeve
4. Remove the cover under the rear seats. To do this, fold up the carpet at the markings and
screw off four fastening nuts → Fuel tank openings in body .
Fig 5: Identifying Fuel Tank Covers
5. Left opening
1. 5.1. Release and disconnect cable plug

Fig 6: Disconnecting Cable Plug
6. Right opening
1. 6.1. Release and disconnect two cable plugs -1 and 2- .
2. 6.2. Release and disconnect the fuel line -3- at the tank.
Information
Lower the fuel tank slightly in order to release the fuel line.
3. 6.3. Remove the fuel line -4- from the holder and release and disconnect it.
Fig 7: Identifying Fuel Line And Cable Plugs
7. Disconnect cable plug for fuel pump control unit.

Fig 8: Disconnecting Cable Plug For Fuel Pump Control Unit
8. Remove cover in wheel housing at the rear right. To do this, unscrew three fastening screws
-arrow- and pull off the cable holder.
Fig 9: Locating Stone Guard
9. Unscrew fastening screws on the filler neck and degassing tank -3- .
Fig 10: Identifying Filler Neck And Degassing Tank Screws
10. Remove the line bracket under the stone guard by pressing in the center plug -arrow- .
Fig 11: Identifying Line Bracket
11. Release and disconnect two lines -1 and 2- on the active carbon filter.
Fig 12: Identifying Lines
12. Loosen the tank attachment band, which runs in direction of travel -arrows- . Support the tank
using the Master Gear Unit Elevating Platform WE 1206 .
Fig 13: Locating Tank Attachment Band
13. Get another worker to help you to loosen and remove the remaining restraining straps. Slowly
lower the fuel tank using the Master Gear Unit Elevating Platform WE 1206 . Also guide out
the degassing tank in the right wheel housing.
Fig 14: Identifying Fuel Tank Mounting Components
Do not damage fuel tank and Do not damage fuel tank and
Fuel Tank 1 connected lines. Lines cannot connected lines. Lines cannot
be replaced individually. be replaced individually.
Before releasing the restraining

Restraining The direction of travel arrow
-2- 1 straps, make sure that the tank
Strap, Front Left must be pointing forward.
cannot fall down.
Fastening Screw,
-3- 10
M8 x 25
Plastic Covers,
-4- 2
Left
Plastic Cover,
-5- 1
Right

Strap, Rear Right must be pointing forward.
cannot fall down.
Restraining Before releasing the restraining

The direction of travel arrow
-7- Strap, Front 1 straps, make sure that the tank
must be pointing forward.
Right cannot fall down.

-8- 1
Strap, Center must be pointing forward.

Strap, Rear Left must be pointing forward.
cannot fall down.
14. Slowly lower the fuel tank using the transmission jack and carefully guide in the degassing tank
in the right wheel housing.
Fig 15: Identifying Tank On Jack

TURBO, CAYENNE GTS & CAYENNE TURBO S) > INSTALLING FUEL TANK
Information
Note direction arrow stamped on the restraining straps and install these in the direction of travel .
1. Lift the fuel tank using the Master Gear unit elevating platform WE 1206 and carefully guide
it into position. Also guide in the degassing tank in the right wheel housing.
2. Right opening
Information
The fuel line must be connected before guiding the fuel tank fully into installation position.
1. 2.1. Connect the fuel line -4- and lock it in the holder.
Fig 1: Identifying Fuel Line
3. Install plastic covers and side restraining straps. → Tightening torque: 33 Nm (24 ft. lb.)
Fig 2: Identifying Fuel Tank Mounting Components
Do not damage fuel tank and Do not damage fuel tank and
Fuel Tank 1 connected lines. Lines cannot connected lines. Lines cannot
be replaced individually. be replaced individually.

strap, front left must be pointing forward.
cannot fall down.
Fastening screw,
-3- 10
M8 x 25
Plastic covers,
-4- 2
left
Plastic cover,
-5- 1
right

strap, rear right must be pointing forward.
cannot fall down.

strap, front right must be pointing forward.
cannot fall down.

-8- 1
strap, center must be pointing forward.

strap, rear left must be pointing forward.
cannot fall down.
4. Fit the tank attachment band, which runs in direction of travel -arrows- . → Tightening
torque: 33 Nm (24 ft. lb.)
Fig 3: Locating Tank Attachment Band
5. Connect and lock two lines -1 and 2- on the active carbon filter.
Fig 4: Identifying Lines
6. Replace the line bracket and fit it on the longitudinal member. Clip in lines. → Line bracket
Fig 5: Identifying Line Bracket
7. Screw in fastening screws -3- on the filler neck. → Tightening torque: 9 Nm (6.5 ft. lb.)
Fig 6: Identifying Filler Neck Screws
8. Install cover in the wheel housing and fit cable holder. → Tightening torque: 9 Nm (6.5 ft.
lb.)
Fig 7: Locating Stone Guard
9. Connect cable plug for fuel pump control unit.

Fig 8: Connecting Fuel Pump Control Unit
10. Right opening
1. 10.1. Connect two cable plugs -1 and 2- .
2. 10.2. Connect the fuel line -3- to the fuel tank.

Fig 9: Identifying Fuel Line
11. Left opening
1. 11.1. Connect cable plug.

Fig 10: Connecting Cable Plug
12. Fit the cover. Then tighten the four fastening nuts → Fuel tank openings in body . →
Tightening torque: 9 Nm (6.5 ft. lb.) Refit the carpet and secure with double-sided adhesive
tape.
Fig 11: Locating Fuel Tank Covers
13. Screw in two fastening screws and fit rubber sleeve around the tank filler neck. → Tightening
torque: 9 Nm (6.5 ft. lb.)
Fig 12: Locating Screws And Rubber Sleeve
14. Install the filler flap and screw in the fastening screw on the hook.

TURBO, CAYENNE GTS & CAYENNE TURBO S) > SUBSEQUENT WORK FOR FUEL
TANK
2. Install underbody cover at the left and right. → Installing Cover For Centre Underbody - section
on "Installing"
3. Install rear wheel housing liner at the right. → 536919 REMOVING AND INSTALLING REAR
WHEEL HOUSING LINER
4. Install rear axle housing. → Installing rear axle - section on "Installing"
5. Connect the battery. → 2X00IN WORK INSTRUCTIONS AFTER DISCONNECTING THE

BATTERY
2. Install underbody cover at the left and right. → Installing Cover For Centre Underbody - section
on "Installing"
WHEEL HOUSING LINER
4. Install rear axle housing. → Installing Rear Axle - section on "Installing"

BATTERY
WM 2015K2 CALIBRATING FUEL LEVEL SENDER (CAYENNE S, CAYENNE (3.0),

CAYENNE S E-HYBRID & CAYENNE TURBO) > TOOLS

CAYENNE S E-HYBRID & CAYENNE TURBO) > PRELIMINARY WORK
Information
Calibration of the fuel level sender is required after replacing the fuel tank, fuel level sender or
instrument cluster .
The fuel level sender does not have to be calibrated if the battery is disconnected or if a plug
connection on the instrument cluster or sender is disconnected. The values remain stored on the
The fuel tank must be completely empty before starting calibration .
1. Empty the fuel tank completely. → 200317 DRAINING AND FILLING FUEL
2. Wait for a short time (approx. 2 minutes) to allow the fuel-level sensor to settle down to the
level.
CAYENNE S E-HYBRID & CAYENNE TURBO) > CALIBRATING FUEL LEVEL SENDER
Information
Tester releases.
ignition.
3. Select Instrument cluster control unit in the overview and press [F12] to continue.
5. Calibrate fuel-level sensor must be selected. Then press [F12] to continue.
7. The message Fuel-level sensor calibration completed successfully appears on the Tester
screen.
8. Press [F12] to exit.
9. Select Save fuel level sensor comparison values to rear-end electronics control unit and
press [F12]
10. Start the procedure by pressing [F8].
11. Press [F12] to end the procedure.
12. Check the fuel gauge in the instrument cluster. The fuel gauge must show empty.
WM 201519 REMOVING AND INSTALLING FUEL LEVEL SENSOR (ALL MODELS) >
TOOLS
wrench VW tool T10202

TECHNICAL VALUES
Tolerance
2

Fastening nuts on cover Tightening 10 Nm (7.5 ft.

plate torque lb.)
INFORMATION
Information
The two senders have different shapes and may not be switched .
The float installed in the left direction of travel is flat, while the float installed in the right direction of
travel is spherical .
The removal of both senders is explained in parallel in this description. If only one sender has to be
removed, the other side of the tank can remain untouched .
left - Fuel level sender 1 installed in vehicle tank on the right.
right - Fuel level sender 2 installed in vehicle tank on the left.
Fig 1: Identifying Fuel Level Sensors

PRELIMINARY WORK
Information
Information
If the tank must be opened for emptying, disconnect all connections .

BATTERY
3. Drain the fuel tank if necessary. → Draining Fuel - section on "Draining"

5. Remove the left and right cap -arrows- . To do this, remove the carpeted floor. Then loosen
the four fastening nuts and remove the cap.

7. Disconnect electric plug connection on the left connection unit.

Fig 4: Identifying Connector For Left Connection Unit
8. Open the left and right lock using Wrench T10202 and lift up the connection unit. → Special
tool on cap
Fig 5: Inserting Special Tool On Cap
REMOVING FUEL LEVEL SENSOR > RIGHT FUEL LEVEL SENSOR
Fig 1: Identifying Fixing Device For Right Fuel Level Sensor
1. Right fuel level sensor clipped into floor holder
Fig 2: Identifying Left And Right Connection Unit

1. Disconnect all connections apart from the fuel line -3- on the underside of the right connection
unit.
2. The fuel line -3- cannot be disconnected from the pressure regulator (right connection unit).
Fig 3: Identifying Fuel Line On Pressure Regulator
3. Disconnect the fuel line -3- from the left connection unit.
Fig 4: Identifying Fuel Line On Left Connection Unit
4. Attach a piece of wire or similar item to the fuel line in order to pull the line back through the
fuel tank during installation.
5. Remove the right connection unit (with pressure regulator) completely.
6. To make it easier to remove the sensor, remove the fuel pump by pulling it upwards. →
Removing Fuel Pump - section on "Removing"
7. Press the retaining spring on the sensor by hand while at the same time pulling the sensor up.
→ Fig 6 Removing fuel level sensor
Fig 5: Removing Fuel Level Sensor

Fig 6: Identifying Left Fuel Level Sensor
1. Left sucking jet pump and holder clipped into floor holder
2. Left fuel level sensor clipped into floor holder


8. Unplug electric plug connection -1- for the fuel filter.
Fig 8: Identifying Plug Connection For Fuel Filter
9. Pull both lines -2 and 3 - off the fuel filter.

Fig 9: Identifying Fuel Filter Lines
10. Press the retaining spring on the sensor by hand while at the same time pulling the sensor up
-arrow- .
Fig 10: Removing Fuel Level Sensor
INSTALLING FUEL LEVEL SENSOR > RIGHT FUEL LEVEL SENSOR
1. Install a new fuel level sensor. Press the sensor into its mounting. The retaining spring must
Fig 1: Locating Right Fuel Level Sensor
2. Install fuel pump. → Installing Fuel Pump - section on "Installing"
3. Fit a new seal in the opening of the tank at the left and right. → Seal
Fig 2: Installing Seal
4. Pull the fuel line on the pressure regulator through the fuel tank to the left connection unit using
the attached piece of wire or similar item.
5. Clip in the fuel line -3- on the left connection unit.

6. Connect all connections on the underside of the right connection unit.
7. Fit the right connection unit with the pressure regulator in the tank. When doing so, make sure
that the plastic lugs are pointing forward.
Left fuel level sensor
8. Install a new fuel level sensor. Press the sensor into its mounting. The retaining spring must
Fig 4: Locating Left Fuel Level Sensor
9. Fit the left connection unit with the fuel filter in the tank. When doing so, make sure that the
plastic lugs are pointing forward.
10. Fit new seals in the openings on the tank. → Seal for opening on tank
Fig 5: Installing Seal For Opening On Tank
11. Connect both lines -2 and 3 - to the left connection unit.


Fig 7: Identifying Fuel Filter Plug Connection
SUBSEQUENT WORK
Information
If the fuel level sender is replaced, the sender must be calibrated following replacement.
tighten using special tool Wrench T10202 . → Cap → Tightening torque: 145 Nm (107 ft.
lb.) +/-5 Nm (+/-3.5 ft. lb.)
Fig 1: Inserting Fuel Level Sensor Cap
2. Fit all connections for the right connection unit (fuel lines, ventilation tubes and electric
connectors).

4. Fit left and right lid. Then tighten the four fastening nuts on each to → Tightening torque: 10
Nm (7.5 ft. lb.) . Refit carpeted floor and fix in place with double-sided adhesive tape.
6. If the fuel level sender was replaced, the fuel level sender must be calibrated. → 2015K2
CALIBRATING FUEL LEVEL SENDER
7. Fill the fuel tank. → Filling With Fuel (Filling Fuel Tank) - section on "Filling"
8. Close the filler flap.

BATTERY
WM 2015K2 CALIBRATING FUEL LEVEL SENDER (ALL MODELS) > TOOLS

WM 2015K2 CALIBRATING FUEL LEVEL SENDER (ALL MODELS) > PRELIMINARY

WORK
Information
Calibration of the fuel level sender is required after replacing the fuel tank, fuel level sender or
The fuel level sender does not have to be calibrated if the battery is disconnected or if a plug
connection on the instrument cluster or sender is disconnected. The values remain stored on the
The fuel tank must be completely empty before starting calibration .
1. Empty the fuel tank completely. → 200317 DRAINING AND FILLING FUEL
2. Wait for a short time (approx. 2 minutes) to allow the fuel-level sensor to settle down to the
level.
WM 2015K2 CALIBRATING FUEL LEVEL SENDER (ALL MODELS) > CALIBRATING

FUEL LEVEL SENDER
Information
Tester releases.
ignition.
3. Select the Instrument Cluster control unit in the Overview and press [F12] to continue.
4. Select Maintenance/Repairs .
5. Select Calibrate Fuel-Level Sensor and press [F12].

7. The message Fuel-Level Sensor Calibration Completed Successfully appears on the
Tester screen.
8. Press [F12] to exit.
9. Select Save Fuel Level Sensor Comparison Values To Rear-End Electronics Control Unit
and press [F12]
10. Start the procedure by pressing [F8]
11. Press [F11] to end the procedure.
12. Check the fuel gauge in the instrument cluster. Fuel gauge shows empty.
WM 2015K2 CALIBRATING FUEL LEVEL SENDER (ALL MODELS) > SUBSEQUENT

WORK
2. Check the fuel gauge in the instrument cluster. Wait a few minutes. Fuel gauge shows full.
WM 202319 REMOVING AND INSTALLING TANK VENT VALVE (ALL MODELS) >
PRELIMINARY WORK
1. Remove design cover at the right (under the upper torque support). → 108319 REMOVING
AND INSTALLING ENGINE COVER (DESIGN COVER)
2. Pull design cover off the throttle valve.
3. Remove Y-shaped pipe ahead of the throttle valve. → 243519 REMOVING AND INSTALLING
AIR BOX FOR THROTTLE HOUSING (INTAKE PORTS UPSTREAM OF THROTTLE VALVE)
REMOVING TANK VENT VALVE
1. Disconnect engine ventilation line at the valve cover, cylinder bank 1 to 4. Naturally aspirated
engine -1- or turbo engine -1-
2. Detach and remove tank ventilation and tank vent valve. Naturally aspirated engine -3- or
turbo engine -3- . Disconnect cable plug.
Fig 1: Identifying Engine Ventilation Line Of Naturally Aspirated Engines
3. Tank ventilation
4. Aluminum holder
5. Aluminum screw (holder)

Fig 2: Identifying Engine Ventilation Line Of Turbo Engines
2. Check valve for full-throttle ventilation with lines secured
3. Tank ventilation
4. Aluminum holder
5. Aluminum screw (holder)
6. Belt tensioner
7. Holder
8. Fastening screw
INSTALLING TANK VENT VALVE
The tank vent valve is installed in reverse order to removal.
SUBSEQUENT WORK
1. Fit Y-shaped pipe ahead of the throttle valve. → 243519 REMOVING AND INSTALLING AIR
BOX FOR THROTTLE HOUSING (INTAKE PORTS UPSTREAM OF THROTTLE VALVE)
2. Fit design cover. → 108319 REMOVING AND INSTALLING ENGINE COVER (DESIGN
COVER)
WM 202319 REMOVING AND INSTALLING TANK VENT VALVE (CAYENNE TIP &
CAYENNE TIP "PLATINUM EDITION") > REMOVING TANK VENT VALVE
1. Loosen tank vent valve with hoses and set it aside.
1. 1.1. Pull off cable plug -1- .
2. 1.2. Disconnect fuel tank breather hose -2- in the plenum panel area.
3. 1.3. Remove tank vent valve -3- from the holder.

Fig 1: Removing Tank Vent Valve
2. Loosen clamps -1- and pull hoses off the tank vent valve -2- .
Fig 2: Removing Tank Vent Valve Hoses
WM 202319 REMOVING AND INSTALLING TANK VENT VALVE (CAYENNE TIP &
CAYENNE TIP "PLATINUM EDITION") > INSTALLING TANK VENT VALVE
WM 202519 REMOVING AND INSTALLING CARBON CANISTER (CAYENNE S,

CAYENNE TURBO, CAYENNE GTS & CAYENNE TURBO S) > TECHNICAL VALUES
Carbon canister Tightening torque 9 Nm (6.5 ft. lb.)
Carbon canister Tightening torque 9 Nm (6.5 ft. lb.)

CAYENNE TURBO, CAYENNE GTS & CAYENNE TURBO S) > PRELIMINARY WORK
Remove rear right wheel housing liner. → Removing Rear Wheel Housing Liner - section on "Removing"

CAYENNE TURBO, CAYENNE GTS & CAYENNE TURBO S) > GENERAL WARNING
NOTES > GROUP 20 - FUEL SUPPLY, CONTROL
Information

CAYENNE TURBO, CAYENNE GTS & CAYENNE TURBO S) > REMOVING CARBON
CANISTER > REMOVING CARBON CANISTER - ROW (REST OF THE WORLD)
Fig 1: Overview Of Carbon Canister
1. Carbon canister
2. Fastening screws
3. Thick blue hose
4. Thin black hose
5. Electric line
1. Unscrew three fastening screws -2- on the carbon canister -1- .
2. Release hose connections -3 + 4- by pressing them together and pull them off.
3. Unclip electric line -5- at the back of the carbon canister from the brackets.

CAYENNE TURBO, CAYENNE GTS & CAYENNE TURBO S) > REMOVING CARBON
CANISTER > REMOVING CARBON CANISTER - USA
Fig 1: Overview Of Carbon Canister With Leakage Diagnosis Pump
1. Carbon canister
2. Fastening screws
3. Thick blue hose
4. Thin black hose
5. Electric line
6. Leakage diagnosis pump
7. Vacuum line for leakage diagnosis pump
1. Unscrew three fastening screws -2- on the carbon canister -1- .
2. Release hose connections -3 + 4- by pressing them together and pull them off.
3. Unclip electric line -5- at the back of the carbon canister from the brackets.
4. Pull off vacuum line -7- on leakage diagnosis pump -6- .
5. Release and pull off electric plug connection on leakage diagnosis pump -6- .

CAYENNE TURBO, CAYENNE GTS & CAYENNE TURBO S) > INSTALLING CARBON
CANISTER > INSTALLING CARBON CANISTER - ROW (REST OF THE WORLD)
Fig 1: Overview Of Carbon Canister
1. Carbon canister
2. Fastening screws
3. Thick blue hose
4. Thin black hose
5. Electric line
1. Clip electric line -5- at the back of the carbon canister into the brackets.
2. Attach hose connections -3 + 4- to the carbon canister -1- .
3. Tighten three fastening screws -2- on the carbon canister -1- to → Tightening torque: 9 Nm
(6.5 ft. lb.) .

CAYENNE TURBO, CAYENNE GTS & CAYENNE TURBO S) > INSTALLING CARBON
CANISTER > INSTALLING CARBON CANISTER - USA
Fig 1: Overview Of Carbon Canister With Leakage Diagnosis Pump
1. Carbon canister
2. Fastening screws
3. Thick blue hose
4. Thin black hose
5. Electric line
7. Vacuum line for leakage diagnosis pump
1. Clip electric line -5- at the back of the carbon canister into the brackets.
2. Connect vacuum line -7- for the leakage diagnosis pump -6- .
3. Plug in electric plug connection on leakage diagnosis pump -6- until the connector engages
securely.
4. Attach hose connections -3 + 4- to the carbon canister -1- .
5. Tighten three fastening screws -2- on the carbon canister -1- to → Tightening torque: 9 Nm
(6.5 ft. lb.) .

CAYENNE TURBO, CAYENNE GTS & CAYENNE TURBO S) > SUBSEQUENT WORK
Install rear right wheel housing liner. → Installing Rear Wheel Housing Liner - section on "Installing"
WM 203819 REMOVING AND INSTALLING FUEL SUPPLY LINE (CAYENNE) > TOOLS
transmission jack Workshop

WE 1082
VAG 1383 A equipment
WM 203819 REMOVING AND INSTALLING FUEL SUPPLY LINE (CAYENNE) >

TECHNICAL VALUES
Tolerance Tolerance
1 2
Fastening screws on restraining Tightening 23 Nm (17

M8
straps torque ft. lb.)
Collar nut on heat shield M6
torque ft. lb.)
Fastening screw on heat shield M6
torque ft. lb.)
Fastening screws securing heat Tightening 10 Nm (7.5

M6
shield to cardan shaft torque ft. lb.)
Collar nut securing heat shield to Tightening 20 Nm (15

M8
cardan shaft torque ft. lb.)

PRELIMINARY WORK
1. Remove the engine. → Removing Engine - section on "Removing"
2. Remove rear cardan shaft. → Removing rear cardan shaft - section on "Removing"
3. Remove rear right wheel housing liner. → Removing rear wheel housing liner - section on
"Removing"
4. Remove filler neck. → Removing Fuel Tank


REMOVING FUEL SUPPLY LINE
Information
The description applies to all engine types .
The setup and procedures required may differ slightly from the illustrations or procedures
described due to engine-specific differences .
Component Overview And Line Routing:

Fig 1: Fuel Line Routing Diagram
1. Remove covers for the two fuel tank flanges.
1. 1.1. To do this, cut out the carpeted floor at the perforation using a carpet knife and
fold it over.
2. 1.2. Then unscrew the M6 fastening nuts -arrows- and remove the covers.
Fig 2: Locating Fuel Tank Flange Covers
2. Disconnect the fuel pressure line (supply) -1- at the flange.
1. 2.1. Press the two release buttons at the same time and pull the rapid-action
coupling up and off.
Fig 3: Disconnecting Fuel Pressure Line (Supply)

Fig 4: Identifying Tank Flange Connection
3. Disconnect fuel lines at the connection points in the engine compartment.
1. 3.1. Pull off plastic cover -1- .
2. 3.2. Loosen the screw-in sleeve (width across flats 17) on the pressure line -2- and
counter at the hexagon (width across flats 19) on the connecting line at the same
time.
3. 3.3. Disconnect line for tank ventilation -3- .
4. 3.4.
5. 3.5. Open the line bracket at the bulkhead.

Fig 5: Identifying Fuel Line Connection Points
4. Remove heat shields -1- .
1. 4.1. Unscrew three M6 collar nuts -3- and one M6 screw -1- and remove the heat
shields.
Fig 6: Identifying Heat Shields On Underbody (Bulkhead Area)
5. Remove heat shield -1- on cardan shaft.
1. 5.1. Unscrew two M6 screws -2- and one M8 collar nut -3- and remove the heat
shield.
Fig 7: Identifying Heat Shield On Cardan Shaft
6. Lower the fuel tank.
1. 6.1. Place a transmission jack (e.g. transmission jack VAG 1383 A WE 1082 ) in
position to support and secure the fuel tank.
2. 6.2. Unscrew fastening screws for the restraining straps and carefully lower the fuel
tank.
7. Open all line brackets on the underbody and remove the wire harness.

INSTALLING FUEL SUPPLY LINE > INSTALLING
Information
The description applies to all engine types .
The setup and procedures required may differ slightly from the illustrations or procedures
described due to engine-specific differences .
1. The fuel supply line is installed in reverse order to removal.
2. Tighten fastening screws on restraining straps to → Tightening torque: 23 Nm (17 ft. lb.) .
3. Tighten three M6 collar nuts to → Tightening torque: 10 Nm (7.5 ft. lb.) and one M6
fastening screw to → Tightening torque: 10 Nm (7.5 ft. lb.) .
4. Tighten two fastening screws for the heat shield on the cardan shaft to → Tightening torque:
10 Nm (7.5 ft. lb.) and one collar nut for the heat shield on the cardan shaft to → Tightening
torque: 20 Nm (15 ft. lb.) .

SUBSEQUENT WORK
2. Secure the filler neck. → Installing Fuel Tank - section on "Installing"
4. Install rear right wheel housing liner.
→ Installing Rear Wheel Housing Liner .
5. Install rear cardan shaft. → Installing Rear Cardan Shaft - section on "Installing"
6. Install the engine. → Installing Engine - section on "Installing"
WM 204819 REMOVING AND INSTALLING LEAKAGE DIAGNOSIS MODULE

(CAYENNE S E-HYBRID) > GENERAL WARNING NOTES > GROUP 20 - FUEL SUPPLY,
CONTROL

Information

1. Remove rear right wheel. → 440519 REMOVING AND INSTALLING WHEEL
WHEEL COVER

(CAYENNE S E-HYBRID) > REMOVING LEAKAGE DIAGNOSIS MODULE
1. Remove leakage diagnosis module -1- .
1. 1.1. Disconnect lines -4- on the leakage diagnosis module -1- .
3. 1.3. Unclip electric line -3- at the holder.
4. 1.4. Unscrew nuts -2- .

Fig 1: Identifying Leakage Diagnosis Module And Electric Line

(CAYENNE S E-HYBRID) > INSTALLING LEAKAGE DIAGNOSIS MODULE

WHEEL COVER
2. Install rear right wheel. → 440519 REMOVING AND INSTALLING WHEEL
WM 204819 REMOVING AND INSTALLING LEAKAGE DIAGNOSIS PUMP (CAYENNE

S, CAYENNE TURBO, CAYENNE GTS & CAYENNE TURBO S) > GENERAL WARNING
NOTES > GROUP 20 - FUEL SUPPLY, CONTROL
Information

S, CAYENNE TURBO, CAYENNE GTS & CAYENNE TURBO S) > PRELIMINARY WORK
1. Remove carbon canister and place it on a clean surface. → Removing Carbon Canister -
S, CAYENNE TURBO, CAYENNE GTS & CAYENNE TURBO S) > REMOVING LEAKAGE
DIAGNOSIS PUMP (LDP)
Fig 1: Identifying Leakage Diagnosis Pump Installation Position
1. Pull air hose -4- off the leakage diagnosis pump -1- (-B- ).
Fig 2: Removing Leakage Diagnosis Pump

2. Carbon canister
3. Rubber flange
4. Air hose
5. Fastening screws
3. Pull leakage diagnosis pump -1- off the carbon canister -2- (-A- ).

S, CAYENNE TURBO, CAYENNE GTS & CAYENNE TURBO S) > INSTALLING
LEAKAGE DIAGNOSIS PUMP (LDP)
1. Check rubber flange -3- for damage and replace it if necessary.

Fig 1: Installing Leakage Diagnosis Pump
2. Carbon canister
3. Rubber flange
4. Air hose
5. Fastening screws
2. Fit rubber flange -3- on the connection piece on the leakage diagnosis pump and fit leakage
diagnosis pump -1- on the carbon canister -2- (-B- ).
3. Screw in three fastening screws.
4. Fit air hose -4- on the leakage diagnosis pump -1- (-B- ).

S, CAYENNE TURBO, CAYENNE GTS & CAYENNE TURBO S) > SUBSEQUENT WORK
1. Install carbon canister. → Installing Carbon Canister - section on "Installing"
WM 204819 REMOVING AND INSTALLING LEAKAGE DIAGNOSIS PUMP (LDP)

(CAYENNE TIP, CAYENNE S, CAYENNE TURBO, CAYENNE S HYBRID, CAYENNE TIP
(3.0), CAYENNE GTS & CAYENNE TURBO S) > GENERAL WARNING NOTES >
GROUP 20 - FUEL SUPPLY, CONTROL
Information


(3.0), CAYENNE GTS & CAYENNE TURBO S) > PRELIMINARY WORK
1. Remove carbon canister and place it on a clean surface. → Removing Carbon Canister -

(3.0), CAYENNE GTS & CAYENNE TURBO S) > REMOVING LEAKAGE DIAGNOSIS
PUMP (LDP)
Fig 1: Installation Position Of Leakage Diagnosis Pump
1. Pull air hose -4- off the leakage diagnosis pump -1- (-B- ).
Fig 2: Removing Leakage Diagnosis Pump
2. Carbon canister
3. Rubber flange
4. Air hose
5. Fastening screws
3. Pull leakage diagnosis pump -1- off the carbon canister -2- (-A- ).

(3.0), CAYENNE GTS & CAYENNE TURBO S) > INSTALLING LEAKAGE DIAGNOSIS
PUMP (LDP)
1. Check rubber flange -3- for damage and replace it if necessary.

Fig 1: Installing Leakage Diagnosis Pump
2. Carbon canister
3. Rubber flange
4. Air hose
5. Fastening screws
2. Fit rubber flange -3- on the connection piece on the leakage diagnosis pump and fit leakage
diagnosis pump -1- on the carbon canister -2- (-B- ).
3. Screw in three fastening screws.
4. Fit air hose -4- on the leakage diagnosis pump -1- (-B- ).

(3.0), CAYENNE GTS & CAYENNE TURBO S) > SUBSEQUENT WORK
1. Install carbon canister. → Installing Carbon Canister - section on "Installing"
WM 205019 REMOVING AND INSTALLING SUCKING JET PUMP (CAYENNE S,

1. Remove fuel level sensor at the left → Removing Fuel Level Sensor - section on "Removing"
2. Detach and lift up the right flange.

CAYENNE TURBO, CAYENNE GTS & CAYENNE TURBO S) > INFORMATION >
COMPONENT INFORMATION
Fig 1: Identifying Sucking Jet Pump
1. Fuel Pump
2. Sucking Jet Pump
3. Fuel Level Sensor, Right
4. Fuel Level Sensor, Left

CAYENNE TURBO, CAYENNE GTS & CAYENNE TURBO S) > REMOVING SUCKING
JET PUMP
1. Disconnect the sucking jet pump at the fuel pump. To do this, press on the left and right
-arrows- and pull off the connections -1 and 2- .
Fig 1: Locating Jet Pump Connections
2. Release connection -3- and unclip it -a- .
3. Release the sucking jet pump -1- from the bracket -2- on the fuel tank floor at the right
-arrow- and unclip it.
Fig 2: Releasing Jet Pump
4. Remove the sucking jet pump through the opening in the left connection unit.
Fig 3: Removing Jet Pump

CAYENNE TURBO, CAYENNE GTS & CAYENNE TURBO S) > INSTALLING SUCKING
JET PUMP
1. Slide the sucking jet pump into the fuel tank through the opening in the left connection unit.
2. Position the sucking jet pump -1- in the fuel tank and clip it into the holder -2- .
Fig 1: Installing Jet Pump
3. Connect the sucking jet pump connections -1 and 2- at the fuel pump. These must lock with
an audible click.
Fig 2: Connecting Sucking Jet Pump Connections
4. Connect the connection -3- until it engages securely.

1. Fit the flange.
2. Install fuel level sensor at the left. → Installing Fuel Level Sensor - section on "Installing"
WM 206019 REMOVING AND INSTALLING FINE FUEL FILTER (CAYENNE S,

CAYENNE (3.0), CAYENNE S E-HYBRID & CAYENNE TURBO) > TOOLS


CAYENNE (3.0), CAYENNE S E-HYBRID & CAYENNE TURBO) > TECHNICAL VALUES
Tolerance
2


plate torque lb.)

CAYENNE (3.0), CAYENNE S E-HYBRID & CAYENNE TURBO) > PRELIMINARY WORK


BATTERY

5. Loosen the left cap (figure shows left and right caps) -arrows- . To do this, remove the
carpeted floor. Then loosen the four fastening nuts and remove the cap.


7. Open the left lock using special tool wrench T10202 and lift up the connection unit. → Special
tool on cap
Fig 4: Inserting Special Tool On Cap

CAYENNE (3.0), CAYENNE S E-HYBRID & CAYENNE TURBO) > INSTALLING FUEL
FILTER
1. Fit a new seal in the opening of the tank. → Seal

Fig 1: Installing Seal Of Fuel Filter
2. Connect both lines -2 and 3 - to the left connection unit.



CAYENNE (3.0), CAYENNE S E-HYBRID & CAYENNE TURBO) > SUBSEQUENT WORK
1. Close the fuel tank. To do this, fit the sheetmetal ring on the left connection unit and tighten
using special tool Wrench T10202 . → Cap → Tightening torque: 145 Nm (107 ft. lb.) +/-5
Nm (+/-3.5 ft. lb.)
Fig 1: Fitting Wrench T10202 To Sheetmetal Ring

3. Fit the left cap (figure shows left and right caps). Then tighten the four fastening nuts to →
Tightening torque: 10 Nm (7.5 ft. lb.) . Refit carpeted floor and fix in place with double-sided
adhesive tape.

BATTERY
WM 206601 CHECKING QUANTITY DELIVERED BY FUEL PUMP (CAYENNE S,

CAYENNE TURBO, CAYENNE GTS & CAYENNE TURBO S) > TOOLS

K-Jetronic Tester Workshop
WE 1291
VAG 1318 equipment
Measuring adapter Special tool 9705
connection line Special tool 9705/3


Tolerance Tolerance
1 2

plate torque lb.)

CAYENNE TURBO, CAYENNE GTS & CAYENNE TURBO S) > INFORMATION > FUEL
PRESSURE CHECK AND FUEL QUANTITY CHECK
Information
Before checking the fuel quantity, a pressure check must first be performed in accordance with the
instructions in the Checking Fuel Pressure article.
→ 200201 CHECKING FUEL PRESSURE


Information
1. Relieve the fuel pressure →
2. 1.2. Pull out the fuse for the fuel pump.
3. 1.3. Start the engine and wait until the engine starts up automatically.

4. Remove the right cap (figure shows both caps) -arrows- . To do this, remove the carpeted
floor. Then loosen the four fastening nuts and remove the cap.
5. Carefully pull off the fuel supply line -arrow- at the right connection unit (place several cloths
underneath to absorb the fuel that squirts out).

CAYENNE TURBO, CAYENNE GTS & CAYENNE TURBO S) > TOOLS AND
MATERIALS > TOOLS FOR CHECKING FUEL PRESSURE AND FUEL DELIVERY RATE
Fig 1: Identifying Fuel Pressure And Fuel Delivery Rate Testing Tool
1. Measuring adapter 9705 ; with rapid-action coupling => used for checking the fuel delivery
rate. Generates the required counter-pressure of 2.5 bar.
3. Connecting line connection line 9705/3 ("female" rapid-action coupling)

5. Adapter 1318/15 (one-piece connecting piece); accessory for K-Jetronic Tester VAG 1318
WE 1291 ; => used for checking the fuel delivery pressure.
6. Connecting line connection line 9705/3 ("male" rapid-action coupling) => used for checking
the fuel delivery pressure.
7. Adapter 1318/17 (A) from K-Jetronic Tester VAG 1318 WE 1291 ; connection to measuring
adapter 9705 => used for checking the fuel delivery rate.

CAYENNE TURBO, CAYENNE GTS & CAYENNE TURBO S) > CHECKING FUEL
DELIVERY RATE (LOW-PRESSURE DELIVERY RATE)
Information
If you suspect that a pump in the fuel tank is defective (particularly if symptoms include a very low fuel
level), always check the sucking jet pump for dirt or blockages.
1. Open the bonnet.
2. Connect a charger to the vehicle battery. The voltage should be approx. 12.5 V (no rapid
charging allowed because the voltage is too high!).
3. Connect pressure gauge with stopcock tester K-Jetronic Tester VAG 1318 WE 1291 using
adapter 1318/7 and connecting line connection line 9705/3 ("female" rapid-action coupling)
on the side of the stopcock. On the other side of the stopcock, connect connecting line
1318/17 (A) with measuring adapter 9705 . The tool setup must be fitted with sealing rings
(copper, aluminum, or plastic, etc.) between the individual components. The setup must be
fully sealed.
Fig 1: Checking Fuel Delivery Rate
1. Measuring adapter 9705 ; with rapid-action coupling => used for checking the fuel
delivery rate. Generates the required counter-pressure of 2.5 bar.
2. Adapter 1318/17 (A) from K-Jetronic Tester VAG 1318 WE 1291 ; connection to
measuring adapter 9705 => used for checking the fuel delivery rate.
5. Connecting line connection line 9705/3 ("female" rapid-action coupling)
4. Connect measuring tool to the output of the connection unit -1- . Hold open end of hose of
measuring adapter 9705 into a large measuring tub or bucket (with a volume of at least 5
liters) -2- . The stopcock is set to flow.
Fig 2: Connecting Measuring Tool
5. Connect the Tester and get it ready. PIWIS Tester II 9818

1. 5.1. The fuel pump can be activated and deactivated as follows:
2. 5.2. [Diagnostics] => [Cayenne] => [DME] => [Drive link test/checks] => [Drive links]
=> [Fuel pump activation]
3. 5.3. The fuel pump starts to deliver fuel when you press [Start].
4. 5.4. The fuel pump stops when you press [Start] again.
6. Activate the fuel pump and remove all air from the measuring apparatus. Ensure that the open
part of the hose is securely retained in the measuring tub. Remove the rest of the pumped fuel
from the measuring tub.
7. Get a second mechanic to help perform the measurement if necessary.
8. Have a stopwatch ready.
9. The fuel pump must deliver at least 3 liters of fuel during an operating time of 1 minute .
Continue to measure the fuel for 20 seconds (stopwatch). The measured result in milliliters
delivered is multiplied by 3 . For example: After pumping for 20 seconds, around 1, 050 ml of
fuel is measured. Multiplying the result by 3 gives a delivery rate of 3, 150 liters per minute.
The pressure gauge shows a fuel pressure of 2.5 to 2.7 bar during the measurement. This
pressure is generated by the counter-pressure of the pressure regulator at the measuring
adapter 9705 .

1. Disconnect tool and reconnect vehicle connections. Absorb and wipe off residual fuel with a
cloth.
2. Fit the right cap (figure shows both caps). Then tighten the four fastening nuts on each to →
Tightening torque: 10 Nm (7.5 ft. lb.) . Refit carpeted floor and fix in place with double-sided
adhesive tape.
5. Air the vehicle with the windows open.
WM 206619 REMOVING AND INSTALLING FUEL PUMP (CAYENNE TURBO, CAYENNE

TURBO S, CAYENNE S & CAYENNE GTS) > TOOLS


TURBO S, CAYENNE S & CAYENNE GTS) > TECHNICAL VALUES
Tolerance
2


plate torque lb.)

TURBO S, CAYENNE S & CAYENNE GTS) > PRELIMINARY WORK

BATTERY

5. Remove the left and right cap -arrows- . To do this, remove the carpeted floor. Then loosen
the four fastening nuts and remove the cap.

6. Disconnect all connections on the right connection unit. Pull off electric plug connections.

tool on cap
Fig 5: Identifying Special Tool On Cap

TURBO S, CAYENNE S & CAYENNE GTS) > INFORMATION > COMPONENT
INFORMATION
Fig 1: Overview Of Fuel Pump
1. Fuel Pump
2. Sucking Jet Pump
3. Fuel Level Sensor, Right
4. Fuel Level Sensor, Left

TURBO S, CAYENNE S & CAYENNE GTS) > REMOVING FUEL PUMP
unit.
6. Disconnect the sucking jet pump at the fuel pump. To do this, press on the left and right
-arrows- and pull off the connections -1 and 2- .
Fig 4: Locating Sucking Jet Pump Connections
7. Release connection -3- and unclip it -a- .
8. Turn the fuel pump approx. 90° to the left until it disengages at the tank floor. Remove the fuel
pump from the tank.
Fig 5: Turning Fuel Pump

TURBO S, CAYENNE S & CAYENNE GTS) > INSTALLING FUEL PUMP
1. Place the pump in the holder on the tank floor and turn it approx. 90° to the right until it is
seated securely.
Fig 1: Turning Fuel Pump
2. Connect the sucking jet pump connections -1 and 2- at the fuel pump. These must lock with
an audible click.
Fig 2: Identifying Jet Pump Connections
3. Connect the connection -3- until it engages securely.
Fig 3: Installing Seal

Fig 4: Connecting Fuel Line On Left Connection Unit
8. Insert the left and right connection unit into the tank. When doing so, make sure that the plastic
lugs are pointing forward.

TURBO S, CAYENNE S & CAYENNE GTS) > SUBSEQUENT WORK
tighten using special tool Wrench T10202 . → Cap → Tightening torque: 145 Nm (107 ft.
lb.) +/-5 Nm (+/-3.5 ft. lb.)
Fig 1: Inserting Cap
2. Fit all connections of the right connection unit (fuel lines, ventilation tubes and electric
connectors). → Fuel supply and connection points at right connection unit

4. Fit the left lid (figure shows both lids). Then tighten the four fastening nuts to → Tightening
torque: 10 Nm (7.5 ft. lb.) . Refit carpeted floor and fix in place with double-sided adhesive
tape.

BATTERY
WM 207019 REMOVING AND INSTALLING CONTROL UNIT FOR FUEL PUMP

(CAYENNE S, CAYENNE (3.0), CAYENNE S E-HYBRID & CAYENNE TURBO) >
PRELIMINARY WORK
1. Remove rear right wheel. → 440519 REMOVING AND INSTALLING WHEEL

REMOVING CONTROL UNIT FOR FUEL PUMP
NOTE: Voltage peaks
Information

Fig 1: Fuel Pump Control Unit Installation Position

Fig 2: Identifying Connector On Control Unit For Fuel Pump

Fig 3: Removing Control Unit For Fuel Pump
3. Remove control unit for fuel pump from the bracket -3- (-B- ).

INSTALLING CONTROL UNIT FOR FUEL PUMP

SUBSEQUENT WORK
1. Install rear right wheel. → 440519 REMOVING AND INSTALLING WHEEL
WM 208055 REPLACING ACCELERATOR PEDAL MODULE (CAYENNE TURBO,

CAYENNE TURBO S, CAYENNE S & CAYENNE GTS) > TECHNICAL VALUES
Tolerance
2
Accelerator pedal module Tightening 10 Nm (7.5 ft. +/-1 Nm (+/- 0.5 ft.
to bracket torque lb.) lb.)

CAYENNE TURBO S, CAYENNE S & CAYENNE GTS) > PRELIMINARY WORK
2. Remove cover under dashboard in the footwell. → 702219 REMOVING AND INSTALLING
3. Remove securing bracket A for the lower dashboard cover at the accelerator pedal module.
To do this, pull the securing bracket out of the guide.

CAYENNE TURBO S, CAYENNE S & CAYENNE GTS) > REPLACING ACCELERATOR
PEDAL
Fig 1: Removing Accelerator Pedal
1. Pull plug connection -B- off the accelerator pedal module.
2. Remove accelerator pedal module. To do this, remove the three fastening screws -C- .
3. Take the accelerator pedal module out of the footwell and remove the pedal cap -D- by pulling
it downwards.
PEDAL > INSTALLING ACCELERATOR PEDAL
Fig 1: Installing Accelerator Pedal
1. Slide pedal cap -D- onto the new accelerator pedal module.
2. Fit new accelerator pedal module on the bracket -E- using the three fastening screws -C- . →
Tightening torque: 10 Nm (7.5 ft. lb.) +/-1 Nm (+/-0.5 ft. lb.)
3. Connect plug connection -B- .

PEDAL > PERFORMING KICKDOWN ADAPTATION
1. Connect the Porsche System Tester and switch on the ignition.
2. Select the relevant vehicle and call up the "Diagnostics" menu.
3. Control unit overview screen.
1. 3.1. Control unit search ends and DME control unit is displayed.
2. 3.2. Read out the fault memory of the DME control unit and correct and erase faults if
necessary.
3. 3.3. Select the "Maintenance/repairs" menu.
4. Maintenance/repairs screen.
1. 4.1. Select the Adaptations test.
2. 4.2. Follow the menu prompting.
5. Adaptations/preconditions screen.
1. 5.1. The following preconditions are displayed and must always be observed:
1. No faults stored in the fault memory
2. Engine off
3. Ignition on
4. Accelerator pedal not pressed
5. Parking brake on
6. Engine temperature: 60 °C...90 °C
2. 5.2. Follow the menu prompts.
6. Adaptations/overview screen.
1. 6.1. Select Kickdown threshold adaptation.
2. 6.2. Follow the menu prompts.
7. V6 and Hybrid: Adaptation/Kickdown switch screen.
1. 7.1. The message "Press accelerator pedal" is displayed.
2. 7.2. The accelerator pedal must be pressed within 5 seconds. Otherwise, an error
message will appear.
3. 7.3. If the accelerator pedal was pressed within the specified time, the message
"System OK" should appear on the Porsche System Tester.
4. 7.4. If the Porsche System Tester displays an error message, check the
preconditions again and repeat the adaptation test again from the start.
5. 7.5. Press [F8] or STOP on the touchscreen to end the test.
8. V8 naturally aspirated engine and turbo engine: Adaptation/Kickdown switch screen:
1. 8.1. The message "Press the accelerator as far as the mechanical stop and keep it
pressed for at least 30 seconds" is displayed.
2. 8.2. After 30 seconds, the message "System OK" should appear on the Porsche
System Tester.
3. 8.3. If the Porsche System Tester displays an error message, check the
preconditions again and repeat the adaptation test again from the start.
4. 8.4. Press [F8] or STOP on the touchscreen to end the test.
9. The test is now complete.
10. Disconnect the Porsche System Tester from the vehicle.
11. Error messages.
1. 11.1. Error messages can be displayed if:
1. Not all the preconditions were met.
2. The prompt "Press accelerator pedal" was ignored for more than 8 seconds.
2. 11.2. If the Porsche System Tester displays an error message, the adaptation test
must be repeated from the start.

CAYENNE TURBO S, CAYENNE S & CAYENNE GTS) > SUBSEQUENT WORK
1. Insert securing bracket A for the lower dashboard cover into the guide on the accelerator
pedal module.
2. Fit cover under dashboard. → 702219 REMOVING AND INSTALLING COVER UNDER
DASHBOARD
WM 209319 REMOVING AND INSTALLING SHUT-OFF VALVE (CHECK VALVE)

(CAYENNE S E-HYBRID) > GENERAL WARNING NOTES > GROUP 20 - FUEL SUPPLY,
CONTROL
Information

1. Remove right connection unit -1- with pressure regulator. (see →206619 REMOVING AND
INSTALLING FUEL PUMP
Fig 1: Identifying Connection Units At Left And Right

(CAYENNE S E-HYBRID) > REMOVING CHECK VALVE
1. Unclip check valve -1- on the fuel pipe -2- .

Fig 1: Identifying Check Valve

(CAYENNE S E-HYBRID) > INSTALLING CHECK VALVE
1. Clip in check valve -1- on the fuel pipe -2- .
1. 1.1. Check that the check valve -1- is fitted correctly.

Fig 1: Identifying Check Valve

1. Install right connection unit with pressure regulator. → 206619 REMOVING AND INSTALLING
FUEL PUMP
Service Manual: 21 - EXHAUST TURBOCHARGING -- 92A CAYENNE
WM 211401 CHECKING COMPRESSOR FOR LEAKS [CAYENNE S E-HYBRID &
CAYENNE (3.0)] > TOOLS
Ultrasonic Detector Workshop

WE 1038
UD 150 Equipment
Sealing Elements VW Tool T40206/2

CAYENNE (3.0)] > TOOLS AND MATERIALS > TOOLS
Sealing Elements T40206/2

CAYENNE (3.0)] > PRELIMINARY WORK
2. Secure the compressor on the engine and gearbox support for leak testing. → 211413
SECURING COMPRESSOR ON ENGINE AND GEARBOX SUPPORT FOR LEAK TEST
3. Control flap control unit installed. → 211919 REMOVING AND INSTALLING COMPRESSOR
CONTROL FLAP

CAYENNE (3.0)] > CHECKING COMPRESSOR FOR LEAKS
Information
For illustration purposes, the compressor is shown without the gear support.
1. Secure the Hose Adapter -VAG 1687/13-1- at the bottom of the compressor housing.
Secure hose connections with hose clamps.
Fig 1: Identifying Hose Adapter VAG (1687/13-1)
2. -Hose Adapter VAG 1687/13-3- must be secured at the top of the compressor housing.

Fig 2: Identifying Hose Adapter VAG. (1687/13-3)
3. Secure hose adapter -VAG 1687/13-2 - to the compressor housing with adapter -VAG
1687/10- .

Fig 3: Identifying VAG. (1687/13-2) With Adapter VAG (1687/10)
4. Prepare Charge Air System Tester -VAG 1687- as follows:
Unscrew pressure control valve -2- completely and close valves -3- and -4- .
Fig 4: Identifying Charge Air System Tester Components
5. Connect the charge air system tester to compressed air -1- and to the Adapter -VAG
1687/10- as shown.
Fig 5: Connecting Tester To Adapter
6. If there is water in the inspection glass, open the drain screw -6- and drain the water.
Open valve -3- .

7. Use the pressure control valve -2- to set the pressure to 0.5 bar .
Open valve -4- and wait until the test circuit is full. Set the pressure to 0.5 bar again if
necessary.
Close valve -3- and check the pressure gauge.

8. The pressure must not drop by more than 0.1 bar in 30 seconds .
9. Check the charge air system for leaks by listening for hissing noise, by touch, using
commercially available leak detection spray or using the ultrasonic detector UD 150 WE
1038 .
WM 211413 SECURING COMPRESSOR ON ENGINE AND GEARBOX SUPPORT FOR

ASSEMBLY WORK [CAYENNE S E-HYBRID & CAYENNE (3.0)] > TOOLS

Engine Bracket VAS Workshop
WE 1337
6095/1-4 Equipment
Gearbox Support VW tool T40206
Sealing elements VW tool T40206/2

ASSEMBLY WORK [CAYENNE S E-HYBRID & CAYENNE (3.0)] > TOOLS AND
MATERIALS > TOOLS
Engine Bracket VAS 6095/1-4 WE 1337

Fig 1: Identifying Engine And Gearbox Support VAS (6095)
Gearbox support T40206

Fig 2: Identifying Gearbox Support (T40206)
Sealing elements T40206/2

ASSEMBLY WORK [CAYENNE S E-HYBRID & CAYENNE (3.0)] > SECURING
COMPRESSOR
Information
During assembly work, the openings at the bottom of the compressor housing are designed to give the
mechanic a clear view and easy access to the charge-air coolers.
1. Compressor removed. → 211419 REMOVING AND INSTALLING COMPRESSOR
2. Insert gearbox support and sealing elements into the engine bracket.
3. Secure the compressor on the gearbox support as shown. For fitting screws -1- , use the
bores "1", "4", "9" and "13" .
On the front right, use screw -2- to screw the support -T40206/2- directly to the compressor
housing.
Fig 1: Securing Compressor To Gearbox Support
Installation Position Of Sealing Elements:
The seals -arrow 1- on the sealing elements are pointing downwards.
The openings -arrow 2- in the compressor housing give the mechanic a clear view and easy access to
the charge-air coolers.
Fig 2: Locating Sealing Elements Installation Position

LEAK TEST [CAYENNE S E-HYBRID & CAYENNE (3.0)] > TOOLS
Engine Bracket VAS Workshop

WE 1337
6095/1-4 Equipment
Gearbox Support VW tool T40206
Sealing Elements VW tool T40206/2

LEAK TEST [CAYENNE S E-HYBRID & CAYENNE (3.0)] > TOOLS AND MATERIALS >
TOOLS
Engine Bracket VAS 6095/1-4 WE 1337

Fig 1: Identifying Engine And Gearbox Support VAS (6095)
Gearbox Support T40206

Fig 2: Identifying Gearbox Support (T40206)
Sealing Elements T40206/2

LEAK TEST [CAYENNE S E-HYBRID & CAYENNE (3.0)] > SECURING COMPRESSOR
Information
For the leak test, the seals on the sealing elements should seal the openings in the compressor housing.
1. Compressor removed. → 211419 REMOVING AND INSTALLING COMPRESSOR
2. Insert gearbox support and sealing elements into the engine bracket.
3. Secure the compressor on the gearbox support as shown. For fitting screws -1- , use the
bores "1", "4", "9" and "13" .
On the front right, use screw -2- to screw the support -T40206/2- directly to the compressor
housing.
Fig 1: Securing Compressor To Gearbox Support
Installation Position Of Supports:
The seals on the supports seal the openings in the compressor housing.
Fig 2: Identifying Supports Installation Position
WM 211419 REMOVING AND INSTALLING COMPRESSOR [CAYENNE S E-HYBRID &

CAYENNE (3.0)] > TOOLS

CAYENNE (3.0)] > TECHNICAL VALUES
Tolerance Tolerance
1 2
Fastening screw on engine Tightening 27 Nm (20 ft.

suspension eyelet torque lb.)
Fastening screw on insulation Tightening 5 Nm (3.5 ft.

plate torque lb.)
Fastening screw on throttle valve Tightening 10 Nm (7.5

control unit torque ft. lb.)
Fastening screw for connection Tightening 10 Nm (7.5

piece torque ft. lb.)

torque lb.)
Fastening screw on regulating Tightening 10 Nm (7.5

valve control unit torque ft. lb.)
Fastening screw for intake air Tightening 10 Nm (7.5

Replace
temperature sensor torque ft. lb.)

Fastening nut on compressor
torque lb.)
Fastening screw for boost Tightening 10 Nm (7.5

Replace
pressure sensor torque ft. lb.)

CAYENNE (3.0)] > PRELIMINARY WORK

FOR COMPRESSOR

CAYENNE (3.0)] > REMOVING COMPRESSOR > ASSEMBLY OVERVIEW -
COMPRESSOR
Fig 1: Overview Of Compressor Assembly
2. Screw → Tightening torque: 27 Nm (20 ft. lb.)
3. Compressor
4. Insulation plate
5. Screw → Tightening torque: 5 Nm (3.5 ft. lb.)
6. Rubber sleeve
10. O-rings/replace
19. Screw replace → Tightening torque: 10 Nm (7.5 ft. lb.)
21. O-rings/replace
22. Nut → Tightening torque: 20 Nm (15 ft. lb.)
23. O-ring/replace
24. Threaded pin
27. Seals replace
28. O-ring replace
30. O-ring replace

CAYENNE (3.0)] > REMOVING COMPRESSOR > REMOVING COMPRESSOR
WARNING: Hot fluid

Danger of scalding
1. Close off coolant hoses with hose clamps Hose Clamp 3094 and remove from the coolant
pipes on the compressor by releasing the hose clamps -arrows- .
Fig 1: Locating Coolant Hoses On Compressor
3. Remove solenoid valve.
1. 3.1. Disconnect electric plug connection -1- on solenoid valve for the carbon canister
and remove vacuum hose -2- .
2. 3.2. Take the solenoid valve for the carbon canister out of the holder and set it aside
together with the connected hose.
Fig 3: Locating Solenoid Valve For Carbon Canister
4. Disconnect electric plug connection -arrow- on the throttle valve control unit.
Fig 4: Locating Throttle Valve Control Unit Connector
5. Disconnect electric plug connection -arrow- on the regulating valve control unit.
Fig 5: Locating Regulating Valve Control Unit Connector
6. Disconnect electric plug connection -1, 2, 3- .
Information
Mark installation position of vacuum hoses for re-installation.
Pull off vacuum hoses -4 through 7- .

Fig 6: Identifying Connectors And Vacuum Hoses
Information
Ignore arrows.
7. Disconnect electric plug connection -1- on the intake air temperature sensor/intake manifold
pressure sensor.
Fig 7: Locating Intake Air Temperature Sensor Connector
8. Expose vacuum hose -1- .
Unscrew screws at the left and right -arrows- and remove cover -2- .
Fig 8: Locating Cover Screws
9. Expose vacuum hose -2- for the brake booster at the holder -1- .
Fig 9: Identifying Brake Booster Vacuum Hose
10. Remove compressor.
1. 10.1. Disconnect electric plug connection -1- and -2- .
1. Material damage
→ Thoroughly clean connection points and adjacent areas before loosening them. If
the engine is very dirty, wash it before starting disassembly work.
→ Lay removed parts on a clean surface and cover them. Do not use fibre-shedding
cloths.
→ Carefully cover components or seal them if repair work will not be carried out
immediately. Place rubber caps on connections. Seal intake openings with film or
adhesive tape.
→ Only install clean parts. Do not take spare parts out of the packaging until just
before installation.
1. Material damage
cloths.
adhesive tape.
2. 10.2. Unscrew nuts -arrows- and remove compressor with charge-air cooler in an
upward direction.
Fig 10: Locating Compressor Nuts

CAYENNE (3.0)] > INSTALLING COMPRESSOR
Information
1. 1.1. Replace seals.
2. When fitting the compressor, make sure that the connection piece for positive crankcase
ventilation is installed at the correct position.
Fig 1: Locating Connection Piece Of Positive Crankcase Ventilation

CAYENNE (3.0)] > SUBSEQUENT WORK

FOR COMPRESSOR
2. Check cooling system and coolant level. → 190101 CHECKING COOLING SYSTEM
WM 211437 DISASSEMBLING AND ASSEMBLING COMPRESSOR [CAYENNE S

E-HYBRID & CAYENNE (3.0)] > TOOLS

Used Oil Collection And Extraction Workshop
WE 1385
Unit VAG 1782 Equipment

E-HYBRID & CAYENNE (3.0)] > PRELIMINARY WORK
1. Secure compressor on the engine and gearbox support. → 211413 SECURING

COMPRESSOR ON ENGINE AND GEARBOX SUPPORT FOR ASSEMBLY WORK
2. Remove coolant pipes on the compressor. → 196120 REMOVING AND INSTALLING

COOLANT PIPES
3. Position compressor vertically on the engine and gearbox support. The drive head is facing
upwards.

E-HYBRID & CAYENNE (3.0)] > DISASSEMBLING COMPRESSOR > REMOVING DRIVE
HEAD
1. Unscrew screws -arrows- .

Fig 1: Locating Screws On Drive Head
2. To avoid loosening the bearing cover -1- and having to seal it again, do not remove the drive
head -2- using a hammer but only using expanding pliers -arrows- as shown below.
Fig 2: Removing Drive Head From Bearing Cover
3. Carefully press the drive head off the bearing cover and remove it.
Remove decoupling spring.
4. Using Used Oil Collection And Extraction Unit VAG 1782 WE 1385 , extract all the oil for
the compressor drive from the bearing cover and from oil pockets -arrows- between the ribs.
Fig 3: Identifying Oil In Bearing Cover

E-HYBRID & CAYENNE (3.0)] > ASSEMBLING COMPRESSOR > INSTALLING DRIVE
HEAD
Information
1. Clean sealing faces to remove any oil and grease.
2. Before installation, always clean the threaded bores for the drive head in the bearing cover
with a thread cutter to remove any residual particles.
Information
It will not be possible to check the oil level later.
3. Fill 150 ml of compressor oil into the bearing cover.
4. Insert decoupling spring into the decoupling element.

1. 4.1. The end -1- of the decoupling spring must engage in the bore -arrow- in the
decoupling element at the rear.
Fig 1: Identifying Decoupling Spring
5. Apply a thin coat of sealant on the sealing face of the drive head.
6. Fit drive head on the compressor housing (be careful with the dowel sleeves).
7. At the same time, turn the poly-V-belt pulley until the other end of decoupling spring engages
in the bore in the decoupling element at the front.

E-HYBRID & CAYENNE (3.0)] > SUBSEQUENT WORK
1. Check compressor for leaks. → 211401 CHECKING COMPRESSOR FOR LEAKS
2. Remove coolant pipes on the compressor. → 196120 REMOVING AND INSTALLING

COOLANT PIPES
WM 211919 REMOVING AND INSTALLING COMPRESSOR CONTROL FLAP

[CAYENNE S E-HYBRID & CAYENNE (3.0)] > TOOLS

Tolerance Tolerance
1 2
Fastening screw on engine Tightening 27 Nm (20 ft.

suspension eyelet torque lb.)
Fastening screw on insulation Tightening 5 Nm (3.5 ft.

plate torque lb.)
Fastening screw on throttle valve Tightening 10 Nm (7.5

control unit torque ft. lb.)
Fastening screw for connection Tightening 10 Nm (7.5

piece torque ft. lb.)

torque lb.)
Fastening screw on regulating Tightening 10 Nm (7.5

valve control unit torque ft. lb.)
Fastening screw for intake air Tightening 10 Nm (7.5

Replace
temperature sensor torque ft. lb.)

Fastening nut on compressor
torque lb.)
Fastening screw for boost Tightening 10 Nm (7.5
Replace
pressure sensor torque ft. lb.)

1. Remove engine cover. → 108319 REMOVING AND INSTALLING ENGINE COVER (DESIGN
COVER)

[CAYENNE S E-HYBRID & CAYENNE (3.0)] > REMOVING COMPRESSOR CONTROL
FLAP > ASSEMBLY OVERVIEW - COMPRESSOR
Fig 1: Overview Of Compressor Assembly
2. Screw → Tightening torque: 27 Nm (20 ft. lb.)
3. Compressor
4. Insulation plate
6. Rubber sleeve
10. O-rings replace
21. O-rings/replace
22. Nut → Tightening torque: 20 Nm (15 ft. lb.)
23. O-ring replace
24. Threaded pin
27. Seals replace
28. O-ring replace
30. O-ring replace

[CAYENNE S E-HYBRID & CAYENNE (3.0)] > REMOVING COMPRESSOR CONTROL
FLAP > REMOVING COMPRESSOR CONTROL FLAP
1. Loosen fuel pipe fastening points -arrows- . Do not disconnect fuel hoses.
Fig 1: Identifying Fastening Points For Fuel Line
2. Remove compressor control flap.
1. 2.1. Pull electric plug connection -3- off the compressor control flap.
2. 2.2. Remove screws -5- and -6- .
3. 2.3. Remove connecting tube -1- with adapter (intermediate flange) -2- and
compressor control flap -4- .
Fig 2: Identifying Compressor Control Flap Components

[CAYENNE S E-HYBRID & CAYENNE (3.0)] > INSTALLING COMPRESSOR CONTROL
FLAP
Information
1. Install compressor control flap:
1. 1.1. Install connecting tube -1- with adapter (intermediate flange) -2- and
compressor control flap -4- with new O-rings.
2. 1.2. Tighten screws -5- and -6- hand-tight.
3. 1.3. Tighten screws -6- to the specified tightening torque.
4. 1.4. Tighten screws -5- to the specified tightening torque.
5. 1.5. Re-connect electric plug connection -3- .

Fig 1: Identifying Compressor Control Flap Components
2. Screw on fuel pipe -arrows- .

Fig 2: Locating Fastening Points For Fuel Line
Information
The PIWIS Tester II 9818 instructions take precedence and in the event of a discrepancy
these are the instructions that must be followed. Deviations may occur with later software
versions.
4. If the compressor control flap was replaced, adapt the engine control unit.
1. 4.1. Connect and start PIWIS Tester II.
2. 4.2. [Maintenance/repairs] must now be selected.
3. 4.3. [Short test] must be selected and activated.
4. 4.4. Adaptation values are then reset.
Information
The PIWIS Tester II 9818 instructions take precedence and in the event of a
discrepancy these are the instructions that must be followed. Deviations may occur
with later software versions.
5. Check the function of the control flap.
1. 5.1. Connect and start PIWIS Tester II.
2. 5.2. [Drive links] must be selected.
3. 5.3. [Compressor control flap] must be selected and activated by pressing [F8].

1. Install engine cover. → 108319 REMOVING AND INSTALLING ENGINE COVER (DESIGN
COVER)
WM 212419 REMOVING AND INSTALLING INTAKE MANIFOLD (CAYENNE TURBO &


value 1 2
Hose clamp connection on Tightening 5.5 Nm (4 ft.

turbocharger intake pipe torque lb.)

CAYENNE TURBO S) > PRELIMINARY WORK > PRELIMINARY WORK FOR
REMOVING AND INSTALLING INTAKE MANIFOLD
1. Remove front trim (engine compartment). → 700219 REMOVING AND INSTALLING FRONT
2. Remove air cleaner housing. → 242519 REMOVING AND INSTALLING AIR CLEANER
HOUSING
3. Remove pressure pipe.

CAYENNE TURBO S) > REMOVING INTAKE MANIFOLD
Fig 1: Identifying Turbocharger Intake Pipe
1. Loosen hose clamp -1- and pull off hose for recirculating air valve -2- .
NOTE: Sheared-off sealing grommet on turbocharger intake pipe
1. Risk of damage to turbocharger
→ A previously used intake pipe must not be re-used
→ Replace intake pipe and sealing grommet
→ Replace hose clamp
→ Coat area around sealing grommet on new intake pipe with water during fitting
2. Loosen hose clamp -3- and remove intake manifold -4- .
Dispose of intake manifold and hose clamp .

CAYENNE TURBO S) > INSTALLING INTAKE MANIFOLD
Fig 1: Identifying Turbocharger Intake Pipe
NOTE: Sheared-off sealing grommet on turbocharger intake pipe
Risk of damage to turbocharger
→ A previously used intake pipe must not be re-used
→ Replace intake pipe and sealing grommet
→ Replace hose clamp
→ Coat area around sealing grommet on new intake pipe with water during fitting
1. Install new intake manifold -4- with a new sealing grommet
Observe marking for correct installation position → Installation position of intake manifold
Fig 2: Identifying Intake Manifold Installation Position
2. Fit and tighten new hose clamp -3- . → Tightening torque: 5.5 Nm (4 ft. lb.)
3. Fit hose for recirculating air valve -2- and tighten hose clamp -1- .

1. Install pressure pipe.
2. Install air cleaner housing. → Installing Air Cleaner Housing
3. Install front trim (engine compartment). → Installing Front Trim Panel (Engine Compartment)
WM 213019 REMOVING AND INSTALLING CHARGE AIR COOLER (CAYENNE TURBO

& CAYENNE TURBO S) > TECHNICAL VALUES
Tolerance Tolerance
1 2
Fastening screw for charge air Tightening

7 Nm (5 ft. lb.)
cooler torque
Charge air line to charge air Tightening 5.5 Nm (4 ft.
cooler torque lb.)

& CAYENNE TURBO S) > PRELIMINARY WORK
1. Remove front apron. → Removing Front Apron - section on "Removing".
2. Remove front wheel housing liner. → Removing Front Wheel Housing Liner - section on
"Removing"
3. Remove front cover (engine compartment). → Removing Front Trim Panel (Engine
Compartment) - section on "Removing"

& CAYENNE TURBO S) > REMOVING CHARGE AIR COOLER
Fig 1: Identifying Charge Air Cooler Installation Position
Unless specified otherwise, removal and installation is the same on both sides .
1. Remove suction hose.
Fig 2: Removing Suction Hose
1. 1.1. Remove foam part -1- .
2. 1.2. Remove suction hose -2- by turning and pulling it.
2. Remove charge air line on air box for throttle housing (Y-shaped pipe).
1. 2.1. Open hose clamp -1- and slide it back.
2. 2.2. Unclip vacuum hose from the two clips under the charge air line.
3. 2.3. Remove circlip -2- on holder -4- for charge air hose -3- and slide charge air
hose backwards out of the bracket.
Fig 3: Removing Charge Air Line
4. 2.4. Right side only: Remove hose -1- at the charge air line by pressing the circlip
together at the sides -A- and pull off the hose -1- (-B- ).
Fig 4: Locating Hose On Right Charge Air Line
3. Remove pressure pipe.
1. 3.1. Raise the vehicle.
→ 4X00IN LIFTING THE VEHICLE
2. 3.2. Lever out wire clip -1- using a screwdriver and pull the pressure pipe -3- off the
charge air cooler -2- .
3. 3.3. Put wire clip -1- back into installation position immediately.
Fig 5: Removing Pressure Pipe
4. Remove charge air cooler.
1. 4.1. Unscrew three fastening screws -1- .
2. 4.2. Pull charge air cooler and charge air line outwards -arrow- .
Fig 6: Removing Charge Air Cooler

& CAYENNE TURBO S) > INSTALLING CHARGE AIR COOLER
1. Install charge air cooler.
1. 1.1. Guide charge air cooler and charge air line inwards from the outside -arrow- .
2. 1.2. Tighten three fastening screws -1- to → Tightening torque: 7 Nm (5 ft. lb.) .
Fig 1: Installing Charge Air Cooler
2. Install pressure pipe.
1. 2.1. Push pressure pipe -3- into the connection piece on the charge air cooler -2-
until it clicks into place.
Fig 2: Installing Pressure Pipe
2. 2.2. Lower the vehicle.
3. Install charge air line.
1. 3.1. Push charge air line -3- onto the holder -4- and slide it into the air box for
throttle housing (Y-shaped pipe).
2. 3.2. Fit circlip -2- for holder.
3. 3.3. Tighten hose clamp -1- .
4. 3.4. Clip vacuum hose into the two clips under the charge air line.
Fig 3: Installing Charge Air Line
5. 3.5. Right side only: Push hose -1- onto the connection piece for the charge air
line -2- .
Fig 4: Installing Hose On Charge Air Line

& CAYENNE TURBO S) > REPLACING CHARGE AIR COOLER
1. Remove accessories.
1. 1.1. Unscrew fastening screws -1- for the charge air line -2- at the charge air cooler
-3- .
Fig 1: Identifying Charge Air Line To Charge Air Cooler Screws
2. 1.2. At the rear air guide -1- , unclip the side locking mechanisms -2- and pull out
the air guide.
Fig 2: Removing Rear Air Guide From Charge Air Cooler
3. 1.3. At the front air guide -2- , unclip the side locking mechanisms -1- and pull out
the air guide.
Fig 3: Removing Front Air Guide From Charge Air Cooler
2. The accessories are installed in reverse order to removal.
1. 2.1. Tighten fastening screws on the intake manifold to → Tightening torque: 5.5
Nm (4 ft. lb.) .

& CAYENNE TURBO S) > SUBSEQUENT WORK
1. Install front apron. → Installing Front Apron - section on "Installing"
2. Install front wheel housing liner. → Installing Front Wheel Housing Liner - section on "Installing"
3. Install front cover (engine compartment). → Installing Front Trim Panel (Engine Compartment)
WM 213019 REMOVING AND INSTALLING TURBOCHARGER (CAYENNE S &

1. Remove engine. → 100119 REMOVING AND INSTALLING ENGINE
2. Remove primary catalytic converter. → 267619 REMOVING AND INSTALLING PRIMARY

CATALYTIC CONVERTER (TURBO)
3. Only for cylinders 4-6:

Remove air-conditioning compressor. → 873419 REMOVING AND INSTALLING

CAYENNE GTS) > REMOVING TURBOCHARGER > REMOVING TURBOCHARGER ON
CYLINDERS 4 - 6
Information
When removing the turbocharger, take note of the connection points for the lines .
Mark the installation position of the lines that are screwed to the turbocharger .
During re-installation, the lines must be tension-free and must not be bent .
Bent lines must be replaced .
Information
1. Loosen intake pipe on the turbocharger and remove intake pipe.
2. Disconnect pressure pipe at the turbocharger.
3. Remove heat protection from the turbocharger.
4. Loosen turbocharger oil lines -1- and -2- on the engine.
1. 4.1. Unscrew screws -3- and pull off oil supply line -1- at the cylinder head.
2. 4.2. Unscrew screw -5- and pull off oil return line -2- at the oil pan.
3. 4.3. Collect emerging oil.
4. 4.4. Close off openings using suitable stoppers.

Fig 1: Identifying Turbocharger Oil Circuit (Cylinders 4-6)
5. Disconnect turbocharger coolant lines -1 - and -2- on the engine.
1. 5.1. Loosen clamp and pull off coolant line -1- .
2. 5.2. Unscrew screw -4- and pull off coolant line -2- at the coolant distributor.

Fig 2: Identifying Turbocharger Cooling Related Components (Cylinders 4-6)
6. Disconnect control line at the vacuum unit using pointed-nose pliers or a plastic spatula.
7. Pull off control line -2- at the vacuum unit.
Fig 3: Identifying Vacuum Unit Control Line
8. Remove turbocharger.
1. 8.1. Unscrew nuts in the sequence -9 - 1- .
2. 8.2. Remove turbocharger and seal.

Fig 4: Identifying Exhaust Manifold/Turbocharger Nut Loosening Sequence

CAYENNE GTS) > REMOVING TURBOCHARGER > REMOVING TURBOCHARGER ON
CYLINDERS 1 - 3
Information
When removing the turbocharger, take note of the connection points for the lines .
Mark the installation position of the lines that are screwed to the turbocharger .
During re-installation, the lines must be tension-free and must not be bent .
Bent lines must be replaced .
Information
1. Loosen intake pipe on the turbocharger and remove intake pipe.
2. Disconnect pressure pipe at the turbocharger.
3. Remove heat protection on the turbocharger.
1. 3.1. Unscrew nut -7 - and remove heat protection -4- .

Fig 1: Identifying Exhaust Manifold/Turbocharger Components (Cylinders 1-3)
4. Loosen ATF line -1- on the cylinder head.
2. 4.2. Unscrew screw -3- on the oil cooler -4- .
3. 4.3. Guide out ATF line.

Fig 2: Removing ATF Line
5. Pull off control line -1- at the vacuum unit.

Fig 3: Identifying Vacuum Unit Control Line

6. Remove turbocharger coolant lines -1- and -2- .
2. 6.2. Disconnect coolant line -2- at the coolant distributor.
3. 6.3. Loosen clamp and pull off coolant line -1- .

Fig 4: Identifying Turbocharger Cooling Lines (Cylinders 1-3)
7. Remove turbocharger oil lines -1- and -2- .
1. 7.1. Unscrew screws -5- and pull off oil line -2- .
2. 7.2. Unscrew screw -6- and pull off oil line -1- at the oil pan.
3. 7.3. Collect emerging oil.

Fig 5: Identifying Turbocharger Oil Circuit (Cylinders 1-3)
8. Remove turbocharger.
1. 8.1. Unscrew nuts in the sequence -9 - 1- .
2. 8.2. Remove turbocharger and seal.

Fig 6: Identifying Exhaust Manifold/Turbocharger Nut Loosening Sequence

CAYENNE GTS) > INSTALLING TURBOCHARGER > INSTALLING TURBOCHARGER
ON CYLINDERS 1-3
Information
Information
Before installing the new turbocharger, remove all the stoppers on the turbocharger -1 and 2- .
Ensure, in particular, that the conical rubber stopper on the connecting flange for the oil line -2- is
also removed.
In some cases, the rubber stopper, as shown in -bottom, 2- , may be pressed slightly into the bore
when the turbocharger is supplied. As a result, it is not immediately visible from the outside - particularly
when fitting the oil line.
Always remove rubber stoppers before fitting the oil line .

Fig 1: Identifying Stoppers On Turbocharger
Item 1: Plastic stoppers (not always fitted - depends on the type of packaging in which the
turbocharger is supplied) -1- .
Item 2: Rubber stopper (always fitted) -2- .
1. Clean sealing faces between the exhaust manifold -1- cylinder head and replace seal -2- .
2. Fit turbocharger with exhaust manifold -1- on cylinder head for cylinders 1 - 3.
3. Use new fastening nuts -5- .
Fig 2: Identifying Exhaust Manifold/Turbocharger Related Components (Cylinders 1-3)
4. Tighten new fastening nuts to the specified tightening torque in the sequence -1-9- .
Fig 3: Identifying Exhaust Manifold/Turbocharger Nut Tightening Sequence

CAYENNE GTS) > INSTALLING TURBOCHARGER > INSTALLING TURBOCHARGER
ON CYLINDERS 4-6
Information
Information
Before installing the new turbocharger, remove all the stoppers on the turbocharger -1 and 2- .
Ensure, in particular, that the conical rubber stopper on the connecting flange for the oil line -2- is
also removed.
In some cases, the rubber stopper, as shown in -bottom, 2- , may be pressed slightly into the bore
when the turbocharger is supplied. As a result, it is not immediately visible from the outside - particularly
when fitting the oil line. Always remove rubber stoppers before fitting the oil line .
Fig 1: Identifying Stoppers On Turbocharger
Item 1: Plastic stoppers (not always fitted - depends on the type of packaging in which the
turbocharger is supplied) -1- .
Item 2: Rubber stopper (always fitted) -2- .
1. Clean sealing faces between the exhaust manifold -1- cylinder head and replace seal -2- .
2. Fit turbocharger with exhaust manifold -1- on cylinder head for cylinders 4 - 6.
3. Use new fastening nuts -3- .
Fig 2: Identifying Exhaust Manifold/Turbocharger Related Components (Cylinders 4-6)
4. Tighten new fastening nuts to the specified tightening torque in the sequence -1-9- .
Fig 3: Identifying Exhaust Manifold/Turbocharger Nut Tightening Sequence

1. Install air-conditioning compressor. → 873419 REMOVING AND INSTALLING

2. Install primary catalytic converter.
→ 267619 REMOVING AND INSTALLING PRIMARY CATALYTIC CONVERTER (TURBO)
3. Install engine.
→ 100119 REMOVING AND INSTALLING ENGINE
WM 213919 REMOVING AND INSTALLING MOLDED HOSE (CAYENNE S & CAYENNE


value 1 2
Screw-type clamp securing pressure Tightening 5.5 Nm (4

pipe to air box for throttle valve torque ft. lb.)

1. Remove engine compartment trim panel for the relevant side. → 700219 REMOVING AND

GTS) > REMOVING MOLDED HOSE
Information
1. Remove molded hose -1- .
1. 1.1. Release safety clip -arrow- and pull molded hose -1- off the charge-air cooler
-2- .
2. 1.2. Loosen screw-type clamp -3- and remove molded hose -1- from air box for the
throttle valve -4- .
Fig 1: Identifying Molded Hose

GTS) > INSTALLING MOLDED HOSE
Information
Replace O-rings .
Grease O-rings with a light coating of Kluber Syntheso Glep (Part No.: 000.043.204.68) .
1. 1.1. Coat O-ring.
2. 1.2. Tightening torque for screw-type clamp: Tightening torque 5.5 Nm (4 ft. lb.)

1. Install engine compartment trim panel for the relevant side. → 700219 REMOVING AND
WM 214319 REMOVING AND INSTALLING CHARGE-AIR COOLER [CAYENNE S


Levering device VW tool 2036

E-HYBRID & CAYENNE (3.0)] > TECHNICAL VALUES

value 1 2
Fastening screw securing charge-air Tightening 10 Nm (7.5

Self-locking
cooler to compressor housing torque ft. lb.)
Fastening screw securing charge-air Tightening 10 Nm (7.5

Self-locking
cooler to compressor housing torque ft. lb.)

2. Secure compressor on engine and gearbox support for assembly work. → 211413 SECURING
COMPRESSOR ON ENGINE AND GEARBOX SUPPORT FOR ASSEMBLY WORK

E-HYBRID & CAYENNE (3.0)] > REMOVING CHARGE-AIR COOLER > ASSEMBLY
OVERVIEW - CHARGE-AIR COOLER
Fig 1: Overview Of Charge-Air Cooler Assembly
1. Seal replace
2. O-ring replace
3. O-ring replace
5. Seal replace
6. Right charge-air cooler
8. Seal
3. Coat with engine oil during installation
10. Left charge-air cooler
11. Seal
3. Coat with engine oil during removal and installation

E-HYBRID & CAYENNE (3.0)] > REMOVING CHARGE-AIR COOLER > REMOVING
CHARGE-AIR COOLER
1. Charge-air cooler, left:
1. 1.1. Unclip holder -1- for vacuum hose. Disregard item 2.
2. 1.2. Remove boost pressure sensor for cylinder bank 2. → 219019 REMOVING AND
INSTALLING BOOST PRESSURE SENSOR
Fig 1: Unclipping Vacuum Hose
2. Charge-air cooler, right:
1. 2.1. Remove throttle housing unit. → 244219 REMOVING AND INSTALLING

THROTTLE HOUSING
2. 2.2. Remove boost pressure sensor. → 219019 REMOVING AND INSTALLING

BOOST PRESSURE SENSOR
3. Continue as follows for both sides:
4. Unscrew screws -1- and -2- and remove coolant pipes on the compressor.
Fig 2: Identifying Coolant Pipes On Charge-Air Cooler
5. Unscrew screws -1, 2- for left charge-air cooler and -3, 4- for right charge-air cooler.
Fig 3: Identifying Screws Of Charge-Air Cooler
Information
1. Coat seals on the charge-air cooler with engine oil through the intake-air openings .
6. Levering Device 2036 with -2036/1- must be secured on the compressor as shown.
Fit socket-wrench insert (a/f 32) at the front of the charge-air cooler.
Push the charge-air cooler slowly and with moderate force to the rear out of the compressor
housing using a levering device.
Fig 4: Removing Charge-Air Cooler

E-HYBRID & CAYENNE (3.0)] > INSTALLING CHARGE-AIR COOLER
Information
1. Charge-Air Cooler Seals:
1. 1.1. Check the seal -5- on the charge-air cooler -4- .
2. 1.2. The seal must not be cracked or damaged.
3. 1.3. Push the seal -1- onto the charge-air cooler.
4. 1.4. Insert O-ring -2- into the opening on the compressor housing -3- .
Fig 1: Identifying Charge-Air Cooler Seals
2. Charge-Air Cooler Sealing Surfaces:
1. 2.1. Coat the sealing surface -arrow A- and seal -arrow B- on the charge-air cooler
-1- with engine oil.
2. 2.2. Also coat the inner sealing surface in the compressor housing with engine oil.
Fig 2: Locating Charge-Air Cooler Sealing Surfaces
Information
To make it easier to slide in and press back the charge-air cooler, position the
compressor housing vertically in the engine and gearbox support VAS 6095.
3. When fitting the charge-air cooler, make sure that the seals are aligned with the cut-outs in the
compressor housing -arrows- .
Fig 3: Locating Charge-Air Seals And Cut-Outs
4. Slide the charge-air cooler as far as it will go by hand into the compressor housing -arrow A-
. To do this, slide the front of the charge-air cooler into the bore -arrow B- in the compressor
housing.
Fig 4: Sliding Charge-Air Cooler
5. Guide the charge-air cooler through the openings -arrows- on the compressor housing by
hand if necessary when inserting it.
As soon as the screw length allows it, screw in two screws loosely by hand to guide the
charge-air cooler further.
Fig 5: Identifying Compressor Housing Openings
6. Tighten screws -1, 2- for the charge-air cooler at the left and -3, 4- for the charge-air cooler at
the right in diagonally opposite sequence and in small steps.
Fig 6: Identifying Charge-Air Cooler Screws

1. Install throttle housing unit. → 244219 REMOVING AND INSTALLING THROTTLE HOUSING
2. Check compressor for leaks. → 211401 CHECKING COMPRESSOR FOR LEAKS
WM 219019 REMOVING AND INSTALLING BOOST PRESSURE SENSOR [CAYENNE S

E-HYBRID & CAYENNE (3.0)] > TECHNICAL VALUES

value 1 2
Fastening screw for charge-air Tightening 9 Nm (6.5 ft.

cooler torque lb.)
torque lb.)

torque lb.)
Fastening screw for boost pressure Tightening 5 Nm (3.5 ft.

sensor torque lb.)
Screw-type clamp securing air Tightening 5.5 Nm (4 ft.

guide hose to adapter torque lb.)

E-HYBRID & CAYENNE (3.0)] > INFORMATION > ASSEMBLY OVERVIEW -
CHARGE-AIR COOLER
Fig 1: Overview Of Charge-Air Cooler Assembly
1. Air guide for charge-air cooler
2. O-ring on air guide hose for turbocharger
3. Air guide hose for turbocharger
4. Fastening screw for charge-air cooler → Tightening torque: 9 Nm (6.5 ft. lb.)
5. Fastening screw for adapter → Tightening torque: 9 Nm (6.5 ft. lb.)
6. Air guide hose for right charge-air cooler
7. Adapter
8. Fastening screw for adapter → Tightening torque: 9 Nm (6.5 ft. lb.)
9. O-ring on boost pressure sensor replace
11. Fastening screw for boost pressure sensor → Tightening torque: 5 Nm (3.5 ft. lb.)
12. Air guide hose to throttle valve control unit
13. O-ring on adapter on charge-air cooler replace
14. Charge-air cooler
15. Screw-type clamp securing air guide hose to adapter → Tightening torque: 5.5 Nm (4 ft. lb.)

E-HYBRID & CAYENNE (3.0)] > REMOVING BOOST PRESSURE SENSOR
1. Disconnect electric plug connection -arrow- on the boost pressure sensor.

Fig 1: Identifying Boost Pressure Sensor Connector
2. Remove screws. Pull boost pressure sensor out of the adapter.

E-HYBRID & CAYENNE (3.0)] > INSTALLING BOOST PRESSURE SENSOR
Information
Information
Replace sealing ring.


E-HYBRID & CAYENNE (3.0)] > REMOVING BOOST PRESSURE SENSOR
1. Cylinder bank 2 (left):
1. 1.1. Expose vacuum hose -1- .
2. 1.2. Unscrew screws -arrows- and remove cover -2- .

Fig 1: Exposing Boost Pressure Sensor For Cylinder Bank 2
2. Continue as follows for both sides:
1. Material damage
cloths.
adhesive tape.
2. 2.2. Unscrew screws -arrows- and remove boost pressure sensor.

Fig 2: Removing Boost Pressure Sensor

E-HYBRID & CAYENNE (3.0)] > INSTALLING BOOST PRESSURE SENSOR
Information
1. 1.1. The self-locking screws and O-ring must be replaced.
2. 1.2. Before installation, remove all residual sealant from the threaded bores for the
boost pressure sensor in the compressor housing using a thread cutter.


Service Manual: 24 - FUEL SYSTEM - ELECTRONIC IGNITION -- 92A CAYENNE
WM 240919 REMOVING AND INSTALLING FUEL PRESSURE SENSOR (HIGH-
PRESSURE) (CAYENNE S & CAYENNE GTS) > TOOLS
Open-Jawed Commercially
Nr. 96
Wrench Insert Available Tool

PRESSURE) (CAYENNE S & CAYENNE GTS) > PRELIMINARY WORK
1. Pull out the fuse for the fuel pump or disconnect the battery. This prevents the fuel pump from
starting when the door is opened.

DISTRIBUTOR

PRESSURE) (CAYENNE S & CAYENNE GTS) > REMOVING FUEL PRESSURE
SENSOR (HIGH-PRESSURE SENSOR)

Emerging fuel
Risk of fire
Material damage
Information
Information
1. Pull off cable plug -arrow- .

Fig 1: Identifying Fuel Pressure Sensor (High-Pressure Sensor) And Connector
2. Place cloths around the fuel pressure sensor. Relieve fuel pressure at fuel collection pipe by
slowly opening the sensor -1- using a ring wrench.
3. Remove fuel pressure sensor. Visually check the thread and sealing ball to make sure they are
not damaged.

PRESSURE) (CAYENNE S & CAYENNE GTS) > INSTALLING FUEL PRESSURE
SENSOR (HIGH-PRESSURE SENSOR)
Information
1. Visually check the thread and sealing cone on the fuel pressure sensor to make sure they are
not damaged.
2. Visually check the threaded bore and sealing cone on the high-pressure collection pipe to
make sure they are not damaged.
3. As in the leak test, blow fuel residues out of the fuel collection pipe by blowing helium through
the opening on the sensor. For details, see → 243001 CHECKING FUEL DISTRIBUTOR PIPE
FOR LEAKS
4. Fit fuel pressure sensor -1- .
1. 4.1. Carefully screw the fuel pressure sensor by hand into the thread of the fuel
distributor pipe. Check that it screws in easily.
2. 4.2. Tighten fuel pressure sensor using an Open-Jawed Wrench Insert Nr. 96 and
a suitable torque wrench.
5. Connect cable plug to the fuel pressure sensor -arrow- .

Fig 1: Installing Fuel Pressure Sensor
6. Check fuel collection pipe for leaks. → 243001 CHECKING FUEL DISTRIBUTOR PIPE FOR
LEAKS

PRESSURE) (CAYENNE S & CAYENNE GTS) > SUBSEQUENT WORK
1. Fit the fuse for the fuel pump or connect the battery.

DISTRIBUTOR
3. Fill and bleed the fuel high-pressure system. → 2430B1 FILLING AND BLEEDING THE FUEL
DISTRIBUTOR PIPE
WM 240919 REMOVING AND INSTALLING FUEL PRESSURE SENSOR

(LOW-PRESSURE SENSOR) (CAYENNE S & CAYENNE GTS) > TOOLS
Open-Jawed Commercially
Nr. 96
Wrench Insert Available Tool

(LOW-PRESSURE SENSOR) (CAYENNE S & CAYENNE GTS) > PRELIMINARY WORK
1. Pull out the fuse for the fuel pump or disconnect the battery. This prevents the fuel pump from
starting when the door is opened.

(LOW-PRESSURE SENSOR) (CAYENNE S & CAYENNE GTS) > REMOVING FUEL
PRESSURE SENSOR (LOW-PRESSURE SENSOR)

Emerging fuel
Risk of fire
Material damage
Information
Information
1. Pull off cable plug -arrow- .
2. Remove fuel pressure sensor -2- .
1. 2.1. Place cloths around the fuel pressure sensor.
2. 2.2. Counter with an open-ended wrench -1- .
3. 2.3. Relieve fuel pressure by slowly opening the fuel pressure sensor -2- using a
ring wrench.
4. 2.4. Slowly open the fuel pressure sensor using a ring wrench and carefully relieve
the fuel pressure.
Fig 1: Removing/Installing Fuel Pressure Sensor (Low-Pressure Sensor)

(LOW-PRESSURE SENSOR) (CAYENNE S & CAYENNE GTS) > INSTALLING FUEL
PRESSURE SENSOR (LOW-PRESSURE SENSOR)

Emerging fuel
Risk of fire
Material damage
Information
Information
1. Visually check the thread and sealing cone on the fuel pressure sensor to make sure they are
not damaged.
2. Visually check the threaded bore and sealing cone to make sure they are not damaged.
3. Fit fuel pressure sensor -2- .
1. 3.1. Carefully screw the fuel pressure sensor by hand into the thread of the fuel line.
Check that it screws in easily.
2. 3.2. Tighten fuel pressure sensor using an Open-Jawed Wrench Insert Nr. 96 and
a suitable torque wrench. Counter with an open-ended wrench -1- while doing this.
3. 3.3. Push on cable plug -arrow- .

Fig 1: Removing/Installing Fuel Pressure Sensor (Low-Pressure Sensor)

(LOW-PRESSURE SENSOR) (CAYENNE S & CAYENNE GTS) > SUBSEQUENT WORK
WM 240919 REMOVING AND INSTALLING FUEL PRESSURE SENSOR (CAYENNE) >

TOOLS
Socket-Wrench Commercially
Nr. 188
Insert Available Tool

TECHNICAL VALUES
High-Pressure Sensor M10 Tightening Torque 22 Nm (16 ft. lb.)

PRELIMINARY WORK
1. Remove left engine compartment cover. For details, see → REMOVING FRONT TRIM PANEL
2. Pull the fuse for the fuel pump out of the slot in the central electrical system or disconnect the
battery. This prevents the fuel pump from starting when a door is opened.

REMOVING FUEL PRESSURE SENSOR > REMOVING HIGH-PRESSURE SENSOR
(RAIL PRESSURE SENSOR)

Material damage
Emerging fuel
Risk of fire
Information
Information
1. Remove cable plug for the high-pressure sensor -3- .

Fig 1: Identifying High-Pressure Sensor
2. Place a cloth under the high-pressure sensor and remove the high-pressure sensor slowly
using a long socket (e.g. Hazet 900 Lg Socket-Wrench Insert Nr. 188 or a similar tool).
Relieve the fuel pressure by slowly opening the high-pressure sensor.
3. Visually check the thread and sealing ball to make sure they are not damaged.

INSTALLING > INSTALLING HIGH-PRESSURE SENSOR (RAIL PRESSURE SENSOR)
1. Visually check the thread and sealing cone to make sure they are not damaged.
2. It must be possible to turn the high-pressure sensor slightly by hand. Lightly lubricate the
high-pressure sensor with engine oil.
3. Screw on high-pressure sensor using a long socket (e.g. Hazet 900 Lg Socket-Wrench Insert
Nr. 188 or a similar tool) -3- . → Tightening Torque: 22 Nm (16 ft. lb.)
Fig 1: Identifying High-Pressure Sensor

4. Connect cable plug for high-pressure sensor.
5. Check high-pressure distributor pipe for leaks. Following a test drive, visually inspect the
high-pressure sensor with a mirror and lamp at idle speed.

SUBSEQUENT WORK
2. Fit engine compartment cover. For details, see → INSTALLING FRONT TRIM PANEL
WM 242419 REMOVING AND INSTALLING AIR-CLEANER ELEMENT (CAYENNE S

Tolerance Tolerance
1 2
Fastening Screw On Lower Part Tightening 9 Nm (6.5 ft.

Of Air Cleaner Torque lb.)

HYBRID) > ASSEMBLY OVERVIEW - AIR CLEANER
Fig 1: Overview Of Air Cleaner Assembly
1. Water drain Clean
2. Air guide from lock support
4. Lower part of air cleaner Clean To Remove Salt Residues, Dirt And Leaves
5. Air guide pipe Clean To Remove Salt Residues, Dirt And Leaves
6. Air-cleaner element
7. Vent hose
8. Upper part of air cleaner Clean To Remove Salt Residues, Dirt And Leaves
9. O-ring Replace
10. Hose for secondary air pump motor
11. Rubber sleeve

HYBRID) > REMOVING AIR-CLEANER ELEMENT
1. Remove right engine compartment cover.
2. Remove air guide hose -2- by loosening the hose clamp -1- .
Fig 1: Identifying Air Guide Hose
3. Remove suction hose for secondary air -2- by pressing the release buttons -1- .
Fig 2: Identifying Suction Hose For Secondary Air
4. Release retaining clips -arrows- .

Fig 3: Locating Air Cleaner Retaining Clips
5. Press upper part of air cleaner -1- off lower part of air cleaner -2- and pull it up out of the
openings for the retaining lugs -arrows- .
Fig 4: Locating Lower Part Of Air Cleaner
6. Remove air-cleaner element -arrow- .

Fig 5: Locating Air-Cleaner Element

HYBRID) > INSTALLING AIR-CLEANER ELEMENT
Information
Information
Always use an original air-cleaner element .
The air cleaner housing must always be perfectly clean .
Use (silicone-free) sliding compound for fitting the air guide hoses .
Secure all hose connections with standard hose clamps .
Always check the following when blowing out the air cleaner housing: To avoid malfunctions, cover
critical air-supply components, such as air guide pipes, etc. with a clean cloth .
Observe disposal regulations!

1. Clean the air cleaner housing:
1. 1.1. Remove salt residues, dirt or leaves from the upper and lower part of the air
cleaner housing using a suction device.
2. 1.2. Blow out the water drain -arrow- at the bottom of the air cleaner housing using
compressed air.
3. 1.3. Check the air guide from the lock support to the air cleaner housing for dirt and
leaves.
Fig 1: Locating Water Drain Plug On Air Cleaner Housing
2. When installing the air-cleaner element, make sure it is centered in the mounting in the lower
part of the air cleaner.
3. Carefully position the upper part of the air cleaner on the lower part of the air cleaner without
excessive force. Check that the air guide hoses are seated securely on the upper part of the
air cleaner.
WM 242455 REPLACING AIR-CLEANER ELEMENT (CAYENNE, CAYENNE S,

1. Remove engine compartment trim panel at the right. → REMOVING FRONT TRIM PANEL
2. Remove air cleaner housing lid. → REMOVING AIR CLEANER HOUSING - section on
"Removing"

CAYENNE TURBO, CAYENNE GTS & CAYENNE TURBO S) > REPLACING
AIR-CLEANER ELEMENT
Information
If an air cleaner housing, which was last replaced four years ago, is opened before the relevant
service interval is reached (e.g. visual inspection at the request of the customer or similar
situation), the air-cleaner element must be replaced and the housing must be cleaned .
A used air-cleaner element (which was last replaced four years ago) must not be re-installed due
to the risk of leaks in the housing (loss of elasticity in the air-cleaner seal over time) .
Always replace the air-cleaner element when you open the air cleaner housing (which was last
replaced four years ago)!
Information
Under particularly difficult conditions (dusty environments) it may be necessary to change the filter
element outside the maintenance intervals .
The description only applies to changing one filter element. The second element is changed in the
same way .
Information
If the air-cleaner element has become damp for various reasons, it must be replaced. It cannot be
re-installed.
1. Remove the air-cleaner element from the air cleaner housing.

Fig 1: Identifying Air-Cleaner Element
2. Insert filter element in the housing.
Check that the air-cleaner element is seated correctly.

Fig 2: Checking Filter Element Inserted Correctly

1. Install air cleaner housing lid. → INSTALLING AIR CLEANER HOUSING - section on
"Installing"
2. Install engine compartment trim panel at the right. → INSTALLING FRONT TRIM PANEL
WM 242519 REMOVING AND INSTALLING AIR CLEANER HOUSING (CAYENNE S,

Air Cleaner Housing M6 screw Tightening Torque 10 Nm (7.5 ft. lb.)

1. Remove the relevant wheel housing liner. → REMOVING FRONT WHEEL HOUSING - section
on "Removing"
2. Remove the relevant engine compartment cover. → REMOVING FRONT TRIM PANEL

CAYENNE TURBO, CAYENNE GTS & CAYENNE TURBO S) > REMOVING AIR
CLEANER HOUSING
Fig 1: Identifying Air Cleaner Housing - V8 S

Fig 2: Identifying Air Cleaner Housing - V8 Turbo
1. Remove the air guide. → REMOVING AIR GUIDE - section on "Removing"
2. Loosen connections on the air cleaner covers. To do this, turn the bolts 180° and pull them out
→ Loosening connections on air cleaner . Pull off intake pipes.
Fig 3: Loosening Connections On Air Cleaner
3. Open the cover on the air cleaner housing.
To do this, unclip the two fastening clamps -arrows- using a suitable tool.
Fig 4: Locating Fastening Clamps
4. Fold the cover -1- of the air cleaner housing -2- forward at the top -A- and pull it out in an
upward direction -B- .
Fig 5: Removing Cover On Air Cleaner Housing
5. Remove air-cleaner element. → REPLACING AIR-CLEANER ELEMENT - section on

"Replacing"
6. Loosen the fastening screw -arrow- on the air cleaner housing.

Fig 6: Locating Fastening Screw
7. Lift the air cleaner housing, tip it towards the engine and remove it from the engine
compartment. → Air cleaner housing
Fig 7: Identifying Air Cleaner Housing

CAYENNE TURBO, CAYENNE GTS & CAYENNE TURBO S) > INSTALLING AIR
CLEANER HOUSING
1. Insert the air cleaner housing into the engine compartment at an angle from above. → Air
cleaner housing
Fig 1: Identifying Air Cleaner Housing
2. Guide the two retaining bolts on the underside into the take-up bores in the body -arrows- .
From the wheel housing, check to make sure that the blue rubber washers are present and
make sure that the bolts are fitted properly.
Fig 2: Locating Fastening Bolts And Rubber Washers
3. Tighten the fastening screw -arrow- on the air cleaner housing. → Tightening Torque: 10
Nm (7.5 ft. lb.)
4. Insert air-cleaner element. → REPLACING AIR-CLEANER ELEMENT - section on

"Replacing"
5. Fit the cover -1- of the air-cleaner box using the side guides -2- on the air cleaner housing -3-
.
Fig 4: Fitting Air Cleaner Cover
1. 5.1. Slide the cover down -A- .
2. 5.2. The guides -4- on the cover must fit into the mountings -5- on the air cleaner
housing.
6. Fold the cover -1- up towards the air cleaner housing -2- (-A- ).
Fig 5: Installing Air Cleaner Cover
7. Clip in the two upper fastening clamps -arrows- on the air cleaner housing.
Fig 6: Locating Fastening Clamps
8. Slide the intake port into the cover of the air cleaner housing.
Push the bolts fully into the mountings and turn them 180° → Securing connections on air
cleaner .
Fig 7: Securing Connections On Air Cleaner
9. Insert the air guide into the air cleaner housing. → INSTALLING FRONT WHEEL HOUSING
LINER - section on "Installing"

1. Install the relevant wheel housing liner. → INSTALLING FRONT WHEEL HOUSING LINER -
2. Install the relevant engine compartment cover. → INSTALLING FRONT TRIM PANEL
WM 243519 REMOVING AND INSTALLING AIR BOX FOR THROTTLE HOUSING

[CAYENNE S HYBRID & CAYENNE TIP (3.0)] > REMOVING AIR BOX FOR THROTTLE
HOUSING
Material damage
1. Remove engine cover -1- .

Fig 1: Identifying Engine Cover (Similar To Illustration)
1. 2.1.

[CAYENNE S HYBRID & CAYENNE TIP (3.0)] > INSTALLING AIR BOX FOR THROTTLE
HOUSING
1. 1.1. Clean inside of air guide pipe.
WM 243001 CHECKING FUEL DISTRIBUTOR PIPE (HIGH-PRESSURE SYSTEM) FOR

LEAKS (CAYENNE TURBO & CAYENNE TURBO S) > TOOLS

Air-Spring Strut Filling Workshop
WE 1282
Unit VAS 6231 Equipment
Adapter Special Tool 9759

LEAKS (CAYENNE TURBO & CAYENNE TURBO S) > TECHNICAL VALUES
High-Pressure Pump Pressure 10 bar
Fuel Supply Line M16 x 1.5 thread Tightening Torque 35 Nm (26 ft. lb.)

LEAKS (CAYENNE TURBO & CAYENNE TURBO S) > PRELIMINARY WORK

Material damage
Emerging fuel
Risk of fire
Information
Information
After disassembly work on the high-pressure injection system, fit the components to the prescribed
torques.
Visible threaded joints must be inspected for leaks with the engine idling after a test drive.
For the check to be performed correctly, the components to be checked must not contain any fuel.
When dismantling, remove fuel from the lines.
1. Remove rear engine-compartment cover. → REMOVING FRONT TRIM PANEL (ENGINE

2. Pull out fuse for the fuel pump in the central electrical system or disconnect the battery. This
ensures that the fuel pump does not start up when a door is opened.

LEAKS (CAYENNE TURBO & CAYENNE TURBO S) > INFORMATION > COMPONENT
OVERVIEW
Fig 1: Identifying Fuel Injectors And Related Components
-1- - Retainer for injectors; with twist lock and cut-out for the injector's color clip
-2- - M8 screw
-3- - High-pressure fuel injector

Fig 2: Identifying Fuel Distributor Pipe And Related Components
-1- - Fuel distributor pipe (fuel gallery, rail)
-2- - Stopper
-3- - High-pressure sensor

Fig 3: Identifying High-Pressure Pump And Related Components (Turbo Engine)
-1- - High-pressure pump; replace sealing ring
-2- - High-pressure line; screw on both union nuts hand-tight, align union nut no. 4
-3- - Low-pressure line (fuel line); counter at the high-pressure pump hexagon; maintain
distance from high-pressure line
-4- - Screw socket for high-pressure line
-5- - Screw socket for high-pressure pump
-6- - Crash panel
-7- - Screws on crash panel
-8- - Screw on high-pressure pump
-A- - Naturally aspirated and turbo engine; maintain distance from high-pressure line
Fig 4: Identifying High-Pressure Pump Related Components (Naturally Aspirated Engine)
-1- - High-pressure pump; replace sealing ring
-2- - High-pressure line; screw on both union nuts hand-tight, align union nut no. 4
-3- - Low-pressure line (fuel line); counter at the high-pressure pump hexagon; maintain
distance from high-pressure line
-4- - Screw socket for high-pressure line
-5- - Screw socket for high-pressure pump
-6- - Crash panel
-7- - Screws on crash panel
-8- - Screw on high-pressure pump
-A- - Naturally aspirated and turbo engine; maintain distance from high-pressure line

LEAKS (CAYENNE TURBO & CAYENNE TURBO S) > CHECKING FUEL DISTRIBUTOR
PIPE (FUEL RAIL) FOR LEAKS
Emerging fuel
Risk of fire
1. Place a cloth under the fuel supply line (low-pressure) and open the line using two open-ended
wrenches. -1- only
Fig 1: Identifying Tank Ventilation And Low-Pressure Line
Information
1. Check that the tool fittings are clean before starting the leak test .
2. Blow out the tool fittings before assembly using gentle bursts of pressure to prevent dust
and foreign bodies from getting into the high-pressure system during the leak test .
3. Ensure that the tools for the leak test remain clean and free of dirt when stored .
2. Adapter 9759 → Adapter 9759 with sealing ring must be screwed hand-tight and fully sealed
onto the fuel low-pressure line. -arrow-
Fig 2: Identifying Adapter (9759) With Sealing Ring

Fig 3: Identifying Adapter (9759) And Fuel Low-Pressure Line
WARNING: Working with compressed air
2. Risk of damaging and dirtying components
→ Wear protective goggles with side eye protection.
→ Protect the point at which the compressed air emerges with suitable material.
→ Place the point at which the compressed air emerges on suitable surfaces.
Information
The use of unapproved test gases results in incorrect test results. Only approved test gases
guarantee comparability with fuel high-pressure systems at pressures of up to 10 bar .
3. Fit test gas bottle with pressure reducer and Air-Spring Strut Filling Unit VAS 6231 WE
1282 securely so that no gas can escape → Test equipment setup . Set pressure reducer to
max. 10 bar pressure → Adjusting pressure reducer to between 7 and 9 bar of test gas
pressure .
Fig 4: Identifying Air-Spring Strut Filling Unit (VAS 6231)

Fig 5: Identifying Test Equipment Setup

Fig 6: Adjusting Pressure Reducer To Between 7 And 9 Bar Of Test Gas Pressure
4. Air-Spring Strut Filling Unit VAS 6231 WE 1282 must then be connected to the Adapter
9759 (-1- ). Tighten the connection if necessary.
Fig 7: Connecting Air-Spring Strut Filling Unit To Adapter
5. Depending on the high-pressure connections that were loosened (removed fuel distribution
pipe or removed high-pressure pump), complete the following steps =>
If the fuel distribution pipe (high-pressure rail) was removed =>
6. Before screwing the fuel distribution pipe (high-pressure rail) to the engine, quickly blow out
residual fuel from the high-pressure pump and high-pressure line (intake) to the high-pressure
rail.
through the line into a cloth or receptacle. → Blowing out high-pressure line
Fig 8: Blowing Out High-Pressure Line
2. 6.2. Drain residual fuel from the high-pressure distribution pipe before fitting it. Shake
the high-pressure pipe over a cloth to do this.
7. Fit high-pressure distribution pipe (high-pressure rail) and tighten it to the correct tightening
torques. → INSTALLING FUEL DISTRIBUTOR PIPE (FUEL RAIL) - section on "Installing"
8. Use Air-Spring Strut Filling Device VAS 6231 WE 1282 to apply test gas pressure of
between 7 and just under 10 bar to the completely fitted high-pressure system -2- . The
pressure is distributed slowly in the system and can increase slightly on the pressure gauge. If
there is a constant drop in pressure, there is leak in the system.
Fig 9: Identifying Completely Fitted High-Pressure System
9. Spray all connection points in the high-pressure system with commercially available
also spray the soldered joints and connecting pipes as well as the high-pressure pump and
test equipment with leak-locating spray.
10. If there is a leak, Gently Sashaying , Moving And Growing air bubbles
→ Leak will emerge. These could be caused by a damaged seal, loose connections or
incorrectly fitted union nuts, for example. The cause must be determined and corrected.
Fig 10: Checking Connection For Leak
If the high-pressure pump was removed →
11. Before screwing the high-pressure line (intake) to the high-pressure pump, residual fuel must
be blown out of the high-pressure pump.
through the connection piece into a cloth. → Blowing out high-pressure pump
Fig 11: Blowing Out High-Pressure Pump
12. Screw high-pressure line correctly to the high-pressure pump. → INSTALLING

HIGH-PRESSURE PUMP - section on "Installing"
13. Use Air-Spring Strut Filling Device VAS 6231 WE 1282 to apply test gas pressure of
between 7 and just under 10 bar to the fitted high-pressure pump -2- . The pressure is
distributed slowly in the system and can increase slightly on the pressure gauge. If there is a
constant drop in pressure, there is leak in the system.
Fig 12: Identifying Fitted High-Pressure Pump
14. Spray all connection points for the high-pressure pump with commercially available
also spray other connection points as well as the high-pressure pump and test equipment with
leak-locating spray.
15. If there is a leak, Gently Sashaying , Moving And Growing air bubbles will emerge (union
nut on injector is shown) → Leak . These could be caused by a damaged seal, loose
connections or incorrectly fitted union nuts, for example. The cause must be determined and
corrected.
Fig 13: Checking Connection For Leak

LEAKS (CAYENNE TURBO & CAYENNE TURBO S) > SUBSEQUENT WORK
1. Remove tool setup.
2. Fit the fuel line. To do this, fit the fuel supply line (low pressure) at the marking correctly.
Counter while doing this. → Tightening Torque: 35 Nm (26 ft. lb.)
3. Fit engine cover. For details, see → INSTALLING FRONT TRIM PANEL (ENGINE
4. Fit the fuse or connect the battery.
5. Bleed the fuel high-pressure system. → 2430B1 FILLING AND BLEEDING THE FUEL
HIGH-PRESSURE SYSTEM (INCLUDES BLEEDING FUEL DISTRIBUTOR PIPE)
WM 243019 REMOVING AND INSTALLING FUEL DISTRIBUTOR PIPE (FUEL RAIL) ON

DFI ENGINES (CAYENNE) > TECHNICAL VALUES

value 1 2
M8 x 55; tighten fuel
Tightening 30 Nm
Fuel Distributor distributor evenly from the
Torque (22 ft. lb.)
inside out

Torque
Fuel Distributor distributor evenly from the 90°
angle
inside out
Tightening 22 Nm
Screw Plug
Torque (16 ft. lb.)
Tightening 22 Nm
High-Pressure Line
Torque (16 ft. lb.)
Adapter At High-Pressure Tighten high-pressure line Tightening 40 Nm

Pump prior to connecting Torque (30 ft. lb.)
Tightening 27 Nm
Low-Pressure Line
Torque (20 ft. lb.)
Adapter At High-Pressure Tighten high-pressure line Tightening 28 Nm

Pump prior to connecting Torque (21 ft. lb.)
10 Nm
M6 x 65 (7.5 ft.
High-Pressure Pump Torque
lb.)
Fuel Pressure Sensor Tightening 22 Nm

(High Pressure Sensor) Torque (16 ft. lb.)
Tightening 22 Nm
Connecting Line
Torque (16 ft. lb.)

Tightening 30 Nm
Torque (22 ft. lb.)
inside out

Torque
angle
inside out
Tightening 22 Nm
Fuel Line To Fuel Rail
Torque (16 ft. lb.)
Fuel Line To Fuel Line At

Tightening 35 Nm
Plenum Panel Transfer
Torque (26 ft. lb.)
Point

DFI ENGINES (CAYENNE) > PRELIMINARY WORK
1. Remove high-pressure pump. → REMOVING HIGH-PRESSURE PUMP - section on

"Removing"
2. Remove intake-air distributor. The lower fuel distributor pipe must be removed during
disassembly. → REMOVING INTAKE-AIR DISTRIBUTOR - section on "Removing"
DFI ENGINES (CAYENNE) > INFORMATION > COMPONENT OVERVIEW
Fig 1: Identifying DFI Injection System Related Components
1. Sealing ring on long fuel injectors for cylinders 1, 3 and 5; replace; coat with clean engine oil
2. Long fuel injectors for cylinders 1, 3 and 5 Long Fuel Injectors Must Not Be Disassembled!
3. Spring element; replace; ensure secure seating

4. Support washer; replace if damaged
5. Sealing ring; not used on the Cayenne
6. Screw M8 x 55; replace; tighten fuel distributor evenly from the inside out; → Tightening
Torque: 30 Nm (22 ft. lb.) , then → Torque angle: 90°
7. Fuel distributor for cylinders 1, 3 and 5; the spring elements of the fuel injectors must always
be replaced before installation; tighten evenly from the inside out
8. from fuel tank
9. Fuel supply hose (low-pressure line); counter with a wrench at the supply line of the fuel
distributor when loosening and tightening the union nut; pay attention to marking
10. Pressure control valve; replace removed valve; press in by hand using 8 mm hexagon wrench
11. → Tightening Torque: 22 Nm (16 ft. lb.)
12. Fuel high-pressure line → Tightening Torque: 22 Nm (16 ft. lb.) ; the fuel pressure in the
high-pressure line can reach 120 bar! Wear goggles and protective clothing to prevent injury
and skin contact. Place a cloth around the connection before loosening the fuel lines. Then
release pressure by carefully loosening the union nuts; counter with a wrench at the adapter
for the high-pressure pump when loosening and tightening the union nut; before installation:
first re-tighten the adapter at the high-pressure pump → Tightening Torque: 40 Nm (30 ft.
lb.) ; do not install too tightly; to install, first tighten the union nuts by hand
13. Fuel low-pressure line → Tightening Torque: 27 Nm (20 ft. lb.) ; counter with a wrench at the
adapter for the high-pressure pump when loosening and tightening the union nut; before
installation: first re-tighten the adapter at the high-pressure pump; → Tightening Torque: 28
Nm (21 ft. lb.) ; do not install too tightly; to install, first tighten the union nuts by hand
14. Fuel pressure sensor for low pressure; not installed in the Cayenne
15. → Tightening Torque: 10 Nm (7.5 ft. lb.)
16. High-pressure pump; with control valve for fuel pressure; counter with a wrench at the adapter
when loosening and tightening the fuel lines
17. Tappet; coat with clean engine oil before installing
18. Fuel pressure sensor → Tightening Torque: 22 Nm (16 ft. lb.) ; coat front sealing ball and
thread with clean engine oil before fitting
20. Short fuel injectors for cylinders 2, 4 and 6
21. Connecting line; do not install too tightly; to install, first tighten the union nuts by hand; →

DFI ENGINES (CAYENNE) > INSTALLING FUEL DISTRIBUTOR PIPE (FUEL RAIL)
Cylinders 1, 3 and 5
1. The sealing rings between the injectors and the fuel rail must be replaced. For details of other
components to be replaced or checked, see → 244019 REMOVING AND INSTALLING
HIGH-PRESSURE FUEL INJECTOR (DFI)
2. Coat the sealing rings between the injectors and the fuel rail with clean engine oil.
3. Hold fuel rail with both hands and press into position by joggling it. Make sure that the injectors
slide correctly into the bores on the fuel rail. Fit four new screws on the fuel rail for cylinders 1,
3 and 5. -2- → Tightening Torque: 30 Nm (22 ft. lb.) , then → Torque angle: 90°
Fig 1: Identifying Fuel Rail Of Cylinders 1, 3 And 5
4. Fit fuel low-pressure line at the transfer point on the plenum panel or directly on the fuel rail.
Always counter while fitting. Fuel line to fuel rail → Tightening Torque: 22 Nm (16 ft. lb.) ;
fuel line to fuel line at plenum panel transfer point → Tightening Torque: 35 Nm (26 ft. lb.)
Cylinders 2, 4 and 6
5. The sealing rings between the injectors and the fuel rail must be replaced. For details of other
components to be replaced or checked, see → 244019 REMOVING AND INSTALLING
HIGH-PRESSURE FUEL INJECTOR (DFI)
6. Coat the sealing rings between the injectors and the fuel rail with clean engine oil.
7. Fit intake-air distributor. The lower fuel distribution pipe (fuel rail for cylinders 2, 4 and 6) must
be fitted during assembly. → INSTALLING INTAKE-AIR DISTRIBUTOR - section on
"Installing"

DFI ENGINES (CAYENNE) > SUBSEQUENT WORK
1. Fit intake-air distributor. The lower fuel distribution pipe must be fitted during assembly. →
INSTALLING INTAKE-AIR DISTRIBUTOR - section on "Installing"
2. Fit high-pressure pump. → INSTALLING HIGH-PRESSURE PUMP - section on "Installing"
WM 243019 REMOVING AND INSTALLING FUEL DISTRIBUTOR PIPE (CAYENNE

Socket-Wrench Commercially
Nr. 18-1
Insert Available Tool
Open-Ended
Commercially
Socket Ring Nr. 185
Available Tool
Wrench

1. Disconnect the battery. For instructions, see → REMOVING BATTERY and →


"Removing".

TURBO & CAYENNE TURBO S) > REMOVING FUEL DISTRIBUTOR PIPE
Material damage
Emerging fuel
Risk of fire
Information

Fig 1: Overview Of Fuel Distributor Pipe Component

-2- - Stopper for purge connection
1. Unplug electric plug connection on the high-pressure sensor -2- .

Fig 2: Identifying High-Pressure Fuel Distribution
2. Place a cloth around the high-pressure connection on the high-pressure line -3- .
Relieve the fuel pressure by slowly opening the high-pressure line with an open-ended wrench.
3. Loosen all eight union nuts for the high-pressure fuel injectors -1- .
Use an open socket Socket-Wrench Insert Nr. 18-1 or similar tool to do this → Socket .
Fig 3: Identifying Socket-Wrench Insert
4. Remove screws on fuel distributor pipe (fuel rail) -1 and 2- and lift off fuel rail.
The screw on the thermostat housing is longer.

The rear right screw can only be reached using a thin Torx wrench.
Fig 4: Identifying Fuel Distributor Pipe Mount And Related Components
1. Screw, M6 x 16
2. Screw, M6 x 25
3. Connection for high-pressure line
4. Connection to injector (high-pressure fuel injector)
5. Remove fuel rail from the engine by twisting it -arrow- .

Fig 5: Removing Fuel Rail From Engine

TURBO & CAYENNE TURBO S) > INSTALLING FUEL DISTRIBUTOR PIPE
WARNING: Loose purge connection
Emerging fuel
Risk of fire
→ Check that the purge connection of the fuel distribution pipe is seated securely.
→ Tighten the purge connection of the fuel distribution pipe to the correct tightening torque.
Information
Fig 1: Identifying Fuel Distributor Pipe And Related Components
-2- - Stopper, purge connection
1. Using the leak test equipment, blow the fuel out of the high-pressure pump and the
high-pressure line into a cloth.
Shake the fuel distributor pipe over a cloth to remove fuel residues. → 243001 CHECKING
FUEL DISTRIBUTOR PIPE FOR LEAKS .
2. Fit fuel rail on the engine by twisting it -arrow- .

Fig 2: Fitting Fuel Rail On Engine
Information
When fitting the union nuts, make sure that the connection taper of the high-pressure line is
loose in the injector. It should be possible to screw on the union nut easily without greasing it
and without the use of force (check that it is straight and screws on easily). Loosen the injector
retainers and correct the positions of the various components if necessary.
3. Fit fuel rail.

1. 3.1. Carefully lift up the coolant vent line at the rear if necessary and slide the fuel rail
2. 3.2. Screw fuel rail on loosely. Screw union nuts loosely onto the injectors.
Information
When fitting the union nuts, make sure that the connection taper of the high-pressure
line is loose in the injector. It should be possible to screw on the union nut easily
without greasing it and without the use of force (check that it is straight and screws
on easily). Loosen the injector retainers and correct the positions of the various
components if necessary.
Only Fit Screws And Union Nuts -1- Loosely Until Everything Fits!
3. 3.3. Also fit the high-pressure line -3- between the rail and high-pressure pump.
4. Fit screws on fuel distributor pipe (fuel rail) -1 and 2- .
The screw on the thermostat housing is longer.
The rear right screw can only be reached using a long, thin Torx wrench.
Fig 4: Identifying Fuel Distributor Pipe Mount And Related Components
1. Screw, M6 x 16
2. Screw, M6 x 25
3. Connection for high-pressure line
4. Connection to injector (high-pressure fuel injector)
5. When all threaded joint positions fit correctly and without tension, tighten all threaded joints
according to the prescribed tightening torques.
The union nuts for the injectors and the high-pressure feed line must first be tightened initially,
then loosened and then tightened finally.
Use an open socket Socket-Wrench Insert Nr. 18-1 → Socket or similar tool to screw on the
injectors.
Fasten the high-pressure line with an Open-Ended Socket Ring Wrench Nr. 185 and a
torque wrench.
It is essential to comply with the tightening torques → 1001IN TIGHTENING TORQUES,

TIGHTENING SEQUENCES, ASSEMBLY OVERVIEWS
Fig 5: Open-Ended Socket Ring Wrench
6. Check the high-pressure system for leaks. → 243001 CHECKING FUEL DISTRIBUTOR PIPE
FOR LEAKS .
7. Plug in electric plug connection on the high-pressure sensor. -2-

1. Fit intake-air distributor → INSTALLING INTAKE-AIR DISTRIBUTOR - section on "Installing".
2. Connect the battery. For instructions, see → INSTALLING BATTERY and → CONNECTING
THE BATTERY2X00IN WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY
WM 2430B1 FILLING AND BLEEDING THE FUEL HIGH-PRESSURE SYSTEM

(INCLUDES BLEEDING FUEL DISTRIBUTOR PIPE) (ALL MODELS) > INFORMATION >
PRELIMINARY WORK
1. Repairs in the high-pressure area resulting in air getting into the high-pressure system (e.g.
replacing the high-pressure pump, removing and installing fuel distribution pipes).
2. Low-pressure area and the fuel supply system are in perfect condition.
1. Fuel level is sufficient.
2. Fuel feed system is working perfectly.
WM 2430B1 FILLING AND BLEEDING THE FUEL HIGH-PRESSURE SYSTEM

(INCLUDES BLEEDING FUEL DISTRIBUTOR PIPE) (ALL MODELS) > FILLING >
FILLING AND BLEEDING THE DFI FUEL HIGH-PRESSURE SYSTEM
1. Start the engine and leave it running at idle speed. This can result in a rough-running engine
and the Check Engine warning light in the instrument cluster can be activated.
2. Stop the engine and switch off the ignition.
4. Use the PIWIS Tester to read out and erase the fault memory of the DME control unit.
6. Switch on the ignition and start the engine.
7. The bleeding process is complete when the engine runs smoothly, the Check Engine light is no
longer activated and no additional faults are entered in the fault memory.
8. Perform a test drive.

(INTAKE PIPES UPSTREAM OF THROTTLE VALVE) (CAYENNE) > PRELIMINARY
WORK
1. Remove engine compartment cover at the front and left. → REMOVING FRONT TRIM PANEL
2. Pull off throttle cover. → REMOVING ENGINE COVER (DESIGN COVER) - section on
"Removing"

(INTAKE PIPES UPSTREAM OF THROTTLE VALVE) (CAYENNE) > REMOVING AIR
BOX FOR THROTTLE HOUSING (INTAKE PIPES UPSTREAM OF THROTTLE VALVE)
1. Loosen screw-type clamp on the throttle housing. Disconnect cable plug of mass air flow
meter. -arrows-
Fig 1: Locating Intake Pipe Screw-Type Clamp
2. Turn both fastening bolts on the air cleaner housing from the initial mark to the removal mark.
→ Fastening bolts
Fig 2: Turning Fastening Bolts
3. Pull out both fastening bolts with pointed-nose pliers. Pull intake pipe out of air cleaner housing
by joggling it. → Pulling out fastening bolts
Fig 3: Pulling Out Fastening Bolts
4. Carefully raise intake pipe and pull off cable for mass air flow meter on the intake pipe
underneath the intake pipe. → Cable on intake pipe
Fig 4: Identifying Cable On Intake Pipe
5. Remove intake pipe.

(INTAKE PIPES UPSTREAM OF THROTTLE VALVE) (CAYENNE) > INSTALLING AIR
BOX FOR THROTTLE HOUSING (INTAKE PIPES UPSTREAM OF THROTTLE VALVE)
1. Place intake manifold in installation position.
2. Insert cable for mass air flow meter on the intake pipe underneath the intake pipe. → Cable on
intake pipe
Fig 1: Identifying Cable On Intake Pipe
3. Press intake manifold into the air-cleaner housing. Push in both fastening bolts as far as they
will go.
4. Turn both fastening bolts on the air cleaner housing from the removal mark back to the initial
mark. → Fastening bolts
Fig 2: Turning Fastening Bolts
5. Move intake pipe into installation position, fit screw-type clamp on throttle housing. Connect
cable plug for mass air flow meter. -arrows-
Fig 3: Locating Intake Pipe Screw-Type Clamp

(INTAKE PIPES UPSTREAM OF THROTTLE VALVE) (CAYENNE) > SUBSEQUENT
WORK
1. Press on throttle cover.→ INSTALLING ENGINE COVER (DESIGN COVER) - section on

"Installing"
2. Fit engine compartment cover at the front and left.→ INSTALLING FRONT TRIM PANEL

(CAYENNE S & CAYENNE GTS) > TECHNICAL VALUES

(CAYENNE S & CAYENNE GTS) > REMOVING AIR BOX FOR THROTTLE HOUSING

2. Remove air box for throttle housing -1- .
1. 2.1. Release and disconnect electric connector -2- for pressure sensor.
2. 2.2. Loosen clamp -3- and pull off vacuum line -4- .
3. 2.3. Loosen clamp -5- and pull off fuel positive crankcase ventilation line -6- .
Replace clamp.
4. 2.4. Loosen vacuum line for recirculating air valve -7- from air box for throttle valve
-1- at the bottom.
5. 2.5. Loosen screw-type clamps -8- and pull off pressure hoses -9- .
6. 2.6. Turn air box for throttle valve -1- in -direction of arrow- and remove it by
pulling it forward.
Fig 1: Identifying Air Box For Throttle Housing

(CAYENNE S & CAYENNE GTS) > INSTALLING AIR BOX FOR THROTTLE HOUSING
1. Install air box for throttle housing -1- .
1. 1.1. Fit air box for throttle valve -1- and turn it in the Opposite Direction to direction
of arrow.
2. 1.2. Connect electric connector -2- for pressure sensor.
3. 1.3. Connect vacuum line -4- and secure with a clamp -3- .
4. 1.4. Connect positive crankcase ventilation line -6- and secure using a New clamp
-5- .
5. 1.5. Secure vacuum line for recirculating air valve -7- to air box for throttle valve -1-
at the bottom.
6. 1.6. Connect pressure hoses -9- and secure with screw-type clamps -8- .
Tightening Torque for screw-type clamp -8- :
Fig 1: Identifying Air Box For Throttle Housing
WM 243519 REMOVING AND INSTALLING COWL FOR THROTTLE HOUSING (Y-PIPE)

(CAYENNE S, CAYENNE TURBO, CAYENNE GTS & CAYENNE TURBO S) >
TECHNICAL VALUES
Tolerance Tolerance
1 2
Screw-Type Clamps On Intake Tightening 5.5 Nm (4 ft.

Pipes Torque lb.)

PRELIMINARY WORK
1. Remove design cover on throttle valve. → REMOVING ENGINE COVER (DESIGN COVER) -
Naturally-aspirated engines →
2. Remove front cover (engine compartment). → REMOVING FRONT TRIM PANEL (ENGINE

REMOVING COWL FOR THROTTLE HOUSING (Y-PIPE)
Turbo Engines →
1. On turbo engine: Disconnect boost pressure sensor. -1- (ignore 2 and 3)

Fig 1: Identifying Boost Pressure Sensor
2. Lever off clip under the Y-pipe with a screwdriver. -arrow-

Fig 2: Removing Line Holder Under Y-Pipe
3. Detach fitted control line -1- under the Y-pipe.
4. Loosen screw-type clamps -2- between the Y pipe and the pressure pipe.
5. Release both locking pins -3- on the Y-pipe in a clockwise direction and pull them off. Pull
Y-pipe off the throttle housing.
Fig 3: Removing Y-Pipe
Naturally-Aspirated Engines →
6. Loosen screw-type clamp -1- on the throttle housing.
7. Release the locking pins -2- of the Y-pipe on both sides in a clockwise direction and pull them
off.
Fig 4: Removing Naturally Aspirated Engine Y-Pipe

INSTALLING COWL FOR THROTTLE HOUSING (Y-PIPE)
The components are installed in reverse order to removal.
Screw-type clamps → Tightening Torque: 5.5 Nm (4 ft. lb.)
The pressure and intake pipes must be checked to ensure they are seated securely after being
fitted (check by pulling on the pipes).

SUBSEQUENT WORK
1. Install design cover on throttle valve. → INSTALLING ENGINE COVER (DESIGN COVER) -
Naturally-Aspirated Engines →
2. Install front trim (engine compartment). → INSTALLING FRONT TRIM PANEL (ENGINE
WM 243619 REMOVING AND INSTALLING AIR GUIDE (CAYENNE TIP, CAYENNE S,

CAYENNE TURBO, CAYENNE S HYBRID, CAYENNE TIP (3.0), CAYENNE GTS &
1. Remove front apron. → REMOVING FRONT APRON - section on "Removing"
2. Remove wheel housing liner. → REMOVING FRONT WHEEL HOUSING LINER - section on
"Removing"

CAYENNE TURBO S) > REMOVING AIR GUIDE
Information

Fig 1: Identifying Air Guide - V8
1. Pull the air guide -1- forward -arrow- out of the air cleaner housing -2- from the wheel
housing.
Unclip it carefully at the locking lugs using a suitable tool if necessary.

2. Remove the air guide -1- .

1. 2.1. Pull the air guide -1- forward -A- .
2. 2.2. While pulling it out of the lock carrier -2- , turn the air guide anti-clockwise -B- .
3. 2.3. Remove the air guide completely from the vehicle.

CAYENNE TURBO S) > INSTALLING AIR GUIDE
1. Slide the air guide -1- through the lock carrier -2- into the vehicle -A- while turning it
clockwise -B- .
When guiding in the air guide, make sure not to kink the edge on the lock carrier.
Fig 1: Installing Air Guide
2. Make sure that the air box on the air guide is seated correctly in the sound absorber on the
lock carrier.
3. Insert the air guide -1- into the air cleaner housing -2- from the wheel housing and engage the
retaining lugs -3- into the cut-outs -4- on the air cleaner housing.
Fig 2: Fitting Air Guide

1. Install wheel housing liner. → INSTALLING FRONT WHEEL HOUSING LINER - section on
"Installing"
2. Install front apron. → INSTALLING FRONT APRON - section on "Installing"
WM 244019 REMOVING AND INSTALLING HIGH-PRESSURE FUEL INJECTOR

(CAYENNE) > TOOLS

Repair Kit VW Tool T10133
Supplement Set VW Tool T10133/11-15


value 1 2

Tightening 30 Nm
Torque (22 ft. lb.)
inside out

Torque
angle
inside out
Tightening 22 Nm
Screw Plug
Torque (16 ft. lb.)
Tightening 22 Nm
High-Pressure Line
Torque (16 ft. lb.)
Adapter At Tighten high-pressure line Tightening 40 Nm

High-Pressure Pump prior to connecting Torque (30 ft. lb.)
Tightening 27 Nm
Low-Pressure Line
Torque (20 ft. lb.)
Adapter At Tighten high-pressure line Tightening 28 Nm

High-Pressure Pump prior to connecting Torque (21 ft. lb.)
Fastening Screw For Tightening 10 Nm

M6 x 65
High-Pressure Pump Torque (7.5 ft. lb.)
Fuel Pressure Sensor Tightening 22 Nm

(High Pressure Sensor) Torque (16 ft. lb.)
Tightening 22 Nm
Connecting Line
Torque (16 ft. lb.)

1. Read out engine control unit fault memory before getting started and print log.
2. Switch off the ignition and all loads when working on the fuel system.
4. Remove intake-air distributor (intake module). → REMOVING INTAKE-AIR DISTRIBUTOR -

5. Pull cable plugs off the injectors.
6. Remove both high-pressure distribution pipes (fuel rails) for all injectors. → REMOVING FUEL
DISTRIBUTOR PIPE (FUEL RAIL) - section on "Removing"

Fig 1: Identifying DFI Injection System And Related Components
1. Sealing ring on long fuel injectors for cylinders 1, 3 and 5; replace; coat with clean engine oil
2. Long fuel injectors for cylinders 1, 3 and 5 Long Fuel Injectors Must Not Be Disassembled!
3. Spring element; replace; ensure secure seating
4. Support washer; replace if damaged
5. Sealing ring; not used on the Cayenne

6. Screw M8 x 55; replace; tighten fuel distributor evenly from the inside out; → Tightening
Torque: 30 Nm (22 ft. lb.) , then → Torque angle: 90°
8. from fuel tank
9. Fuel supply hose (low-pressure line); counter with a wrench at the supply line of the fuel
distributor when loosening and tightening the union nut; pay attention to marking
10. Pressure control valve; replace removed valve; press in by hand using 8 mm hexagon wrench
11. → Tightening Torque: 22 Nm (16 ft. lb.)
12. Fuel high-pressure line → Tightening Torque: 22 Nm (16 ft. lb.) ; the fuel pressure in the
high-pressure line can reach 120 bar! Wear goggles and protective clothing to prevent injury
and skin contact. Place a cloth around the connection before loosening the fuel lines. Then
release pressure by carefully loosening the union nuts; counter with a wrench at the adapter
for the high-pressure pump when loosening and tightening the union nut; before installation:
first re-tighten the adapter at the high-pressure pump → Tightening Torque: 40 Nm (30 ft.
lb.) ; do not install too tightly; to install, first tighten the union nuts by hand
13. Fuel low-pressure line → Tightening Torque: 27 Nm (20 ft. lb.) ; counter with a wrench at the
adapter for the high-pressure pump when loosening and tightening the union nut; before
installation: first re-tighten the adapter at the high-pressure pump; → Tightening Torque: 28
Nm (21 ft. lb.) ; do not install too tightly; to install, first tighten the union nuts by hand
14. Fuel pressure sensor for low pressure; not installed in the Cayenne
15. → Tightening Torque: 10 Nm (7.5 ft. lb.)
16. High-pressure pump; with control valve for fuel pressure; counter with a wrench at the adapter
when loosening and tightening the fuel lines;
17. Tappet; coat with clean engine oil before installing
18. Fuel pressure sensor → Tightening Torque: 22 Nm (16 ft. lb.) ; coat front sealing ball and
thread with clean engine oil before fitting
20. Short fuel injectors for cylinders 2, 4 and 6
21. Connecting line; do not install too tightly; to install, first tighten the union nuts by hand; →

(CAYENNE) > REMOVING HIGH-PRESSURE FUEL INJECTOR

Material damage
Emerging fuel
Risk of fire

Information
Information
Information
The tool numbers refer to the individual parts of the tools in the Repair Kit T10133 and the Supplement
Set T10133/11-15 (unless indicated otherwise).
1. Pull injector out of the cylinder head by hand (using a glove!). Turn injector slightly if
necessary.
If The Injector Is Stuck In The Cylinder Head Due To Coking Of The Injector Tips,
Proceed As Follows:
2. Pull upper O-ring on the injector upwards by hand as shown → Fuel injector sealing rings and
remove it. Use a small screwdriver to help, if necessary.
Fig 1: Identifying Fuel Injector Sealing Rings
3. Bolt impact hammer no. 3 to puller no. 15 -1- .

Fig 2: Assembling Impact Hammer
4. Fit impact hammer with puller no. 15 into the groove -arrow- on the fuel injector.
Fig 3: Locating Fuel Injector Groove
5. Tap gently on the fuel injector to remove it. Use impact hammer -1- and puller -2- as shown.
Fig 4: Pulling Out Fuel Injector

(CAYENNE) > REPLACING TEFLON SEALING RING ON HIGH-PRESSURE FUEL
INJECTOR
NOTE: Incorrect handling of injectors
Leaks in combustion chamber
→ Teflon sealing rings must always be replaced after removal and before refitting injectors.
→ Do not replace Teflon sealing rings until just before fitting the injector.
→ Install injector immediately after replacing the Teflon sealing ring.
Information
Installation Position Of Teflon Sealing Ring: -arrow-
Fig 1: Locating Teflon Sealing Ring
1. Remove high-pressure fuel injector.
2. Replace large sealing ring for long fuel injectors for cylinders 1, 3 and 5.
3. Clean fuel injector carefully using a plastic brush (or cloth) and acetone or solvent naphtha.
Hold sealing ring gently using pointed-nose pliers and carefully pull off Teflon sealing ring -1- .
Do not scratch valve body.
Fig 2: Removing Teflon Sealing Ring
4. Also clean sealing ring groove in the area of the sealing ring. Remove any deposits (coking).
5. Place new sealing ring -2- onto mounting cone no. 5 -1- .
Fig 3: Identifying Teflon Sealing Ring On Mounting Cone
6. Using assembly sleeve no. 6 (knurled side facing the sealing ring) -3- push sealing ring gently
as far as it will go onto mounting cone no. 5 → Teflon sealing ring on mounting cone .
7. Turn assembly sleeve no. 6 -3- around (knurled side now no longer facing sealing ring), and
push sealing ring -2- onto the end of mounting cone no. 5 -1- .
Fig 4: Identifying Assembly Sleeve Turned Around
8. Place mounting cone no. 5 -1- with sealing ring onto the fuel injector from the front. Using
assembly sleeve no. 6 -2- push sealing ring further onto the fuel injector.
Fig 5: Fitting Teflon Sealing Ring
The Teflon Sealing Ring Is Not Yet Seated In Its Groove!
9. Remove assembly sleeve no. 6 and mounting cone no. 5. Push sealing ring into the ring
groove using assembly sleeve no. 6.
Calibration (Shaping) Of Teflon Sealing Ring:
1. 9.1. Push spacer sleeve no. 11 -1- onto the valve body.
Fig 6: Identifying Spacer Sleeve
2. 9.2. Press calibrating sleeve no. 7 -2- over the sealing ring until it stops against
spacer sleeve no. 11.
3. 9.3. Pull off calibrating sleeve no. 7 again.
4. 9.4. Press calibrating sleeve no. 8 -4- over the sealing ring until it stops against
spacer sleeve no. 11 -3- .
Fig 7: Identifying Calibrating Sleeve
The Teflon Sealing Ring Now Has The Correct Installation Dimension .
10. The injector should now be installed immediately, as the Teflon sealing ring will soon start to
swell (prevents leaks when installed).

(CAYENNE) > INSTALLING HIGH-PRESSURE FUEL INJECTOR
Information
1. Clean bores for fuel injectors in the cylinder head thoroughly using the nylon brush no. 4
-arrow- . Coat brush with acetone or solvent naphtha.
Fig 1: Cleaning Bore In Cylinder Head
2. Check plastic support washer for damage and replace it if necessary.
To Replace The Damaged Plastic Support Washer:
1. 2.1. Remove O-ring -3- .

Fig 2: Removing O-Ring
2. 2.2. Cut open support washer -2- using small side cutters and remove it.
3. 2.3. Pull off spring element for fuel injector -1- and slide on tab washer no. 12 -1-
instead.
4. 2.4. Push new support washer -3- on to mounting cone no. 13 -2- and fit it on the
fuel injector as shown.
5. 2.5. Push the support washer -3- using calibrating sleeve no. 14 (knurled side facing
the fuel injector) -4- on to the fuel injector as far as the first groove -arrow- .
Fig 3: Replacing Support Washer
6. 2.6. Turn calibrating sleeve no. 14 -3- around (knurled side no longer facing fuel
injector).
Fig 4: Turning Calibrating Sleeve
7. 2.7. Push calibrating sleeve -3- over the support washer -2- in direction of arrow
until it stops against tab washer no. 12 -1- .
8. 2.8. Remove calibrating sleeve no. 14 again. The Support Washer Now Has The
Correct Installation Dimension .
3. Replace O-ring -3- , Teflon sealing ring and spring element for injector -1- . Fit a new spring
element - and a new O-ring - in front of the support washer instead of tab washer no. 12.
Replace Teflon sealing ring → INFORMATION - section on "Information".
Fig 5: Identifying Spring Element And O-Ring
4. Immediately install injector into the cylinder head at the correct installation position. To do this,
insert the grease- and oil-free injector into the clean cylinder bore.

1. Fit high-pressure distribution pipes (fuel rails). → INSTALLING FUEL DISTRIBUTOR PIPE
(FUEL RAIL) - section on "Installing"
2. Connect cable plugs for injectors.
3. Fit intake-air distributor (intake module). → INSTALLING INTAKE-AIR DISTRIBUTOR - section

on "Installing"
5. Perform a test drive. Make sure the high-pressure pipes and threaded joints are sealed
properly (visual inspection → with engine running).
6. Read out engine control unit fault memory after completing the work and print log. Compare
with the previous log.
WM 244020 REMOVING AND INSTALLING FUEL INJECTORS [CAYENNE S, CAYENNE
(3.0)] > TOOLS
Puller Special Tool 9859
Repair Kit VW Tool T10133
Supplement Set VW Tool T10133/11-15

(3.0)] > TECHNICAL VALUES
Calibrating Sleeve For Teflon Sealing Ring Time 1 Minute

(3.0)] > PRELIMINARY WORK
1. Read out engine control unit fault memory before getting started and print log.
2. Switch off the ignition and all loads when working on the fuel system.

DISTRIBUTOR
5. Remove fuel collection pipe. → 243019 REMOVING AND INSTALLING FUEL DISTRIBUTOR
PIPE

(3.0)] > REMOVING FUEL INJECTOR
Material damage
Information
1. Disconnect cable plugs for the fuel injectors.
2. Screw impact hammer Repair Kit T10133 no. 3 to the Puller 9859 -1- .
Fig 1: Identifying Impact Hammer And Puller
3. Fit impact hammer and puller onto the thread hand-tight and remove carefully by tapping
straight down. Note: If the fuel injector is damaged irreparably during removal, the complete
fuel injector must be replaced. → see Fig 2
Fig 2: Fitting Impact Hammer On Injector
4. Remove fuel injectors -4- .
1. 4.1. Place fuel injectors -4- on a clean surface.


(3.0)] > REPLACING TEFLON SEALING RING
Information
Information
Installation Position Of Teflon Sealing Ring: -arrow-

Fig 1: Identifying Teflon Sealing Ring Installation Position
1. Remove high-pressure fuel injector.
2. Clean fuel injector carefully using a plastic brush (or cloth) and acetone or solvent naphtha.
Hold Teflon sealing ring gently using a pointed-nose pliers and carefully pull off Teflon sealing
ring -1- . Do not scratch the valve body.
Fig 2: Removing Teflon Sealing Ring
3. Also clean sealing ring groove in the sealing ring area. Remove any deposits (coking).
4. Fit new sealing ring -2- on mounting cone no. 5 -1- . Using assembly sleeve no. 6 -3-
(knurling facing the sealing ring), push sealing ring gently as far as it will go onto mounting
cone no. 5.
Fig 3: Identifying Teflon Sealing Ring On Mounting Cone
5. Turn assembly sleeve no. 6 -3- around (knurled side now no longer facing sealing ring), and
push sealing ring -2- onto the end of mounting cone no. 5 -1- .
Fig 4: Identifying Assembly Sleeve Turned Around
6. Place mounting cone no. 5 with sealing ring onto the fuel injector from the front -1- . Push
sealing ring further onto the fuel injector using assembly sleeve no. 6 -2- .
Fig 5: Fitting Teflon Sealing Ring
The Sealing Ring Is Not Yet Seated In Its Groove!
7. Remove assembly sleeve no. 6 and mounting cone no. 5. Push sealing ring into the ring
groove using assembly sleeve no. 6. → Pushing Teflon sealing ring into ring groove
Calibration (Shaping) Of Teflon Sealing Ring:

Fig 6: Pushing Teflon Sealing Ring Into Ring Groove
1. 7.1. Press calibrating sleeve no. 8 -1- as far as it will go over the sealing ring. Leave
calibrating sleeve no. 8 → Time: 1 Minute on the sealing ring. If calibrating sleeve
no. 8 does not fit immediately because the Teflon sealing ring has expanded, use
calibrating sleeve no. 7 in the same way as in the previous step.
Fig 7: Calibrating Teflon Sealing Ring
The Teflon Sealing Ring Now Has The Correct Installation Dimension .
8. The injector should now be installed immediately, as the Teflon sealing ring will soon start to
swell (prevents leaks when installed). Otherwise leave calibrating sleeve no. 8 -1- on the
Teflon sealing ring for longer or fit calibration cap (transport sleeve for new injectors) -2- .

(3.0)] > INSTALLING FUEL INJECTOR
1. Clean bores for fuel injectors in the cylinder head thoroughly using nylon brush no. 4. Coat
brush with acetone or solvent naphtha.
2. Replace damper ring (damping ring for retainer) -1- and Teflon sealing ring -arrow- .
1. 2.1. Grease damper ring (damping ring for retainer) -1- with Kluber Syntheso GLEP
1.
Fig 1: Identifying Damper Ring
Installation Position Of Teflon Sealing Ring: -Arrow-

Fig 2: Identifying Teflon Sealing Ring Installation Position
3. Install fuel injectors -4- in the cylinder head.


(3.0)] > SUBSEQUENT WORK
1. Clean remaining fuel from the high-pressure system before starting the leak test.
2. Fit fuel collection pipe. → 243019 REMOVING AND INSTALLING FUEL DISTRIBUTOR PIPE
3. Perform a leak test on the high-pressure system. → 243001 CHECKING FUEL DISTRIBUTOR
PIPE FOR LEAKS

DISTRIBUTOR
6. Perform a test drive. Make sure the high-pressure pipes and threaded joints are sealed
properly (visual inspection with engine running).
7. Read out engine control unit fault memory after completing the work and print log. Compare
with the previous log.
WM 244219 REMOVING AND INSTALLING THROTTLE HOUSING (CAYENNE) >

TECHNICAL VALUES

value 1 2
Throttle Housing M6
Torque ft. lb.)
Fastening Screw M8
Torque ft. lb.)
Intake-Air Distributor (Variable Intake Tightening 8 Nm (6.0

M6
Manifold) To Cylinder Head Torque ft. lb.)
Fastening Screw M8
Torque ft. lb.)
Throttle Housing
Torque lb.)

PRELIMINARY WORK
1. → REMOVING AIR BOX FOR THROTTLE HOUSING (INTAKE PIPES UPSTREAM OF

THROTTLE VALVE) - section on "Removing"

REMOVING THROTTLE HOUSING
1. Pull off cable plugs on the throttle housing and pull cable out of the clip -arrows- .
Fig 1: Locating Cable Clips On Throttle Adjuster
2. Loosen the four screws on the throttle housing -arrows- . Remove throttle housing and check
the condition of the sealing ring. Replace the sealing ring if necessary.
Fig 2: Loosening Throttle Housing

INSTALLING THROTTLE HOUSING > THROTTLE HOUSING AND INTAKE SYSTEM
Fig 1: Identifying Intake System And Related Components
4 - Screw → Tightening Torque: 7 Nm (5.0 ft. lb.)
6 - Sealing ring; check and replace if damaged
7 - Screw → Tightening Torque: 23 Nm (17 ft. lb.)
8 - Transport eyebolt on exhaust side
9 - Screw
10 - Shift mechanism on variable intake manifold (intake-air distributor)
16 - Vacuum line
17 - Change-over valve
18 - Coolant pipe
25 - Holder
26 - Heat shield (cover plate)
27 - Clamp
28 - Plug (vacuum)
29 - Positive crankcase ventilation

30 - Heat socket
31 - Sealing ring
32 - Sealing ring
33 - Locking pin
34 - Intake-air distributor (intake module)
35 - Coolant pipe screw
36 - Spring band clamp
37 - Tank ventilation (active carbon filter) hose
38 - Tank ventilation (active carbon filter) valve
40 - Rapid-action coupling
41 - Vacuum line
62 - Brake booster vacuum line
1. Check the condition of the sealing ring for the throttle housing. Replace the sealing ring if
necessary. Place throttle housing in installation position. Fit and tighten the four screws on the
throttle housing -arrows- . → Tightening Torque: 7 Nm (5 ft. lb.)
Fig 2: Tightening Throttle Housing
2. Attach cable plugs and cable to throttle housing -arrows- .

Fig 3: Locating Cable Clips On Throttle Adjuster

SUBSEQUENT WORK
Information
The new throttle valve must be taught when replacing the throttle valve .
Conditions: The vehicle is stationary, engine is off, engine temperature is between 5 and 100°C,
intake air temperature is more than 5°C, battery voltage is at least 9 volts
After replacing the throttle valve, switch on the ignition - but do not press the accelerator pedal -
and wait for one minute .
1. Secure intake port on throttle housing. For details, see → INSTALLING AIR BOX FOR
THROTTLE HOUSING (INTAKE PIPES UPSTREAM OF THROTTLE VALVE) - section on
"Installing"
WM 244519 REMOVING AND INSTALLING AIR FLOW SENSOR (CAYENNE) >

PRELIMINARY WORK
1. Remove front engine compartment trim panel.→ REMOVING FRONT TRIM PANEL (ENGINE
COMPARTMENT) - "Removing" section.

REMOVING HOT-FILM MASS AIR FLOW SENSOR
1. Pull off cable plug on mass air flow sensor.

Fig 1: Disconnecting Cable Plug From Air Flow Sensor
2. Loosen hose clamp of connecting tube to the air flow sensor and carefully press in the two
plastic clips on the air cleaner side. Disconnect air flow sensor from the connecting tube. If
necessary, lever out with a small screwdriver. -arrow-
Fig 2: Loosening Hose Clamp Using Screwdriver

INSTALLING HOT-FILM MASS AIR FLOW SENSOR
1. Press air flow sensor onto connecting tube. Make sure the clip connections on the air cleaner
side engage correctly. Fasten hose clamp.
2. Connect cable plug for mass air flow meter.

Fig 1: Locating Cable Plug Of MAF Sensor

SUBSEQUENT WORK
1. Install engine compartment cover. → INSTALLING FRONT TRIM PANEL (ENGINE

WM 244619 REMOVING AND INSTALLING INTAKE-AIR DISTRIBUTOR (CAYENNE) >

TECHNICAL VALUES

value 1 2
Throttle Housing M6
Torque ft. lb.)
Tightening 23 Nm
Fastening Screw M8
Torque (17 ft. lb.)
Intake-Air Distributor
(Variable Intake Manifold) M6
Torque ft. lb.)
To Cylinder Head
Tightening 20 Nm
Fastening Screw M8
Torque (15 ft. lb.)

Tightening 30 Nm
Torque (22 ft. lb.)
inside out

Torque
angle
inside out
Intake-Air Distributor Tightening 8 Nm (6

M6 4 ea. (3 integrated)
(Induction Module) Torque ft. lb.)

M8
intake-air distributor Torque (15 ft. lb.)

M8
intake-air distributor Torque (15 ft. lb.)
Fastening Screw On Tightening 20 Nm

M8
Intake-Air Distributor Torque (15 ft. lb.)
Tightening 23 Nm
Fastening Screw On Eyelet M8
Torque (17 ft. lb.)
Tightening 25 Nm
Belt Tensioner M8
Torque (19 ft. lb.)

PRELIMINARY WORK
1. Remove engine compartment cover. → REMOVING FRONT TRIM PANEL (ENGINE

2. Pull design cover off the throttle valve.
3. Remove intake manifold. → REMOVING AIR BOX FOR THROTTLE HOUSING (INTAKE
PIPES UPSTREAM OF THROTTLE VALVE) - section on "Removing"
4. Remove air-cleaner element and air cleaner housing cover. → REMOVING AIR-CLEANER
ELEMENT - section on "Removing"
5. Loosen the drive belt from the generator. For details, see → 137819 REMOVING AND
INSTALLING DRIVE BELT ON V6 DFI ENGINES
6. Remove belt tensioner. Unscrew the three screws on the drive belt and remove drive belt.
7. Loosen the generator and tilt it towards the air cleaner housing. Remove upper screw and only
loosen the lower screw. → Removing generator

Fig 1: Identifying Intake-Air Distributor And Related Components
6 - Sealing ring; check and replace if damaged
8 - Transport eyebolt on exhaust side
9 - Screw
10 - Shift mechanism on variable intake manifold (intake-air distributor)
16 - Vacuum line
17 - Change-over valve
18 - Coolant pipe
25 - Support
26 - Heat protection panel (cover plate)
27 - Clamp
28 - Plug (vacuum)
29 - Positive crankcase ventilation

30 - Heat socket
31 - Sealing ring
32 - Sealing ring
33 - Locking pin
34 - Intake-air distributor (intake module)
35 - Coolant pipe screw
36 - Spring band clamp
38 - Tank ventilation (active carbon filter) valve
40 - Rapid-action coupling
41 - Vacuum line
62 - Brake booster vacuum line
Fig 2: Identifying Intake Distributor (Bottom)

Fig 3: Identifying Intake Distributor (Side)

REMOVING INTAKE-AIR DISTRIBUTOR

Material damage
Emerging fuel
Risk of fire
Information
Information

1. Remove connections and accessories on intake-air distributor.
1. 1.1. Screw off oil filler cover. -1-
2. 1.2. Remove eyelet. Loosen two screws. -2-
3. 1.3. Disconnect throttle valve and expose cable. -3-
4. 1.4. Loosen tank ventilation line and release it from the intake-air distributor. -6-
5. 1.5. Loosen positive crankcase ventilation line and release it from the intake-air
distributor. -5-
6. 1.6. Disconnect crankcase heater. -4-

Fig 1: Identifying Intake-Air Distributor Connections
2. Remove upper screw on sheetmetal holder. -Top arrow-

Fig 2: Locating Heat Protection Panel On Exhaust Manifold
3. Pull vacuum line out of the intake-air distributor. Use a screwdriver to prise it off if necessary.
-arrow-
Fig 3: Locating Vacuum Line
4. Expose throttle housing cable -1- . Remove screw on intake-air distributor. -2-
Fig 4: Identifying Throttle Valve
5. Remove rear screw on intake-air distributor. -1-

Fig 5: Identifying Fastening Screw On Intake-Air Distributor
6. Press the two coolant hoses aside and remove screw on oil dipstick. Pull out oil dipstick. -1-
Fig 6: Pressing Coolant Hoses
7. Pull off vacuum line on vacuum unit for intake-air distributor -1- . Unclip change-over valve,
disconnect it and set it aside. -2 and 3-
Fig 7: Identifying Vacuum Lines
8. Loosen water tube. To do this, remove the screw on the intake-air distributor -1- and press the
water tube forward -arrow- . Take the water tube out of the notches and press it down
-arrow- .
Fig 8: Loosening Water Tube
9. Disconnect cable plug for high-pressure sensor. Remove high-pressure pump. → REMOVING
HIGH-PRESSURE PUMP - section on "Removing"
10. Remove high-pressure line between the fuel distributor pipes. To do this, loosen the union nuts
and remove line. -1 and 2- See illustrationFig 9-21- .
Fig 9: Identifying High-Pressure System Lines

11. Loosen three screws on the intake-air distributor at the sides in the center of the intake-air
distributor. Use a thin Torx socket (e.g. Klann KL-4041-240) to do this. → Intake-air distributor
screws These three screws are integrated in the intake-air distributor so that they cannot be
lost.
Fig 11: Loosening Intake-Air Distributor Screws
12. Remove one front screw at the side of the intake-air distributor. → Side screws on intake-air
distributor
Fig 12: Removing Screws From Side Of Intake-Air Distributor
1. The lower fuel distribution pipe also secures the intake-air distributor .
2. Always open the fuel high-pressure system when removing the intake-air distributor .
3. The intake-air distributor sits under the fuel distribution pipe for cylinders 2, 4 and 6
13. Loosen lower fuel distributor pipe (for cylinders 2, 4 and 6). To do this, insert a suitable
extension in between the water tube and remove the three screws using a multiple-tooth
socket → Accessing screws on lower fuel distributor pipe . Other illustration, see -19- in Fig
10.
Fig 13: Accessing Screws On Lower Fuel Distributor Pipe
14. Lift off the intake-air distributor complete with the lower fuel distributor pipe. To do this, first
raise the intake-air distributor on the exhaust side and tilt it -1- , then lift it off the cylinder head
on the intake side. -2-
Fig 14: Removing Intake-Air Distributor

INSTALLING INTAKE-AIR DISTRIBUTOR

Material damage
Emerging fuel
Risk of fire
Information
Information
Information
The lower fuel distribution pipe also secures the intake-air distributor .
Always open the fuel high-pressure system when removing the intake-air distributor .
The intake-air distributor sits under the fuel distribution pipe for cylinders 2, 4 and 6
1. Replace intake-air distributor seals.
2. Replace the seals between the fuel injectors and fuel distributor pipe (cylinders 2, 4 and 6) and
coat them with clean engine oil.
3. Only Complete The Following Step If Screws Are Defective: To replace the integrated
screws for the intake-air distributor, carefully drill out the three openings using a 13-mm drill bit.
When doing so, make sure that the drill holes do not exceed a max. depth of 15 mm. → Drilling
out to allow access to screws
Fig 1: Drilling Out To Allow Access To Screws

4. Insert the lower fuel distributor pipe (cylinders 2, 4 and 6) into the removed intake-air
distributor. → Pre-fitting lower fuel distributor pipe
Fig 2: Pre-Fitting Lower Fuel Distributor Pipe
5. Fit intake-air distributor complete with the lower fuel distributor pipe. To do this, first guide it in
on the intake side -1- , then tilt it to the cylinder head on the exhaust side. -2-
Fig 3: Installing Intake-Air Distributor
6. Fit screws on the intake-air distributor. Use a thin Torx socket (e.g. Klann KL-4041-240) to
screw in the screws hand-tight. → Intake-air distributor screws → Side screws on intake-air
distributor
Fig 4: Fitting Intake-Air Distributor Screws

Fig 5: Fitting Screws On Side Of Intake-Air Distributor
Information
1. The lower fuel distribution pipe also secures the intake-air distributor .
2. Always open the fuel high-pressure system when removing the intake-air distributor .
3. The intake-air distributor sits under the fuel distribution pipe for cylinders 2, 4 and 6
7. Good Lighting Is Essential When Working In Confined Spaces! Fit lower fuel distributor
pipe (cylinders 2, 4 and 6) together with the intake-air distributor. To do this, press the lower
fuel distributor pipe correctly onto the injectors. Move fuel distributor pipe into installation
position. Fit screws and tighten by hand. To do this, insert a suitable extension in between the
water tube and fit the three screws using a multiple-tooth socket → Accessing screws on lower
fuel distributor pipe .
Fig 6: Accessing Screws On Lower Fuel Distributor Pipe
8. Tighten screws on the intake-air distributor and fuel distributor pipe. → Tightening Torque: 30
Nm (22 ft. lb.) , then → Torque angle: 90° → Tightening Torque: 8 Nm (6 ft. lb.)
9. Fit high-pressure line between the fuel distributor pipes. To do this, fit union nuts loosely. -1
and 2- See illustrationFig 7, item -21- .
Fig 7: Identifying High-Pressure System Lines

10. Fit high-pressure pump. → INSTALLING HIGH-PRESSURE PUMP - section on "Installing"

Connect cable plug for high-pressure sensor.
11. Fit water tube. To do this, insert the water tube into the latch on the intake-air distributor and
slide it back towards the plenum panel -arrow- . Fit the screw into the intake-air distributor -1-
.
Fig 9: Fitting Coolant Pipe
12. Connect vacuum line to the vacuum unit of the intake-air distributor -1- . Clip on change-over
valve and fit cable plugs. -2 and 3-
Fig 10: Identifying Vacuum Lines
13. Press the two coolant hoses onto the intake-air distributor and fit screw on oil dipstick. Insert oil
dipstick. -1-
Fig 11: Pressing Coolant Hoses
14. Fit rear screw on intake-air distributor. -1- → Tightening Torque: 20 Nm (15 ft. lb.)
Fig 12: Fitting Fastening Screw On Intake-Air Distributor
15. Insert vacuum line into the intake-air distributor. Grease connection and seal -2- with Kluber
Syntheso Glep 1 as required. -arrow-
Fig 13: Locating Vacuum Line
16. Fit throttle housing cable -1- . Fit screw on intake-air distributor. -2- → Tightening Torque: 20
Nm (15 ft. lb.)
Fig 14: Identifying Throttle Valve
17. Fit upper screw on sheetmetal holder. -Top arrow- → Tightening Torque: 20 Nm (15 ft. lb.)
Fig 15: Locating Heat Protection Panel On Exhaust Manifold
18. Fit connections and accessories on intake-air distributor.
1. 18.1. Screw on oil filler cover. -1-
2. 18.2. Fit eyelet. Tighten two screws. -2- → Tightening Torque: 23 Nm (17 ft. lb.)
3. 18.3. Connect cable plug for throttle valve. -3-
4. 18.4. Fit tank vent line. -6-
5. 18.5. Fit positive crankcase ventilation line. -5-
6. 18.6. Connect cable plug for crankcase heater. -4-

Fig 16: Identifying Intake-Air Distributor Connections

SUBSEQUENT WORK
-arrows 3- . For details, see → INSTALLING GENERATOR - section on "Installing"
2. Fit belt tensioner. Tighten the three screws on the belt tensioner. → Tightening Torque: 25
Nm (19 ft. lb.)
3. Fit drive belt. For details, see → 137819 REMOVING AND INSTALLING DRIVE BELT ON V6
DFI ENGINES
4. Fit air-cleaner element and air cleaner housing cover. → INSTALLING AIR-CLEANER
ELEMENT - section on "Installing"
5. Install intake manifold. → INSTALLING AIR BOX FOR THROTTLE HOUSING (INTAKE PIPES
UPSTREAM OF THROTTLE VALVE) - section on "Installing"
6. Press design cover onto the throttle valve.
7. Fit engine compartment cover. → INSTALLING FRONT TRIM PANEL (ENGINE

WM 244719 REMOVING AND INSTALLING INTAKE MANIFOLD (INCLUDES

REPLACING VACUUM ACTUATOR FOR INTAKE MANIFOLD FLAP CONTROL)
value 1 2
Fastening Screw Securing Tightening 2.5 Nm (2

Potentiometer To Intake Manifold Flap Torque ft. lb.)
Fuel Pressure Sensor Oil thread
Torque ft. lb.)
Fastening Screw For High-Pressure Tightening 9 Nm (6.5

Line Holder Torque ft. lb.)
Union Nut For Fuel High-Pressure Tightening 27 Nm (20

Lines Torque ft. lb.)
Fastening Screw Securing Fuel Tightening

9 Nm
High-Pressure Line To Holder Torque
Fastening Nut
Torque ft. lb.)
Fastening Screw Securing Retaining Tightening 9 Nm (6.5

Bar For Fuel Distributor Torque ft. lb.)
Tightening 2.5 Nm (2
Fastening screw
Torque ft. lb.)
Union Nut For Fuel Distributor
Torque ft. lb.)

Information
The procedure for removing and installing the lower part of the intake manifold on the left is described
below. The procedure for the other side is practically identical.
2. Press vacuum hoses aside.

[CAYENNE S E-HYBRID & CAYENNE (3.0)] > PRELIMINARY WORK > PRELIMINARY
WORK ON VACUUM ACTUATOR FOR INTAKE MANIFOLD FLAP CONTROL
Left side, cylinders 4-6: .
2. Remove engine-bay guard. → 108019 REMOVING AND REINSTALLING ENGINE-BAY

GUARD
3. Draining low-temperature cooling system coolant. → 193817 DRAINING AND FILLING

[CAYENNE S E-HYBRID & CAYENNE (3.0)] > INFORMATION > ASSEMBLY OVERVIEW
- LOWER PART OF INTAKE MANIFOLD
Fig 1: Overview Of Intake Manifold Assembly (Lower Part)

1. Screw → Tightening Torque: 2.5 Nm (2 ft. lb.)
3. Sealing ring Replace If Damaged
4. Sleeve
5. Fuel pressure sensor → Tightening Torque: 22 Nm (16 ft. lb.)
6. Holder
8. High-pressure lines → Tightening Torque: 27 Nm (20 ft. lb.)
9. Screw → Tightening Torque: 9 Nm
10. Nut → Tightening Torque: 9 Nm (6.5 ft. lb.)
14. Union nut → Tightening Torque: 40 Nm (30 ft. lb.)
16. Seal Replace
18. Seal Replace
19. Support ring
20. O-ring Replace, Coat With Engine Oil Before Installation
21. Spacer ring Replace If Damaged
22. Fuel injector
25. Circlip
26. Combustion chamber sealing ring Replace

[CAYENNE S E-HYBRID & CAYENNE (3.0)] > REMOVING LOWER PART OF INTAKE
Information
The procedure for removing and installing the lower part of the intake manifold on the left is described
below. The procedure for the other side is practically identical.
1. Remove lower part of intake manifold.
1. 1.1. Disconnect electric plug connection -4- on the fuel pressure sensor.
2. 1.2. Unscrew union nut -1- . Counter at the screw socket while doing this.
1. Material damage
cloths.
adhesive tape.
3. 1.3. Unscrew screws and nuts -arrows- and pull off lower part of intake manifold
together with the fuel distributor.
4. 1.4. Disconnect electric plug connection -2- on the potentiometer for the intake
manifold flap and pull off the vacuum hose -3- .
Fig 1: Removing Lower Part Of Intake Manifold

[CAYENNE S E-HYBRID & CAYENNE (3.0)] > REPLACING VACUUM ACTUATOR FOR
INTAKE MANIFOLD FLAP CONTROL > REPLACING VACUUM ACTUATOR FOR
INTAKE MANIFOLD FLAP CONTROL CYLINDERS 1-3
1. Disconnect secondary-air line.
1. 1.1. Disconnect secondary-air line -1- (-arrow- ).
2. 1.2. Open holder -2- and unclip line.

Fig 1: Disconnecting Secondary-Air Line
2. Remove vacuum actuator -1- .
1. 2.1. Remove screws -2- .
2. 2.2. Remove potentiometer -3- for intake manifold flap.
3. 2.3. Loosen ball socket -4- of actuating lever -5- for vacuum actuator -1- .
Fig 2: Identifying Vacuum Actuator And Related Components
3. Install vacuum actuator -1- .
1. 3.1. Grease actuating lever -5- for vacuum actuator
2. 3.2. Fasten ball socket -4- to actuating lever -5- for vacuum actuator.
3. 3.3. Replace and grease O-ring -7- .
4. 3.4. Fit potentiometer -3- for intake manifold flap -8- .

4. Fasten secondary-air lines.

[CAYENNE S E-HYBRID & CAYENNE (3.0)] > REPLACING VACUUM ACTUATOR FOR
INTAKE MANIFOLD FLAP CONTROL > REPLACING VACUUM ACTUATOR FOR
INTAKE MANIFOLD FLAP CONTROL CYLINDERS 4-6
1. Unscrew screws -1 through 3- for the coolant pipes.

Fig 1: Unscrewing Screws For Coolant Pipes
2. Loosen coolant lines at the compressor.
1. 2.1. Loosen clamps -arrows - and pull off coolant lines.
2. 2.2. Remove screw -2- .

Fig 2: Locating Front Left Coolant Hoses
3. Loosen vacuum line.
1. 3.1. Loosen clamp -1- and pull off hose -2- .
2. 3.2. Pull vacuum lines off the connection points -3- -arrows- .
Fig 3: Locating Vacuum Lines
4. Remove vacuum actuator -1- .
1. 4.1. Remove screws -2- .
2. 4.2. Remove potentiometer -3- for intake manifold flap.
3. 4.3. Loosen ball socket -4- of actuating lever -5- for vacuum actuator -1- .
5. Install vacuum actuator -1- .
1. 5.1. Grease actuating lever -5- for vacuum actuator
2. 5.2. Fasten ball socket -4- to actuating lever -5- for vacuum actuator.
3. 5.3. Replace and grease O-ring -7- .
4. 5.4. Fit potentiometer -3- for intake manifold flap -8- .


[CAYENNE S E-HYBRID & CAYENNE (3.0)] > INSTALLING LOWER PART OF INTAKE
Material damage
Information
Information
Replace seals and O-rings .
Lightly lubricate O-rings for fuel injectors with clean engine oil .
Information
Mark installation position of baffle plates before removal .
Install baffle plates at the correct installation position again following removal .
2. The intake manifold flaps must be moved -in direction of arrow- when installing the lower
part of the intake manifold.
Fig 1: Installing Intake Manifold Flaps

3. Connect a hand vacuum pump.
1. 3.1. Connect a hand vacuum pump to the connector on the vacuum actuator for
intake manifold flap control as shown.
Information
If the intake manifold flaps will not be opened, the flaps can be clamped with the
guide plates in the cylinder head when installing the lower part of the intake manifold.
2. 3.2. Create a vacuum using the hand vacuum pump -VAS 6213- .
Fig 2: Fitting Vacuum Pump On Intake Manifold Flaps
4. Press lower part of intake manifold evenly onto the fuel injectors.
5. Tighten screws and nuts for lower part of intake manifold in diagonally opposite sequence to
the specified torque. → 1001IN TIGHTENING TORQUES FOR ENGINE
6. Pull hand vacuum pump off the connection on the vacuum actuator for intake manifold flap
control.
7. Install lower part of intake manifold.
1. 7.1. Fit electric plug connection -4- onto the fuel pressure sensor.
2. 7.2. Tighten union nut -1- . Counter at the screw socket while doing this.
3. 7.3. For tightening torque, see assembly overview for lower part of intake manifold.
→ 1001IN TIGHTENING TORQUES FOR ENGINE
4. 7.4. Check that the high-pressure fuel line is not strained.

Fig 3: Installing Lower Part Of Intake Manifold


[CAYENNE S E-HYBRID & CAYENNE (3.0)] > SUBSEQUENT WORK > SUBSEQUENT
WORK ON VACUUM ACTUATOR FOR INTAKE MANIFOLD FLAP CONTROL
1. Fill coolant for low-temperature system. → 193817 DRAINING AND FILLING COOLANT
(INCLUDES BLEEDING)
2. Install engine-bay guard. → 108019 REMOVING AND REINSTALLING ENGINE-BAY GUARD
WM 245419 REMOVING AND INSTALLING VACUUM RESERVOIR (CAYENNE S &


value 1 2
Fastening Screw With Guide Sleeve Tightening 10 Nm (7.5

For Vacuum Reservoir To Crankcase Torque ft. lb.)

CAYENNE GTS) > TECHNICAL VALUES > VACUUM RESERVOIR
Fig 1: Identifying Vacuum Reservoir And Related Components
1. Vacuum reservoir
2. Screw with guide sleeve → Tightening Torque: 10 Nm (7.5 ft. lb.)
3. Decoupling element


DISTRIBUTOR
2. Remove secondary-air pump. → 266519 REMOVING AND INSTALLING SECONDARY-AIR

PUMP

CAYENNE GTS) > REMOVING VACUUM RESERVOIR
1. Remove vacuum reservoir.
1. 1.1. Release electric plug connection -1- for the boost pressure control cycle valve
and pull it off.
2. 1.2. Pull off pressure line -2- for boost pressure control at the cycle valve.
3. 1.3. Release and pull off plug connections -3- for the tank vent line. Unclip tank vent
line from the bracket.
4. 1.4. Release and pull off electric plug connection -4- for the tank vent valve.
5. 1.5. Pull off circulating air line -5- .
6. 1.6. Release and pull off electric plug connection -6- for change-over valve for
recirculated air.
7. 1.7. Loosen screw -7- on the fuel connection line holder.
8. 1.8. Loosen connections -8- for the fuel connection line.
9. 1.9. Loosen screws -9- on the vacuum reservoir.
10. 1.10. Remove vacuum reservoir.

Fig 1: Overview Of Vacuum Reservoir

CAYENNE GTS) > INSTALLING VACUUM RESERVOIR
Information
1. Install vacuum reservoir.
1. 1.1. Insert vacuum reservoir.
2. 1.2. Screw in and tighten screws.
3. 1.3. Tighten connections for the fuel connection line.
4. 1.4. Tighten screw on the fuel connection line holder.
5. 1.5. Plug in and lock electric plug connection for change-over valve for recirculated
air.
(Check locking mechanism by pulling on it)
6. 1.6. Plug in and lock electric plug connection for tank vent valve.
7. 1.7. Plug in and lock plug connections for the tank vent line. Clip tank vent line into
the bracket.
8. 1.8. Insert pressure line for boost pressure control at the cycle valve.
9. 1.9. Plug in and lock electric plug connection for the boost pressure control cycle
valve.

Fig 1: Overview Of Vacuum Reservoir

1. Install secondary-air pump. → 266519 REMOVING AND INSTALLING SECONDARY-AIR

PUMP

DISTRIBUTOR
WM 245819 REMOVING AND INSTALLING FUEL PRESSURE REGULATOR (CAYENNE

Wrench VW Tool T10202

TURBO & CAYENNE TURBO S) > TECHNICAL VALUES
Tolerance
2
Sheetmetal Ring On Tightening 145 Nm (107 +/-5 Nm (+/- 3.5

Connection Unit Torque ft. lb.) ft. lb.)
Fastening Nuts On Cover Tightening 10 Nm (7.5 ft.

Plate Torque lb.)

Information
The Fuel Filter Is Integrated In The Left Connection Unit, While The Pressure Regulator Is In The
Right Connection Unit. The Instructions For Opening The Fuel Tank Can Be Used For Both
Connection Units (Pressure Regulator In The Right And Fuel Filter In The Left) .
Both Flanges Must Be Opened As They Are Joined Together .

BATTERY
3. Drain the fuel tank if necessary. → DRAINING FUEL - section on "Draining"

5. Remove the relevant cap -arrows- . To do this, remove the carpeted floor. Then loosen the
four fastening nuts and remove the cap.
Fig 1: Locating Fastening Nuts On Caps

Fig 2: Identifying Connection Units At Left (Fuel Filter) And Right (Pressure Regulator)

Fig 4: Identifying Connector Of Left Connection Unit
tool on cap

TURBO & CAYENNE TURBO S) > REMOVING PRESSURE REGULATOR
unit.

TURBO & CAYENNE TURBO S) > INSTALLING PRESSURE REGULATOR
Information
The pressure regulator is integrated into the connection unit .
The connection unit together with integrated pressure regulator is replaced as a complete unit and
not disassembled .
Fig 1: Fitting Seal

5. Insert the left and right connection unit into the tank. When doing so, make sure that the plastic
lugs are pointing forward.

1. Close the fuel tank. To do this, fit the sheetmetal ring on the left and right connection unit and
tighten using special tool wrench T10202 . → Cap → Tightening Torque: 145 Nm (107 ft.
lb.) +/-5 Nm (+/-3.5 ft. lb.)
2. Fit all connections for the right connection unit (fuel lines, ventilation tubes and electric
connectors). → Fuel supply and connection points at right connection unit

Fig 3: Identifying Connector Of Left Connection Unit
4. Fit left and right lid. Then tighten the four fastening nuts on each to → Tightening Torque: 10
Nm (7.5 ft. lb.) . Refit carpeted floor and fix in place with double-sided adhesive tape.
Fig 4: Locating Fastening Nuts On Caps
6. Fill the fuel tank. → FILLING WITH FUEL (FILLING FUEL TANK) - section on "Filling"
WM 246319 REMOVING AND INSTALLING HIGH-PRESSURE PUMP (CAYENNE) >

TOOLS


TECHNICAL VALUES
Tolerance Tolerance
1 2
Fuel Supply Connection (Low Tightening 30 Nm (22 ft.

Pressure) Torque lb.)

Adapter For High-Pressure Line
Torque lb.)

Adapter For Low-Pressure Line
Torque lb.)
Fastening Screw For Tightening 8 Nm (6 ft.

High-Pressure Pump Torque lb.)
Screw Plug For Pressure Control Tightening 22 Nm (16 ft.

Valve Torque lb.)

Fuel Pressure Sensor
Torque lb.)
Fastening Screw On Fuel Initial 30 Nm (22 ft.

Distributor tightening lb.)
Fastening Screw On Fuel

Final tightening +90°
Distributor

Fuel High-Pressure Pipe
Torque lb.)

Fuel Connecting Tube
Torque lb.)

High-Pressure Pump M6
Torque lb.)

Fuel High-Pressure Pipe
Torque lb.)
PRELIMINARY WORK
Information
Before replacing the high-pressure pump if you suspect that it is faulty, check the performance of the fuel
pumps in the tank. → 200201 CHECKING FUEL PRESSURE (LOW PRESSURE) ON DFI ENGINES or
→ 206601 CHECKING FUEL DELIVERY RATE (LOW PRESSURE DELIVERY RATE) ON DFI
ENGINES
1. Remove engine compartment cover at the plenum panel at the middle and left. → REMOVING
FRONT TRIM PANEL (ENGINE COMPARTMENT) - section on "Removing"
2. Pull out the fuses for the two fuel pumps. This prevents the fuel pumps from starting when a
door is opened.

INFORMATION > ASSEMBLY OVERVIEW
Fig 1: Overview Of Fuel Distributor, High-Pressure Pump And Fuel Injectors Assembly
1. Fuel supply connection (low pressure) → Tightening Torque: 30 Nm (22 ft. lb.)
2. Fuel pressure sensor for low-pressure
3. Fuel supply hose; if the fuel hose is removed from the fuel distributor, it must always be
replaced as it will be damaged by the corrugated connection piece during removal.
4. Spring band clamps

5. Fuel low-pressure hose between high-pressure pump and fuel distributor; always replace the
fuel hose as it will be damaged by the corrugated connection piece during removal.
6. Cam follower; coat with clean engine oil
7. Sealing ring Replace ; coat with clean engine oil
8. High-pressure pump; with control valve for fuel pressure; to loosen and tighten the fuel lines,
counter at the adapters with a wrench; → Tightening Torque: 40 Nm (30 ft. lb.) →
10. O-ring; coat with clean engine oil
11. Pressure control valve Replace Removed Valve ; coat O-ring with clean engine oil before
fitting.
12. Screw plug for pressure control valve → Tightening Torque: 22 Nm (16 ft. lb.)
13. Fuel pressure sensor; coat front sealing cone and the thread with clean engine oil. →
14. Fuel distributor; for cylinders 2, 4 and 6
16. O-ring; coat with clean engine oil.
17. Support washer Replace If Damaged
18. Spring element Replace Whenever The Fuel Distributor Is Removed
19. Fuel injector for cylinders 2, 4 and 6
20. Fuel distributor; for cylinders 1, 3 and 5
21. Fuel injector for cylinders 1, 3 and 5
22. Sealing ring
23. Fuel high-pressure pipe → Tightening Torque: 28 Nm (21 ft. lb.) ; the fuel pipe must not be
touching any other components. The fuel pressure in the high-pressure line can be up to 120
bar! Wear goggles and protective clothing to prevent injury and skin contact. Place a cloth
around the connection before loosening the fuel lines. Then release pressure by carefully
loosening the union nuts; counter with a wrench at the adapter for the high-pressure pump
when loosening and tightening the union nut; before installation: first re-tighten the adapter on
the high-pressure pump
24. Connecting tube; the fuel pipe must not be touching any other components. → Tightening

REMOVING HIGH-PRESSURE PUMP

Material damage
Emerging fuel
Risk of fire
Information
1. Place a cloth under the high-pressure pump. This absorbs leaking fuel.
2. Pull off cable plug on the high-pressure sensor -arrow- . Use Assembly Tool T10118 to do
this.
Fig 1: Locating High-Pressure Line On High-Pressure Pump
Information
Always replace the fuel hose as it will be damaged by the corrugated connection piece during
removal.
3. Disconnect the fuel supply hose (not shown) and fuel low-pressure hose -A- at the spring
band clamps and remove the fuel lines.
Fig 2: Locating Fuel Low-Pressure Lines
4. Release high-pressure line (fuel line) at the union nuts -2- . To do this, counter at the hexagon
and remove the line.
5. Unscrew the three screws for the high-pressure pump -1- . For the bottom screw, use a thin
tool and very carefully press the coolant pipe down. -2-
Fig 4: Locating Mount Screw Of High-Pressure Pump

Fig 5: Removing Bottom Screw
6. Remove the high-pressure pump, turn it slightly and release the bottom cable plug for the flow
control valve using Assembly Tool T10118 or by hand. -arrow-
Fig 6: Locating Cable Plug Of Flow Control Valve
7. Remove the high-pressure pump. → Removing high-pressure pump

Fig 7: Removing High-Pressure Pump
8. Remove the drive tappet -1- and check for signs of damage. The drive tappet has a twist lock
on the side. -2-
Fig 8: Removing Drive Tappet

INSTALLING HIGH-PRESSURE PUMP

Material damage
Emerging fuel
Risk of fire
Information
Information

1. Check that the drive tappet -1- is installed correctly. The drive tappet has a twist lock on the
side. -2-
Fig 1: Installing Drive Tappet
2. Check sealing ring of high-pressure pump for signs of damage and replace if necessary. Avoid
shearing off the sealing ring during installation.
3. Place high-pressure pump in installation position → High-pressure pump . Then insert bottom
left screw.
Fig 2: Placing High-Pressure Pump In Installation Position
4. Connect the lower cable plug for the flow control valve. -arrow-
Fig 3: Locating Cable Plug Of Flow Control Valve
5. Insert the three screws for the high-pressure pump. For the bottom screw, use a thin tool and
very carefully press the coolant pipe down -2- . Press the high-pressure pump against the
resistance of the spring and screw in screws (twist crankshaft if necessary until the drive
tappet is at its lowest point). Fit screws -1- . → Tightening Torque: 10 Nm (7.5 ft. lb.)
Fig 4: Locating Mount Screw Of High-Pressure Pump

Fig 5: Inserting Bottom Screw
6. Tighten the high-pressure line -A- uniformly and counter the high-pressure line in -direction
of arrow- at the same time. Once tightened, the high-pressure line -A- and low-pressure
hose -B- must not be touching.
Tightening Torque: → Tightening Torque: 28 Nm (21 ft. lb.)

Fig 6: Tightening Fuel High-Pressure Pipe
Information
removal.
Information
removal.
7. Fit the fuel supply hose (not shown) and fuel low-pressure hose -A- and secure with spring
band clamps. Check installation position -arrows- .
Fig 7: Locating Fuel Low-Pressure Lines
8. Connect cable plug for the high-pressure sensor -arrow- .

9. Inspect high-pressure system for leaks. → 243001 CHECKING FUEL DISTRIBUTION PIPE
(FUEL RAIL) ON DFI ENGINES FOR LEAKS

SUBSEQUENT WORK
1. Fit engine compartment cover at the plenum panel at the middle and left. → INSTALLING
FRONT TRIM PANEL (ENGINE COMPARTMENT) - section on "Installing"
2. Fit the fuses for the two fuel pumps.
WM 246919 REMOVING AND INSTALLING OXYGEN SENSOR (CAYENNE) > TOOLS

Bonnet Stay Special Tool 9704
PIWIS Tester Special Tool 9718
Torque Wrench, Only in

Signal-Transmitting Commercially conjunction
Nr. 90
With Changeover Available Tool with wrench
Ratchet inserts
Open-End Ring Commercially

Nr. 96-3
Wrench Available Tool
Accessories For
Various overall
Torque Wrench:
Commercially lengths, e.g.
Angled Nr. 97
Available Tool Hazet 4681-1
Open-End/Ring
to 3
Wrench
Open-End Ring Commercially

Nr. 98
WM 246919 REMOVING AND INSTALLING OXYGEN SENSOR (CAYENNE) >

TECHNICAL VALUES

value 1 2
Fastening Nuts Securing Catalytic Tightening 23 Nm (17

Replace
Converter To Manifold Torque ft. lb.)
Fastening Screw For Catalytic Tightening 23 Nm (17

Converter Holder Torque ft. lb.)
Fastening Screw Securing Catalytic Tightening 23 Nm (17

Converter To Body Torque ft. lb.)



Replace
Oxygen Sensor M18 x 1.5
Torque ft. lb.)

PRELIMINARY WORK
1. Raise the bonnet. Move bonnet to service position using Bonnet Stay 9704 .
2. Put on the protection covers.
3. Remove engine compartment trim panels on the right. → REMOVING FRONT TRIM PANEL

Fig 1: Overview Of Catalytic Converters Assembly
1. Exhaust manifold, bank 1
2. Seal Replace
3. Oxygen sensor upstream of catalytic converters, bank 1
4. Catalytic converter, bank 1

5. Nuts Replace → Tightening Torque: 23 Nm (17 ft. lb.)
7. Oxygen sensor downstream of catalytic converter, bank 1
8. Suspension Replace If Damaged
15. Holder for catalytic converter
16. Seal Replace
18. Oxygen sensor upstream of catalytic converter, bank 2

REMOVING OXYGEN SENSORS UPSTREAM OF CATALYTIC CONVERTER >
REMOVING OXYGEN SENSORS AHEAD OF CATALYTIC CONVERTER
Information
After installing the oxygen sensor cables, use the PIWIS Tester 9718 to check that the oxygen sensors
have not been interchanged. Release the oxygen sensor cable so that the cable can turn when you
unscrew or screw in the sensor. Otherwise, the Check Engine light will come on and there may be a
change in the vehicle's exhaust gas behavior.
1. Disconnect cable plugs on the oxygen sensors ahead of the catalytic converter and expose
cables. To do this, trace cable routing to the oxygen sensors ahead of the catalytic converter
and disconnect the corresponding cable plugs. → Cable plugs for oxygen sensors
Fig 1: Locating Cable Plugs Of Oxygen Sensors
2. Remove oxygen sensors ahead of catalytic converter. -1- → Detaching oxygen sensor using
open-ended wrench (oxygen sensor behind catalytic converter for cylinders 1 to 3 shown)
Unscrew both oxygen sensors ahead of the catalytic converter using a ring or open-ended
wrench (a/f 22) or using Open-End Ring Wrench Nr. 96-3 or Open-End Ring Wrench Nr.
98 .
Fig 2: Identifying Oxygen Sensors Installation Position

Fig 3: Detaching Oxygen Sensor Using Open-Ended Wrench (Oxygen Sensor Behind Catalytic
Converter For Cylinders 1 To 3 Shown)

INSTALLING OXYGEN SENSORS UPSTREAM OF CATALYTIC CONVERTER
Information
1. Carefully coat the thread of the oxygen sensors -1- with 000.043.207.07 and screw in by
hand.

Fig 2: Removing And Installing Oxygen Sensors

Fig 3: Identifying Special Tools Of Oxygen Sensors
→ Special Tools For Oxygen Sensors - Accessories For Torque Wrench: Angled
Open-End/Ring Wrench Nr. 96-3
Open-End/Ring Wrench Nr. 97
Open-End/Ring Wrench For Assembly Nr. 98
→ Special Tools For Oxygen Sensors - Torque Wrench, Signal-Transmitting With

Change-Over Ratchet Nr. 90
2. Route cables for oxygen sensors → Cable plugs on oxygen sensors . Connect oxygen
sensors.
Fig 4: Identifying Cable Plugs On Oxygen Sensors

SUBSEQUENT WORK
1. Install engine compartment trim panels.
→ 700219 REMOVING AND INSTALLING FRONT TRIM PANEL (ENGINE COMPARTMENT)

.
2. Secure bonnet using original bonnet stay and close it.
WM 246919 REMOVING AND INSTALLING OXYGEN SENSOR UPSTREAM OF

CATALYTIC CONVERTER (CAYENNE S & CAYENNE GTS) > TOOLS

Support Special Tool 9866

CATALYTIC CONVERTER (CAYENNE S & CAYENNE GTS) > TECHNICAL VALUES

value 1 2
Oxygen Coat oxygen sensor thread with Tightening 55 Nm (41

Sensor assembly grease 000.043.207.07 Torque ft. lb.)

CATALYTIC CONVERTER (CAYENNE S & CAYENNE GTS) > PRELIMINARY WORK
1. Remove engine compartment trim panel. → 700219 REMOVING AND INSTALLING FRONT
TRIM PANEL (ENGINE COMPARTMENT)

CATALYTIC CONVERTER (CAYENNE S & CAYENNE GTS) > REMOVING OXYGEN
SENSOR UPSTREAM OF CATALYTIC CONVERTER
NOTE: Incorrect handling of oxygen sensors
Damage to oxygen sensors
Different exhaust emission behavior
→ Do not remove the plastic cap on the thread until just prior to fitting.
→ Protect oxygen sensors from impact of any kind.
→ Do not kink or twist the cables when screwing in the sensors.
→ Do not re-use dirty or damaged components.
Information

Fig 1: Identifying Support Special Tool (9866)
1. Remove oxygen sensor -1- at the left upstream of catalytic converter.
1. 1.1. Loosen tie-wrap -arrows- and expose electric line -2- .
2. 1.2. Release and disconnect electric connector -3- .
3. 1.3. Loosen connector housing -4- from the holder -5- .

4. 1.4. Disconnect electric line -2- completely and expose it.
5. 1.5. Loosen and unscrew oxygen sensor -1- .

Fig 2: Identifying Left Oxygen Sensor Upstream Of Catalytic Converter
2. Remove oxygen sensor -1- at the right upstream of catalytic converter.
1. 2.1. Loosen electric line -2- from the holder -3- .
2. 2.2. Loosen tie-wrap -arrow- .
3. 2.3. Release and disconnect electric connector -4- .
4. 2.4. Loosen connector housing -5- from the holder -6- .

5. 2.5. Disconnect electric line -2- completely and expose it.
6. 2.6. Loosen and unscrew oxygen sensor -1- .

Fig 3: Identifying Right Oxygen Sensor Upstream Of Catalytic Converter

CATALYTIC CONVERTER (CAYENNE S & CAYENNE GTS) > INSTALLING OXYGEN
SENSOR UPSTREAM OF CATALYTIC CONVERTER > INSTALLING OXYGEN SENSOR
NOTE: Incorrect handling of oxygen sensors
Damage to oxygen sensors

Different exhaust emission behavior
→ Do not remove the plastic cap on the thread until just prior to fitting.
→ Protect oxygen sensors from impact of any kind.
→ Do not kink or twist the cables when screwing in the sensors.
→ Do not re-use dirty or damaged components.
Information
1. 1.1. Coat oxygen sensor thread with assembly grease 000.043.207.07.
2. 1.2. Tightening Torque: Tightening Torque 55 Nm (41 ft. lb.)
3. 1.3. Replace tie-wrap.

CATALYTIC CONVERTER (CAYENNE S & CAYENNE GTS) > SUBSEQUENT WORK
1. Install engine compartment trim panel. → 700219 REMOVING AND INSTALLING FRONT
TRIM PANEL (ENGINE COMPARTMENT)
WM 247019 REMOVING AND INSTALLING DME CONTROL UNIT (ALL MODELS) >
TOOLS
TECHNICAL VALUES
Tolerance Tolerance
1 2
DME Control Unit To Tightening 9 Nm (6.5 ft.
-1-
Bracket Torque lb.)
DME Control Unit To Tightening 9 Nm (6.5 ft.

-1-
Bracket Torque lb.)
Bracket For DME Control Tightening

8 Nm (6 ft. lb.)
Unit Torque
Tightening
DME Control Unit Bracket 8 Nm (6 ft. lb.)
Torque
PRELIMINARY WORK
Tester II 9818 prior to removing the "old" DME control unit. → 247055 REPLACING DME
CONTROL UNIT .
2. Remove the right cowl panel cover.
REMOVING DME CONTROL UNIT
Fig 1: Identifying DME Control Unit Installation Position
Information
1. Switch off ignition and remove remote control (hand-held transmitter) and control panel.
2. Unscrew both fastening screws -1- on the control unit bracket and remove water drip pan -2- .
Fig 2: Identifying Water Drip Pan
NOTE: Voltage peaks
1. Risk of damage to electrical load or to the control unit
Information
Left-hand drive vehicles are fitted with a protection cap over the connector. This must be folded
upwards before releasing and disconnecting the connector.
3. Release electric plug connection -1- (-a- ) and pull it off -B- .
Fig 3: Releasing Plug Connections From DME Control Unit
4. Release electric plug connection -2- (-a- ) and pull it off -B- .
5. Remove DME control unit with bracket by pulling it upwards.
REMOVING DME CONTROL UNIT > REMOVING DME CONTROL UNIT WITH
ANTI-THEFT PROTECTION
1. Move the bonnet into service position.
2. Unscrew both fastening screws -1- on the control unit bracket and remove water drip pan -2- .
Fig 1: Removing Water Drip Pan
Information
Left-hand drive vehicles are fitted with a protection cap over the connector. This must be folded
upwards before releasing and disconnecting the connector.
3. Unclip DME cables at the two holders -1- and lift DME control unit including anti-theft
protection bar and connected cables up and out.
Fig 2: Unclipping DME Control Unit Cables
4. Fit A Large Vice-Grip Wrench (at least 300 mm long) at the side of the weld nut on the
projecting neck of the three shear bolts -1- several times and unscrew anti-clockwise, then
remove the anti-theft protection bar -2- .
Fig 3: Front And Rear View Of DME Control Unit With Anti-Theft Protection Bar

Fig 4: Fitting Large Vice-Grip Wrench On Shear Bolt
5. Release the two electric plug connections and pull them off one after the other.
REPLACING DME CONTROL UNIT
1. Unscrew four fastening screws -1- on the bracket.

Fig 1: Replacing DME Control Unit (Shown As Example)
2. Screw in four fastening screws -1- on the bracket. → Tightening Torque: 9 Nm (6.5 ft. lb.)
REPLACING DME CONTROL UNIT > REPLACING DME CONTROL UNIT WITH
1. Unscrew four fastening screws -1- on the bracket.

2. Screw the new anti-theft protection holder -1- to the new DME control unit with two shear bolts
-2- until the bolt head shears off.
Do NOT Re-Use the old anti-theft protection holder as the procedure for removing the two
shear bolts would be too complicated.
Fig 2: Screwing Anti-Theft Protection Holder To DME Control Unit
3. Screw in four fastening screws -1- on the bracket. → Tightening Torque: 9 Nm (6.5 ft. lb.)
INSTALLING DME CONTROL UNIT
1. Fit bracket for DME control unit on the guide pins -1- .
Fig 1: Installing DME Control Unit
2. Plug in electric plug connection -2- (-B- ) and lock it -a- .

Fig 2: Plugging In Plug Connection On DME Control Unit
3. Plug in electric plug connection -1- (-B- ) and lock it -a- .
Information
For left-hand drive vehicles, check that the protection cap is placed back over the connector
correctly and prevents water from leaking in.
4. Fit water drip pan -2- and screw in two fastening screws -1- on bracket for DME control unit.
→ Tightening Torque: 8 Nm (6 ft. lb.)
Fig 3: Installing Water Drip Pan
INSTALLING DME CONTROL UNIT > INSTALLING DME CONTROL UNIT WITH
1. Plug in the two electric plug connections one after the other and lock them.
2. Position anti-theft protection bar -2- and screw in three shear bolts -1- until the bolt head
shears off.
Fig 1: Front And Rear View Of DME Control Unit With Anti-Theft Protection Bar
3. Fit bracket for DME control unit on the guide pins -1- .
Fig 2: Installing DME Control Unit
4. Clip in DME cables at two places -1- .

Fig 3: Clipping In DME Control Unit Cables
Information
For left-hand drive vehicles, check that the protection cap is placed back over the connector
correctly and prevents water from leaking in.
5. Fit water drip pan -2- and screw in using the two fastening screws -1- for the DME control unit
bracket. → Tightening Torque: 8 Nm (6 ft. lb.)
Fig 4: Installing Water Drip Pan
6. Move the bonnet out of service position.
SUBSEQUENT WORK
PIWIS Tester II 9818 . → 247055 REPLACING DME CONTROL UNIT .
2. Install the right cowl panel cover.
WM 247025 PROGRAMMING DME CONTROL UNIT [CAYENNE S, CAYENNE S

E-HYBRID, CAYENNE TURBO & CAYENNE (3.0)] > TOOLS


E-HYBRID, CAYENNE TURBO & CAYENNE (3.0)] > TECHNICAL VALUES

E-HYBRID, CAYENNE TURBO & CAYENNE (3.0)] > PROGRAMMING DME CONTROL
UNIT
Information
Tester releases.
Information
by the vehicle.
NOTE: Voltage drop

→ Connect a battery charger with a current rating of at least → Nominal Value: 40 A to the vehicle
battery.
1. PIWIS Tester II 9818 must be connected to the vehicle.
2. Start the Tester.
3. Switch on ignition using original remote control (hand-held transmitter).
5. Select DME using the cursor keys and press [F12] to continue.
6. Select Control Unit Replacement using the cursor keys and press [F12] to continue.
7. Select Read Out Values (vehicle data) using the cursor keys and press [F12] to continue.
8. The message Values Were Read Out appears on the Tester screen.
9. Switch off ignition and replace control unit. → 247019 REMOVING AND INSTALLING DME
CONTROL UNIT
10. After installing the new DME control unit, re-load the data that was read out under Control
Unit Replacement by selecting Write Values .
11. Switch to the Programming menu.
12. Automatic Programming must now be selected. Then press [F12] to continue.
Information
The wiper comes on once when DME programming is complete.
1. Do not place any objects on the windscreen .
2. Do not touch the windscreen during programming .
13. Switch ignition off and on again.
15. Select On-Line Teaching Function on the Start page.
16. Vehicle must now be selected. Then press [F12] to continue.
17. Vehicle data will be read out.
if necessary.

23. Follow the instructions on the Tester and select the required menu.
example:
2 keys taught
Front BCM: taught
ELV: taught
Rear BCM: taught
DME: taught
25. Press [F12] to continue.
26. Press [EXIT] To End The On-line Teaching Function and select the Vehicle Type on the
Start page.
27. For the learning and adaptation routine of the throttle valve (electronic accelerator), switch the
ignition off and then on again for 60 seconds without starting the engine. Do not press the
accelerator pedal. Switch ignition off again for at least 10 seconds. Switch on ignition. This
completes the adaptation of the throttle valve adjusting unit and the teaching process is
complete.
29. Perform DME control unit adaptation during a test drive and read out the fault memories again.
WM 247055 REPLACING DME CONTROL UNIT (CAYENNE TIP, CAYENNE S,

CAYENNE TURBO, CAYENNE S HYBRID, CAYENNE TIP (3.0), CAYENNE GTS,
CAYENNE TURBO S, CAYENNE TIP "PLATINUM EDITION" & CAYENNE TIP (3.0)
"PLATINUM EDITION") > TOOLS

"PLATINUM EDITION") > TECHNICAL VALUES

"PLATINUM EDITION") > INFORMATION: ADAPTATION OF THE DME (DFI) CONTROL
UNIT
Information
If the DME (DFI) control unit is replaced, it must be programmed using the PIWIS Tester II 9818 . This
adapts the DME (DFI) control unit to the vehicle, country version and equipment. The DME (DFI) control
unit is located in the plenum panel close to the right wing.
Before the DME (DFI) control unit is removed and replaced, a read-out of the vehicle data should be
obtained (if possible) using the PIWIS Tester II 9818 .
Information
When replacing one of the following components >> DME (DFI) Control Unit And/Or High-Pressure
Pump (Also When Replacing The Engine) << from the fuel system, the adaptations in the DME (DFI)
control unit must be adapted to the system again.
Rough engine running is possible until the adaptations are completed.
Noticeable decreases in engine performance may also occur.
The Following Sequence Must Be Followed In The Correct Order For The Adaptation Of The Fuel
High-Pressure Control System:
1. PIWIS Tester II 9818 must be connected to the vehicle and started.
2. Select vehicle type and DME/DFI control unit.
3. Select the Actual Values, Input Signals menu and press [>>].
4. Actual values B_Fuel , T_Temperature
WARNING: Test drive with the Tester connected
1. Driver impeded/steers off course during test drive
2. Danger to other people on the roads

→ When the Tester is connected and switched on, route the diagnostic cable so that the driver
is not impeded.
→ Only get one other person to read off the values on the Tester.
→ Only drive the vehicle to achieve the RPM and speed ranges specified in the document in
accordance with road traffic regulations and if the road, weather and traffic conditions are
conducive to such driving.
5. Select the required items and press [>>]:
1. 5.1. Engine Temperature
2. 5.2. Fuel High-Pressure Adaptation Range 1
6. Start the vehicle and let the engine warm up. During the test drive, at an engine temperature of
at least 55 °C , see Tester value for Engine Temperature , gradually approach the engine
speed range of more than 2000 RPM, then switch from operation under load to overrun and
maintain this operating condition for at least 5 sec. [>>] The Leakage Adaptation has now
been completed. This value Cannot be read out under the Actual Values .
Information
If it is not possible to drive at the specified speeds, the adaptation ranges 1 to 5 can also be
achieved by increasing the engine load relative to the specified speed. A defined fuel
throughput must be achieved for the adaptation to be completed.
The specified time stipulation of 15 sec. is cumulative, i.e. the time may also be broken down
into 5 + 5 + 5 seconds, for example.
7. Fuel High-Pressure Adaptation Range 1 must be reached: gradually approach the speed
range of 60 - 85 km/h (40 - 55 mph) and maintain this for at least 15 sec. The Tester indicates
when the value changes upwards or downwards by 1.00. [>>] This completes the adaptation of
Range 1 .
Information
If it is not possible to drive at the specified speeds, the adaptation ranges 1 to 5 can also be
achieved by increasing the engine load relative to the specified speed. A defined fuel
throughput must be achieved for the adaptation to be completed.
The specified time stipulation of 15 sec. is cumulative, i.e. the time may also be broken down
into 5 + 5 + 5 seconds, for example.
8. Fuel High-Pressure Adaptation Range 2 must be completed: gradually approach the speed
range of 120 - 140 km/h (75 - 90 mph) and maintain this for at least 15 sec. The Tester
indicates when the value changes upwards or downwards by 1.00. [>>] This completes the
adaptation of Range 2 .
9. Fuel High-Pressure Adaptation Of Range 3, 4, 5 These ranges do Not need to be

achieved for the adaptation drive.
1. 9.1. Range 3 requires constant driving for 15 sec. in the speed range of 210 - 220
km/h (130 - 140 mph). [>>] Not Required for the adaptation drive.
2. 9.2. Range 4 requires multiple full-load acceleration, each time for approx. 10 sec. at
an engine speed of more than 4000 RPM. [>>] Not Required for the adaptation
drive.
3. 9.3. Range 5 is only for V8 turbo engines. Multiple full-load acceleration, each time
for approx. 10 sec. at an engine speed of more than 5000 RPM. [>>] Not required
For the adaptation drive.
10. Once ranges 1 and 2 have been adapted, the values must be between 0.75 and 1.25. If the
values are < 0.75 or > 1.25, a fault is entered in the DME (DFI) control unit. If the values are in
the stipulated range, another test drive must be performed for a distance of approx. 15 km/10
miles (if feasible [>>] combination of motorway, cross-country and city driving). It is important
that the drive includes different load and RPM ranges.
11. If range 1 and 2 are not within the stipulated range, the fault memory must be read out and the
cause of the fault entries corrected.
12. Following the test drive, check the fault memory. If there are faults stored, the cause of the fault
entries must be corrected.

"PLATINUM EDITION") > PROGRAMMING DME CONTROL UNIT > TEACHING NEW
DME CONTROL UNIT
Tester releases.
Information
by the vehicle.
NOTE: Voltage drop
→ Connect a battery charger with a current rating of at least → Nominal Value: 40 A to the vehicle
battery.
1. PIWIS Tester II 9818 must be connected to the vehicle before starting the System Tester.
Switch on ignition using original remote control.
2. Select the vehicle type.
3. Select DME with the cursor keys and press the [>>] key.
4. Select Control Unit Replacement with the cursor keys and press the [>>] key.
5. Select Read Out Values (vehicle data) with the cursor keys and press [>>].
6. The message Values Were Read Out appears on the Tester screen.
7. Switch off ignition and replace control unit. → REMOVING DME CONTROL UNIT - section on
"Removing"
8. After you have installed the new Kessy control unit, select Write Values in the Control Unit
Replacement menu to re-load the data that was read out.
9. Switch to the Programming menu.
10. Select Automatic Programming and press [>>].
The wiper comes on once when DME programming is complete.
1. Do not place any objects on the windscreen .
2. Do not touch the windscreen during programming .
11. Switch ignition off and on again.
14. Select Vehicle and press [>>]. Vehicle data will be read out.
15. The vehicle identification number (VIN) is displayed. Adapt the vehicle identification number if
necessary.
16. Enter the repair order number and press [>>].
17. Enter the PPN user name and password and press [>>].
19. The Tester displays the message Login Successful . Press [>>].
20. Follow the instructions on the Tester to select the required menu.
example:
2 keys taught
Front BCM: taught
ELV: taught
Rear BCM: taught
DME: taught
22. [>>].
23. Press [EXIT] to exit the On-line Teaching Function and select the Vehicle Type on the Start
page.
24. For the learning and adaptation routine of the throttle valve (electronic accelerator), switch the
ignition off and then on again for 60 seconds without starting the engine. Do not actuate the
accelerator pedal. Switch ignition off again for at least 10 seconds. Switch on ignition. This
completes the adaptation of the throttle valve adjusting unit and the teaching process is
complete.
26. Perform DME control unit adaptation during a test drive and read out the fault memories again.
WM 247319 REMOVING AND INSTALLING OXYGEN SENSORS DOWNSTREAM OF

CATALYTIC CONVERTER (CAYENNE) > TOOLS

Bonnet Stay Special Tool 9704
PIWIS Tester Special Tool 9718
Open-End/Ring Commercially
Nr. 96-3
Open-End/Ring Commercially
Nr. 98

CATALYTIC CONVERTER (CAYENNE) > TECHNICAL VALUES

value 1 2

Replace





Replace
Oxygen Sensor M18 x 1.5
Torque ft. lb.)

CATALYTIC CONVERTER (CAYENNE) > PRELIMINARY WORK
1. Raise the bonnet. Move bonnet to service position using Bonnet Stay 9704 .
2. Put on the protection covers.
3. Remove engine compartment trim panels on the right. → REMOVING FRONT TRIM PANEL

CATALYTIC CONVERTER (CAYENNE) > INFORMATION > ASSEMBLY OVERVIEW
2. Seal Replace
3. Oxygen sensor upstream of catalytic converters, bank 1

8. Suspension replace if damaged
15. Holder for catalytic converter
16. Seal Replace
18. Oxygen sensor upstream of catalytic converter, bank 2

CATALYTIC CONVERTER (CAYENNE) > REMOVING OXYGEN SENSOR
DOWNSTREAM OF CATALYTIC CONVERTER
Information
1. Disconnect cable plugs for oxygen sensors downstream of catalytic converter and expose
cables. To do this, trace cable routing to the oxygen sensors downstream of catalytic converter
and disconnect the corresponding cable plugs. → Cable plugs for oxygen sensors
Fig 1: Identifying Cable Plugs Of Oxygen Sensors
2. Remove oxygen sensors downstream of catalytic converter -2- . Unscrew both oxygen
sensors downstream of catalytic converter using a ring wrench or open-ended wrench (a/f 22)
or using open-end/ring wrench Nr. 96-3 or open-end/ring wrench Nr. 98 .

Fig 3: Detaching Oxygen Sensor Using Open-Ended Wrench (Oxygen Sensor Behind Catalytic
Converter For Cylinders 1 To 3 Shown)

CATALYTIC CONVERTER (CAYENNE) > INSTALLING OXYGEN SENSOR
DOWNSTREAM OF CATALYTIC CONVERTER
1. Install oxygen sensors. To do this, grease thread of oxygen sensors with Optimoly Paste MF
(000 043 207 07) before fitting them. Make sure that the paste does not get into the slits in the
sensor body. Screw in both oxygen sensors downstream of catalytic converter -2- using a ring
wrench or open-ended wrench (a/f 22) or using Open-End/Ring Wrench Nr. 96-3 or
Open-End/Ring Wrench Nr. 98 . → Tightening Torque: 50 Nm (37 ft. lb.)

Fig 2: Removing And Installing Oxygen Sensors
Information
After installing the oxygen sensor cables, use the PIWIS Tester 9718 to check that the oxygen
sensors have not been interchanged. Release the oxygen sensor cable so that the cable can
turn when you unscrew or screw in the sensor. Otherwise, the Check Engine light will come on
and there may be a change in the vehicle's exhaust gas behavior.
2. Connect oxygen sensors. Route cable for oxygen sensors, clip it in and connect cable plugs
for oxygen sensors downstream of catalytic converter. → Cable plugs on oxygen sensors
Fig 3: Identifying Cable Plugs On Oxygen Sensors

CATALYTIC CONVERTER (CAYENNE) > SUBSEQUENT WORK
1. Fit engine compartment cover. → 700219 REMOVING AND INSTALLING FRONT COVER
(ENGINE COMPARTMENT) .
2. Secure the bonnet.
WM 248019 REMOVING AND INSTALLING INTAKE PIPE PRESSURE SENSOR

(CAYENNE TURBO & CAYENNE TURBO S) > TECHNICAL VALUES
Tolerance Tolerance
1 2
Pressure Sensor To Intake Tightening 4 Nm (3 ft.

5 x 16
System Torque lb.)

1. Remove rear engine compartment cover at the middle. For details, see → 700219 REMOVING
AND INSTALLING FRONT TRIM (ENGINE COMPARTMENT)

(CAYENNE TURBO & CAYENNE TURBO S) > REMOVING AND INSTALLING
PRESSURE SENSOR
The intake pipe pressure sensor is at a central position on the intake-air distributor and is facing the
plenum panel. -4- .
Fig 1: Identifying Intake Air Module And Related Components On Turbo Engine
1. Intake module
2. Decoupling module (fastening part); observe specified tightening sequence
3. Screw, 5 x 16 → Tightening Torque: 4 Nm (3 ft. lb.)
4. Pressure sensor
5. Intake module seal; Check That Seal Is Aligned And Fitted Correctly!
6. Heat socket
7. Screw, 6 x 50
9. Seal
10. Ball socket

1. Remove pressure sensor.
1. 1.1. Pull off cable plug.
2. 1.2. Remove screw.
3. 1.3. Remove pressure sensor by levering and turning it slightly.
2. If the sealing ring is damaged, the sensor must be replaced.
3. Fit the pressure sensor into the intake-air distributor by turning it slightly.
1. 3.1. Position and fit the screw.
2. 3.2. Connect cable plug.

1. Fit rear engine compartment cover at the middle. For details, see → 700219 REMOVING AND
WM 249019 REMOVING AND INSTALLING FUEL LINE (HIGH-PRESSURE) [CAYENNE

S E-HYBRID & CAYENNE (3.0)] > TOOLS
Crow Foot Commercially

Nr. 195

S E-HYBRID & CAYENNE (3.0)] > TECHNICAL VALUES

value 1 2
Fastening Screw Securing Tightening 2.5 Nm (2

Potentiometer To Intake Manifold Flap Torque ft. lb.)
Fuel Pressure Sensor Oil thread
Torque ft. lb.)
Fastening Screw For High-Pressure Tightening 9 Nm (6.5

Line Holder Torque ft. lb.)
Union Nut For Fuel High-Pressure Tightening 27 Nm (20
Lines Torque ft. lb.)
Fastening Screw Securing Fuel Tightening

9 Nm
High-Pressure Line To Holder Torque
Fastening Nut
Torque ft. lb.)
Fastening Screw Securing Retaining Tightening 9 Nm (6.5

Bar For Fuel Distributor Torque ft. lb.)
Tightening 2.5 Nm (2
Fastening Screw
Torque ft. lb.)
Union Nut For Fuel Distributor
Torque ft. lb.)

S E-HYBRID & CAYENNE (3.0)] > PRELIMINARY WORK

S E-HYBRID & CAYENNE (3.0)] > REMOVING FUEL LINE > ASSEMBLY OVERVIEW -
LOWER PART OF INTAKE MANIFOLD
Fig 1: Overview Of Intake Manifold Assembly (Lower Part)
4. Sleeve
5. Fuel pressure sensor → Tightening Torque: 22 Nm (16 ft. lb.)
6. Holder
8. High-pressure lines → Tightening Torque: 27 Nm (20 ft. lb.)
9. Screw → Tightening Torque: 9 Nm
14. Union nut → Tightening Torque: 40 Nm (30 ft. lb.)
16. Seal Replace
18. Seal Replace
19. Support ring
20. O-ring/Replace, Coat With Engine Oil Before Installation
21. Spacer ring Replace If Damaged
22. Fuel injector
25. Circlip
26. Combustion chamber sealing ring Replace

S E-HYBRID & CAYENNE (3.0)] > REMOVING FUEL LINE > REMOVING FUEL LINE

WARNING: Emerging fuel
→ Do not work on the fuel system when the engine is hot.
→ Keep clear of naked flames and ignition sources.
Material damage
1. Move secondary air hose -arrow- forward out of the holder and disconnect it by pressing the
release buttons.
2. Remove screws -arrows- and move the potentiometer for the intake manifold flap together
with the vacuum actuator for the intake manifold flap aside.
Fig 2: Locating Potentiometer Of Intake Manifold Flaps
3. Screw off nuts -arrows- and remove protective plate -1- .

Fig 3: Locating High-Pressure Pump Protective Plate Nuts
NOTE: Incorrect handling of pipe and line connections
2. Leaks
→ Do not put too much pressure on pipe and line connections.
→ Always counter the lines when loosening and fastening them.
4. Remove screws -arrows- and threaded joint -1- . Screw off union nuts -2- and -3- and
counter at the screw socket while doing this.
Fig 4: Removing High-Pressure Line
5. Remove high-pressure line.

S E-HYBRID & CAYENNE (3.0)] > INSTALLING FUEL LINE

Material damage
Information
1. First tighten the union nut as much as you can by hand. Check that the high-pressure line is
not strained when doing this.
1. Emerging fuel
2. Risk of fire
NOTE: Incorrect handling of pipe and line connections
2. Leaks
→ Do not put too much pressure on pipe and line connections.
→ Always counter the lines when loosening and fastening them.
2. Use a Crow Foot Wrench Nr. 195 to tighten the union nut to the specified torque. At the
same time, counter at the hexagon of the screw socket on the fuel distributor using an
open-ended wrench.
3. Do not tighten the screw for the fastening clip until you have tightened the high-pressure line.

S E-HYBRID & CAYENNE (3.0)] > SUBSEQUENT WORK

Service Manual: 26 - EXHAUST SYSTEM -- 92A CAYENNE
WM 260119 REMOVING AND INSTALLING EXHAUST SYSTEM (CAYENNE TURBO,
CAYENNE TIP, CAYENNE S, CAYENNE TURBO S, CAYENNE S DIESEL, CAYENNE
TURBO S & CAYENNE TIP "PLATINUM EDITION") > TECHNICAL VALUES
Exhaust Clamp Maximum Inclination Adjustment Value 10°

TURBO S & CAYENNE TIP "PLATINUM EDITION") > INFORMATION > COMPONENT
OVERVIEW
Fig 1: Identifying Exhaust System Components - V8 Naturally Aspirated Engines (Tailpipe Covers Not
Shown)
1. Exhaust System
2. Connection Point Marking
3. Exhaust Clamps (Clamping Sleeves)
4. Centre Bracket
5. Bracket On Rear Silencer

Fig 2: Identifying Exhaust System Components - V8 Turbo Engines (Tailpipe Covers Not Shown)
1. Exhaust System
2. Connection Point Marking
3. Exhaust Clamps (Clamping Sleeves)
4. Centre Bracket
5. Bracket On Rear Silencer

TURBO S & CAYENNE TIP "PLATINUM EDITION") > REMOVING EXHAUST SYSTEM
CAUTION: Hot components
Risk of burns
→ Let hot components cool down.

Risk of squashing
Information
converter and exhaust system. Slide exhaust clamps onto the exhaust system. Exhaust
clamps must not be re-used.
Fig 1: Loosening Clamp Nuts
2. Get another person to help secure the exhaust system.
3. Unscrew fastening screw -6- on the center bracket -4- .

Fig 2: Loosening Centre Bracket
Unscrew four fastening screws -7- from the brackets on the rear silencer -5- .
Fig 3: Removing Bracket On Rear Silencer
4. Get another person to help you remove the exhaust system.

TURBO S & CAYENNE TIP "PLATINUM EDITION") > INSTALLING EXHAUST SYSTEM
Information
Fig 1: Fitting Clamps
2. Get another person to help secure the exhaust system.
3. Position the exhaust system under the vehicle. Do not install too tightly.
4. Tighten four fastening screws for the brackets on the rear silencer.
Fig 2: Securing Bracket On Rear Silencer
5. Tighten fastening screw on the center bracket.

Fig 3: Tightening Centre Bracket
6. The threaded joint on the exhaust clamps must be pointing downwards. Adjust to maximum
inclination and ensure the assembly length is the same on both exhaust pipes. → see Fig 4→
Adjustment value: 10°
Fig 4: Identifying Exhaust Clamp Installation Position
1. Gap of approx. 5 mm between the exhaust pipes
2. Length of exhaust clamp
3. Maximum inclination
WM 260519 REMOVING AND INSTALLING CONTROL UNIT FOR ACOUSTIC

SIMULATOR (CAYENNE S E-HYBRID) > TECHNICAL VALUES
Tolerance Tolerance
1 2
Plastic Nut Securing Control Unit Tightening 2 Nm (1.5 ft.

Holder To Body Torque lb.)

SIMULATOR (CAYENNE S E-HYBRID) > PRELIMINARY WORK
1. Loosen the right front seat and tilt it to the rear with lines connected. → 720119 REMOVING
2. Remove inner door sill trim at the right. → 680519 REMOVING AND INSTALLING INNER
DOOR SILL TRIM

SIMULATOR (CAYENNE S E-HYBRID) > REMOVING CONTROL UNIT FOR ACOUSTIC
SIMULATOR
NOTE: Voltage peaks
Information
1. Pull carpet to the left and move it aside.
2. Release electric plug connection -arrow- and disconnect it -arrow- .
3. Unscrew and remove plastic nuts -3- .

Fig 1: Removing Control Unit For Acoustic Simulator
4. Remove control unit for acoustic simulator -1- with holder -2- .
5. Release locking lugs -arrow- and pull control unit for acoustic simulator -1- out of the holder
-2- .
Fig 2: Removing Control Unit For Acoustic Simulator From Holder

SIMULATOR (CAYENNE S E-HYBRID) > INSTALLING CONTROL UNIT FOR ACOUSTIC
SIMULATOR
2. Tighten plastic nuts. Tightening Torque 2 Nm (1.5 ft. lb.)

SIMULATOR (CAYENNE S E-HYBRID) > SUBSEQUENT WORK
1. Install inner door sill trim at the right. → 680519 REMOVING AND INSTALLING INNER DOOR
SILL TRIM
2. Install right front seat. → 720119 REMOVING AND INSTALLING FRONT SEAT
WM 261019 REMOVING AND INSTALLING EXHAUST MANIFOLD (CAYENNE) >

TECHNICAL VALUES

value 1 2
Fastening Screw For Heat Shield Tightening 20 Nm (15

Holder Torque ft. lb.)

Fastening Nut Securing Exhaust Tightening 23 Nm (17

Manifold To Cylinder Head Torque ft. lb.)
Fastening Nut Securing Catalytic Tightening 23 Nm (17

Replace
Converter To Exhaust Manifold Torque ft. lb.)

PRELIMINARY WORK
1. Remove engine compartment covers at the right → 700219 REMOVING AND INSTALLING

INFORMATION > OVERVIEW
Fig 1: Overview Of Exhaust Manifold Assembly
1. Seal Replace
2. Heat Shield
4. Holder
6. Holder
8. Seal With Heat Shield Replace
9. Nut Replace → Tightening Torque: 23 Nm (17 ft. lb.)
10. Exhaust Manifold

REMOVING EXHAUST MANIFOLD > REMOVING EXHAUST MANIFOLD FOR
CYLINDER 1-3 (FRONT)
1. Unscrew fastening screw securing heat shield to intake-air distributor at the top and remove
heat shield.
2. Unscrew fastening nuts -right arrows- used to secure the catalytic converter to the exhaust
manifold for Cylinders 1-3 .
Fig 1: Locating Catalytic Converter To Exhaust Manifold Nuts
3. Unscrew fastening nuts -right arrow- on the exhaust manifold for Cylinders 1-3 .
4. Press exhaust manifold back and remove it.
Fig 2: Removing Exhaust Manifold

REMOVING EXHAUST MANIFOLD > REMOVING EXHAUST MANIFOLD, CYLINDERS
4-6 (REAR)
1. Unscrew fastening screw securing heat shield to intake-air distributor at the top and remove
heat shield.
2. Unscrew fastening nuts -left arrows- used to secure the catalytic converter to the exhaust
manifold for Cylinders 4-6 .
3. Unscrew fastening nuts -arrows- on the exhaust manifolds.

Fig 2: Removin Exhaust Manifold
4. Press exhaust manifold for Cylinders 1-3 back slightly.
Press exhaust manifold for Cylinders 4-6 back slightly and remove it.

INSTALLING EXHAUST MANIFOLD
1. 1.1. Replace all fastening nuts that were loosened.
2. 1.2. Replace seals on connections that were opened.

SUBSEQUENT WORK
1. Install engine compartment cover at the front right.
WM 263355 REPLACING REAR SILENCER (CAYENNE S, CAYENNE TURBO,

Chain Pipe Commercially

Nr. 166
Cutter Available Tool
Ratchet Pipe Commercially

Nr. 166-1
Cutter Available Tool

CAYENNE GTS & CAYENNE TURBO S) > TECHNICAL VALUES
Tolerance Tolerance
1 2
Exhaust System Holder Tightening 23 Nm (17 ft.

M8
To Body Torque lb.)
Replace, Tighten Tightening 33 Nm (24 ft.

Exhaust Clamp
Uniformly Torque lb.)

CAYENNE GTS & CAYENNE TURBO S) > REPLACING REAR SILENCER
Risk of burns

Risk of squashing
1. There is a small notch on the underside of the exhaust pipes that is level with the rear axle
differential. The notch marks the connection point. -arrows-
Fig 1: Identifying Exhaust Pipe Connection Points
2. Place the pipe cutter chain Chain Pipe Cutter Nr. 166 or Ratchet Pipe Cutter Nr. 166-1 (or
similar tool) around the exhaust pipe close to the connection point marking and engage it at
the other end of the pipe cutter. Then clamp the chain firmly by turning the handle. → Placing
pipe cutter chain around exhaust pipe
Fig 2: Placing Pipe Cutter Chain Around Exhaust Pipe
3. Swivel the pipe cutter to and fro in wide movements until the pipe is cut. While doing this, keep
tightening the chain by turning the handle. → Cutting through pipe with pipe cutter
Fig 3: Cutting Through Pipe With Pipe Cutter
4. Remove rear holders for the rear silencer.
1. 4.1. Secure the rear silencer with the help of another person or a transmission jack.
2. 4.2. Unscrew two fastening screws -1- on each holder.
3. 4.3. Remove rear silencer.

Fig 4: Identifying Rear Silencer Holder Screws
5. Deburr cut on inside and outside of exhaust pipe. If necessary, remove rust from exhaust pipe
using suitable polishing agents and manually restore to roundness.
6. Fit new suspension rubbers or holders if necessary.
7. Push new exhaust clamp onto exhaust pipe.
8. Lift the rear silencer into installation position with the help of another person or a transmission
jack. Tighten two fastening screws -1- on each holder to the specified tightening torque. →
Fig 5: Identifying Rear Silencer Holder Screws
9. Position clamping sleeves in the center of the cutting location during installation.
Fit clamping sleeves in such a way that the ends of the screws do not protrude over the lower
edge of the clamping sleeve. The clamping sleeve must not touch any other components, even
when the exhaust system is moving quite significantly.
→ Tightening Torque: 33 Nm (24 ft. lb.)

Fig 6: Positioning Clamping Sleeves
WM 263415 ADJUSTING TAILPIPES (CAYENNE TIP, CAYENNE S, CAYENNE TURBO,

CAYENNE S HYBRID, CAYENNE DIESEL, CAYENNE S DIESEL, CAYENNE TIP (3.0),
CAYENNE GTS & CAYENNE TURBO) > TECHNICAL VALUES

value 1 2
X = Distance From Upper Part Of Gap

V8 Turbo 18 mm
Rear Apron Dimension X
Y = Work Out Distance At Sides Gap

V8 Turbo 18 mm
To The Left And Right Uniformly Dimension Y
Gap
Gap Between Tailpipes V8 Turbo 5 mm
Dimension Z
X = Distance From Upper Part Of V8 Naturally Gap

20 mm
Rear Apron Aspirated Engine Dimension X
Y = Work Out Distance At Sides V8 Naturally Gap

20 mm
To The Left And Right Uniformly Aspirated Engine Dimension Y
WM 263415 ADJUSTING TAILPIPES (CAYENNE TIP, CAYENNE S, CAYENNE TURBO,
CAYENNE S HYBRID, CAYENNE DIESEL, CAYENNE S DIESEL, CAYENNE TIP (3.0),
CAYENNE GTS & CAYENNE TURBO) > ADJUSTING AND ALIGNING TAILPIPES
NOTE: Tailpipe not fitted correctly
Components can heat up
→ Observe exact gap dimensions.
→ After the test drive, check the gap dimensions again and re-adjust if necessary.
Information
If the gap dimensions of the tailpipes with respect to the rear apron are different due to design changes,
the tailpipes must be adjusted to a uniform distance from the rear apron.
Check Gap Dimensions Of Tailpipe With Respect To Rear Apron. →
Tailpipe - V8 Turbo
Fig 1: Identifying Tailpipe Gap Dimension - V8 Turbo
X - Gap with respect to top of rear apron → Gap Dimension X: 18 mm
Y - Work out gap at sides to the left and right uniformly → Gap Dimension Y: 18 mm
Z - Gap between tailpipes → Gap Dimension Z: 5 mm

Tailpipe - V8 naturally aspirated engine and basic variant
Fig 2: Identifying Tailpipe Gap Dimension - V8 Naturally Aspirated Engine And Basic Variant
X - Gap with respect to top of rear apron → Gap Dimension X: 20 mm
Y - Work out gap at sides to the left and right uniformly → Gap Dimension Y: 20 mm
Tailpipe, V6 engine
Fig 3: Identifying Tailpipe Gap Dimension - V6 Engine
X - Centre distance at the sides evenly to the left and right
WM 263419 REMOVING AND INSTALLING TAILPIPES (CAYENNE TIP, CAYENNE S,

CAYENNE TURBO, CAYENNE S HYBRID, CAYENNE DIESEL, CAYENNE TIP (3.0),
CAYENNE GTS, CAYENNE TURBO S & CAYENNE S DIESEL) > TECHNICAL VALUES
Ball Clamp Tightening Torque 30 Nm (22 ft. lb.)

CAYENNE GTS, CAYENNE TURBO S & CAYENNE S DIESEL) > INFORMATION >
COMPONENT OVERVIEW
Fig 1: Overview Of Tailpipes Component - V8 Naturally-Aspirated Engines & V6 Engines
1. Rear Silencer
2. Tailpipe
3. Ball Clamp
4. Fastening Screw On Ball Clamp

Fig 2: Overview Of Tailpipes Component - V8 Turbo Engines
1. Rear Silencer
2. Tailpipe
3. Ball Clamp
4. Fastening Screw On Ball Clamp

CAYENNE GTS, CAYENNE TURBO S & CAYENNE S DIESEL) > REMOVING TAILPIPES
Risk of burns
Information
This description also applies for all other tailpipe variants (single or dual pipe)
1. Loosen fastening screw -arrow- on ball clamp.

Fig 1: Locating Fastening Screw Of Tailpipe
2. Loosen tailpipes by turning and pulling off.

CAYENNE GTS, CAYENNE TURBO S & CAYENNE S DIESEL) > INSTALLING
TAILPIPES
1. Clean extension positions and replace ball clamp if necessary, depending on its condition.
2. Put tailpipes in installation position and align → 263415 ALIGNING TAILPIPES .
3. Tighten fastening screw on ball clamp to → Tightening Torque: 30 Nm (22 ft. lb.) .
Fig 1: Locating Fastening Screw Of Tailpipe Clamp
WM 266029 CLEANING SECONDARY-AIR INJECTION SYSTEM (CAYENNE S


1. Remove spark plugs.
→ WM 287020 REMOVING AND INSTALLING SPARK PLUGS
2. Remove catalytic converter.
→ 267319 (REMOVING AND INSTALLING (MAIN) CATALYTIC CONVERTER

1. Install spark plugs.

→ WM 287020 REMOVING AND INSTALLING SPARK PLUGS
2. Install catalytic converter.
→ 267319 (REMOVING AND INSTALLING (MAIN) CATALYTIC CONVERTER
3. Start the high-voltage system.
→ 2X00IN ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER

SUPPLY/STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM
4. When cleaning in winter (outside temperatures < 0 °C): Leave engine running for at least 10-15
minutes.
5. Change oil.
→ 170117 CHANGING ENGINE OIL AND OIL FILTER
WM 266519 REMOVING AND INSTALLING SECONDARY-AIR PUMP (CAYENNE S &



CAYENNE GTS) > REMOVING SECONDARY-AIR PUMP
1. Remove secondary-air pump.
1. 1.1. Release and disconnect electric connector -1- and unclip it from the holder
2. 1.2. Loosen hose clamp -2- and pull off secondary air hose -3- .
3. 1.3. Unscrew fastening screws -4- . Remove secondary-air pump -5- .

Fig 1: Identifying Secondary-Air Pump And Related Components

WM 266901 CHECKING COMBINATION VALVE FOR SECONDARY AIR [CAYENNE S

Hand Vacuum Pump Workshop

WE 1341
VAS 6213 Equipment
WM 266901 CHECKING COMBINATION VALVE FOR SECONDARY AIR [CAYENNE S
E-HYBRID & CAYENNE (3.0)] > CHECKING COMBINATION VALVE FOR SECONDARY
AIR
Test Conditions:
Vacuum lines and hose connections are leak-tight.
Vacuum lines are not clogged.
1. Remove engine cover. → 108319 REMOVING AND INSTALLING ENGINE COVER (DESIGN
COVER) .
2. Pull off vacuum hose on secondary air inlet valve to be checked.
1. -1- Secondary air inlet valve for bank 1 (right)
2. -2- Secondary air inlet valve for bank 2 (left)
Hand Vacuum Pump VAS 6213 WE 1341 must be connected to the vacuum hose
of the secondary air inlet valve to be checked.
Fig 1: Identifying Connections Of Secondary Air Combination Valves
the release buttons.
4. Blow with your mouth into the hose connected to the combination valves using light pressure
(Do Not Use Compressed Air ).
The combination valves for the secondary air system must be closed. It must not be possible
to blow through them.
5. Hand vacuum pump VAS 6213 WE 1341 must now be operated.
The relevant combination valve should open; it should now be possible to blow through it.
6. If the relevant combination valve for the secondary air system does not open, replace it. →
266919 REMOVING AND INSTALLING COMBINATION VALVE FOR SECONDARY AIR
SYSTEM
7. Assembly is carried out in reverse order.
WM 266919 REMOVING AND INSTALLING SECONDARY AIR COMBINATION VALVE


value 1 2
Screw Plug On Secondary-Air Duct Tightening 10 Nm (7.5
To Cylinder Head Torque ft. lb.)
Secondary Air Valve To Cylinder Tightening 10 Nm (7.5

M6
Head Torque ft. lb.)

With Engine Installed →
1. Remove high-pressure pump on cylinder bank 5 to 8. → 246319 REMOVING AND

2. Pull off cable plug on solenoid valve for valve lift switchover.
3. Remove vacuum pump on cylinder bank 1 to 4. → 477619 REMOVING AND INSTALLING

VACUUM PUMP
If Cylinder Head Is Replaced →
5. Remove screw plug with sealing ring. -1-

Fig 1: Removing Screw Plug From Secondary-Air Duct

1. Screw plug on secondary-air duct; if re-used: → Tightening Torque: 10 Nm (7.5 ft.
lb.)

(CAYENNE TURBO & CAYENNE TURBO S) > INFORMATION > COMPONENT
OVERVIEW
Fig 1: Identifying Secondary Air Valves Installation Position
1. Secondary Air Valve, Cylinder Bank 5 To 8
2. M6 Screw

Fig 2: Identifying Secondary-Air Hoses Related Components
1. Secondary-Air Pipe
2. Holder With Clamp
3. Clamp

(CAYENNE TURBO & CAYENNE TURBO S) > REMOVING SECONDARY AIR VALVE
1. Disconnect secondary-air hoses and pipe.

Fig 1: Identifying Secondary-Air Hoses And Related Components
3. Clamp
2. Detach secondary air valve connections.
3. Remove screw -2- and carefully pull the secondary air valve -1 or 3- out of the cylinder head.

(CAYENNE TURBO & CAYENNE TURBO S) > INSTALLING SECONDARY AIR VALVE
1. Fit secondary air valve with a new, lightly greased sealing ring into the cylinder head.
2. Fit secondary air valve with an M6 screw. → Tightening Torque: 10 Nm (7.5 ft. lb.) Fit
secondary air valve connections.
3. Fit secondary-air hoses.

1. Fit cable plug on solenoid valve for valve lift switchover.
2. Fit high-pressure pump on cylinder bank 5 to 8. → 246319 REMOVING AND INSTALLING

HIGH-PRESSURE PUMP
3. Attach cable plug on solenoid valve for valve lift switchover on cylinder bank 1 to 4.
WM 266919 REMOVING AND INSTALLING COMBINATION VALVES FOR SECONDARY

AIR [CAYENNE S E-HYBRID & CAYENNE (3.0)] > TECHNICAL VALUES
value 1 2
Fastening Screws On Combination Tightening 9 Nm (6.5

Valve Torque ft. lb.)
Fastening Screws On Secondary Air Tightening 5 Nm (3.5

Fastening Nut On Holder For Tightening 9 Nm (6.5

Secondary Air Pump Motor Torque ft. lb.)

AIR [CAYENNE S E-HYBRID & CAYENNE (3.0)] > PRELIMINARY WORK
1. Remove the relevant catalytic converter. → 267319 REMOVING AND INSTALLING MAIN
CATALYTIC CONVERTER

AIR [CAYENNE S E-HYBRID & CAYENNE (3.0)] > REMOVING COMBINATION VALVES
FOR SECONDARY AIR > ASSEMBLY OVERVIEW - AIR INJECTION SYSTEM
Fig 1: Overview Of Air Injection System Assembly
1. Vacuum Hose From Secondary-Air Injection Valve 1
2. Right Combination Valve For Secondary Air
3. Screws → Tightening Torque: 9 Nm (6.5 ft. lb.)
4. Sender 1 For Secondary Air Pressure

5. O-ring Replace
6. Screws → Tightening Torque: 5 Nm (3.5 ft. lb.)
7. Left combination valve for secondary air
9. Seal Replace
10. Hose For Secondary Air On Pressure Side
11. Rubber-Metal Mount
12. Motor For Secondary Air
13. Holder/Riveted To Body
15. O-rings Replace If Damaged
16. Hose For Secondary Air On Intake Side
17. Secondary Air Pipe
18. Seal Replace

FOR SECONDARY AIR > REMOVING LEFT COMBINATION VALVE FOR SECONDARY
AIR
1. Unscrew screws -arrows- and remove the heat shield -1- .

Fig 1: Locating Heat Shield On Left Combination Valve
2. Remove combination valve:
1. 2.1. Pull vacuum line -2- off the combination valve for secondary air.
3. 2.3. Pull combination valve up slightly and unscrew screws -3- for secondary air
pipe.
Fig 2: Identifying Left Combination Valve

FOR SECONDARY AIR > REMOVING RIGHT COMBINATION VALVE FOR
SECONDARY AIR
1. Unscrew screws -arrows- and remove the heat shield -1- .

Fig 1: Locating Heat Shield On Right Combination Valve
2. Remove combination valve:
1. 2.1. Pull vacuum line -2- off the combination valve for secondary air.
2. 2.2. Unscrew screws -3- , pull off combination valve and unscrew screws -1- for
secondary air pipe.
Fig 2: Identifying Right Combination Valve

AIR [CAYENNE S E-HYBRID & CAYENNE (3.0)] > INSTALLING COMBINATION VALVES
FOR SECONDARY AIR > INSTALLING LEFT COMBINATION VALVE FOR SECONDARY
AIR
Information
1. 1.1. Replace seal.
2. 1.2. First screw in secondary air pipe, then tighten combination valve.

AIR [CAYENNE S E-HYBRID & CAYENNE (3.0)] > INSTALLING COMBINATION VALVES
FOR SECONDARY AIR > INSTALLING RIGHT COMBINATION VALVE FOR
SECONDARY AIR
Information
1. 1.1. Replace seal.
2. 1.2. First screw in secondary air pipe, then tighten combination valve.

AIR [CAYENNE S E-HYBRID & CAYENNE (3.0)] > SUBSEQUENT WORK
1. Install catalytic converter. → INSTALLING CATALYTIC CONVERTER
WM 266919 REMOVING AND INSTALLING SECONDARY AIR VALVE (CAYENNE S,


value 1 2
Screw Plug On Secondary-Air Duct Tightening 10 Nm (7.5

To Cylinder Head Torque ft. lb.)
Secondary Air Valve To Cylinder Tightening 10 Nm (7.5

M6
Head Torque ft. lb.)

1. Remove high-pressure pump on cylinder bank 5 to 8. → 246319 REMOVING AND

3. Remove vacuum pump on cylinder bank 1 to 4. → 477619 REMOVING AND INSTALLING

VACUUM PUMP
If Cylinder Head Is Replaced →
5. Remove screw plug with sealing ring. -1-

Fig 1: Removing Screw Plug From Secondary-Air Duct
1. Screw plug on secondary-air duct; if re-used: → Tightening Torque: 10 Nm (7.5 ft.

lb.)

CAYENNE TURBO, CAYENNE GTS & CAYENNE TURBO S) > INFORMATION >
COMPONENT OVERVIEW
2. M6 Screw

3. Clamp

CAYENNE TURBO, CAYENNE GTS & CAYENNE TURBO S) > REMOVING
SECONDARY AIR VALVE
1. Disconnect secondary-air hoses and pipe.

1. Secondary-air pipe
2. Holder with clamp
3. Clamp
2. Detach secondary air valve connections.
3. Remove screw -2- and carefully pull the secondary air valve -1 or 3- out of the cylinder head.

CAYENNE TURBO, CAYENNE GTS & CAYENNE TURBO S) > INSTALLING
SECONDARY AIR VALVE
1. Fit secondary air valve with a new, lightly greased sealing ring into the cylinder head.
2. Fit secondary air valve with an M6 screw. → Tightening Torque: 10 Nm (7.5 ft. lb.) Fit
secondary air valve connections.
3. Fit secondary-air hoses.

With engine installed =>
1. Fit cable plug on solenoid valve for valve lift switchover.
2. Fit high-pressure pump on cylinder bank 5 to 8. → 246319 REMOVING AND INSTALLING

HIGH-PRESSURE PUMP
3. Attach cable plug on solenoid valve for valve lift switchover on cylinder bank 1 to 4.
WM 267319 REMOVING AND INSTALLING (MAIN) CATALYTIC CONVERTER

TECHNICAL VALUES

value 1 2
Main Catalytic Converter To Tightening 23 Nm (17

Primary Catalytic Converter Torque ft. lb.)

Transmission Bracket Torque ft. lb.)
Maximum Adjustment
Exhaust Clamp 10°
Inclination Value
M8, Replace; Tightening 33 Nm (24

Exhaust Clamp
Tighten Uniformly Torque ft. lb.)

Fig 1: Overview Of Main Catalytic Converter Components
1. Main Catalytic Converter
2. Fastening Nuts For Primary Catalytic Converter
3. Exhaust Clamp (Clamping Sleeve)
4. Transmission Bracket
5. Fastening Screw On Transmission Bracket

REMOVING (MAIN) CATALYTIC CONVERTER
Risk of burns
Information
converter and exhaust system. Slide exhaust clamp onto the exhaust system. The exhaust
clamp must not be re-used.
Fig 1: Loosening Clamps
2. Unscrew fastening screw -5- on bracket for transmission -4- .

Fig 2: Loosening Screws On Transmission Bracket
3. Screw off three fastening nuts -2- on the connection between the main catalytic converter -1-
and primary catalytic converter -6- . The fastening nuts must not be re-used.
Fig 3: Loosening Primary Catalytic Converter Nuts
4. Remove main catalytic converter by pulling it forward.
5. Remove seal between main catalytic converter and primary catalytic converter. The seal must
always be replaced.

INSTALLING (MAIN) CATALYTIC CONVERTER
Information
Refer to the relevant repair instructions for tightening torques regarding parts belonging to the relevant
body, transmission, chassis, electrical component groups.
2. Fit new seal between main catalytic converter and primary catalytic converter.
3. Fit main catalytic converter from the front.
4. Tighten three new fastening nuts -2- on the connection between the main catalytic converter
-1- and primary catalytic converter -6- to → Tightening Torque: 23 Nm (17 ft. lb.) .
Fig 2: Tightening Primary Catalytic Converter Nuts
5. Tighten fastening screw -5- on bracket for transmission -4- to → Tightening Torque: 23 Nm
(17 ft. lb.) .
Fig 3: Tightening Screws On Transmission Bracket
inclination and ensure that assembly length of both exhaust pipes is the same. → Installation
position of exhaust clamp → Adjustment value: 10° → Tightening Torque: 33 Nm (24 ft.
lb.)
WM 267319 REMOVING AND INSTALLING MAIN CATALYTIC CONVERTER (CAYENNE

TIP (3.0) & CAYENNE TIP (3.0) "PLATINUM EDITION") > TECHNICAL VALUES

value 1 2
Fastening Nut Securing

Tightening 23 Nm
Catalytic Converter To Front Replace
Torque (17 ft. lb.)
Silencer

Replace And Grease Tightening 23 Nm
Catalytic Converter To
With Hot Screw Paste Torque (17 ft. lb.)
Exhaust Manifold

for left catalytic converter Torque (17 ft. lb.)

Replace And Grease Tightening 23 Nm
Catalytic Converter To
With Hot Screw Paste Torque (17 ft. lb.)
Exhaust Manifold

Tightening 23 Nm
Catalytic Converter To Front Replace
Torque (17 ft. lb.)
Silencer
Fastening Screw On Support Tightening 23 Nm
For Right Catalytic Converter Torque (17 ft. lb.)

For Right Front Silencer Torque (17 ft. lb.)

For Left Front Silencer Torque (17 ft. lb.)
Fastening Nut On Clamping Tightening 35 Nm

Sleeve Torque (26 ft. lb.)
Fastening Nut On Clamping Tightening 35 Nm

Sleeve Torque (26 ft. lb.)

TIP (3.0) & CAYENNE TIP (3.0) "PLATINUM EDITION") > PRELIMINARY WORK
1. Remove cardan shaft. → REMOVING FRONT CARDAN SHAFT - section on "Removing"
2. Remove air guide pipe.
1. 2.1. Loosen hose clamps. -arrows-


TIP (3.0) & CAYENNE TIP (3.0) "PLATINUM EDITION") > REMOVING CATALYTIC
CONVERTER > REMOVING LEFT CATALYTIC CONVERTER
Risk of burns
1. Remove engine compartment cover.
2. Remove oxygen sensor 2 downstream of catalytic converter.
3. Screw off nuts that can be reached from above -2- .

Fig 1: Identifying Catalytic Converter To Exhaust Manifold Nuts
4. Screw off mounting for catalytic converter -right arrow- .

Fig 2: Locating Catalytic Converter Mounting Nut
5. Remove left front silencer -A- .

Fig 3: Identifying Left Front Silencer
6. Screw off nuts that can be reached from below -1- and -3- from connection for front exhaust
pipe on the exhaust manifold.

TIP (3.0) & CAYENNE TIP (3.0) "PLATINUM EDITION") > REMOVING CATALYTIC
CONVERTER > REMOVING RIGHT CATALYTIC CONVERTER
Risk of burns
1. Remove engine compartment cover.
2. Remove oxygen sensor downstream of catalytic converter.
3. Screw off nuts that can be reached from above -2- .

4. Disconnect wiring harness and set it aside.
5. Remove front silencer -B- at the right.

Fig 2: Identifying Right Front Silencer
6. Unscrew support for catalytic converter -arrow- .

Fig 3: Locating Catalytic Converter Support Bolt
7. Screw off nuts that can be reached from below -1- and -3- from connection for front exhaust
pipe on the exhaust manifold.

TIP (3.0) & CAYENNE TIP (3.0) "PLATINUM EDITION") > INSTALLING CATALYTIC
CONVERTER > CATALYTIC CONVERTER AND FRONT SILENCER
Fig 1: Overview Of Catalytic Converters And Front Silencers Assembly
1. Left Front Silencer
2. Seal Replace
4. Oxygen Sensor 2 Downstream Of Catalytic Converter

5. Catalytic Converter For Cylinder Bank 2 (Left)
7. Seal Replace
8. Support For Left Catalytic Converter
10. Support For Right Catalytic Converter
12. Seal Replace
13. Oxygen Sensor Downstream Of Catalytic Converter
14. Catalytic Converter For Cylinder Bank 1 (Right)
15. Nut → Tightening Torque: 23 Nm (17 ft. lb.)
16. Seal Replace
17. Right Front Silencer
20. Support For Right Front Silencer
21. Support For Left Front Silencer
24. Right Clamping Sleeve
25. Left Clamping Sleeve

CONVERTER > INSTALLING LEFT CATALYTIC CONVERTER
1. 1.1. Refit tie-wraps at the same position during installation.
2. 1.2. Replace seals and self-locking nuts.
3. 1.3. Fit exhaust system without tension.
2. Tightening Torques:
1. 2.1. Drive: → 1001IN TIGHTENING TORQUES FOR ENGINE

CONVERTER > INSTALLING RIGHT CATALYTIC CONVERTER
1. 1.1. Refit tie-wraps at the same position during installation.
3. 1.3. Fit exhaust system without tension.
4. 1.4. Secure wiring harness.
2. Tightening Torques:
1. 2.1. Drive: → 1001IN TIGHTENING TORQUES FOR ENGINE

TIP (3.0) & CAYENNE TIP (3.0) "PLATINUM EDITION") > SUBSEQUENT WORK
1. Install cardan shaft. → INSTALLING FRONT CARDAN SHAFT
2. Install air guide pipe.
WM 267319 REMOVING AND INSTALLING CATALYTIC CONVERTER (CAYENNE

TURBO & CAYENNE TURBO S) > TECHNICAL VALUES

value 1 2

Primary Catalytic Converter Torque ft. lb.)

Transmission Bracket Torque ft. lb.)
Maximum Adjustment
Exhaust Clamp 10°
Inclination value
M8, Replace; Tightening 33 Nm (24

Exhaust Clamp
Tighten Uniformly Torque ft. lb.)

TURBO & CAYENNE TURBO S) > INFORMATION > COMPONENT OVERVIEW
Fig 1: Overview Of Main Catalytic Converter Components
1. Main Catalytic Converter
2. Fastening Nuts For Primary Catalytic Converter
3. Exhaust Clamp (Clamping Sleeve)
4. Transmission Bracket
5. Fastening Screw On Transmission Bracket

TURBO & CAYENNE TURBO S) > REMOVING (MAIN) CATALYTIC CONVERTER
Risk of burns
Information
converter and exhaust system. Slide exhaust clamp onto the exhaust system. The exhaust
clamp must not be re-used.
Fig 1: Loosening Clamps
2. Unscrew fastening screw -5- on bracket for transmission -4- .

Fig 2: Loosening Screws On Transmission Bracket
3. Screw off three fastening nuts -2- on the connection between the main catalytic converter -1-
and primary catalytic converter -6- . The fastening nuts must not be re-used.
Fig 3: Loosening Primary Catalytic Converter Nuts
4. Remove main catalytic converter by pulling it forward.
5. Remove seal between main catalytic converter and primary catalytic converter. The seal must
always be replaced.

TURBO & CAYENNE TURBO S) > INSTALLING (MAIN) CATALYTIC CONVERTER
Information
Refer to the relevant repair instructions for tightening torques regarding parts belonging to the relevant
body, transmission, chassis, electrical component groups.
2. Fit new seal between main catalytic converter and primary catalytic converter.
3. Fit main catalytic converter from the front.
4. Tighten three new fastening nuts -2- on the connection between the main catalytic converter
-1- and primary catalytic converter -6- to → Tightening Torque: 23 Nm (17 ft. lb.) .
Fig 2: Tightening Primary Catalytic Converter Nuts
5. Tighten fastening screw -5- on bracket for transmission -4- to → Tightening Torque: 23 Nm
(17 ft. lb.) .
Fig 3: Tightening Screws On Transmission Bracket
inclination and ensure that assembly length of both exhaust pipes is the same. → Installation
position of exhaust clamp → Adjustment value: 10° → Tightening Torque: 33 Nm (24 ft.
lb.)
WM 267319 REMOVING AND INSTALLING CATALYTIC CONVERTER (CAYENNE) >

TOOLS
Engine And Gearbox Workshop

WE 1082
Jack VAG 1383 A Equipment

TECHNICAL VALUES

value 1 2

Replace





Replace

1. Exhaust Manifold, Bank 1
2. Seal Replace
3. Oxygen Sensor Upstream Of Catalytic Converters, Bank 1
4. Catalytic Converter, Bank 1

7. Oxygen Sensor Downstream Of Catalytic Converter, Bank 1
12. Oxygen Sensor Downstream Of Catalytic Converter, Bank 2
14. Catalytic Converter, Bank 2
15. Holder For Catalytic Converter
16. Seal Replace
18. Oxygen Sensor Upstream Of Catalytic Converter, Bank 2
19. Exhaust Manifold, Bank 2

PRELIMINARY WORK

REMOVING CATALYTIC CONVERTER
Risk of squashing
Risk of burns

Information
Please read the most important working regulations and warning notes → The most important
working regulations and warning notes .
Information
Disregard 1 and 2 , as well as the down arrows !
1. Unscrew top screw -arrow- on the exhaust manifold heat shield and remove the heat shield.
Fig 1: Locating Heat Shield On Exhaust Manifold (Similar Illustration)
2. Release and unplug all oxygen sensor connectors. Disconnect and expose the oxygen
sensors lines.
3. Screw off the nuts -arrows- on the threaded joint securing the catalytic converter to the
exhaust manifold.
4. Unscrew fastening screws -arrows- for the catalytic converter on bank 1.

Fig 3: Locating Fastening Screws Of Catalytic Converter (Bank 1)
5. Screw off suspension -1- and -2- . Loosen clamps -arrows- .

Fig 4: Locating Catalytic Converter Suspension And Clamps
6. Support the transmission using Engine And Gearbox Jack VAG 1383 A WE 1082 .
7. Unscrew screws -1- and -2- for the transmission support.

Fig 5: Loosening Transmission Support
Information
Disregard 1 and 2 !
8. Unscrew screws -arrows- and remove transmission support.

Fig 6: Removing Transmission Support
9. Remove front cardan shaft. → 390219 REMOVING AND INSTALLING FRONT CARDAN
SHAFT
10. Unscrew fastening screw -arrow- for the catalytic converter on bank 2.
Fig 7: Locating Mounting Screw Of Catalytic Converter (Bank 2)
11. Remove catalytic converters:
1. 11.1. Remove catalytic converter for bank 2 (top) in a downward direction.
2. 11.2. Remove catalytic converter for bank 1.

INSTALLING CATALYTIC CONVERTER
2. 1.2. Attach all tie-wraps at the same places during installation.

SUBSEQUENT WORK
WM 267619 REMOVING AND INSTALLING PRIMARY CATALYTIC CONVERTER


value 1 2
Fastening Screw On Catalytic Tightening 23 Nm (17

Converter Holder, M8 Torque ft. lb.)
Primary Catalytic Converter To Fastening nut, Tightening 23 Nm (17

Exhaust Manifold M8 Torque ft. lb.)
Fastening Screw On Catalytic Tightening 23 Nm (17

Primary Catalytic Converter To Fastening Nut, Tightening 23 Nm (17

Exhaust Manifold M8 Torque ft. lb.)
Heat Shield To Steering Gear, M6 Tightening 10 Nm (7.5

X 16 Torque ft. lb.)
Coolant Pipes To Transmission
Torque ft. lb.)
Self-Locking Nuts, M8
Torque ft. lb.)

Self-Locking Nuts, M8
Torque ft. lb.)

Heat Shield To Steering Gear, M6 Tightening 10 Nm (7.5

X 16 Torque ft. lb.)

1. Remove engine compartment cover above the oxygen sensor connectors. → 700219
REMOVING AND INSTALLING FRONT COVER (ENGINE COMPARTMENT)
2. Remove main catalytic converter. → 267319 REMOVING AND INSTALLING (MAIN)

CATALYTIC CONVERTER
3. Remove the cardan shaft on the right side (cylinder bank 1 to 4). → 390219 REMOVING AND
INSTALLING FRONT CARDAN SHAFT

(CAYENNE TURBO & CAYENNE TURBO S) > REMOVING PRIMARY CATALYTIC
CONVERTER > REMOVING PRIMARY CATALYTIC CONVERTER ON CYLINDER BANK
1-4
Risk of burns
1. Disconnect the oxygen sensor connector for the oxygen sensor behind the catalytic converter
at the water splash panel (follow cable routing) and unclip the cables from the holder. →
Oxygen sensor connector
2. Expose oxygen sensor cable -1- and route it down to the primary catalytic converter.
Fig 2: Identifying Catalytic Converter On Naturally Aspirated Engine
3. Remove sheetmetal holders for the primary catalytic converter -7, 8, 10- .
Fig 3: Identifying Catalytic Converter Holder And Related Components (Naturally Aspirated
Engine)
1. Exhaust Manifold, Right
2. Exhaust Manifold, Left
3. Seal
4. Nut
5. Primary Catalytic Converter, Left
6. Holder, Left
7. Screw
8. Holder, Right
9. Primary Catalytic Converter, Right
10. Bolts Between Transmission And Engine (Holder)
NOTE: Studs and nuts not loosened correctly
1. Threaded bolts can break off exhaust manifold
→ Replace damaged exhaust manifold.
→ Clean the studs and nuts on the exhaust manifold before loosening them and spray with
anti-rust agent.
→ Loosen nuts carefully. Loosen the nuts by carefully turning them in both directions if they are
very stiff.
→ Heat the threaded joint if necessary.
4. Carefully loosen the flange nuts using a change-over ratchet and several extensions. -2- →
Flange bolts securing primary catalytic converter to exhaust manifold
1 to 5 - Tightening sequence for nuts

Fig 5: Identifying Catalytic Converter To Exhaust Manifold Nut Tightening Sequence
NOTE: Projecting ceramic catalytic converter
1. Risk of damage to ceramic catalytic converter
→ Ensure that your work area is well illuminated.
→ Carefully guide the projecting ceramic catalytic converter past the studs on the exhaust
manifold.
→ Cover and store the ceramic monolith for the primary catalytic converter in a safe place until
you are ready to install it.
→ Protect the ceramic monolith from damage while you are working on the primary catalytic
converter. If there are deep cracks or large chips, replace the primary catalytic converter. Slight
superficial damage will not impair its function.
5. Carefully remove the primary catalytic converter with the help of another worker.
1. Primary Catalytic Converter
2. Ceramic Monolith
3. Exhaust Manifold
4. Seal
5. Studs In Exhaust Manifold

Fig 6: Identifying Ceramic Monolith Installation Position
6. Remove sheetmetal seal -4- . Clean sealing surfaces.

5-8
Risk of burns
1. Disconnect the oxygen sensor connector for the oxygen sensor behind the catalytic converter
at the water splash panel (follow cable routing) and unclip the cables from the holder. →
Oxygen sensor connectors (figure shows cylinders 1 to 4)
2. Expose oxygen sensor cable -1- and route it down to the primary catalytic converter.
Fig 2: Identifying Catalytic Converter - Naturally Aspirated Engine
3. Remove heat shield on the cardan joint of the steering column. -arrows-
Fig 3: Locating Heat Shield On Steering Gear
4. Unscrew two coolant pipe screws on the converter bell housing -arrow- . Loosen the coolant
pipe.
Fig 4: Locating Coolant Pipes On Converter Bell Housing
5. Remove sheetmetal holders for the primary catalytic converter -6, 7, 10- .
Fig 5: Identifying Catalytic Converter Holder Related Components - Naturally Aspirated Engine
3. Seal
4. Nut
6. Holder, Left
7. Screw
8. Holder, Right
NOTE: Studs and nuts not loosened correctly
1. Threaded bolts can break off exhaust manifold
→ Replace damaged exhaust manifold.
→ Clean the studs and nuts on the exhaust manifold before loosening them and spray with
anti-rust agent.
→ Loosen nuts carefully. Loosen the nuts by carefully turning them in both directions if they are
very stiff.
→ Heat the threaded joint if necessary.
6. Carefully loosen the flange nuts using a change-over ratchet and several extensions. -2- →
Flange bolts securing primary catalytic converter to exhaust manifold

Fig 7: Identifying Primary Catalytic Converter To Exhaust Manifold Nut Tightening Sequence
manifold.
7. Carefully remove the primary catalytic converter with the help of another worker.
2. Ceramic Monolith
3. Exhaust Manifold
4. Seal

Fig 8: Identifying Ceramic Monolith Installation Position
8. Remove sheetmetal seal -4- . Clean sealing surfaces.

(CAYENNE TURBO & CAYENNE TURBO S) > INSTALLING PRIMARY CATALYTIC
CONVERTER > INSTALLING PRIMARY CATALYTIC CONVERTER ON CYLINDER
BANK 1-4
1. Ensure sealing faces of exhaust system are clean.
2. Replace flange gasket -4- and slide it over the studs on the exhaust manifold -5- .
2. Ceramic Monolith
3. Exhaust Manifold
4. Seal

Fig 1: Identifying Ceramic Monolith And Flange Gasket
manifold.
3. Carefully move primary catalytic converter into installation position.
4. Fit new fastening nuts between the exhaust manifold and primary catalytic converter, but leave
them loose.
5. Make sure that the sheetmetal holder for the primary catalytic converter fits correctly on the
exhaust manifold after you tighten the nuts -8- .
Fig 2: Identifying Catalytic Converter Holder Related Components (Naturally Aspirated Engine)
1. Exhaust manifold, right
2. Exhaust manifold, left
3. Seal
4. Nut
5. Primary catalytic converter, left
6. Holder, left
7. Screw
8. Holder, right
9. Primary catalytic converter, right
10. Bolts between transmission and engine (holder)
6. Fit fastening screw on catalytic converter holder and nuts to the specified tightening torque and
according to the specified tightening sequence → Flange bolts securing primary catalytic
converter to exhaust manifold → Tightening Torque: 23 Nm (17 ft. lb.) → Tightening
Torque: 23 Nm (17 ft. lb.) . For details of tightening torque for transmission screws, see
Removing and installing transmission or Removing and mounting transmission.

Fig 3: Identifying Primary Catalytic Converter To Exhaust Manifold Flange Nut Tightening
Sequence
WARNING: Cables not fitted or removed correctly
1. Risk of burns
2. Risk of short circuit or fire.
→ Check for correct fitting.
→ Replace damaged components.
7. Lay oxygen sensor cable and clip it in. -1-

8. Plug in the connector for the oxygen sensor behind the catalytic converter at the water splash
panel.

BANK 5-8
1. Ensure sealing faces of exhaust system are clean.
2. Replace flange gasket -4- and slide it over the studs on the exhaust manifold -5- .
2. Ceramic Monolith
3. Exhaust Manifold
4. Seal

Fig 1: Identifying Ceramic Monolith And Flange Gasket
manifold.
3. Carefully move primary catalytic converter into installation position.
4. Fit new fastening nuts between the exhaust manifold and primary catalytic converter, but leave
them loose.
5. Make sure that the sheetmetal holder for the primary catalytic converter fits correctly on the
exhaust manifold after you tighten the nuts -8- .
Fig 2: Identifying Catalytic Converter Holder Related Components - Naturally Aspirated Engine
3. Seal
4. Nut
6. Holder, Left
7. Screw
8. Holder, Right

6. Fit fastening screw on catalytic converter holder and nuts to the specified tightening torque and
according to the specified tightening sequence → Flange bolts securing primary catalytic
converter to exhaust manifold → Tightening Torque: 23 Nm (17 ft. lb.) → Tightening
Torque: 23 Nm (17 ft. lb.) . For details of tightening torque for transmission screws, see
Removing and installing transmission or Removing and mounting transmission.
Fig 3: Identifying Primary Catalytic Converter To Exhaust Manifold Flange Nut Tightening
Sequence
1. Risk of burns

7. Lay oxygen sensor cable and clip it in. -1-
8. Fit heat shield on the cardan joint of the steering column. -arrows- → Tightening Torque: 10
Nm (7.5 ft. lb.)
Fig 5: Locating Heat Shield On Steering Gear
9. Fit coolant pipe on converter bell housing -arrow- . → Tightening Torque: 9 Nm (6.5 ft. lb.)
Fig 6: Locating Coolant Pipes On Converter Bell Housing
10. Plug in the connector for the oxygen sensor behind the catalytic converter at the water splash
panel.

1. Install main catalytic converter. → 267319 REMOVING AND INSTALLING (MAIN) CATALYTIC
CONVERTER
2. Fit the cardan shaft on the right side (cylinder bank 1 to 4). → INSTALLING FRONT CARDAN
SHAFT
3. Fit engine compartment cover above the oxygen sensor connectors. → INSTALLING FRONT
TRIM PANEL (ENGINE COMPARTMENT) - section on "Installing"

(CAYENNE TURBO & CAYENNE TURBO S) > PRELIMINARY WORK > PRELIMINARY
WORK FOR REMOVING PRIMARY CATALYTIC CONVERTER ON CYLINDER BANK 1-4
1. Remove wheel. → REMOVING WHEEL - section on "Removing"

2. Remove engine compartment cover above the oxygen sensor connectors. → REMOVING
3. Remove main catalytic converter. → REMOVING (MAIN) CATALYTIC CONVERTER

(CAYENNE TURBO & CAYENNE TURBO S) > PRELIMINARY WORK > PRELIMINARY
WORK FOR REMOVING PRIMARY CATALYTIC CONVERTER ON CYLINDER BANK 5-8
1. Remove engine compartment cover above the oxygen sensor connectors. → REMOVING
2. Remove main catalytic converter. → REMOVING (MAIN) CATALYTIC CONVERTER - section

on "Removing"

1-4
Risk of burns
Information
Spray all fastening nuts on primary catalytic converter with penetrating oil and allow to work in .
Information
To loosen and tighten fastening nuts on flange of turbocharger, several extensions and joints must
be used .
Good lighting and a mirror make removal and fitting easier at places very difficult to reach .
Fig 1: Identifying Catalytic Converter Holder And Related Components (Turbo Engine)
1. Positioning Lug On Left Side, Viewed In Direction Of Travel
2. Positioning Lug On Right Side, Viewed In Direction Of Travel
3. Turbocharger, Left
4. Seal
5. Nut
7. Screw
8. Sheetmetal Holder (Support)
11. Turbocharger, Right
12. Screw
13. Mounting Point On Crankcase
1. Disconnect the oxygen sensor connectors for the oxygen sensors on the catalytic converter at
the water splash panel (follow cable routing) and unclip the cables from the holders. → Oxygen
sensor connectors (figure shows cylinders 1 to 4)
Fig 2: Identifying Oxygen Sensor Connectors (Cylinders 1 To 4)
2. Route the oxygen sensor cables to the catalytic converter. -1-

Fig 3: Identifying Catalytic Converter On Turbo Engine

3. Screw off side catalytic converter holder at the transmission -3- .
Fig 4: Identifying On Turbo Engine
4. Carefully pull the oxygen sensor cable down.
5. Loosen the five fastening nuts for the turbocharger.

Fig 5: Locating Catalytic Converter To Turbocharger Fastening Nuts
6. Remove primary catalytic converter. To do this, carefully turn and pull the primary catalytic
converter.
7. Remove and replace flange gaskets.

5-8
Risk of burns
Information
Spray all fastening nuts on primary catalytic converter with penetrating oil and allow to work in .
Information
be used .
Fig 1: Identifying Catalytic Converter Holder Related Components (Turbo Engine)
4. Seal
5. Nut
7. Screw
12. Screw
1. Disconnect the oxygen sensor connectors for the oxygen sensors on the catalytic converter at
the water splash panel (follow cable routing) and unclip the cables from the holders. → Oxygen
sensor connectors (figure shows cylinders 1 to 4)
Fig 2: Identifying Oxygen Sensor Connectors (Cylinders 1 To 4)
2. Route the oxygen sensor cables to the catalytic converter. -1-

3. Remove the heat protection shield on the steering gear connection. To do this, loosen the
fastening screws. → Fastening screws securing heat shield to steering gear connection
Fig 4: Locating Fastening Screws Securing Heat Shield To Steering Gear Connection
4. Screw off side catalytic converter holder at the transmission -3- .

5. Loosen the five fastening nuts on the turbocharger.

Fig 6: Locating Turbocharger Fastening Nuts
6. Remove primary catalytic converter. To do this, carefully turn and pull the primary catalytic
converter. Move the steering if necessary and pull the primary catalytic converter past it.
7. Remove and replace flange gasket.

BANK 1-4
Information
be used .
Fig 1: Identifying Catalytic Converter Holder Related Components (Turbo Engine)
4. Seal
5. Nut
7. Screw
12. Screw
1. Replace flange gasket and push over the studs.
2. Place primary catalytic converter on the studs of the turbocharger. To do this, carefully turn and
push the primary catalytic converter into installation position.
Fig 2: Placing Primary Catalytic Converter On Studs Of Turbocharger
3. Fit side catalytic converter holders.
4. Position new self-locking nuts at the connection points of the catalytic converter and tighten to
the specified tightening torque. → Tightening Torque: 23 Nm (17 ft. lb.)
5. Tighten side catalytic converter holders to the specified tightening torque → Tightening
Torque: 23 Nm (17 ft. lb.) . For details of transmission flange screws, see → 373519
REMOVING AND INSTALLING TRANSMISSION
1. Risk of burns
6. Route oxygen sensor cables upwards so that the oxygen sensor cables are not touching the
exhaust manifold or the exhaust system and clip them into position -1- . A useful aid here is a
piece of wire with a hook.
7. Connect the oxygen sensor connectors for the oxygen sensors at the water splash panel and
clip the cables into the holders. → Oxygen sensor connectors (figure shows cylinders 1 to 4)

BANK 5-8
Information
be used .
Fig 1: Identifying Catalytic Converter Holder And Related Components (Turbo Engine)
4. Seal
5. Nut
7. Screw
12. Screw
1. Replace flange gasket and push over the studs of the turbocharger.
2. Position the primary catalytic converter on the bolts on the turbocharger. To do this, carefully
turn and pull the primary catalytic converter. Move the steering if necessary and move the
primary catalytic converter into installation position.
Fig 2: Placing Primary Catalytic Converter On Studs Of Turbocharger
3. Fit side catalytic converter holders.
4. Position new self-locking nuts at the connection points of the catalytic converter and tighten to
the specified tightening torque. → Tightening Torque: 23 Nm (17 ft. lb.)
5. Tighten side catalytic converter holders to the specified tightening torque → Tightening
Torque: 23 Nm (17 ft. lb.) . For details of transmission flange screws, see → 373519
REMOVING AND INSTALLING TRANSMISSION
6. Fit the heat shield on the steering gear connection. To do this, fit the fastening screws. →
Tightening Torque: 10 Nm (7.5 ft. lb.)
Fig 3: Locating Fastening Screws Securing Heat Shield To Steering Gear Connection
1. Risk of burns
7. Route oxygen sensor cables upwards so that the oxygen sensor cables are not touching the
exhaust manifold or the exhaust system and clip them into position -1- . A useful aid here is a
piece of wire with a hook.
8. Connect the oxygen sensor connectors for the oxygen sensors at the water splash panel and
clip the cables into the holders. → Oxygen sensor connectors (figure shows cylinders 1 to 4)

(CAYENNE TURBO & CAYENNE TURBO S) > SUBSEQUENT WORK > SUBSEQUENT
WORK FOR INSTALLING PRIMARY CATALYTIC CONVERTER ON CYLINDER BANK
1-4
1. Install main catalytic converter. → INSTALLING (MAIN) CATALYTIC CONVERTER

(CAYENNE TURBO & CAYENNE TURBO S) > SUBSEQUENT WORK > SUBSEQUENT
WORK FOR INSTALLING PRIMARY CATALYTIC CONVERTER ON CYLINDER BANK
5-8
1. Install main catalytic converter. → INSTALLING (MAIN) CATALYTIC CONVERTER
Porsche Cayenne
Service Manual: 27 - STARTER, POWER SUPPLY, CRUISE CONTROL -- 92A CAYENNE

Tester II 9818 prior to removing the "old" control unit. → 270455 REPLACING VOLTAGE
CONVERTER FOR START/STOP .

COMPARTMENT

(ALL MODELS) > REMOVING VOLTAGE CONVERTER FOR START/STOP
Information

Fig 1: Identifying Voltage Converter For Start/Stop Installation Position
NOTE: Voltage peaks
1. Unscrew and remove fastening screw -1- and fastening nut -2- from the bracket for the
voltage converter.
Fig 2: Removing Voltage Converter From Bracket
2. Remove bracket with voltage converter from the dashboard bracket.
3. Release electric plug connection -3- (-a- ) and unplug it from the voltage converter.

(ALL MODELS) > INSTALLING VOLTAGE CONVERTER FOR START/STOP
Information
1. Plug electric plug connection -3- into the voltage converter and lock it -a- .
2. Position bracket with voltage converter on the dashboard bracket.
3. Secure voltage converter for Start/Stop to the dashboard bracket using the fastening screw -1-
and fastening nut -2- .
Fig 2: Installing Bracket Fasteners


COMPARTMENT
PIWIS Tester II 9818 . → 270455 REPLACING VOLTAGE CONVERTER FOR START/STOP .

MODELS) > TOOLS



MODELS) > READING AND WRITING VALUES
NOTE: Voltage drop
battery.
Information
Tester releases.
3. Select the Gateway control unit in the overview and press [F12] to continue.
4. Select the DC/DC converter control unit.
9. Check the chassis number.
VOLTAGE CONVERTER FOR START/STOP .
11. Switch on ignition, select Maintenance/repairs , Control unit replacement , Write data and
press [F12] to continue. Then press [F8] to start.
The data that was read out is loaded.
12. The System Tester displays the message: Data has been written , press [F12] to continue.

TECHNICAL VALUES
Tolerance Tolerance
1 2
Terminal clamp to battery Tightening 6 Nm (4.5 ft.

terminal Torque lb.)
Ground line for battery to Tightening 20 Nm (15 ft.

body Torque lb.)

PRELIMINARY WORK
1. Remove battery cover. → ________271219 Removing and installing battery cover

REMOVING BATTERY SENSOR
Information
Information
The battery sensor and battery ground strap form one unit and can only be replaced together.
2. Release electric plug connection on the battery sensor and disconnect it -arrow- .
3. Disconnect ground line for battery. → 270619 REMOVING AND INSTALLING BATTERY
4. Open the service flap in the driver's footwell.
5. Unscrew fastening nut -1- and guide battery sensor with ground line -2- through the opening
-arrow- in the battery box.
6. Remove battery sensor with ground line -2- .
Fig 2: Locating Battery Sensor With Ground Line

INSTALLING BATTERY SENSOR
Information
After replacing the battery sensor, the battery sensor will be detected automatically by the gateway
control unit.
2. Tighten fastening nut securing ground line to the body. Tightening Torque 20 Nm (15 ft. lb.)
3. Tighten terminal clamp on ground line. Tightening Torque 6 Nm (4.5 ft. lb.)
4. Check that the rubber sleeve is seated correctly in the opening of the battery box.

SUBSEQUENT WORK
WM 270619 REMOVING AND INSTALLING BATTERY (ALL MODELS) > TECHNICAL

VALUES

value 1 2
Terminal clamp to battery terminal
Torque ft. lb.)
Fastening screw securing battery in Tightening 23 Nm (17

battery housing Torque ft. lb.)
Fastening screw securing retaining Tightening 8 Nm (6 ft.

bracket to battery housing Torque lb.)
WM 270619 REMOVING AND INSTALLING BATTERY (ALL MODELS) > PRELIMINARY

WORK
1. Remove battery cover. → 271219 REMOVING AND INSTALLING BATTERY COVER
WM 270619 REMOVING AND INSTALLING BATTERY (ALL MODELS) > REMOVING

BATTERY
necessary.
Battery can explode
Information
Fig 1: Identifying Battery Installation Position
Information
1. Release and disconnect electric plug connection at the battery sensor.

2. Risk of short circuit! First disconnect the negative cable, then the positive cable.
Fig 3: Disconnecting Cables
3. Unscrew the fastening screw -1- on the sheetmetal bracket and remove the battery mount.
4. Unscrew the screw for the battery mount -2- and remove the battery mount.
5. Pull the vent hose -3- off the battery.

Fig 4: Removing Battery Mount
6. Lift the battery up and out.
WM 270619 REMOVING AND INSTALLING BATTERY (ALL MODELS) > INSTALLING

BATTERY
Danger of injury
Loss of torque
Information
Make sure that the two ends of the vent hose are routed and inserted correctly .
1. The battery is installed in reverse order to removal.
2. Fit battery mount and secure with the fastening screw. Tightening Torque 23 Nm (17 ft. lb.)
3. Fit sheetmetal bracket and secure with the fastening screw. Tightening Torque 8 Nm (6 ft.
lb.)
4. Risk of short circuit! First connect the positive cable, then the negative cable. Tighten fastening
nuts. Tightening Torque 6 Nm (4.5 ft. lb.)
WM 270619 REMOVING AND INSTALLING BATTERY (ALL MODELS) > SUBSEQUENT

WORK
WM 270655 REPLACING BATTERY (ALL MODELS) > PRELIMINARY WORK
1. Remove and install battery. → 270619 REMOVING AND INSTALLING BATTERY
WM 270655 REPLACING BATTERY (ALL MODELS) > REPLACING AGM BATTERY
Information
The AGM (A bsorbent G lass M at) battery is a Maintenance-Free , Sealed battery.
This battery must not be opened. If the battery is opened, it must be replaced .
There is a Serial Number -A- and a Part Number -B- on the top right-hand side of the battery .
Fig 1: Identifying Serial Number And Part Number On Battery
3. Select the Gateway control unit in the Overview and press [F12] to continue.
4. Maintenance/Repairs must then be selected.
5. Change Battery must now be selected. Then press [F12] to continue.
6. Enter The Serial Number And Part Number and press [F12] to continue.
7. Enter the battery size and manufacturer and press [F12] to continue.
WM 270655 REPLACING BATTERY (ALL MODELS) > SUBSEQUENT WORK
WM 2706IN EXTERNAL POWER CONNECTION, JUMP-LEAD STARTING (ALL
MODELS) > INFORMATION
Information
If the battery is flat, jump leads can be used together with the battery of another vehicle to start the
car or to supply external power to the vehicle .
Both batteries must be 12 V batteries.
The capacity (Ah) of the battery supplying the power must not be significantly lower than that of the flat
battery.
WARNING: Live jump leads
Risk of electric shock
Risk of short circuit
→ Route the jump leads so that they do not become entangled in moving parts in the engine
compartment.
→ There must be no contact between the vehicles.
The flat battery must be properly connected to the vehicle electrical system.
1. Remove cover for jump-lead starting terminal.
2. Open protective cover on the positive terminal for jump-lead starting -+- .
Fig 1: Identifying Jump-Lead Starting Terminals
3. Connect the positive cable to the positive terminal for jump-lead starting -+- , then to the
positive terminal of the donor battery.
4. Connect the negative cable to the negative terminal of the donor battery first, then to the
ground point for jump-lead starting - .
5. Have the engine of the vehicle supplying the power run at a higher speed.
6. Start engine. Do not spend longer than 15 seconds trying to start the vehicle with the jump
leads - after 15 seconds have elapsed, wait for at least one minute.
7. Disconnect the two jump leads in reverse sequence when the engine is running.
8. Close protective cover.
9. Position the cover.
WM 270819 REMOVING AND INSTALLING E-BOX (CAYENNE S E-HYBRID) > TOOLS


TECHNICAL VALUES

value 1 2
Tightening 10.1 Nm
E-Box To High-Voltage Battery

Tightening 10.1 Nm
Side Cover Plate To High-Voltage
Battery

Tightening 10.1 Nm
Battery
Fastening screws (M6 x 12) securing Tightening 10.1 Nm

top cover plate to high-voltage battery Torque (7.5 ft. lb.)

Torque ft. lb.)
Battery
Fastening Nuts Securing High-Voltage Tightening 5.9 Nm

Battery Control Unit To E-Box Torque (4.5 ft. lb.)
Fastening nuts securing cover for

Tightening 5.9 Nm
high-voltage battery control unit to
E-box
Fuse
Torque ft. lb.)
Fastening screws securing fuse carrier Tightening 10.1 Nm

cover to high-voltage battery Torque (7.5 ft. lb.)

PRELIMINARY WORK

"Removing"

workstation.

REMOVING E-BOX
Information
Information
If the E-box for the high-voltage system Cannot Be Removed because the screw heads or rivet nuts
are damaged, for example, proceed as follows:
Stop working on the high-voltage battery immediately .
Information
If the Cover On The Fuse Carrier for the high-voltage battery Cannot Be Removed because the
screw heads or rivet nuts are damaged, for example, proceed as follows:
Stop working on the high-voltage battery Immediately .

Fig 1: Identifying Fuse Carrier Cover Screws
Information
voltage.
Fig 2: Checking Absence Of Electric Charge
Information
Information
2. 3.2. Remove cap -1- together with fuse -2- .

3. 3.3. Unclip cap -1- from the fuse and re-insert it on the high-voltage battery to
protect exposed high-voltage contacts.
Fig 4: Installing Battery Cap
4. Remove high-voltage battery control unit.
1. 4.1. Loosen fastening nuts -1, 2- on the cover of the high-voltage battery control unit
and remove cover -3- .
2. 4.2. Remove spacers under the fastening nuts -1- .

Fig 5: Identifying Cover For High-Voltage Battery Control Unit
3. 4.3. Remove ground line -1- from the fastening bolt.

4. 4.4. Loosen fastening nuts -1- on the high-voltage battery control unit and pull off
high-voltage battery control unit -2- .
5. 4.5. Release electric plug connection -1- at the high-voltage battery control unit
completely -arrows a- and disconnect it -arrow A- .
6. 4.6. Release electric plug connection -2- completely -arrow b- and disconnect it
-arrow B- .
7. 4.7. Remove high-voltage battery control unit.
Information
environmental conditions and depending on the service life of the vehicle.
follows:
turn -arrow a- .
easily.
Information
5. Remove top cover plate on the high-voltage battery
2. 5.2. Loosen fastening screws -1, 2- as described above.

Do not remove top cover plate on the high-voltage battery.

Information
.

as follows:
Information

as follows:
sealed.
6. Clean threaded bores -1- for the fastening points for the top cover plate as described above
Using An M6 X 1.0 Tap With Spiral Grooves .
Information
Carefully remove the top cover plate to prevent damage to the E-box wiring harness.
1. 6.1. Carefully lift up the top cover plate on the high-voltage battery and remove it.
Information
1. Stop Working On the high-voltage battery Immediately .
2. To find out what to do next, get in touch with your contact person at your importer's
Technical Competence Centre (TCC) .
7. Check seal on front cover plate and if it is damaged, replace the front cover plate.
1. 7.1. Loosen fastening screws (M6 x 12) -1- as described above.

Fig 17: Removing Front Cover Plate
2. 7.2. Carefully remove front cover plate on the high-voltage battery by pulling it to the
side.
3. 7.3. Clean the threaded bores -1- for the fastening points for the side cover plate as
described above Using An M6 X 1.0 Tap With Spiral Grooves .
8. Remove E-box.
1. 8.1. Loosen tie-wrap -1- on HV line.

Fig 19: Disconnecting HV Line
2. 8.2. Remove wiring harness -1- by pulling it up out of the guide -arrows- .
3. 8.3. Loosen fastening screws -1- for the E-box as described above.
4. 8.4. Carefully pull the E-box straight off the high-voltage battery and make sure not to
tilt the E-box when pulling it off the guide pins -1- .
5. 8.5. Cover exposed terminals on the high-voltage battery -arrows- with adhesive
tape immediately after removing the E-box.
Fig 23: Identifying Battery Terminals
Information

as follows:
sealed.
9. Clean the threaded bores on the upper bar of the high-voltage battery as described above.
1. M8 Through-Bore
2. M8 Blind Hole Bore
3. M6 Through-Bore
4. Fabric Adhesive Tape
1. 9.1. Clean the threaded bores for the fastening points of the top cover plate -1, 2-
using An M8 X 1.25 Tap With Spiral Grooves .
2. 9.2. Clean the threaded bore for the upper fastening points of the E-box -3- using an
M6 X 1.0 Tap With Spiral Grooves .
10. Clean the threaded bores for the fastening points -1- of the E-box as described above.
Fig 27: Cleaning Threaded Bores

INSTALLING E-BOX
Information
Information
When fitting the cover, check that the E-box wiring harness is positioned correctly and is not squashed.
Information
1. Install E-box.
1. 1.1. Remove adhesive tape from the battery terminals -arrows- .

Fig 1: Locating Battery Terminals
2. 1.2. Push E-box onto the guide pins -1- , making sure not to tilt the E-box and
position it flat on the high-voltage battery.
3. 1.3. Screw in and tighten fastening screws -1- on the E-box. → Tightening Torque:
10.1 Nm (7.5 ft. lb.)
4. 1.4. Position the wiring harness -1- at the top of the guide -arrows- and make sure
that the seal -2- is fitted correctly.
Fig 4: Positioning Wiring Harness
5. 1.5. Connect electric plug connection -1- on the E-box -A- until it engages securely.
Check that the wiring harness is routed behind the plug connection -1- as shown.
6. 1.6. Fasten tie-wrap -1- on HV line.

Fig 6: Locating HV Line
Information
When fitting the cover, check that the E-box wiring harness is positioned correctly and is not
squashed.
Information
The high-voltage battery cover must not be re-used and must be replaced by a new cover. The
new cover is supplied without warning signs. These must be ordered separately and affixed on
the cover.
2. Install cover plates on the high-voltage battery.
1. 2.1. Position side cover plate carefully on the high-voltage battery.
lb.)
Fig 7: Identifying Side Cover Plate Screws
3. 2.3. Carefully position top cover plate on the high-voltage battery.
lb.)
Tighten fastening screws (M6 x 12) -2- . → Tightening Torque: 10.1 Nm (7.5 ft.
lb.)
5. 2.5. Tighten fastening screws (M8 x 16) -1- . → Tightening Torque: 13 Nm (9.5 ft.
lb.)
3. Install high-voltage battery control unit.
1. 3.1. Connect electric plug connection -2- on the high-voltage battery control unit -b-
and lock it -B- .
2. 3.2. Connect electric plug connection -1- (-a- ) and lock it -A- .
3. 3.3. Position control unit -2- on the E-box and tighten fastening nuts -1- . →
Tightening Torque: 5.9 Nm (4.5 ft. lb.)
4. 3.4. Push ground line -1- onto the fastening bolts.

5. 3.5. Position spacers on the bolts under fastening nuts -2- .
6. 3.6. Position cover on high-voltage battery control unit -3- and tighten fastening nuts
-1, 2- . → Tightening Torque: 5.9 Nm (4.5 ft. lb.)
4. Remove cap -1- .

5. Verify absence of electric charge at the exposed high-voltage contacts of the high-voltage
battery using a suitable voltage tester at contact points -A, B- .

The measurement also prevents voltages due to the build-up of static charge.
Information
(7.5 ft. lb.)
Information
8. Affix warning signs to the high-voltage battery.

Fig 18: Identifying Warning Sign Stickers

SUBSEQUENT WORK

"Installing"

TOOLS


PRELIMINARY WORK
3. Remove high-voltage battery. → INSTALLING HIGH-VOLTAGE BATTERY - section on

"Removing"
4. Set up a High-Voltage Cordon WE 1589 around the high-voltage workstation.


REMOVING FUSE AT E-BOX
Information
1. Open retaining clip -A- and carefully pull the fuse up and out -B- .

INSTALLING FUSE AT E-BOX

Information
Before installing the fuse, the seal must be checked for damage. If the seal is damaged, the fuse must
be replaced.
1. Carefully insert fuse -A- and lock it with the retaining clip -B- . Check that the retaining clip
locks correctly.
2. Check that the fuse is positioned correctly and fitted securely.

Fig 1: Installing Fuse

SUBSEQUENT WORK

"Installing"

E-HYBRID) > TOOLS
Workshop Crane Workshop

WE 1188
VAS 6100 Equipment
Workshop
Equipment

guide rod Special tool 9860/2


value 1 2
Fastening bracket securing Tightening 23 Nm (17

high-voltage battery to body Torque ft. lb.)
Electric potential line to Tightening 17 Nm (13

high-voltage battery Torque ft. lb.)
Electric potential to body
Torque ft. lb.)
HV line from power Tightening 7 Nm (5 ft.

electronics to battery Torque lb.)
Mounting for cover for HV Lens-head screw Tightening 23 Nm (17

battery (micro-self-locking) Torque ft. lb.)


2. Carry out classification of high-voltage battery. → 2X00IN CLASSIFICATION OF


6. Remove side trim panel for rear luggage compartment. → REMOVING SIDE TRIM PANEL
FOR REAR LUGGAGE COMPARTMENT - section on "Removing"

E-HYBRID) > REMOVING HIGH-VOLTAGE BATTERY
Information
1. Release and pull off breather hoses for the cooling system -6- .
Fig 2: Disconnecting Breather Hoses
2. Release and disconnect high-voltage line for on-board charger -1- from the high-voltage
battery -3- .
3. Unscrew and disconnect high-voltage lines for the power electronics unit -2- from the
high-voltage battery -3- .
4. Electric plug connections for the hybrid or drive CAN -4- must be removed -a - from the
bracket and then released -b - and disconnected -c- .
5. Open cable duct -5- and remove high-voltage lines.
6. Unclip and remove cable duct -5- .

Fig 5: Removing Cable Duct
7. Remove equipotential bonding line -7- .
1. 7.1. Loosen fastening screw for equipotential bonding line at the body -9- .
2. 7.2. Loosen fastening screw for equipotential bonding line at the high-voltage battery
-8- .
3. 7.3. Remove equipotential bonding line.

Information
not be re-used.
8. Unscrew fastening bracket for high-voltage battery -12- and screw in Guide Rod 9860/2 -10-
.
1. 8.1. First loosen the outer fastening screws.
2. 8.2. Guide Rod 9860/2 must then be screwed into the outer thread.
3. 8.3. Loosen inner fastening screws -11- .

Fig 7: Identifying Fastening Bracket
Information
Procedure for loosening micro-self-locking screws .
environmental influences and depending on the service life of the vehicle.
follows:
turn -arrow a- .
easily.
9. Unscrew and remove center fastening screws -13- from the high-voltage battery in order to fit
the adapter plates.
Fig 10: Identifying Adapter Plates
Information
Depending on the workshop crane used, lifting tackle may have to be attached first and then
secured to the adapter plates.
Information
Before removing the high-voltage battery, have a table or trolley and two plastic or rubber
blocks ready for lowering the high-voltage battery. The high-voltage battery must not be
lowered onto the floor to prevent damage to the water drains on the underside of the
Information
When lifting out the battery, it is a good idea to get another person to guide the battery on the
crane.
Fig 12: Lifting Vehicle Battery
13. Lift up the high-voltage battery and get another person to pull it towards the rear and lift it
carefully out of the luggage compartment pan.
Information
The battery must not be left hanging on the crane for a long time.
14. Lift the high-voltage battery up further, push the workshop crane forward slightly and turn it 90
degrees as soon as possible and guide the high-voltage battery out of the vehicle.
Fig 13: Lifting Out High-Voltage Battery
15. Lower the high-voltage battery onto the blocks on the prepared table or trolley.
16. Drain the cooling system completely using compressed air set to max. 2.5 bar .
Information
Close off/mask high-voltage connections on the high-voltage battery using suitable stoppers or
adhesive tape to prevent dirt and fluids from getting in.
17. Disconnect cooling lines -19- for the high-voltage battery -3- at the bayonet lock.
Fig 15: Disconnecting Cooling Line From Battery
18. Fit cooling system stoppers on cooling system connections on the old high-voltage battery and
secure with adhesive tape.

E-HYBRID) > INSTALLING HIGH-VOLTAGE BATTERY
Information
The contact surfaces of the equipotential bonding line must be checked prior to installation.
Information
When connecting or screwing the high-voltage lines to the high-voltage battery connections, carefully
check the plug contacts and make sure that they are connected properly.
The connector pins on conventional plug connections must be checked before connecting them and the
plug connections must be inserted carefully.
Information
Check seal on connector for high-voltage lines for the power electronics unit before installation and
replace it if necessary
Information
Remove stoppers or adhesive tape from the high-voltage connection for the high-voltage battery and
check for dirt and fluid leaking in.
Information
Only a high-voltage battery designed specifically for the Cayenne S E-Hybrid may be used. High-voltage
batteries from other model lines (e.g. Panamera S E-Hybrid) must not be installed.
Information
When inserting the high-voltage battery into the vehicle, make sure that no lines or connectors are
trapped by the battery.
1. Guide Rods 9860/2 -1- must then be screwed into the outer thread.
Fig 1: Identifying Guide Rods
2. Clean the thread if you have not already done so.
Information
.

When cleaning the threaded bores (M6) on the high-voltage battery, always proceed as
follows:
Fig 4: Identifying Adapter Plate
6. Carefully lift the high-voltage battery into the vehicle with the help of another person.
Fig 6: Positioning High-Voltage Battery
7. Guide high-voltage battery -6- fully into the luggage compartment, turn it 90 degrees as soon
as possible and position outer thread of the fastening brackets for the high-voltage battery over
the luggage compartment pan onto the Guide Rods 9860/2 .
8. Get another person to guide the outer thread of the fastening brackets for the high-voltage
battery -7- into all the Guide Rods 9860/2 -1- . Carefully lower the high-voltage battery into
the luggage compartment pan.
Fig 7: Lowering High-Voltage Battery Into Vehicle
Information
re-used.
9. Tighten fastening brackets for high-voltage battery. Tightening Torque 23 Nm (17 ft. lb.)
1. 9.1. Always screw in the inner fastening screws first.
2. 9.2. Guide Rod 9860/2 must be loosened from the outer threads.
3. 9.3. Tighten outer fastening screws.
Information
not be re-used.
10. Loosen fastening screws for the high-voltage battery and remove adapter plate together with
the lifting tackle. Screw fastening screws into the open threaded bores. Tightening Torque 23
Nm (17 ft. lb.)
11. Connect cooling system hoses and secure with hose clamps.
12. Install equipotential bonding line -8- .
1. 12.1. Secure equipotential bonding line -8- to the high-voltage battery -6- .
2. 12.2. Secure equipotential bonding line -8- to the body -9- . Tightening Torque 9
Nm (6.5 ft. lb.)
Fig 8: Securing Equipotential Bonding Line
13. Connect breather hoses for the cooling system and secure with hose clamps.
14. Fit cable duct, insert high-voltage lines and close the cable duct.
15. Plug in electric plug connections for the hybrid or drive CAN until they engage securely.
16. Insert electric plug connections into the bracket.
17. Plug in high-voltage lines for the power electronics unit -10- and secure with fastening screws.
18. Plug in high-voltage line for the on-board charger until it engages securely.
Fig 9: Fitting High-Voltage Lines

1. Install cover for rear lock support. → REMOVING COVER FOR REAR LOCK SUPPORT -
2. Install side trim panel for rear luggage compartment. → REMOVING SIDE TRIM PANEL FOR
REAR LUGGAGE COMPARTMENT - section on "Removing"

(INCLUDES BLEEDING)


Fuse Tightening Torque 10 Nm (7.5 ft. lb.)
Fuse carrier cover Tightening Torque 10.1 Nm (7.5 ft. lb.)


"Removing"

workstation.

(CAYENNE S E-HYBRID) > REMOVING HIGH-VOLTAGE BATTERY FUSE
Information
Information
The covers on the high-voltage batteries are secured using fastening screws with high-strength screw
locking agent. However, these can be difficult to loosen as a result of certain environmental conditions
and depending on the service life of the vehicle.
To avoid breaking off or damaging fastening screws, always loosen the fastening screws as follows:
1. Mark the fastening screw using a felt-tip pen and carefully loosen it by half (1/2) a turn -arrow
a- .
3. Repeat Steps 1 and 2 at least five times (5x) until the loosening torque of the fastening screw
is reduced significantly. The fastening screw can then be turned easily.
4. After Step 3, the torque should be much lower so that the fastening screw can be loosened
completely -arrow c- .

Information
If the Cover On The Fuse Carrier for the high-voltage system Cannot Be Removed
because the screw heads or rivet nuts are damaged, for example, proceed as follows:
Information
voltage.
Information
Information
2. 3.2. Carefully remove cap -1- together with fuse -2- .

Information

as follows:
sealed.
4. Clean the screw threads of the fastening points as described above Using An M6 X 1.0 Tap
With Spiral Grooves .
5. Unclip cap -1- from fuse and insert it on the high-voltage battery again.

(CAYENNE S E-HYBRID) > INSTALLING HIGH-VOLTAGE BATTERY FUSE
Information
Fastening screws for the fuse and fuse carrier cover must not be re-used and must be replaced with new
fastening screws.
1. Remove cap.
2. Verify absence of electric charge at the open terminals of the high-voltage battery fuse using a
suitable voltage tester at contact points -A, B- .

Information
Information
Check seal on fuse carrier cover for damage. The cover must not be re-used if damaged and
must be replaced.
(7.5 ft. lb.) .


"Installing"

TOOLS

WE 1593
Set Equipment
Lifting Tackle VW Tool 3033

TECHNICAL VALUES

value 1 2
Fastening bracket to Lens-head screw (micro- 23 Nm (17

Contact force
high-voltage battery self-locking) ft. lb.)
Mounting For Cover For Lens-Head Screw Tightening 23 Nm (17

HV Battery (Micro-Self-Locking) Torque ft. lb.)
Mounting For Hollow Tightening 10 Nm (7.5

M6 x 14
Section To Battery Torque ft. lb.)

REPLACING HIGH-VOLTAGE BATTERY

"Removing"
2. Remove lifting tackle Lifting tackle 3033 and adapter plates Adapter Plate 9860 from the
3. Drain the cooling system completely using compressed air set to max. 2.5 Bar .

4. Remove the two coolant lines for the high-voltage battery and fit them on the new high-voltage
battery. Check that the lines are fitted and sealed correctly.
5. Fit suitable cooling system caps (from the new high-voltage battery) on the cooling system
connections -1- and high-voltage connections of the old high-voltage battery and secure with
adhesive tape.
Fig 2: Identifying Cooling System Connections
Information
re-used.
6. Unscrew fastening brackets -1- from the removed high-voltage battery and fit them on the new
high-voltage battery -2- . Contact Force 23 Nm (17 ft. lb.)
Fig 3: Identifying Fastening Brackets
7. Unscrew hollow section -1- from the removed high-voltage battery and fit it on the new
high-voltage battery -2- . Tightening Torque 10 Nm (7.5 ft. lb.)
Fig 4: Identifying Hollow Section
Information
8. Affix warning signs to the new high-voltage battery.

Fig 5: Warning Sign Stickers
9. Fit lifting tackle Lifting Tackle 3033 and adapter plates Adapter Plate 9860 on the

"Installing"
Information
not be re-used.
11. Screw fastening screws -1- into the high-voltage battery. Tightening Torque 23 Nm (17 ft.
lb.)
Fig 6: Identifying Screw Fastening Screws
12. Screw grub screws -1- into the center bores.

Fig 7: Identifying Grub Screws

S E-HYBRID) > TOOLS
Workshop Workshop
WE 1188
Crane Equipment
Lifting Tackle VW tool 3033

S E-HYBRID) > PRELIMINARY WORK

"Removing"

S E-HYBRID) > PACKING HIGH-VOLTAGE BATTERY IN TRANSPORT BOX
Information
Always wear safety gloves when packing the high-voltage battery.
1. Prepare the transport box -1- .
1. 1.1. Prepare cut pieces from honeycomb board. Set consists of two cover and floor
elements and six side elements
1. 1.1.1. Remove cover element -2- .
2. 1.1.2. Remove side elements -3- .
3. 1.1.3. Leave floor element -4- fitted.

Fig 1: Identifying Transport Box, Cover Element And Side Elements
2. 1.2. Remove large plastic bag from the upright box.
3. 1.3. Remove desiccant -2- from the upright box.
4. 1.4. Remove Vermiculite bag -1- from the upright box.

Fig 2: Identifying Vermiculite And Desiccant
→ Always drain the high-voltage battery cooling lines completely before

transporting/handling the high-voltage battery.
2. Drain the cooling system completely when it is outside of the vehicle using compressed air set
to max. 2.5 bar .
Information
Cooling line connections must be closed off to prevent fluid from leaking out during transport.
Coolant leaks and the resulting damage to the high-voltage battery can mean that repairs to
the high-voltage battery can no longer be carried out in certain cases.
3. Fit supplied cooling system caps on cooling system connections -1- and secure with adhesive
tape.
Fig 4: Identifying Cooling System Caps
4. Position adapter plates -1- Adapter Plate 9860 on the high-voltage battery and use fastening
screws -2- to fit them on the high-voltage battery.
Fig 5: Identifying Adapter Plates Screws
5. Fit lifting tackle -1- Lifting Tackle 3033 on the adapter plates -2- .
Fig 6: Identifying Lifting Tackle (3033)
Information
Set the workshop crane Workshop Crane WE 1188 to the fourth detent (500 kg).
6. Workshop Crane WE 1188 must be engaged in the lifting tackle Lifting Tackle 3033 . Then
lift it carefully at the center.
7. Centre transport box lengthways with respect to the workshop crane.
8. Place two honeycomb boards -1- at the short side of the box -x1- .
Information
Make sure not to damage the honeycomb boards when positioning the high-voltage battery.
9. Wrap a large plastic bag around the high-voltage battery and lower it until it is flush with the
two positioned honeycomb boards so that four honeycomb boards -x2- can be positioned at
the opposite side of the box.
Fig 7: Wrapping High-Voltage Battery
10. Remove workshop crane Workshop Crane WE 1188 with lifting tackle Lifting Tackle 3033
from the high-voltage battery.
11. Loosen and remove adapter plates Adapter Plate 9860 from the high-voltage battery.
Information
The threads in the high-voltage battery without fastening screws can remain open.
12. Insert the remaining four honeycomb boards -2- at the opposite side of the box for the
high-voltage battery E-box.
Information
If the remaining honeycomb boards cannot be inserted without damaging them, the
high-voltage battery must be lifted up again and re-aligned.
Fig 8: Identifying Honeycomb Boards
13. Centre the desiccant In the large plastic bag on the long sides of the box.
14. Fold over the large plastic bag and seal with commercially available adhesive tape.
Information
A large plastic bag must be wrapped around the sides. The fold of the bag must be centered
on the long side of the box.
15. Place Vermiculite bag diagonally in the corners of the box.
16. Fit honeycomb board cover element -1- on the high-voltage battery.
Fig 9: Identifying Honeycomb Board Cover Element
17. Place a copy of the test log -1- for classification of lithium-ion high-voltage batteries in the box.
Fig 10: Identifying Test Log
18. Fit cover on the box and seal with the supplied clips.
1. 18.1. Push in clips -A- and check that they engage correctly -B- .
Fig 11: Pushing Clips On Box
19. Affix labels -1, 2, 3, 4- to the transport box.
1. 19.1. Affix "Hazardous goods class 9" label -1- to one long side of the box.
2. 19.2. Affix "UN 3480, lithium-ion batteries" label -2- to one long side of the box to the
right of label -1- .
3. 19.3. Affix document bag -3- to one long side of the box to the right of label -2- .
4. 19.4. Affix "Item number" label -4- to one long side of the box to the right of label -3-
.
Fig 12: Identifying Transport Box Labels
20. Complete accompanying documentation and place it in the document bag together with
another copy of the test log for classification of lithium-ion high-voltage batteries.
Information
The original test log for classification of lithium-ion high-voltage batteries must be kept in the
Porsche Centre.
21. Affix "Item number" label -2- to one short side of the box.
Fig 13: Identifying Transport Box Item Number Label

TECHNICAL VALUES
Air vent to battery cover Tightening Torque 2 Nm (1.5 ft. lb.)

PRELIMINARY WORK
1. Loosen the left front seat and tilt it to the rear with lines connected. → 720119 REMOVING

REMOVING AND INSTALLING BATTERY COVER
necessary.
Battery can explode
Information
Fig 1: Identifying Battery Position
Information
1. When removing the carpeted floor for the first time, cut along the perforation using a carpet
knife.
2. Unscrew screw -1- and remove air guide -2- .
3. Open the tension hooks -arrows- on the battery cover -3- using a suitable tool.
4. Remove battery cover -3- .

Fig 2: Removing Battery Cover
5. The battery cover -3- is installed in reverse order to removal.
6. Tighten screw -1- . Tightening Torque 2 Nm (1.5 ft. lb.)

SUBSEQUENT WORK
1. Install left front seat. → 720119 REMOVING AND INSTALLING FRONT SEAT
WM 272219 REMOVING AND INSTALLING GENERATOR (CAYENNE) > TECHNICAL

VALUES
Tolerance Tolerance
1 2
Fastening screw securing Tightening 20 Nm (15

generator to engine, M8 Torque ft. lb.)

B+ line to generator, M8
Torque lb.)
WM 272219 REMOVING AND INSTALLING GENERATOR (CAYENNE) > PRELIMINARY
WORK
1. Before the generator can be removed, the battery must be disconnected and the terminal
covered. → DISCONNECTING THE BATTERY
2. Remove air box for throttle housing (intake manifold). → REMOVING AIR BOX FOR
3. Remove air cleaner housing lid. → 242455 REPLACING AIR-CLEANER ELEMENT
WM 272219 REMOVING AND INSTALLING GENERATOR (CAYENNE) > REMOVING

GENERATOR
1. Release the connector -1- and unplug it -arrow A- (-arrow B- ).
2. Screw off fastening nut -2- and pull off the B+ line -3- (-arrow C- ).
Fig 2: Disconnecting Electric Connections On Generator
3. Unscrew fastening screws -3- and remove the generator to the side -arrow- . Press the
generator out of the bracket using a lever if necessary.
4. Lift generator up and out. Press the upper cooling water hose aside if necessary.
WM 272219 REMOVING AND INSTALLING GENERATOR (CAYENNE) > INSTALLING

GENERATOR
Information
Before installing the new generator, tap the threaded bushes -1- out by approx. 4 mm .
Fig 1: Identifying Generator Bushes
1. Insert the generator -3- from above.
-arrows 3- .. → Tightening Torque: 20 Nm (15 ft. lb.)
3. Connect the B+ line -3- to the generator -arrow A- and secure with the fastening nut -2- . →
4. Plug in connector -1- (-arrow B- ) until it engages securely.

Fig 3: Securing Electric Connections On Generator
WM 272219 REMOVING AND INSTALLING GENERATOR (CAYENNE) > SUBSEQUENT

WORK
1. Install the belt tensioner. → INSTALLING BELT TENSIONER - section on "Installing"
2. Install air cleaner housing lid. → 242455 REPLACING AIR-CLEANER ELEMENT
3. Install air box for throttle housing (intake manifold). → INSTALLING AIR BOX FOR THROTTLE
4. Connect the battery and carry out the work instructions. → CONNECTING THE BATTERY

Tolerance
2
Tightening 45 Nm (33 ft. +8 Nm (+6 ft.

Fastening screw for starter
Torque lb.) lb.)
Fastening nut securing B+ line Tightening 18 Nm (13 ft.
to starter Torque lb.)
Fastening nut securing terminal Tightening 10 Nm (7.5

50 line to starter Torque ft. lb.)

1. Disconnect the battery → DISCONNECTING THE BATTERY .
2. Remove intake-air distributor. → REMOVING INTAKE-AIR DISTRIBUTOR
3. Remove vacuum reservoir. → REMOVING VACUUM RESERVOIR

CAYENNE S) > REMOVING STARTER
Fig 1: Identifying Installation Position Of Starter
1. Loosen screws on the rear cable guide. → Rear cable guide

Fig 2: Locating Rear Cable Guide
2. Screw off fastening nuts -1 and 2- on the electric connections at the starter.
3. Remove electric connections -3 and 4- (-arrow- ).

Fig 3: Fastening Nuts On Electric Connections At Starter
4. Unscrew and remove fastening screws -2- on the cable duct.
5. Disconnect connectors for injectors -1- on cylinder bank 1.

Fig 4: Identifying Cable Duct And Connectors For Injectors
6. Release connector on the rear knock sensor for cylinder bank 1 -1- and disconnect it.
Fig 5: Identifying Cable Plug For Knock Sensor
7. Carefully hold the cable duct to one side.
8. Unscrew and remove fastening screws -1- on the starter.

9. Remove starter.

CAYENNE S) > INSTALLING STARTER
Information

Fig 1: Identifying Starter Installation Position
1. The starter is installed in reverse order to removal.
1. 1.1. Fastening nut securing terminal 50 to starter Tightening Torque 10 Nm (7.5 ft.
lb.)
2. 1.2. Fastening screws for starter Tightening Torque 45 Nm (33 ft. lb.) +8 Nm (+6 ft.
lb.)
3. 1.3. Fastening nut securing B+ line to starter Tightening Torque 18 Nm (13 ft. lb.)


DISTRIBUTOR

S, CAYENNE TURBO & CAYENNE TURBO S) > TECHNICAL VALUES
Basic Tolerance
value 2
Fastening screw securing starter Tightening 45 Nm (33 +8 Nm (+6 ft.

to engine housing Torque ft. lb.) lb.)
Fastening nut for B+ line
Torque ft. lb.)
Tightening 6.5 Nm (5 ft.

Fastening nut for electric line
Torque lb.)


BATTERY .
2. Remove fuel distributor pipe. → REMOVING FUEL DISTRIBUTOR PIPE (FUEL RAIL) -

S, CAYENNE TURBO & CAYENNE TURBO S) > REMOVING STARTER
Fig 1: Installation Position Of Starter
NOTE: Voltage peaks
1. Undo electric change-over valve.
1. 1.1. Pull electric change-over valve -1- off the holder -arrow- and set it aside with
the lines connected.
Fig 2: Removing Electric Change-Over Valve
2. Unscrew fastening nuts -2 and 3- on the starter and remove lines -4 and 5- (-arrow- ).
Fig 3: Removing Fastening Nuts On Starter

4. Remove the starter.
1. 4.1. Pull starter -7- towards the front in direction of travel -arrow A- and lift it up
-arrow B- .
2. 4.2. Remove line -8- (-arrow C- ).
3. 4.3. Lift the starter -7- up and remove it -arrow D- .


S, CAYENNE TURBO & CAYENNE TURBO S) > INSTALLING STARTER
1. Install the starter.
1. 1.1. Insert the starter -7- from above -arrow A- .
2. 1.2. Fit line -8- (-arrow B- ).
3. 1.3. Lower the starter -7- (-arrow C- ) and slide it into the engine housing -arrow
D- .
Fig 1: Installing Starter
2. Secure the starter with the fastening screws -6- and tighten to → Tightening Torque: 45 Nm
(33 ft. lb.) +8 Nm (+6 ft. lb.) .
Fig 2: Identifying Starter Fastening Screws
3. Position lines -4 and 5- on the starter -arrow- and secure with the fastening nuts -2 and 3- .
→ Tightening Torque: 18 Nm (13 ft. lb.) , → Tightening Torque: 6.5 Nm (5 ft. lb.)
Fig 3: Securing Electric Lines To Starter
4. Push electric change-over valve -1- onto the holder -arrow- .

Fig 4: Securing Electric Change-Over Valve

1. Install fuel distributor pipe. → INSTALLING FUEL DISTRIBUTOR PIPE (FUEL RAIL) - section
on "Installing".
WM 276019 REMOVING AND INSTALLING STARTER (VR6) (CAYENNE) > TECHNICAL

VALUES

value 1 2
Fastening screw securing starter on Tightening 75 Nm (56

-6-
the transmission side, M12 Torque ft. lb.)
Fastening screw securing starter to Tightening 75 Nm (56

-8-
engine block, M12 Torque ft. lb.)
Fastening nut on solenoid switch, M6
Torque lb.)
Fastening nut for B+ line, M8 -1-
Torque ft. lb.)

PRELIMINARY WORK
1. Disconnect battery. → REMOVING BATTERY - section on "Removing"; → DISCONNECTING

THE BATTERY
WM 276019 REMOVING AND INSTALLING STARTER (VR6) (CAYENNE) > REMOVING

STARTER
WARNING: Working on the vehicle electrical system
Risk of burns
→ Disconnect the battery.
→ Prevent battery from reconnecting.
→ Cover the battery.
→ Remove ground terminal and cover the terminals.
→ Route electric lines without tensile strength.
→ Secure electric lines to existing lines/components.

Fig 1: Overview Of Starter
1. Open the press-studs -arrow- and remove the heat protection cover on the solenoid switch.
Fig 2: Identifying Press Studs For Heat Insulation Cover
2. Pull off protection cap -A- .
3. Screw off the fastening nut -1- and remove the line from the threaded bolt -B- .
4. Pull off protection cap -3- (-C- ).
5. Screw off the fastening nut -2- and remove the line from the threaded bolt -C- .
Fig 3: Disconnecting Lines On Starter
6. Unscrew the fastening screw -3- and pull line bracket away in a downward direction -A- .
8. Screw off the fastening nuts -5- and remove the holder -B- . To do this, turn the holder slightly
if necessary.
9. Unscrew the fastening screw -6- on the transmission side of the starter.
Fig 5: Fastening Screw For Starter
11. Unscrew the lower fastening screw -8- on the starter.
12. Pull the line carefully downwards -A- and remove the starter -B- . Turn the starter if
necessary.
WM 276019 REMOVING AND INSTALLING STARTER (VR6) (CAYENNE) > INSTALLING

STARTER
Information
Before installing the starter, check the smooth operation of the thread for securing the starter.
Threads that do not open/close smoothly must be repaired before installing the starter .
1. Pull the line carefully downwards -A- and insert the starter -B- . Turn the starter if necessary
-C- .
Fig 1: Inserting Starter
2. Lift the starter forwards and screw in fastening screw -8- but do not tighten it.
3. Screw in the fastening screw -6- on the transmission side and tighten the two fastening
screws on the starter. → Tightening Torque: 75 Nm (56 ft. lb.) , → Tightening Torque: 75
Nm (56 ft. lb.)
Fig 2: Identifying Fastening Screw For Starter
4. Insert the holder -A- and screw on the fastening nuts -5- , but do not tighten them.
5. Screw in and tighten the fastening screw -4- , then tighten the fastening nuts -5- .
6. Place the protective tube in installation position -B- and secure with the fastening screw -3- .
7. Connect the line to the threaded bolt -A- and secure with the fastening nut -2- . → Tightening
8. Fit protection cap -3- (-A- ).
9. Connect the line to the B+ connection -B- and secure with the fastening nut -1- . →
10. Fit protection cap on the B+ connection -C- .
Fig 4: Securing Lines On Starter
11. Place heat protection cover around solenoid switch -A- and secure with the press-studs -B- .
Fig 5: Pressing Studs For Heat Insulation Cover
12. Secure the line with the fastening screw -7- .

Fig 6: Screwing Down Line

SUBSEQUENT WORK
2. Connect the battery. → INSTALLING BATTERY - section on "Installing"; → CONNECTING

THE BATTERY

MODELS) > TOOLS

Wheel Alignment
Workshop
System ML 5000 WE 1272
Equipment
Porsche
Axle Alignment System

Workshop
With DSP508XF WE 1328
Equipment
Sensors
Adjustment Device
Workshop
With Reflector VAS WE 1362
Equipment
6430/1
Mirror For Adjustment Workshop
WE 1363
Device VAS 6430/3 Equipment
T-socket wrench for

Workshop
ACC sensor VAS WE 1364
Equipment
6190/2

The distance measuring sensor must be re-adjusted as part of the following tasks
1. Suspension was aligned and adjusted.
2. The distance measuring sensor (ACC sensor) control unit and/or the control unit holder was
removed, replaced and re-installed.
3. The lock carrier was loosened.
4. The front end is damaged.
5. Fault memory entry: ACC sensor incorrectly adjusted (D00004).
1. 5.1. The misalignment angle is outside of the range -1.5° to +1.5°.

MODELS) > PRELIMINARY WORK > TEST PREREQUISITES
1. The tread depth on one axle must not differ by more than 2 mm.
2. Air pressure of tires in accordance with regulations (regardless of "Comfort" or "Normal" air
pressure).
3. As with complete suspension alignment, make sure that there is no sliding base or turnplate at
the end stop during alignment.
1. 3.1. Take the track width and wheel base into consideration.
4. Check that vehicle weight corresponds to empty weight. Weight of the vehicle ready for driving
(completely full fuel tank and water tank for the windscreen washer/headlight cleaning system,
spare wheel, tool kit, jack) without driver.
5. Spare wheel, tool kit, jack must be located at the positions specified by the vehicle
manufacturer.
6. Vehicle aligned correctly, having been bounced and allowed to settle multiple times.
7. Check wheel suspension, steering and steering linkage for play and damage.
1. 7.1. Carry out repairs if necessary.
3. 8.3. Unlock vehicle, open door and leave open during measurement, switch on
ignition.

MODELS) > PRELIMINARY WORK > DESIGN OF MEASURING SYSTEM
Information
Check that there is sufficient floor space between the vehicle and the adjustment device - the gap
between the adjustment device and vehicle must be approx. 120 cm.
The vehicle can be reversed onto the axle alignment platform if there is not enough floor space in front
of the measuring platform.
The vehicle must be positioned so that the front and rear axles are centered on turnplates/sliding plates.
Information
The procedure described here is for the wheel alignment system ML 5000 Porsche WE 1272 and the
axle alignment system with DSP508XF sensors WE 1328 .
Deviations can occur with other alignment systems.
1. Fit instrument holders onto the wheels on the rear axle.
2. Fit the rear sensors on the rear axle using the spoiler adapter (Beissbarth only, this sets the
sensors to a lower position).
3. Align the rear sensors on the rear axle using the spirit level and clamp the instrument holders
using the wing screws.
Information
longer be moved.
allowing the vehicle to be moved slightly .
repeated .
4. Attach front sensors to the measuring mirror, align using the spirit level and clamp.
1. 4.1. Centre the adjustment tool.
2. 4.2. Set distance of adjustment tool and vehicle in accordance with the specifications
provided by the measuring equipment manufacturer.
the distance between the right sensor and the vehicle -Br- .
5. Switch on (initialize) the sensors.

MODELS) > PRELIMINARY WORK > PREPARATION FOR ADJUSTING DISTANCE
MEASURING SENSOR
1. Connect a battery charger with a current rating of at least 40 A to the external power feed
points.
2. Read out the fault memory using PIWIS Tester II 9818 , create a VAL if necessary → 0X03IN
CREATING VEHICLE ANALYSIS LOG (VAL) and correct any faults.
Fig 1: Identifying Diagnostic Socket

3. 3.3. Unlock vehicle, open door and leave open during the measurement, switch on
ignition.

5. Clean sensor and cover using a commercially available cleaning agent.
6. Fit the front sensors onto the adjustment device, align using spirit levels and clamp using the
wing screws, and switch them on (initialize).
7. The gap between the ACC adjustment device adjustment device with reflector VAS 6430/1
WE 1362 and the vehicle must be approx. 120 cm.
1. 7.1. Position the ACC adjustment device adjustment device with reflector VAS
6430/1 WE 1362 at a distance of 130 +/- 10 cm between the sensor lens and
mirror face mirror for adjustment device VAS 6430/3 WE 1363 .
the distance between the right spirit level and the vehicle -Br- .
8. On the adjustment device, move the mirror into position -2- so that it is aligned with the
marking (-A- number 2 on the rotary knob must point towards the vehicle).
Fig 4: Positioning Adjustment Device
Information
longer be moved.
allowing the vehicle to be moved .
repeated .
9. Release turnplates/sliding plates on One Side Of The Vehicle .
10. Open the corresponding menu (Use Operating Instructions For Measuring Platform) in
order to adjust the distance measuring sensor.
11. Before starting the adjustment process, use the laser beam -3- at the mirror on the adjustment
device (for switching on the laser beam >> see operating instructions for adjustment device) to
check that the laser beam strikes the sensor lens. Info:
1. 11.1. The adjustment device is aligned (positioned) correctly if the laser beam still
strikes the sensor lens even after the identical individual toe values have been set.
2. 11.2. If the laser beam does not strike the sensor lens, alignment of the adjustment
device must be repeated.
Fig 5: Identifying Laser Beam At Mirror
12. Align adjustment device at the side:
1. 12.1. The laser beam of the adjustment device must strike the center of the sensor
lens.
Fig 6: Aligning Adjustment Device
13. Use the adjusting screws -1, 2, 3, 4, 5- on the adjustment device to level the mirror's spirit
levels -A, B- .
Fig 7: Aligning Mirror's Spirit Levels
14. Use the crank -arrow- on the adjustment device to adjust the mirror so that the laser beam
(for switching on the laser beam >> see operating instructions for adjustment device) strikes
the center of the sensor lens on the vertical line.
Fig 8: Example Of Adjustment Bar Display
15. Turn the adjustment bar on the adjustment device to the side using the adjusting screw -5-
until the green indicator on the adjustment bar is displayed on the measuring platform screen.
Fig 9: Example Of Hunter Display

MODELS) > ADJUSTING CONTROL UNIT FOR DISTANCE MEASURING SENSOR
1. A battery charger with a current rating of at least 40 A must be connected to the external
power feed points.
2. Connect PIWIS Tester II 9818 to the vehicle and start it.
4. Select the required vehicle and select Adaptive Cruise Control control unit, then press [F12]
to continue.
5. In the Adaptive Cruise Control menu, select the Maintenance/Repairs submenu and press
[F12] to continue.
6. Follow the instructions on the Tester and, if necessary, adjust the sensor -1- using the
adjusting tool T-Socket Wrench For ACC Sensor VAS 6190/2 WE 1364 in line with the
Tester specifications.
Fig 1: Adjusting Screws For Distance Measuring Sensor
7. The process must be repeated until the message Adjustment Successful is displayed on the
Tester.


2. PIWIS Tester II 9818 can now be disconnected from the vehicle.
3. Disconnect the battery charger.
4. Remove sensors and instrument holders.
Information
following points:
5. Install cover on sensor and clip it in at the top -arrows- .

6. Perform a test drive and check operation of distance measuring sensor control unit.
7. Read out the fault memory of the distance measuring sensor (ACC) control unit and erase it if
necessary.

MEASURING SENSOR (ALL MODELS) > TECHNICAL VALUES

value 1 2
Holder for distance measuring

Internal Torx Tightening 8 Nm (6
sensor control unit to closing
screw, M6 x 12 Torque ft. lb.)
panel

MEASURING SENSOR (ALL MODELS) > REMOVING CONTROL UNIT FOR DISTANCE
MEASURING SENSOR


3. Release electric plug connection -arrow a- and disconnect it -arrow b- .

4. Unclip electric wire harness from holder for distance measuring sensor control unit.

Fig 3: Identifying Sensor Control Unit Screws
6. Remove holder together with control unit for distance measuring sensor.

MEASURING SENSOR (ALL MODELS) > INSTALLING CONTROL UNIT FOR
DISTANCE MEASURING SENSOR
Information
following points:
Tighten fastening screws. Tightening Torque 8 Nm (6 ft. lb.)

MEASURING SENSOR (ALL MODELS) > SUBSEQUENT WORK > SUBSEQUENT
WORK AFTER REMOVING AND INSTALLING CONTROL UNIT FOR DISTANCE
MEASURING SENSOR
If the distance measuring sensor control unit was removed and installed or replaced, the distance
measuring sensor control unit will need to be re-adjusted on a measuring platform using adjustment tool
VAS 6430 . → 278515 ADJUSTING CONTROL UNIT FOR DISTANCE MEASURING SENSOR .


(ALL MODELS) > TECHNICAL VALUES

(ALL MODELS) > READING AND WRITING VALUES
NOTE: Voltage drop
battery.
Information
Tester releases.
4. Select Adaptive cruise control control unit in the overview .
CONTROL UNIT FOR DISTANCE MEASURING SENSOR

(HYBRID MODULE) (CAYENNE S HYBRID) > PRELIMINARY WORK
1. Observe warning notes. → WM 2X00IN GENERAL WARNING NOTES FOR WORKING ON

THE HIGH-VOLTAGE VEHICLE ELECTRICAL SYSTEM (CAYENNE S E-HYBRID)

"Removing".

(HYBRID MODULE) (CAYENNE S HYBRID) > REMOVING ELECTRIC MOTOR WITH

(HYBRID MODULE) (CAYENNE S HYBRID) > INSTALLING ELECTRIC MOTOR WITH

(HYBRID MODULE) (CAYENNE S HYBRID) > SUBSEQUENT WORK

HIGH-VOLTAGE SYSTEM (CAYENNE S E-HYBRID) > TOOLS

HIGH-VOLTAGE SYSTEM (CAYENNE S E-HYBRID) > TECHNICAL VALUES
value 1 2
Cover on power electronics unit
Torque lb.)
Media shield to power electronics Tightening 7 Nm (5 ft.

unit Torque lb.)
Fuse for power electronics unit to Tightening 2 Nm (1.5

power electronics unit Torque ft. lb.)

HIGH-VOLTAGE SYSTEM (CAYENNE S E-HYBRID) > INFORMATION
Information
Further steps may only be carried out if the voltage measured at the power electronics is < 5 V. If this is
not the case, stop working on the system and contact Technical Support.
Fig 1: Identifying Power Electronics Unit Installation Position

HIGH-VOLTAGE SYSTEM (CAYENNE S E-HYBRID) > PRELIMINARY WORK
3. Disconnect the battery. → 978509 LOOSENING AND SECURING GROUND STRAP FOR
BATTERY

HIGH-VOLTAGE SYSTEM (CAYENNE S E-HYBRID) > REMOVING FUSE FOR POWER
ELECTRONICS UNIT
1. Unclip clips for high-voltage line at the media shield.

Fig 1: Identifying Media Shield Screws
3. Release and disconnect high-voltage connector for air-conditioning compressor
2. 3.2. Release 2: Press black knob -b- and pull it off -B-
4. Check that power electronics unit for high-voltage system -1- is de-energized.
Information
Further steps may only be carried out if the voltage measured at the power electronics is < 5 V.
If this is not the case, stop working on the system and contact Technical Support.
Fig 3: Identifying High-Voltage System
5. Unscrew cover on power electronics unit -1- .

Fig 4: Identifying Power Electronics Unit Cover
6. Loosen fastening screws -1- on fuse for power electronics for the high-voltage system -2- and
remove fuse.

HIGH-VOLTAGE SYSTEM (CAYENNE S E-HYBRID) > INSTALLING FUSE FOR POWER
ELECTRONICS UNIT
1. Position fuse for power electronics unit for high-voltage system -2- and tighten fastening
screws -1- . Tightening Torque 2 Nm (1.5 ft. lb.)
Information
As soon as the cover on the power electronics unit is removed, it must be replaced by a new
cover for safety reasons.
2. Fit and secure cover on power electronics unit -1- . Tightening Torque 7 Nm (5 ft. lb.)
Fig 2: Installing Power Electronics Unit Cover
3. Plug in high-voltage connector for air-conditioning compressor at the power electronics unit
Information
Check that the HV connector is locked correctly. The hook (red) must be locked after
connecting the HV connector.
4. Fit and secure media protective plate. Tightening Torque 7 Nm (5 ft. lb.)
5. Clip high-voltage lines onto media protective plate.

HIGH-VOLTAGE SYSTEM (CAYENNE S E-HYBRID) > SUBSEQUENT WORK
COMPARTMENT)
3. Connect the battery. → 978509 LOOSENING AND SECURING GROUND STRAP FOR
BATTERY


WE 1593
Set Equipment


(CAYENNE S E-HYBRID) > TEACHING POWER ELECTRONICS
NOTE: Voltage drop
battery.
Information
Tester releases.
Information
by the vehicle.
1. Switch off ignition and replace power electronics unit. → 279119 REMOVING AND
2. Connect the PIWIS Tester to the vehicle and start the diagnostic application. Switch on ignition.
5. Vehicle must now be selected. Then press [F12] to continue. Vehicle data will be read out.
if necessary.
11. Follow the instructions on the Tester and perform the teaching process.
12. Once the teaching process is completed successfully, the Tester shows the components that
were taught and the overall status of the vehicle, for example: Taught . Press [F12] to
continue.
13. Press [EXIT] To End The On-Line Teaching Function and select the Vehicle Type on the
Start page.
14. Select the High-Voltage Power Electronics control unit in the Overview .
15. Select the Codings/Adaptations menu and carry out the Automatic Coding function in
accordance with the instructions on the Tester.
transmitters).

> PRELIMINARY WORK

"Removing".

> REMOVING ELECTRIC MOTOR

> INSTALLING ELECTRIC MOTOR

> SUBSEQUENT WORK

(HYBRID MODULE) (CAYENNE S E-HYBRID) > TOOLS
Insulated Tool Set Workshop equipment WE 1593

(HYBRID MODULE) (CAYENNE S E-HYBRID) > PRELIMINARY WORK
4. Unscrew transmission from the engine. → REMOVING AUTOMATIC TRANSMISSION

(HYBRID MODULE) (CAYENNE S E-HYBRID) > REMOVING ELECTRIC MOTOR WITH

(HYBRID MODULE) (CAYENNE S E-HYBRID) > INSTALLING ELECTRIC MOTOR WITH

(HYBRID MODULE) (CAYENNE S E-HYBRID) > SUBSEQUENT WORK
1. Install transmission on engine. → 373519 REMOVING AND INSTALLING AUTOMATIC

TRANSMISSION .
3. Read about how to calibrate the electric motor in "Guided Fault Finding" and the latest
Technical Information releases for special tasks to be performed after servicing and repair
work.

> TOOLS

> PRELIMINARY WORK

> REMOVING HIGH-VOLTAGE LINE BETWEEN HIGH-VOLTAGE CHARGER AND
HIGH-VOLTAGE BATTERY > REMOVING HIGH-VOLTAGE LINE
1. Release high-voltage connector -1- from the high-voltage battery -2- and disconnect it.
2. Open cable duct -3- and remove right high-voltage line -4- .
Fig 2: Disconnecting High-Voltage Line
3. Unclipping high-voltage line
4. Release high-voltage connector -1- from the high-voltage charger -2- and disconnect it.
Fig 3: Disconnecting High-Voltage Connector From High-Voltage Charger

> INSTALLING HIGH-VOLTAGE LINE BETWEEN HIGH-VOLTAGE CHARGER AND

> SUBSEQUENT WORK
1. Install cover for rear lock support. → INSTALLING COVER FOR REAR LOCK SUPPORT -

FRONT (CAYENNE S E-HYBRID) > TOOLS

FRONT (CAYENNE S E-HYBRID) > TECHNICAL VALUES
Tolerance Tolerance
1 2



FRONT (CAYENNE S E-HYBRID) > PRELIMINARY WORK
CENTER UNDERBODY .
7. Remove front wheel housing liner at the left. → 505619 REMOVING AND INSTALLING
8. Remove power electronics for high-voltage system. → 279119 REMOVING AND INSTALLING
POWER ELECTRONICS FOR HIGH-VOLTAGE SYSTEM

FRONT (CAYENNE S E-HYBRID) > REMOVING HIGH-VOLTAGE LINE FROM BATTERY
TO POWER ELECTRONICS
1. Release and disconnect high-voltage connector from auxiliary heater (front PTC) -1- .
3. Unscrew coolant line -3- .
4. Cut tie-wraps -4- and unscrew fastening screw for cable guides -5- .
5. Guide high-voltage line down through the gap opening on the heat shield -6- .
Fig 2: Disconnecting High-Voltage Line From Front PTC
downward direction.
Fig 3: Removing High-Voltage Line Cover
7. Unscrew universal joint at the steering column and set it aside. → 481519 REMOVING AND
INSTALLING STEERING COLUMN

11. Unclip the high-voltage lines from the corrugated tube holder -1- (left door sill area, rear).
1. 12.1. Unscrew coolant lines -1- and set them aside.

Fig 7: Removing Coolant Lines
2. 12.2. Unclip high-voltage line from battery to high-voltage charger -1 - .
3. 12.3. Unclip high-voltage line from power electronics to high-voltage charger -6- .
remove it.
5. 12.5. Open the cable duct -4- .
6. 12.6. Release and disconnect high-voltage connector for high-voltage line for
on-board charger -7- .
7. 12.7. Unscrew high-voltage lines from the battery -5- .
body floor (luggage compartment area) down through the body floor -A- .
9. 12.9. Pull out the high-voltage lines in a downward direction -B- .


FRONT (CAYENNE S E-HYBRID) > INSTALLING HIGH-VOLTAGE LINE FROM
BATTERY TO POWER ELECTRONICS
Information
compartment.
1. 1.1. Push the high-voltage lines down through the opening in the luggage
compartment floor -A- .
2. 1.2. Coat the rubber sleeve with sliding compound and press it onto the body until
the rubber sleeve is positioned correctly.
cover -3- and secure with the three fastening nuts -2- . → Tightening Torque: 9
Nm (6.5 ft. lb.) .
4. 1.4. Plug high-voltage lines into the high-voltage battery -5- and secure them. →
270819 REMOVING AND INSTALLING HIGH-VOLTAGE BATTERY
5. 1.5. Plug in high-voltage line for the high-voltage charger -7- until it engages
securely.
6. 1.6. Place high-voltage lines in the cable duct -4- and fit cable duct.
7. 1.7. Clip in high-voltage line from battery to high-voltage charger -1- .
8. 1.8. Clip in high-voltage line from power electronics to high-voltage charger -6- .
9. 1.9. Screw on coolant line -1- .

Fig 2: Identifying Coolant Line Screws

4. Install the high-voltage lines using the two fixing clips -1- (left door sill area, rear).
5. Clip the high-voltage lines into the two corrugated tube holders -1- (left door sill area, center).

6. Secure universal joint to the steering column. → 481519 REMOVING AND INSTALLING
STEERING COLUMN
2. 7.2. Secure the high-voltage line and cover using three tie-wraps -arrow- .
Fig 6: Installing High-Voltage Line Cover
8. Fit high-voltage line through the gap opening on the heat shield -6- into the wheel housing.
9. Secure cable guides using tie-wraps -4- and tighten fastening screw on the cable guides -5- .
11. Plug in high-voltage connector for auxiliary heater (front PTC) -1- until it engages securely.
12. Screw on coolant line -3- .

Fig 7: Securing High-Voltage Line For Front PTC
Information
connector holder.

FRONT (CAYENNE S E-HYBRID) > SUBSEQUENT WORK
1. Install fuel tank. Install the left running board on the fuel tank and fit the two restraining straps
at the front left. → INSTALLING FUEL TANK - section on "Installing".
CENTRE UNDERBODY .
7. Install front wheel housing liner at the left. → 505619 REMOVING AND INSTALLING FRONT
WHEEL HOUSING LINER
8. Install left front wheel.

TOOLS

PRELIMINARY WORK

1. Unclip high-voltage line.

Fig 2: Identifying Media Shield
3. Release high-voltage connector at the power electronics unit and disconnect it.
2. 3.2. Release 2: Press black knob -b- and pull it off -B Removing
4. Release high-voltage line at the air-conditioning compressor and disconnect it.
5. Carefully remove high-voltage line.


SUBSEQUENT WORK

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S E-HYBRID) > TOOLS

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S E-HYBRID) > TECHNICAL
VALUES

value 1 2


Fastening nut -2-


ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S E-HYBRID) > PRELIMINARY
WORK

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S E-HYBRID) > REMOVING
REMOVING HIGH-VOLTAGE LINE
Information
Use new seals.
Use new screws.
1. Unscrew and remove the four fastening screws -1- for the cover. Then lift up the cover and
swivel it to one side.
2. Unscrew and remove the three fastening nuts -2- for the high-voltage line contacts.
3. Unscrew and remove the fastening screws -3- for the high-voltage lines on the electric motor.
motor.

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S E-HYBRID) > INSTALLING
Information
Use new seals.
Use new screws.
Information

Information
(6 ft. lb.) .
Fig 4: Fitting Electric Motor Cover

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S E-HYBRID) > SUBSEQUENT
WORK
1. Install engine. → INSTALLING V6 HYBRID ENGINE - section on "Installing".

POWER ELECTRONICS (CAYENNE S HYBRID) > TECHNICAL VALUES
Tolerance Tolerance
1 2


POWER ELECTRONICS (CAYENNE S HYBRID) > PRELIMINARY WORK
CENTRE UNDERBODY .
6. Empty the fuel tank. → 200317 DRAINING AND FILLING FUEL .
7. Remove fuel tank. → REMOVING FUEL TANK - section on "Removing".
9. Remove left wheel housing liner.

POWER ELECTRONICS (CAYENNE S HYBRID) > REMOVING HIGH-VOLTAGE LINE
Fig 1: Overview Of High-Voltage Line
1. Disengage the holder -arrow- for the two high-voltage lines at the power electronics.
Fig 2: Disengaging High-Voltage Lines From Power Electronics
downward direction.
Fig 3: Removing High-Voltage Line In Engine Area

Fig 4: Removing High-Voltage Line In Centre Area
6. Unclip the two high-voltage lines from the corrugated tube holder -2- (left door sill area, rear).
remove it.
body floor (luggage compartment area) down through the body floor -2- .
3. 7.3. Pull out the high-voltage lines in a downward direction -3- .

Fig 7: Removing High-Voltage Line In Luggage Compartment Area

POWER ELECTRONICS (CAYENNE S HYBRID) > INSTALLING HIGH-VOLTAGE LINE
Information
compartment.
1. 1.1. Slide the high-voltage lines down through the opening on the luggage
compartment floor -2- .
2. 1.2. Coat the rubber sleeve with sliding compound and press it onto the body -1-
until the rubber sleeve is positioned correctly.
cover -3- and secure it with the three fastening nuts -4- . → Tightening Torque: 9
Nm (6.5 ft. lb.) .
Fig 1: Installing High-Voltage Line In Luggage Compartment Area
1. 2.1. Close the corrugated tube holder.

Fig 2: Installing High-Voltage Lines Into Corrugated Tubes
4. Install the two high-voltage lines with the two fixing clips -3- (left door sill area, rear).
Fig 3: Installing High-Voltage Line In Rear Area
5. Clip the two high-voltage lines into the two corrugated tube holders -2- (left door sill area,
center).
1. 5.1. Close the corrugated tube holders.

Fig 4: Installing High-Voltage Line In Centre Area
2. 6.2. Secure the high-voltage line and cover with three tie-wraps -arrow- .
Fig 5: Installing High-Voltage Line In Engine Area
7. Secure high-voltage lines to the power electronics with the holding claw.
Fig 6: Locating High-Voltage Lines To Power Electronics
Information
connector holder.

POWER ELECTRONICS (CAYENNE S HYBRID) > SUBSEQUENT WORK
1. Install the fuel tank. Install the left running board on the fuel tank and fit the two restraining
straps at the front left. → INSTALLING FUEL TANK - section on "Installing".
CENTRE UNDERBODY .

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S HYBRID) > TECHNICAL VALUES

value 1 2


Fastening nut -2-


ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S HYBRID) > PRELIMINARY WORK

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S HYBRID) > REMOVING
Information
Use new seals.
Use new screws.
1. Unscrew the four fastening screws -1- for the cover. Then lift up the cover and swivel it to one
side.
Fig 1: Removing Electric Motor Cover
2. Unscrew the three fastening nuts -2- for the high-voltage line contacts.
3. Unscrew the fastening screws -3- for the high-voltage lines on the electric motor
motor.

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S HYBRID) > INSTALLING
INSTALLING HIGH-VOLTAGE LINE ON POWER ELECTRONICS FOR ELECTRIC
MOTOR
Information
Use new seals.
Use new screws.
Information

Information
(6 ft. lb.) .
Fig 4: Installing Motor Cover

ELECTRONICS TO ELECTRIC MOTOR (CAYENNE S HYBRID) > SUBSEQUENT WORK
1. Install the engine. → INSTALLING V6 HYBRID ENGINE - section on "Installing".

PRELIMINARY WORK
2. The high-voltage system must be isolated from the power supply. Isolate the high-voltage
system from the power supply and complete the relevant documentation. → 2X00IN
Information
The high-voltage lines and connector holder at the power electronics are color-coded
1. Release the high-voltage line -1- at the power electronics (rapid-action coupling) and unplug it.
2. Release the high-voltage line from the power electronics to the air-conditioning compressor
Fig 2: Removing High-Voltage Line From Air-Conditioning Compressor
3. Take the high-voltage line from the power electronics to the air-conditioning compressor out of

Information
The plug connection and connector holder must be checked for wear and damage before connecting the
high-voltage lines.
The high-voltage lines are color-coded and must only be connected to the color-coded connector holder.
The high-voltage lines can only be connected at one position. Check the connection position before
connecting the lines.
1. Plug in the high-voltage line from the power electronics to the air-conditioning compressor
(rapid-action coupling) until the connector engages securely.
Fig 1: Connecting High-Voltage Line To Air-Conditioning Compressor
Replacing high-voltage line
Information
When replacing the high-voltage line, the cable must be routed differently because it now has a
different length and an additional tie-wrap holder must be fitted.
3. Plug in the high-voltage line from the power electronics to the air-conditioning compressor at
the air-conditioning compressor -2- (quick connector) until the connector engages securely.
4. Secure the high-voltage line to the line from the air-conditioning compressor with a tie-wrap
-3- .
Fig 3: Replacing High-Voltage Line

SUBSEQUENT WORK

High-Voltage Workshop
WE 1589
Cordon Equipment
Workshop
Equipment

Tolerance Tolerance
1 2
Tightening 5.9 Nm (4.5 ft.

HV battery control unit
Torque lb.)
Cover for HV battery control Tightening 5.9 Nm (4.5 ft.

unit Torque lb.)

1. If a new control unit has to be installed, the values must be read out using PIWIS Tester II
9818 before removing the "old" control unit. → 279455 REPLACING CONTROL UNIT FOR
HV BATTERY

"Removing"
5. Remove high-voltage battery fuse. → REMOVING HIGH-VOLTAGE BATTERY FUSE - section

on "Removing"

(CAYENNE S E-HYBRID) > REMOVING HIGH-VOLTAGE BATTERY CONTROL UNIT

Information
Fig 1: Caution For Restricted Area For Battery
1. Loosen fastening nuts -1, 2- on the cover of the HV battery control unit and remove cover -3-
.
Fig 2: Identifying HV Battery Control Unit Cover
2. Remove spacers under the fastening nuts -1- .
3. Remove ground line.

Fig 3: Removing Ground Line
4. Loosen fastening nuts -1- on the HV battery control unit and pull off HV battery control unit -2-
.
Fig 4: Removing Control Unit For HV Battery
5. Release electric plug connection -1- at the HV battery control unit completely -a- and
disconnect it -A- .
6. Release electric plug connection -2- completely -b- and disconnect it -B- .
7. Remove control unit for HV battery.
8. Clean screw thread at the fastening points carefully with a vacuum cleaner. Make sure that no
dirt gets into the battery housing. Only use a vacuum cleaner with a plastic nozzle.

(CAYENNE S E-HYBRID) > INSTALLING HIGH-VOLTAGE BATTERY CONTROL UNIT
Information
Information
1. Connect electric plug connection -2- on the HV battery control unit -b- and lock it -B- .
2. Connect electric plug connection -2- (-a- ) and lock it -A- .

3. Push control unit -2- onto the E-box and tighten fastening nuts -1- to → Tightening Torque:
5.9 Nm (4.5 ft. lb.) .
Fig 2: Identifying Control Unit For HV Battery
4. Position spacers on the bolts under fastening nuts -2- .
5. Position cover for HV battery control unit -3- and tighten fastening nuts -1, 2- to →
Tightening Torque: 5.9 Nm (4.5 ft. lb.) .
Fig 3: Identifying Cover For HV Battery Control Unit

1. Install high-voltage battery fuse. → INSTALLING HIGH-VOLTAGE BATTERY FUSE - section

on "Installing"

"Installing"
PIWIS Tester II 9818 . → 279455 REPLACING CONTROL UNIT FOR HV BATTERY

(CAYENNE S HYBRID) > TOOLS

TORX Screwdriver Workshop
WE 1382
Set VAS 6633 Equipment

(CAYENNE S HYBRID) > PRELIMINARY WORK
Tester II 9818 prior to removing the "old" control unit. → 279455 REPLACING BATTERY
MANAGEMENT SYSTEM CONTROL UNIT .
4. Remove the high-voltage battery. → REMOVING HIGH-VOLTAGE BATTERY - section on

"Removing"

(CAYENNE S HYBRID) > REMOVING CONTROL UNIT FOR HV BATTERY
Fig 1: Identifying Control Unit For HV Battery Installation Position
1. Unscrew the eight fastening screws -1- on the E-box cover and remove it.
Fig 2: Identifying E-Box Cover Screws
2. Loosen the two fastening screws -2- on the service disconnector mounting.
Fig 3: Identifying Service Mounting Screws
3. Cut tie-wrap -arrow- for the electric line.
4. Release and unplug the three electric connectors -1, 2, 3- on the HV battery control unit.
Fig 4: Removing Electric Connectors
5. Unscrew the two fastening screws -3- from the HV battery control unit using the TORX
Screwdriver Set VAS 6633 WE 1382 .
Fig 5: Identifying HV Battery Control Unit Screws
6. Lift up the HV battery control unit and release and unplug the electric connectors -4- and -5- .
Fig 6: Removing Connectors
7. Lift the HV battery control unit out of the E-box.

8. To replace the control unit, release and unplug the electric connector -6- on the HV battery
control unit and remove it together with the HV battery wire harness.

(CAYENNE S HYBRID) > INSTALLING CONTROL UNIT FOR HV BATTERY
1. Plug in electric connector -6- with the HV battery wire harness at the control unit until the
connector engages securely.
Fig 1: Installing HV Battery Control Unit And Electric Connectors
2. Insert the HV battery control unit into the E-box and plug in both connectors -4- and -5- until
they engage securely.
Fig 2: Installing HV Battery Control Unit
3. Position HV battery control unit in the E-box.
4. Secure the ground strap (cable shoe) to the HV battery control unit in the E-box.
1. 4.1. Secure the HV battery control unit and ground strap using the two fastening
screws -3- and the TORX Screwdriver Set VAS 6633 WE 1382 .
Fig 3: Securing HV Battery Control Unit
5. Secure the service disconnector mounting with the two fastening screws -2- .
Fig 4: Identifying Service Screws
6. Plug electric connectors -1, 2, 3- into the HV battery control unit until the connectors engage
securely.
Fig 5: Installing Electric Connectors
7. Fit tie-wrap for the electric line -arrow- .
8. Before positioning the E-box cover, check the line routing of the HV battery wire harness from
the E-box.
1. 8.1. The rubber sleeve -arrow- on the wire harness must be engaged properly in the
E-box housing.
Fig 6: Locating E-Box Wire Harness Sleeve
9. Fit E-box cover and secure with the eight fastening screws -1- .
Fig 7: Installing E-Box Cover

(CAYENNE S HYBRID) > SUBSEQUENT WORK
1. Install the high-voltage battery. → INSTALLING HIGH-VOLTAGE BATTERY - section on

"Installing".
3. If the control unit was replaced, the control unit must be adapted to the vehicle using PIWIS
Tester II 9818 . → 279455 REPLACING BATTERY MANAGEMENT SYSTEM CONTROL
UNIT .
4. If the fault memory was erased, the electric motor must be calibrated fully.

E-HYBRID) > TOOLS



E-HYBRID) > READING AND WRITING VALUES
NOTE: Voltage drop
battery.
Information
Tester releases.
ignition.
5. Control unit replacement must now be selected. Then press [F12].
6. Read data must now be selected. Then press [F12].
HIGH-VOLTAGE BATTERY CONTROL UNIT .

TOOLS

TECHNICAL VALUES

NOTE: Voltage drop
battery.
Information
Tester releases.
ignition.
BATTERY MANAGEMENT SYSTEM CONTROL UNIT .

HYBRID) > TOOLS
Hybrid Test Adapter Workshop

WE 1378
VAS 6558/1 Equipment
Workshop
Voltage Tester WE 1380
Equipment

Tolerance Tolerance
1 2



3. Open the loadspace floor.

HYBRID) > REMOVING PILOT LINE CONNECTOR
Information


Fig 1: Removing Service Disconnector Cover
Fig 2: Releasing Service Disconnector

Fig 3: Removing Service Disconnector

The test log Verifying Absence Of Electric Charge and Restarting High-Voltage System

Fig 8: Opening High-Voltage Line Clip
17. Use the Hybrid Test Adapter VAS 6558/1 WE 1378 and the Voltage Tester WE 1380 to
verify the absence of electric charge at the power electronics.
log.
PPN "Verifying Absence Of Electric Charge" and place it in the vehicle documents folder.
20. Release the pilot line connector -1- at the power electronics (rapid-action coupling) and unplug
it.
Fig 10: Removing Pilot Line Connector And High-Voltage Lines For Electric Motor

HYBRID) > INSTALLING PILOT LINE CONNECTOR
Information
Technical Support .
Support .
Information
connector holder.
3. Close the lock for the high-voltage line and connect and lock the pilot line connector -1- (rapid-
action coupling).
Fig 1: Connecting High-Voltage Lines And Pilot Line Connector
Information
The high-voltage lines are colur-coded and must only be connected to the color-coded
connector holder.
3. 6.3. Secure the crash panel with the fastening nut -5- . → Tightening Torque: 9 Nm
(6.5 ft. lb.)
Information
Technical Support .
3. If the Lines are deformed or damaged, stop working on the system and contact Technical
Support .
Information
connector holder.
9. Plug in the pilot line connector until it engages securely.

Fig 6: Plugging In Pilot Line Connector

Fig 7: Installing Service Disconnector


Fig 9: Fitting Service Disconnector Cover

3. Close front and rear lid.
the Cayenne Hybrid.

DISCONNECTOR) (CAYENNE S E-HYBRID) > REMOVING SERVICE DISCONNECTOR
1. Unclip service disconnector.
2. Detach cover -1- using a small screwdriver -2- and remove it from the green housing -3- .
Fig 1: Detaching Service Disconnector Cover
3. Loosen fabric adhesive tape on the cable at the end of the connector and cut it off.
4. Release secondary lock using a small screwdriver.

Information
CAUTION: Risk of damage to locking lugs
5. Release pins -1- using press-out tool VAS 1978/35-2 -2- and pull them out carefully at the
cable -3- .
Fig 3: Pressing Pilot Lines Connector Pins
6. Release and pull off clips -1- on the old connector -2- using a thin screwdriver -3- .
Fig 4: Removing Pilot Lines Connector Clips

DISCONNECTOR) (CAYENNE S E-HYBRID) > INSTALLING SERVICE DISCONNECTOR
1. Prepare new service disconnector for installation.
1. 1.1. Release and pull off cover -1- on the new service disconnector -3- using a small
screwdriver -2- .
Fig 1: Installing Service Disconnector Cover
2. 1.2. Secure clips -1- on the new service disconnector -2- .

Fig 2: Securing Service Disconnector Clips
3. 1.3. Release secondary lock on the new service disconnector using a small
screwdriver.
Information
Check that the pins (upper locking lugs) are aligned correctly
If the locking lugs do not lock with an audible click, bend up the locking lugs at the pin first
using press-out tool
2. Press in pins in the following sequence until they engage securely.
1. 2.1. Red/lilac cable in pin 1
2. 2.2. Red/yellow cable in pin 2
3. 2.3. Green/black cable in pin 3
4. 2.4. Yellow/black cable in pin 4
3. Close secondary lock.
4. Fit black cap on the green connector until it engages securely on both sides.
5. Wrap new fabric tape around the cable.
6. Clip in service disconnector at the same position as before.

E-HYBRID) > TOOLS

Charging socket to body Tightening Torque 9.7 Nm (7.5 ft. lb.)

5. Release and disconnect high-voltage connector for PTC at the front, high-voltage battery and
charging socket at the high-voltage charger. → 279719 REMOVING AND INSTALLING
ON-BOARD CHARGER
6. Release and disconnect electric plug connection at the high-voltage charger. → 279719
REMOVING AND INSTALLING ON-BOARD CHARGER

E-HYBRID) > REMOVING CHARGING SOCKET
Fig 1: Identifying Charging Socket Installation Position
1. Release and disconnect electric plug connection -1- and unclip it from the body.
2. Unscrew fastening nuts -1- on charging socket -2- .

Fig 3: Loosening Charging Socket Nuts
3. Remove charging socket -1- by carefully turning it anti-clockwise -a- .

Fig 4: Removing Charging Socket
4. Cut tie-wrap -2- and pull water drain -1- off the charging socket.
Fig 5: Pulling Water Drain

E-HYBRID) > INSTALLING CHARGING SOCKET
Information
The high-voltage line for the charging socket must be routed behind the 12 V line.
Information
Make sure not to kink the water drain during installation.
1. Installation is performed in reverse order to removal. Tightening Torque 9.7 Nm (7.5 ft. lb.)

1. Plug in electric plug connection at the high-voltage charger until it engages securely. →
279719 REMOVING AND INSTALLING ON-BOARD CHARGER
2. Plug in high-voltage connectors for PTC at the front, high-voltage battery and high-voltage
charger until they engage securely. → 279719 REMOVING AND INSTALLING ON-BOARD
CHARGER
3. Install side trim panel for rear luggage compartment at the left. → REMOVING SIDE TRIM

E-HYBRID) > TOOLS

Tolerance Tolerance
1 2
High-voltage charger to body
Torque ft. lb.)
Equipotential bonding line to Tightening 7 Nm (5 ft.

high-voltage charger Torque lb.)

6. Remove subwoofer. → REMOVING SUBWOOFER - section on "Removing"

E-HYBRID) > REMOVING HIGH-VOLTAGE CHARGER
Fig 1: Identifying High-Voltage Charger Installation Position
1. Disconnect low-temperature lines -1- and seal them on both sides.

Fig 2: Disconnecting Low-Temperature Lines
Information
Collect emerging coolant in a suitable container.
Information
High-voltage connectors are released using the red tab in 2 steps:
1. 1) Release 1: Press red tab -a- and pull it -A-
2. 2) Release 2: Press black knob -b- and pull it off -B-

2. Release and disconnect high-voltage line to PTC at the rear -2- using the red tab.
3. Release and disconnect high-voltage line to PTC at the front -1- using the red tab.
4. Release and disconnect high-voltage line to high-voltage battery -3- .


6. Release and disconnect high-voltage line to charging socket -1- .

Fig 6: Releasing High-Voltage Line
7. Screw off equipotential bonding line -1- at the high-voltage charger.

8. Loosen fastening screws for high-voltage charger and carefully remove high-voltage charger.
Fig 8: Removing High-Voltage Charger

E-HYBRID) > INSTALLING HIGH-VOLTAGE CHARGER
1. Installation is performed in reverse order to removal. Tightening Torque 10 Nm (7.5 ft. lb.)

1. Install subwoofer. → INSTALLING SUBWOOFER - section on "Installing"

Service Manual: 28 - IGNITION SYSTEM -- 92A CAYENNE
WM 280419 REMOVING AND INSTALLING IGNITION STARTER SWITCH (ALL
MODELS) > TOOLS
key Special tool 9800

Union nut Tightening Torque 6 Nm (4.5 ft. lb.)

1. Remove dashboard inset at the bottom. → REMOVING DASHBOARD INSET - section on

"Removing"
2. Remove trim panel under dashboard at the left. → REMOVING TRIM PANEL UNDER
DASHBOARD - section on "Removing"

MODELS) > REMOVING IGNITION STARTER SWITCH
NOTE: Voltage peaks
Fig 1: Identifying Installation Position Of Ignition Starter Switch
1. Fit special tool Key 9800 on the union nut -A- .
2. Screw off union nut -1- using special tool Key 9800 and remove if from the ignition starter
switch -B- .
Fig 2: Removing Union Nut
3. Press ignition starter switch inwards -C- and remove it in a downward direction.
4. Release electric plug connection -a- and disconnect it -arrow- .


MODELS) > INSTALLING IGNITION STARTER SWITCH
2. Tighten union nut. Tightening Torque 6 Nm (4.5 ft. lb.)

1. Install trim panel under dashboard at the left. → INSTALLING TRIM PANEL UNDER
DASHBOARD - section on "Installing"
2. Install dashboard inset at the bottom. → INSTALLING DASHBOARD INSET - section on

"Installing"
WM 282020 REMOVING AND INSTALLING IGNITION COILS (CAYENNE S & CAYENNE

GTS) > TOOLS

insert for torque wrench Special tool 9792

Basic Tolerance
value 2
Initial tightening/do Tightening 25 Nm (19 +1.5 Nm (+1

Spark plugs, NEW
not use lubricant Torque ft. lb.) ft. lb.)
Re-Use/Do Not Use Tightening 31.5 Nm +1.5 Nm (+1

Spark Plugs
Lubricant Torque (23.5 ft. lb.) ft. lb.)
Fastening Screw For Replace Aluminum Initial 4 Nm (3 ft.

Ignition Coil Screw/M6 x 45 Tightening lb.)

+90°
Ignition Coil tightening
Fastening Screw For Knock Tightening 23 Nm (17

Sensor Torque ft. lb.)

Initial 4 Nm (3 ft.
Phase Sensor To Cylinder M6 x 16, AL9/replace
Tightening lb.)
Head

Final
Phase Sensor To Cylinder +60°
tightening
Head
Fastening screw for

hydraulic valve for valve lift
Torque ft. lb.)
control
Cover on fuse box in the Tightening 3.5 Nm (2.5

Internal Torx screw,
plenum panel Torque ft. lb.)

GTS) > TECHNICAL VALUES > IGNITION
Fig 1: Exploded View Of Ignition Components
1. Ignition Coil, Sprinkle With Talcum Powder Before Fitting
2. Spark plugs → Tightening Torque: 25 Nm (19 Ft. Lb.) +.5 Nm (+1 Ft. Lb.) → Tightening
Torque: 31.5 Nm (23.5 Ft. Lb.) +1.5 Nm (+1 Ft. Lb.)
3. Aluminum Screw, M6 x 45 Replace → Initial Tightening: 4 Nm (3 ft. lb.) → Final

Tightening: +90°
4. For Tightening Torque for screw(s), see INSTALLING CYLINDER HEAD COVER
5. For Tightening Torque for screw(s), see INSTALLING CYLINDER HEAD COVER
6. Transport Eyebolt
7. Knock Sensor
8. Screw M8 x 35 → Tightening Torque: 23 Nm (17 ft. lb.)
9. Phase Sensor
10. Aluminum Screw, M6x16/Replace → Initial Tightening: 4 Nm (3 Ft. Lb.) → Final

Tightening: +60°
12. Screw, BM5 x 12 → Tightening Torque: 6 Nm (4.5 ft. lb.)
Tolerance Tolerance
1 2
Cover on fuse box in the Internal Torx Tightening 3.5 Nm (2.5
plenum panel screw, Torque ft. lb.)

Only for cylinder 3:

GTS) > REMOVING IGNITION COILS
Information
1. Disconnect cable guide on the cylinder head cover.
1. 1.1. Unscrew screws -1- and -2- and loosen cable guide.
Cylinders 4-6: Loosen screw -2- using tool Insert For Torque Wrench 9792 and
unscrew it.
2. 1.2.
Fig 1: Identifying Cable Guide Mounting
2. Loosen ignition coils.
1. 2.1. Release electric connectors -arrows- and set cable guide aside.
2. 2.2. Loosen screws -1- on the ignition coils.

Fig 2: Removing Ignition Coil Connectors
3. Remove ignition coils. → see Fig 3

Fig 3: Removing Ignition Coil
4. In difficult-to-reach areas, the ignition coil -1- can also be turned.

Fig 4: Removing Ignition Coil

GTS) > INSTALLING BAR IGNITION MODULES
Information
Information
Shake talcum powder on ignition coil to make removal and fitting easier.
1. The ignition coils are installed in reverse order to removal.

WM 282020 REMOVING AND INSTALLING BAR IGNITION MODULES (CAYENNE) >

TOOLS
puller VW tool T10095 A

TECHNICAL VALUES
Knock sensor holder Tightening Torque 20 Nm (15 ft. lb.)
Knock sensor Tightening Torque 20 Nm (15 ft. lb.)
Hall sender Tightening Torque 10 Nm (7.5 ft. lb.)
Spark plug Tightening Torque 20 Nm (15 ft. lb.)

PRELIMINARY WORK
1. Switch ignition off and remove ignition key
2. Separate the six bar ignition modules from the wire harness. To do this, press the connectors
down slightly, release and remove them using the Assembly Tool T10118 or a suitable aid
(e.g. an angled piece of wire). -1-
Fig 1: Disconnecting Bar Ignition Modules

-1- - Bar Ignition Module
-2- - Cable Plug
-3- - Support
-4- - Screw → Tightening Torque: 20 Nm (15 ft. lb.)
-5- - Cable Plug
-6- - Knock Sensor
-8- - Exhaust Camshaft Adjuster 32A
-9- - Cover Section
-10- - Cable Plug
-11- - Screw → Tightening Torque: 10 Nm (7.5 ft. lb.)
-12- - Hall Sender G163, Exhaust Camshaft
-13- - Sealing Ring; Replace
-14- - Hall Sender G40, Intake Camshaft
-15- - Knock Sensor
-16- - Cable Plug

-17- - Intake Camshaft Adjuster 24E
-18- - Spark Plug → Tightening Torque: 20 Nm (15 Ft. Lb.)
-19- - Timing Chain Housing

REMOVING BAR IGNITION MODULES
1. Pull out bar ignition modules. For securely seated bar ignition modules, use the special tool
Puller T10095 A -A- to do this.
Fig 1: Removing Bar Ignition Modules

INSTALLING BAR IGNITION MODULES
1. Install the plug coils. When doing so, make sure that the smooth surface is pointing upwards.
An audible click indicates that they are installed correctly.
Fig 1: Installing Plug Coils

SUBSEQUENT WORK
1. Reconnect the bar ignition modules. The connectors must lock with an audible click. -arrow-
Fig 1: Connecting Bar Ignition Modules
WM 283919 REMOVING AND INSTALLING HALL SENDER (CAMSHAFT) (CAYENNE S

& CAYENNE GTS) > PRELIMINARY WORK > PRELIMINARY WORK FOR INTAKE
CAMSHAFT HALL SENDERS
Fig 1: Identifying Installation Position Of Intake Camshaft Hall Senders

DISTRIBUTOR

& CAYENNE GTS) > PRELIMINARY WORK > PRELIMINARY WORK FOR OUTLET
CAMSHAFT HALL SENSORS
Fig 1: Identifying Installation Position Of Outlet Camshaft Hall Sender

& CAYENNE GTS) > REMOVING HALL SENDER
Information
Information
1. Loosen screws -3- on the secondary-air line -6- . → 266919 REMOVING AND INSTALLING
SECONDARY AIR VALVE
1. 1.1. Do not unscrew screws -3- fully.
2. Unscrew screws -4- and remove holder -5R- .
3. Unscrew screws -7- and remove holder -5L- .

Fig 1: Identifying Heat Shield For Camshaft Hall Sender
5. Unscrew screws -2- and remove hall sender.
6.
Fig 2: Removing Camshaft Hall Sender

& CAYENNE GTS) > INSTALLING HALL SENDER
Information
Information
1. Carefully install camshaft hall sender.
1. 1.1. Clean the sealing face.
2. 1.2. Check O-ring and replace it if necessary.

3. 1.3. Use new aluminum screw.
4. 1.4. Tightening Torque for aluminum screw:
5. 1.5. Plug in electric connector and lock it.
The connector must lock with an audible click.

& CAYENNE GTS) > SUBSEQUENT WORK > SUBSEQUENT WORK FOR INTAKE
CAMSHAFT HALL SENDER

DISTRIBUTOR
WM 283919 REMOVING AND INSTALLING HALL SENDERS (CAMSHAFTS) ON DFI

ENGINES (CAYENNE) > TOOLS

ENGINES (CAYENNE) > TECHNICAL VALUES
Hall sender Fastening screw, M6 x 13 Tightening Torque 10 Nm (7.5 ft. lb.)

ENGINES (CAYENNE) > PRELIMINARY WORK
1. Remove engine compartment trim panels at the left and at the center plenum panel. For
details, see → 700219 REMOVING AND INSTALLING FRONT TRIM PANEL (ENGINE
COMPARTMENT)

ENGINES (CAYENNE) > REMOVING HALL SENDER
Information
Mark hall sender cable plugs according to position of intake and outlet camshafts .
Have a mirror and lamp to hand in case the installation position is difficult to see .
1. Pull off cable plugs on camshaft hall senders. Use special tool Assembly Tool T10118 or an
angled piece of wire for this purpose.
2. Unscrew the fastening screws on the hall senders -2- and carefully remove the hall senders.
Fig 1: Identifying Fastening Screws For Hall Senders

ENGINES (CAYENNE) > INSTALLING HALL SENDER
Information
Check sealing ring on hall sender and replace complete hall sender if sealing ring is defective .
Make sure not to confuse the electric plug connections for the intake and outlet camshafts .
1. Move hall sender into installation position and insert it into the upper timing chain case. Screw
in fastening screws hand-tight. Tighten fastening screws. → Tightening Torque: 10 Nm (7.5
ft. lb.)
2. Plug in cable plugs on camshaft hall senders.

ENGINES (CAYENNE) > SUBSEQUENT WORK
1. Fit engine compartment trim panels. → 700219 REMOVING AND INSTALLING FRONT TRIM
WM 283919 REMOVING AND INSTALLING HALL SENDER (CAYENNE TURBO &

1. Remove design cover on cylinder head cover for the affected cylinder bank. → 108319
REMOVING AND INSTALLING ENGINE COVER (DESIGN COVER)
Fig 1: Exploded View Of Engine Design Cover
1. Design Cover For Cylinder Bank 1 To 4
3. Screw For Securing Design Cover To Bar Ignition Module
4. Mounting Points (Tapered Rubber Elements)

CAYENNE TURBO S) > REMOVING HALL SENDER
1. Release and unplug connector for camshaft hall sender. → Camshaft hall sender connector
Fig 1: Removing Camshaft Hall Sender Connector
2. Remove fastening screw -3- on hall sender and pull hall sender -4- out carefully.
Fig 2: Identifying Hall Sender (Cylinders 1 To 4)
1. Valve Cover For Cylinders 1 To 4 (Align Over Bar Ignition Modules)
2. Oil Cap
3. Aluminum Screw , M6 x 20; hall sender (phase sensor); always use new aluminum
screws
4. Hall Sender
5. Sealing Ring
6. Valve Cover Seal
7. Valve Cover Seal, Inner
8. Seal For Hydraulic Valve For Camshaft Control

2. Hall Sender
3. Aluminum Screw , M6 x 20; hall sender (phase sensor); always use new aluminum
screws
4. Sealing Ring
5. Valve Cover Seal

CAYENNE TURBO S) > INSTALLING HALL SENDER
Information
The tightening specifications for the basic engine are stored centrally (→ WM 1001IN TIGHTENING
TORQUES, TIGHTENING SEQUENCES, ASSEMBLY OVERVIEWS (CAYENNE S) ).
1. Replace sealing ring.
2. Carefully fit the hall sender -4- . Fit fastening screw -3- on the hall sender.
2. Oil Cap
3. Aluminum Screw , M6 x 20; Hall Sender (Phase Sensor); Always Use New
Aluminum Screws
4. Hall Sender
5. Sealing Ring
6. Valve Cover Seal

2. Hall sender
3. Aluminum Screw , M6 x 20; hall Sender (Phase Sensor); Always Use New
Aluminum Screws
4. Sealing Ring
5. Valve Cover Seal
3. Slide on cable plug. The connector must engage audibly.

Fig 3: Identifying Camshaft Hall Sender Connector

1. Fit design cover for cylinder head cover. → 108319 REMOVING AND INSTALLING ENGINE
Fig 1: Exploded View Of Engine Design Cover
3. Screw For Securing Design Cover To Bar Ignition Module
4. Mounting Points (Tapered Rubber Elements)
WM 284419 REMOVING AND INSTALLING HALL-SENDER ROTOR (CAYENNE S &

CAYENNE GTS) > TOOLS
Insertion Tool Special Tool 9837

Nr. 168
Kit Available Tool
Test Card VW Tool T10473

CAYENNE GTS) > INFORMATION > INSTALLATION INSTRUCTIONS FOR
CRANKSHAFT SEALING RING AND HALL-SENDER ROTOR
Fig 1: Identifying Installation Instructions For Crankshaft Sealing Ring
1. Upper Part Of Crankcase
2. Crankshaft
3. Crankshaft Sealing Ring
4. Hall-Sender Rotor
Installation Dimensions For Shaft Sealing Ring And Hall-Sender Rotor [in mm]
Installation Dimension Reference Point 1 Reference Point 2
2.9 mm Crankshaft Hall-Sender Rotor
7.5 mm Crankcase Crankshaft Sealing Ring
13.0 mm Crankshaft Crankshaft Sealing Ring

1. Remove drive plate. → 136319 REMOVING AND INSTALLING DRIVE PLATE
2. Remove crankshaft pulse sender. → 287319 REMOVING AND INSTALLING CRANKSHAFT

PULSE SENDER

CAYENNE GTS) > REMOVING HALL-SENDER ROTOR > REMOVING ROTOR FOR
HALL SENDER
Information
The work steps for the hall-sender rotor and sealing ring are identical
1. Pull out the crankshaft pulse sender -1- slightly.

Fig 1: Identifying Hall-Sender Rotor
2. Screw in the extractor tip in the "TDC marking" -4- .

Fig 2: Identifying TDC Marking
3. Use the Slide Hammer Kit Nr. 168 to knock out the extractor tip -1- together with the
hall-sender rotor -2- .
Fig 3: Identifying Extractor Tip
4. Clean the crankshaft flange. → Cleaning crankshaft flange
1. 4.1. The crankshaft flange must not be dirty or rusty.
2. 4.2. If necessary clean with brake cleaner and remove rust with a metal-polishing
pad.

CAYENNE GTS) > CHECKING HALL-SENDER ROTOR > CHECKING ROTOR FOR
HALL SENDER
Information
Check the hall-sender rotor before installing it .
The hall-sender rotor must not come into contact with a magnet .
If the hall-sender rotor does come into proximity of a magnet, replace it without exception .
1. Check the condition of the new hall-sender rotor using the Test Card T10473 tool.
1. 1.1. Hold the Test Card T10473 -2- over the hall-sender rotor -1- and turn it.
2. 1.2. Continuous stripes -arrows- on undamaged hall-sender rotor -1- .

Fig 1: Identifying Undamaged Hall-Sender Rotor
2. Only use undamaged hall-sender rotors.
1. 2.1. "TDC marking" -arrow- on undamaged hall-sender rotor.

Fig 2: Locating Undamaged TDC Marking
3. A damaged hall-sender rotor must be replaced.
1. 3.1. The stripes -arrow- cannot be seen on damaged hall-sender rotors.

Fig 3: Locating Damaged Hall-Sender Rotor

CAYENNE GTS) > INSTALLING HALL-SENDER ROTOR > INSTALLING ROTOR FOR
HALL SENDER
Information
Check the hall-sender rotor before installing it .
The hall-sender rotor must not come into contact with a magnet .
If the hall-sender rotor does come into proximity of a magnet, replace it without exception .
Information
1. Fit hall-sender rotor to crankshaft flange using the Insertion Tool 9837 .
1. 1.1. While doing so align the centering notch -1- of the Insertion Tool 9837 to the
centering pin of the crankshaft flange.
2. 1.2. Press rotor for hall sender only slightly onto the crankshaft flange in order to
align the TDC marking.
Fig 1: Identifying 9873 Insertion Tool Centering Notch
2. Tighten the screws -2- .

Fig 2: Tightening Insertion Tool Screws
3. Slide the upper Insertion Tool 9837 -1- onto the lower Insertion Tool 9837 .
1. 3.1. Pay attention to the centering pin -2- .

Fig 3: Identifying Insertion Tool Centering Pin
4. Push centering pin -2- into the "TDC marking" -1- on the hall-sender rotor.
1. 4.1. Turn the hall-sender rotor slightly if necessary.

Fig 4: Identifying Centering Pin And TDC Marking
5. Tighten central screw -1- as far as possible and press in the hall-sender rotor -3- .
Fig 5: Identifying Insertion Tool And Central Screw
6. Unscrew the Insertion Tool 9837 central screw.
1. 6.1. Remove the upper Insertion Tool 9837 .
2. 6.2. Undo the screws -2- and remove the lower Insertion Tool 9837 .
Fig 6: Identifying Insertion Tool And Screws
7. Slide the crankshaft pulse sender -1- onto the hall-sender rotor -2- .
Fig 7: Identifying Hall-Sender Rotor

1. Install crankshaft pulse sender. → 287319 REMOVING AND INSTALLING CRANKSHAFT

PULSE SENDER
2. Install drive plate. → 136319 REMOVING AND INSTALLING DRIVE PLATE
WM 287020 REMOVING AND INSTALLING SPARK PLUGS (CAYENNE) > TOOLS

spark plug wrench VW tool 3122 B
WM 287020 REMOVING AND INSTALLING SPARK PLUGS (CAYENNE) > TECHNICAL

VALUES
Tolerance Tolerance
1 2
Electrode gap of spark

V6 Nominal value 0.9 mm
plug

V6 Maximum value 1.1 mm
plug

V6 Nominal value 0.9 mm
plug

V6 Maximum value 1.1 mm
plug

Spark plugs M12 x 1.25
Torque lb.)
WM 287020 REMOVING AND INSTALLING SPARK PLUGS (CAYENNE) >

PRELIMINARY WORK
Remove bar ignition modules. → REMOVING BAR IGNITION MODULES - section on

"Removing"
WM 287020 REMOVING AND INSTALLING SPARK PLUGS (CAYENNE) > REMOVING

SPARK PLUGS
NOTE: Broken spark plug electrodes
Bits of electrodes can fall into the combustion chamber
→ Only check electrode gap of spark plugs, but do not bend them.
→ Spark plugs with an incorrect electrode gap must be replaced.
Information
Only use spark plugs approved by Porsche AG!
Check electrode gap before screwing in a new spark plug .
1. Remove spark plug using special tool Spark Plug Wrench 3122 B . → Loosening spark plugs
using spark plug wrench
Fig 1: Loosening Spark Plugs Using Spark Plug Wrench
2. Check electrode gap. → Nominal value: 0.9 mm → Maximum value: 1.1 mm → Electrode
gap of spark plug in V6 engine
Fig 2: Checking Electrode Gap Of Spark Plug In V6 Engine
WM 287020 REMOVING AND INSTALLING SPARK PLUGS (CAYENNE) > INSTALLING

SPARK PLUGS
Information
Only use spark plugs approved by Porsche AG!
1. Check electrode gap. → Nominal value: 0.9 mm → Maximum value: 1.1 mm → Electrode
gap of spark plug in V6 engine
Fig 1: Checking Electrode Gap Of Spark Plug In V6 Engine
2. Tighten spark plugs using special tool Spark Plug Wrench 3122 B . → Tightening Torque:
20 Nm (15 ft. lb.) → Tightening spark plugs using spark plug wrench
Fig 2: Tightening Spark Plugs Using Spark Plug Wrench
WM 287020 REMOVING AND INSTALLING SPARK PLUGS (CAYENNE) >

SUBSEQUENT WORK
Install bar ignition modules. → INSTALLING BAR IGNITION MODULES - section on "Installing"
WM 287055 REMOVING AND INSTALLING SPARK PLUGS (CAYENNE S, CAYENNE

TURBO, CAYENNE GTS, CAYENNE TURBO S, CAYENNE TIP "PLATINUM EDITION" &
CAYENNE TIP (3.0) "PLATINUM EDITION") > TOOLS

spark plug wrench VW tool 3122 B

CAYENNE TIP (3.0) "PLATINUM EDITION") > TECHNICAL VALUES

value 1 2
Electrode gap of spark V8 naturally aspirated Control

1.6 mm
plug engine value
Electrode gap of spark Control

V8 turbo engine 0.8 mm +/-0.05 mm
plug value
Electrode gap of spark V8 naturally aspirated Control

1.6 mm
plug engine value
Electrode gap of spark Control

V8 turbo engine 0.8 mm
plug value

CAYENNE TIP (3.0) "PLATINUM EDITION") > PRELIMINARY WORK
MODULES

CAYENNE TIP (3.0) "PLATINUM EDITION") > REMOVING SPARK PLUGS
Information
Use only spark plugs approved by Porsche AG!
1. Loosen spark plugs using special tool Spark Plug Wrench 3122 B .
→ Loosening spark plugs using spark plug wrench
Fig 1: Loosening Spark Plugs Using Spark Plug Wrench
1. Bits of electrodes can fall into the combustion chamber
2. Check electrode gap in V8 naturally aspirated engine. → Control value: 1.6 mm → Electrode
gap of spark plug in V8 naturally aspirated engine
Fig 2: Checking Electrode Gap Of Spark Plug In V8 Naturally Aspirated Engine
3. Check electrode gap in V8 turbo engine. → Control value: 0.8 mm+/- 0.05 mm → Electrode
gap of spark plug in V8 turbo engine
Fig 3: Checking Electrode Gap Of Spark Plug In V8 Turbo Engine

CAYENNE TIP (3.0) "PLATINUM EDITION") > INSTALLING SPARK PLUGS
Information
The tightening specifications for the basic engine are stored centrally (→ WM 1001IN TIGHTENING
TORQUES, TIGHTENING SEQUENCES, ASSEMBLY OVERVIEWS (CAYENNE S) ).
Information
Use only spark plugs approved by Porsche AG!
1. Check electrode gap in V8 naturally aspirated engine. → Control value: 1.6 mm → Electrode
gap of spark plug in V8 naturally aspirated engine
Fig 1: Checking Electrode Gap Of Spark Plug In V8 Naturally Aspirated Engine
2. Check electrode gap in V8 turbo engine. → Control value: 0.8 mm → Electrode gap of spark
plug in V8 turbo engine
Fig 2: Checking Electrode Gap Of Spark Plug In V8 Turbo Engine
3. Tighten spark plugs using special tool Spark Plug Wrench 3122 B . → Tightening spark plugs
using spark plug wrench
Fig 3: Tightening Spark Plugs Using Spark Plug Wrench

CAYENNE TIP (3.0) "PLATINUM EDITION") > SUBSEQUENT WORK
1. Install bar ignition modules. → 282020 REMOVING AND INSTALLING BAR IGNITION
MODULES
WM 287219 REMOVING AND INSTALLING KNOCK SENSORS (CAYENNE) >

TECHNICAL VALUES
Knock sensor holder Tightening Torque 20 Nm (15 ft. lb.)
Knock sensor Tightening Torque 20 Nm (15 ft. lb.)
Hall sender Tightening Torque 10 Nm (7.5 ft. lb.)
Spark plug Tightening Torque 20 Nm (15 ft. lb.)
Knock sensor Fastening screw Tightening Torque 20 Nm (15 ft. lb.)

Knock sensor Fastening screw Tightening Torque 20 Nm (15 ft. lb.)

-1- - Bar Ignition Module
-2- - Cable Plug
-3- - Holder
-5- - Cable Plug
-6- - Knock Sensor
-8- - Outlet Camshaft Controller 32A
-9- - Cover Section
-10- - Cable Plug
-11- - Screw → Tightening Torque: 10 Nm (7.5 ft. lb.)
-12- - Hall Sender G163, Outlet Camshaft
-13- - Sealing Ring; Replace

-14- - Hall Sender G40, Intake Camshaft
-15- - Knock Sensor
-16- - Cable Plug
-17- - Intake Camshaft Controller 24E
-18- - Spark Plug → Tightening Torque: 20 Nm (15 ft. lb.)
-19- - Timing Chain Housing

REMOVING RIGHT KNOCK SENSOR
1. Remove intake manifold. → 243519 REMOVING AND INSTALLING AIR BOX FOR
THROTTLE HOUSING ON DFI ENGINES (INTAKE PIPES UPSTREAM OF THROTTLE
VALVE)
2. Pull off the connector of the right knock sensor (under exhaust manifold) at the front of the
cylinder head cover and expose socket -A, B and E in bottom part of figure- .
Fig 1: Removing Right Cable Lead
3. Unscrew the right knock sensor (under the exhaust manifold). To do this, loosen the fastening
screw -arrow- and remove knock sensor. Unclip cable. Remove knock sensor.
Fig 2: Removing Right Knock Sensor

INSTALLING RIGHT KNOCK SENSOR
Information
Observe the specified Tightening Torque for the knock sensor screw .
Align the housing and cable plug for the knock sensor in such a way that they are not touching .
Otherwise, there is no guarantee that the knock sensor will work correctly .
Information
Clean contact surface of knock sensor with a cloth .
1. Position knock sensor with fastening screw on the cylinder block. Route the cable so that it is
facing the front of the vehicle. Clip in cable. Tighten fastening screw. → Tightening Torque:
20 Nm (15 ft. lb.)
2. Fit cable plug.
3. Fit the intake manifold. → 243519 REMOVING AND INSTALLING AIR BOX FOR THROTTLE
HOUSING ON DFI ENGINES (INTAKE PIPES UPSTREAM OF THROTTLE VALVE)

REMOVING LEFT KNOCK SENSOR
1. The left knock sensor is difficult to reach under the intake-air distributor. First, remove the
intake-air distributor. → 244619 REMOVING AND INSTALLING DFI INTAKE-AIR
DISTRIBUTOR
Fig 1: Identifying Installation Position Of Knock Sensor

Fig 2: Identifying Engine Harness Connectors
1. 1-6 - Connectors For Bar Ignition Module For Cylinders 1-6
2. 7-12 - Connectors For High-Pressure Fuel Injectors (DFI) For Cylinders 1-6
3. 13 - Throttle Valve Connector
4. 14 - Crankcase Heater Connector
5. 15 - Starter Lead For Terminal 50
6. 16 - Knock Sensor Connector On DFI engines, Right
7. 17 - Connector For Oil Level Sensor
8. 18 - Connector For Air-Conditioning Compressor
9. 19 - Connector For Generator

10. 20 - Crankshaft Pulse Sender On DFI Engines
11. 21 - Connector For Oil Pressure Switch
12. 22 - Connector For Knock Sensor On DFI Engines, Left
13. 23 - Connector For High-Pressure Sensor
14. 24 - Connector For Flow Control Valve
15. 25-26 - Connectors For Hydraulic Valves For Camshaft Control On DFI Engines
16. 27 - Connector For Coolant Temperature Gauge
17. 28 - Connector For Additional Coolant Pump
18. 29-30 - Connectors For Hall Senders (Camshafts) On DFI Engines
19. 31 - Connector For Carbon Canister Valve
20. 32 - Connector For Intake Pipe Switchover Valve
21. 33-34 - Plug Connections Between Engine Wire Harness And Main Wire Harness
22. 35 - Connector For DME Control Unit
23. 36 - Ground Strap
2. Pull cable plug off the knock sensor.
3. Remove fastening screw and knock sensor.

INSTALLING LEFT KNOCK SENSOR
Information
Information
Clean attachment surfaces of knock sensor on the cylinder block with a cloth .
The installation position is difficult to reach .
1. Move knock sensor and fastening screw into installation position.
2. Tighten fastening screw to the specified torque. → Tightening Torque: 20 Nm (15 ft. lb.)
3. Connect cable plug for knock sensor.
4. Fit intake-air distributor. → 244619 REMOVING AND INSTALLING DFI INTAKE-AIR

DISTRIBUTOR
WM 287219 REMOVING AND INSTALLING KNOCK SENSOR (CAYENNE S &
1. For the front knock sensors, remove the thermostat housing → REMOVING HOUSING FOR
COOLANT REGULATOR - section on "Removing".
2. For the rear knock sensors, remove the starter → REMOVING STARTER - section on
"Removing".

CAYENNE GTS) > REMOVING KNOCK SENSOR
1. Observe and note installation position of knock sensors.
Pull off cable plug -1- . -arrow-
Fig 1: Removing Cable Plug For Knock Sensor
2. Loosen and unscrew fastening screw -2- and remove knock sensor -1- from the crankcase.
Fig 2: Identifying Knock Sensors
1. Knock sensor
2. Screw, M8 x 35

CAYENNE GTS) > INSTALLING KNOCK SENSOR
Information
Information
Information
Clean contact surface of knock sensor with a cloth .
1. Install knock sensors -1- . Make sure that the knock sensors are aligned as shown in the
illustration.
Fig 1: Identifying Knock Sensors
1. Knock sensor
2. Fastening screw, M8 x 35
2. Tighten fastening screws -2- .
3. Connect cable plug.

1. For the front knock sensor, install the thermostat housing → INSTALLING HOUSING FOR
COOLANT REGULATOR - section on "Installing".
2. For the rear knock sensor, install the starter → INSTALLING STARTER - section on
"Installing".
WM 287319 REMOVING AND INSTALLING CRANKSHAFT PULSE SENDER ON DFI

ENGINES (CAYENNE) > TECHNICAL VALUES
Tolerance Tolerance
1 2
Crankshaft pulse Fastening screw M6 x Tightening 10 Nm (7.5 ft.

sender 13 Torque lb.)

ENGINES (CAYENNE) > PRELIMINARY WORK
1. Remove left engine compartment cover. → REMOVING FRONT TRIM PANEL (ENGINE
2. Remove air cleaner housing cover and air-cleaner element. → REPLACING AIR-CLEANER
ELEMENT - section on "Removing"
3. Remove center engine guard. → REMOVING ENGINE GUARD (underbody panel) on DFI
engines - section on "Removing"

ENGINES (CAYENNE) > REMOVING CRANKSHAFT PULSE SENDER
1. Press the two coolant hoses aside and remove screw on oil dipstick. Pull out oil dipstick. -1-
Fig 1: Moving Coolant Hoses
Information
1. The cable plug for the crankshaft pulse sender is secured in a difficult-to-reach position at
the guide tube for the oil dip stick .
2. Press the cable plug for the crankshaft pulse sender at the guide tube for the oil dip stick
towards the cylinder block (only pushed in) -arrow- . Then disconnect the cable plug.
Fig 2: Removing Cable Plug Of Crankshaft Pulse Sender
Information
1. The cable for the crankshaft pulse sender is installed between the cylinder block and the
oil filter housing/engine support arm .
3. Remove crankshaft pulse sender by loosening the fastening screw -arrow- . Pull crankshaft
pulse sender out of the cylinder block. Carefully pull out the cable.
Fig 3: Locating Crankshaft Pulse Sender

Fig 4: Pulling Out Cable

ENGINES (CAYENNE) > INSTALLING CRANKSHAFT PULSE SENDER
Information
Check the sealing ring on the crankshaft pulse sender and replace it if necessary .
1. Fit crankshaft pulse sender into the cylinder block. Align and screw fastening screw in
hand-tight.
Fig 1: Locating Crankshaft Pulse Sender
2. Tighten the fastening screw. Crankshaft pulse sender → Tightening Torque: 10 Nm (7.5 ft.
lb.)
3. Use a wire or auxiliary cable to guide the cable for the crankshaft pulse sender between the
cylinder block and oil-filter housing/engine carrier.
4. Connect cable plug and slide onto oil dip stick guide tube.
Fig 2: Connecting Cable Plug
5. Press the two coolant hoses onto the intake-air distributor and fit screw on oil dipstick. Insert
dipstick. -1-
Fig 3: Moving Coolant Hoses

ENGINES (CAYENNE) > SUBSEQUENT WORK
1. Install center engine guard. → INSTALLING ENGINE GUARD (underbody panel) on DFI
engines - section on "Installing"
2. Fit air cleaner housing cover and air-cleaner element. → REPLACING AIR-CLEANER
ELEMENT - section on "Installing"
3. Fit left engine compartment cover. → INSTALLING FRONT TRIM PANEL (ENGINE
WM 287319 REMOVING AND INSTALLING CRANKSHAFT PULSE SENDER (CAYENNE

S & CAYENNE GTS) > TECHNICAL VALUES
Tolerance Tolerance
1 2
Fastening screw for crankshaft Tightening 10 Nm (7.5 ft.

pulse sender Torque lb.)
S & CAYENNE GTS) > PRELIMINARY WORK

S & CAYENNE GTS) > PRELIMINARY WORK > REMOVING CRANKSHAFT PULSE
SENDER
1. Remove crankshaft pulse sender.
1. 1.1. Release and pull off electric connector.
2. 1.2. Unscrew screw -2- and pull out the crankshaft pulse sender -1- .
Fig 1: Identifying Crankshaft Pulse Sender

S & CAYENNE GTS) > INSTALLING CRANKSHAFT PULSE SENDER
1. 1.1. Tightening Torque: Tightening Torque 10 Nm (7.5 ft. lb.)

S & CAYENNE GTS) > SUBSEQUENT WORK

Service Manual: EMISSION APPLICATIONS
EMISSION APPLICATIONS
2013 Cayenne Series
(1)
Engine & Fuel System Emission Control Systems & EGR Test No.
Devices
3.0L (183") V6 DI Supercharger PCV, EVAP, (2) TWC, FR, SPK, ...
(2)
Hybrid HO2S, CEC, MIL,
EVAP-LDP, EVAP-VC
3.6L (291") V6 DI PCV, EVAP, (2) TWC, FR, SPK, ...

(2)
HO2S, CEC, MIL EVAP-LDP,
EVAP-VC
4.8L (292") V8 DI PCV, EVAP, (2) TWC, FR, SPK, ...

(2)
HO2S, CEC, MIL EVAP-LDP,
EVAP-VC
4.8L (292") V8 DI Twin Turbo PCV, EVAP, (2) TWC, FR, SPK, ...
(2) HO2S, CEC, MIL,
EVAP-LDP, EVAP-VC
(1) Major emission control systems and devices are listed in bold type. Components and other related
devices are listed in light type.
(2)
Equipped with 4.
Service Manual: EMISSION CONTROL ABBREVIATIONS
"A"
A/C
Air Conditioning
A/C-ISUS
A/C Idle Speed-Up Solenoid
A/F
Air/Fuel
AAI
Air Assist Injector
ACL
Air Cleaner (Thermostatic Air Cleaner)
ACL-BMS
ACL Bimetallic Sensor
ACL-CKV
ACL Check Valve
ACL-DV
ACL Delay Valve
ACL-PVS
ACL Ported Vacuum Switch
ACL-RDV
ACL Reverse Delay Valve
ACL-RDVS
ACL Reverse Delay Valve (Single)
ACL-TCV
ACL Thermal Control Valve
ACL-TS
ACL Temperature Sensor
ACL-TSOV
ACL Temperature Sensor Override Valve
ACL-TVS
ACL Thermal Vacuum Switch
ACL-TVV
ACL Thermal Vacuum Valve
ACL-VCDV
ACL Vacuum Control Delay Valve
ACL-VCV
ACL Vacuum Control Valve
ACL-VM
ACL Vacuum Motor
ACL-WP
ACL Wax Pellet Type Motor
ADS
Anti-Dieseling Solenoid
AFR
Air/Fuel Ratio Sensor
AFS
Air/Fuel Ratio Sensor
AIH
Air Intake Heaters
AIH-TS
AIH Temperature Sensor
AIR
Air Injection System
AIS
Air Injection System
AIS-ACV
AIS Air Control Valve
AIS-AMV
AIS Air Management Valve
AIS-ASV
AIS Air Switching Valve
AIS-BPV
AIS By-Pass Valve
AIS-CC
AIS Computer Controlled
AIS-CKV
AIS Check Valve
AIS-CSV
AIS Control Solenoid Valve
AIS-CV
AIS Combination Valve
AIS-DV
AIS Diverter Valve
AIS-IMCV
AIS Intake Manifold Change-Over Valve
AIS-MCV
AIS Manifold Change-Over Valve
AIS-PAF
AIS Pulse Air Feeder
AIS-PM
AIS Pump Motor
AIS-PV
AIS Pneumatic Valve
AIS-RV
AIS Relief Valve
AIS-SAV
AIS Secondary Air Valve
AIS-SOL
AIS Solenoid
AIS-SV
AIS Solenoid Valve
AIS-VCV
AIS Vacuum Control Valve
AIS-VSV
AIS Vacuum Switching Valve
AIS-VT
AIS Vacuum Tank
AIS-VCV
AIS Vacuum Control Valve
AIS-VSV
AIS Vacuum Switching Valve
AIV
Air Injection Valve
AIV-SOL
Air Injection Valve Solenoid
ALVW
Adjusted Loaded Vehicle Weight
AMV
Air Management Valve
AP
Air Pump Injection System
AP-ACV
AP Air Control Valve
AP-AMV
AP Air Management Valve
AP-ASRV
AP Air Switching Relief Valve
AP-ASS
AP Air Switching Solenoid
AP-ASV
AP Air Switching Valve
AP-BPV
AP By-Pass Valve
AP-CKV
AP Check Valve
AP-CS
AP Control Solenoid
AP-DCTO
AP Dual Coolant Temperature Override
AP-DLY
AP Delay Valve
AP-DV
AP Diverter Valve
AP-EADV
AP Electric Air Control Diverter Valve
AP-EAMR
AP Electric Air Management Relay
AP-EAMS
AP Electric Air Management Solenoid
AP-EAP
AP Electric Air Pump
AP-EC
AP Electromagnetic Clutch
AP-ERLY
AP Electric Air Pump Relay
AP-RDV
AP Reed Valve
AP-RV
AP Relief Valve
AP-SOL
AP Solenoid
AP-SOV
AP Shut-Off Valve
AP-SV
AP Solenoid Valve
AP-SWV
AP Switchover Valve
AP-TV
AP Transmitting Valve
AP-VCS
AP Vacuum Control Solenoid
AP-VCSV
AP Vacuum Controlled Air Shut-Off Valve
AP-VCV
AP Vacuum Control Valve
AP-VSV
AP Vacuum Switching Valve
A/T
Automatic Transmission
ATCV
Air Temperature Control Valve
"B"
BP/EGR
Backpressure EGR System
BP/EGR-BPS
BP/EGR Backpressure Sensor
BP/EGR-BPT
BP/EGR Backpressure Transducer

BP/EGR-BPV
BP/EGR Backpressure Valve
BP/EGR-BS
BP/EGR Bleed Solenoid
BP/EGR-BVSV
BP/EGR Bimetallic Vacuum Switching Valve
BP/EGR-C
BP/EGR Controller
BP/EGR-CLR
BP/EGR Cooler
BP/EGR-CS
BP/EGR Control Solenoid
BP/EGR-CTO
BP/EGR Coolant Temperature Override
BP/EGR-CV
BP/EGR Control Valve
BP/EGR-DCTO
BP/EGR Dual Coolant Temperature Override
BP/EGR-DS
BP/EGR Diagnostic Solenoid
BP/EGR-DSOL
BP/EGR Duty Solenoid
BP/EGR-DTVSW
BP/EGR Distributor Thermal Vacuum Switch
BP/EGR-DV
BP/EGR Delay Valve
BP/EGR-EET
BP/EGR Electric Transducer
BP/EGR-EPV
BP/EGR External Pressure Valve

BP/EGR-FDV
BP/EGR Forward Delay Valve
BP/EGR-LC
BP/EGR Load Control Valve
BP/EGR-PS
BP/EGR Position Sensor
BP/EGR-PT
BP/EGR Pressure Tranducer
BP/EGR-PVS
BP/EGR Ported Vacuum Switch
BP/EGR-RES
BP/EGR Reservoir
BP/EGR-RST
BP/EGR Restrictor
BP/EGR-SOL
BP/EGR Solenoid
BP/EGR-TCTVS
BP/EGR Torque Converter Thermal Vacuum Switch
BP/EGR-TCV
BP/EGR Thermal Control Valve
BP/EGR-TCVLV
BP/EGR Temperature Control Valve
BP/EGR-TS
BP/EGR Temperature Sensor
BP/EGR-TVS
BP/EGR Thermal Vacuum Switch
BP/EGR-TVV
BP/EGR Thermal Vacuum Valve
BP/EGR-VCV
BP/EGR Vacuum Control Valve

BP/EGR-VM
BP/EGR Vacuum Modulator
BP/EGR-VRV
BP/EGR Vacuum Regulator Valve
BP/EGR-VS
BP/EGR Vacuum Switch
BP/EGR-VSOL
BP/EGR Vent Solenoid
BP/EGR-VSV
BP/EGR Vacuum Switching Valve
"C"
C-4
Computer Controlled Catalytic Converter
CAC
Charge Air Cooler
CAS
Clean Air System
CB
Crankcase Breather
CB-VC
Crankcase Breather-Vapor Canister
CBPS
Coasting By-Pass System
CBVC
Crankcase Breather Vapor Canister
CCIEV
Coolant Controlled Idle Enrichment Valve
CCS
Controlled Combustion System
CCV
Closed Crankcase Ventilation
CD-REGVLV
Crankcase Depression Regulator Valve
CDRV
Crankcase Depression Relief Valve
CEAB
Cold Engine Air Bleed
CEAB-TVS
CEAB Thermal Vacuum Switch
CEAB-TVV
CEAB Thermal Vacuum Valve
CEC
Computerized Engine Controls
CESS
Cold Engine Sensor Switch
CETS
Cold Engine Temperature Switch
CFI
Continuous Fuel Injection
CMH
Cold Mixture Heater
CNG
Compressed Natural Gas
CO
Carbon Monoxide
CO2
Carbon Dioxide
CPI
Central Port Injection
CRV
Coasting Richer Valve
CSI
Central Sequential Injection
CTAVS
Cold Temperature Activated Vacuum System
CTOX
Continous Trap Oxidizer
"D"
DCLV
Deceleration Valve
DCS
Deceleration Control System
DDI
Direct Diesel Injection
DFI
Direct Diesel Injection
DI
Direct Injection
DKV
Deceleration Kick Valve
DMCV
Deceleration Mixture Control Valve
DMS
Dual Manifold System
DOC
Diesel Oxidation Catalyst
DOHC
Dual Overhead Cam
DPF
Diesel Particulate Filter

DPFE
Differential Pressure Feedback EGR Valve
DPFEGR
Differential Pressure Feedback EGR Valve
DTM
Deceleration Throttle Modulator
"E"
EAIR
Electric Air Injection System
EAIR-DV
EAIR Diverter Valve
ECM
Electronic Control Module
ECU
Electronic Control Unit
EDC
Electronic Diesel Control
EDS
Electronic Diesel System
EEC
Electronic Engine Control
EFE
Early Fuel Evaporation
EFE-CKV
EFE Check Valve
EFE-CV
EFE Control Valve
EFE-DTVS
EFE Delay Thermal Vacuum Switch
EFE-HTR
EFE Heater
EFE-HCV
EFE Heat Control Valve
EFE-OTS
EFE Oil Temperature Switch
EFE-PTC
EFE Positive Temperature Coefficient (Intake Heater Grid)
EFE-PVS
EFE Ported Vacuum Switch
EFE-SOL
EFE Solenoid
EFE-TVS
EFE Thermal Vacuum Switch
EFE-TVV
EFE Thermal Vacuum Valve
EFE-VSV
EFE Vacuum Switching Valve
EFI
Electronic Fuel Injection
EFI-MA
EFI Mass Airflow Sensor
EFI-MAF
EFI Mass Airflow Sensor
EGR
Exhaust Gas Recirculation System
EGR-BCS
EGR Boost Check Solenoid
EGR-BPBV
EGR By-Pass Backpressure Valve
EGR-BPT
EGR Backpressure Transducer
EGR-BPV
EGR By-Pass Valve
EGR-BS
EGR Bleed Solenoid
EGR-BSSV
EGR Boost Sensor Solenoid Valve
EGR-BVSV
EGR Bimetallic Vacuum Switching Valve
EGR-C
EGR Controller
EGR-CC
EGR Coolant Controlled
EGR-CLR
EGR Cooler
EGR-VSOL
EGR Vacuum Solenoid
EGR-CKV
EGR Check Valve
EGR-CS
EGR Control Solenoid
EGR-CSOL
EGR Cut-Off Solenoid
EGR-CSV
EGR-CTO
EGR Coolant Temperature Override
EGR-CTS
EGR Charge Temperature Sensor
EGR-CTSW
EGR Charge Temperature Switch
EGR-CTTS
EGR Coolant Temperature Thermoswitch
EGR-CV
EGR Control Valve
EGR-CVCV
EGR Constant Vacuum Control Valve
EGR-CVS
EGR Control Vent Solenoid
EGR-DC
EGR Digital Control
EGR-DCTO
EGR Dual Coolant Temperature Override
EGR-DPFE
Differential Pressure Feedback EGR Sensor
EGR-DPFS
EGR Differential Pressure Feedback Sensor
EGR-DS
EGR Diagnostic Solenoid
EGR-DSOL
EGR Duty Solenoid
EGR-DTVS
EGR Delay Thermal Vacuum Switch
EGR-DTVSW
EGR Distributor Thermal Vacuum Switch
EGR-DV
EGR Delay Valve
EGR-EPRS
EGR Exhaust Pressure Regulator Solenoid
EGR-EPRV
EGR Exhaust Pressure Regulator Valve
EGR-EPV
EGR External Pressure Valve
EGR/EVAP-CSV
EGR/EVAP Control Solenoid Valve
EGR-EVR
EGR Vacuum Regulator
EGR-EVRV
EGR Electronic Vacuum Regulator Valve
EGR-FDV
EGR Forward Delay Valve
EGR-FJS
EGR Floor Jet System
EGR-FPS
EGR Feedback Pressure Sensor
EGR-LCV
EGR Load Control Valve
EGR-MAP
EGR Manifold Absolute Pressure Sensor
EGR-PFE
EGR-PFE Sensor
EGR-PS
EGR Position Sensor
EGR-PSW
EGR Pulse Switch
EGR-PVS
EGR Ported Vacuum Switch
EGR-REG
EGR Regulator
EGR-RES
EGR Reservoir
EGR-RST
EGR Restrictor
EGR-SC
EGR Signal Converter
EGR-SEC
EGR, Secondary
EGR-SEN
EGR Sensor
EGR-SOL
EGR Solenoid
EGR-SU
EGR Switchover Valve
EGR-SUB
Sub-EGR Valve
EGR-SVV
EGR Solenoid Vacuum Valve
EGR-T
EGR Temperature Sensor
EGR-TC
EGR Transmission Controlled
EGR-TCTVS
EGR Torque Converter Thermal Vacuum Switch
EGR-TCV
EGR Thermal Control Valve
EGR-TCVLV
EGR Temperature Control Valve
EGR-TRANS
EGR Transducer
EGR-TS
EGR Temperature Sensor
EGR-TSW
EGR Temperature Switch
EGR-TVD
EGR Throttle Valve Diaphragm
EGR-TVS
EGR Thermal Vacuum Switch
EGR-TVSOL
EGR Throttle Valve Solenoid
EGR-TVV
EGR Thermal Vacuum Valve
EGR-VA
EGR Vacuum Amplifier
EGR-VCV
EGR Vacuum Control Valve
EGR-VM
EGR Vacuum Modulator
EGR-VR
EGR Vacuum Regulator
EGR-VRS
EGR Vacuum Regulator Solenoid
EGR-VRSV
EGR Vacuum Regulator Solenoid Valve
EGR-VRV
EGR Vacuum Regulator Valve
EGR-VS
EGR Vacuum Switch
EGR-VSDV
EGR Vacuum Switch Dump Valve
EGR-VSEN
EGR Vacuum Sensor
EGR-VSOL
EGR Vent Solenoid
EGR-VSS
EGR Vacuum Switching Solenoid
EGR-VST
EGR Vacuum Surge Tank
EGR-VSV
EGR Vacuum Switching Valve
EGR-VVCS
EGR Venturi Vacuum Control System
EGRB
EGR Boost Sensor
EGRC
EGRC-BPT
EGR Control Backpressure Transducer
EGRC-SV
EGR Control Solenoid Valve
EHOC
Electronically Heated Oxidation Catalyst
EHTWC
Electronically Heated Three-Way Catalyst
EI
Electronic Ignition System
EIS
Electronic Ignition System
ELB
Electronic Lean Burn
EPR
Exhaust Pressure Regulator
EPR-SOL
EPR Solenoid
ESA
Electronic Spark Advance
ESIM
Evaporative System Integrity Monitor
EVAP
Fuel Evaporative System
EVAP-AAC
EVAP Auxiliary Air Control
EVAP-BPSV
EVAP By-Pass Solenoid Valve
EVAP-BVSV
EVAP Bimetallic Vacuum Switching Valve
EVAP-CAV
EVAP Canister Air Valve
EVAP-CCV
EVAP Control Canister Close Valve
EVAP-CCVSV
EVAP Control Canister Vent Shut Valve
EVAP-CCVVSV
EVAP Closed Canister Valve Vacuum Switching Valve
EVAP-CDCV
EVAP Canister Drain Cut Valve
EVAP-CKV
EVAP Check Valve
EVAP-CPCS
EVAP Canister Purge Control Solenoid
EVAP-CPCSV
EVAP Canister Purge Control Solenoid Valve
EVAP-CPCV
EVAP Canister Purge Control Valve
EVAP-CPRV
EVAP Canister Purge Regulator Valve
EVAP-CPSV
EVAP Canister Vent Shut Valve
EVAP-CPT
EVAP Canister Purge Timer
EVAP-CPTVS
EVAP Canister Purge Thermal Vacuum Switch
EVAP-CPV
EVAP Canister Vent Valve
EVAP-CPVCSV
EVAP Canister Purge Volume Control
EVAP-CPVCV
EVAP Canister Purge Volume Control Valve
EVAP-CPVDV
EVAP Canister Purge Vacuum Delay Valve
EVAP-CPVR
EVAP Canister Purge Valve Resonator
EVAP-CS
EVAP Control Solenoid
EVAP-CSPS
EVAP Control System Pressure Sensor
EVAP-CST
EVAP Canister Surge Tank
EVAP-CT
EVAP Catch Tank
EVAP-CVCS
EVAP Canister Vent Control Solenoid
EVAP-CVCV
EVAP Canister Vent Control Valve
EVAP-CVS
EVAP Canister Vent Solenoid
EVAP-CVSV
EVAP Carburetor Vent Switching Valve
EVAP-CVV
EVAP Canister Vent Valve
EVAP-DCTO
EVAP Dual Coolant Temperature Override
EVAP-DF
EVAP Drain Filter
EVAP-DPS
EVAP Differential Pressure Sensor
EVAP-DV
EVAP-Drain Valve
EVAP-EV
EVAP Emission Valve
EVAP-FBVV
EVAP Fuel Bowl Vent Valve
EVAP-FBVS
EVAP Fuel Bowl Vent Solenoid
EVAP-FCV
EVAP Fuel Cut Valve
EVAP-FLS
EVAP Fuel Level Sensor
EVAP-FOLV
EVAP Fuel Overflow Limiter Valve
EVAP-FS
EVAP Flow Switch
EVAP-FSV
EVAP Flow Switchover Valve<
EVAP-FTEV
EVAP Fuel Tank EVAP Valve
EVAP-FTPCSV
EVAP Fuel Tank Pressure Control Solenoid Valve
EVAP-FTPS
EVAP Fuel Tank Pressure Sensor
EVAP-FTS
EVAP Fuel Temperature Sensor
EVAP-FVCV
EVAP Fuel Vapor Control Valve
EVAP-FVS
EVAP Fuel Vapor Separator
EVAP-FVTS
EVAP Fuel Vapor Temperature Sensor
EVAP-FVV
EVAP Fuel Vent Valve
EVAP-FVVV
EVAP Fuel Vapor Vent Valve
EVAP-IVS
EVAP Inner Vent Solenoid
EVAP-LDP
EVAP Leak Detection Pump
EVAP-LDPAF
EVAP Leak Detection Pump Air Filter
EVAP-LDPF
EVAP Leak Detection Pump Filter
EVAP-LDPVV
EVAP Leak Detection Pump Vent Valve
EVAP-LSEP
EVAP Liquid Separator
EVAP-NVLD
EVAP Natural Vacuum Leak Detection
EVAP-ORVR
Evaporative On-Board Refueling Vapor Recovery System
EVAP-ORVRCV
Evaporative On-Board Refueling Vapor Recovery Check Valve
EVAP-ORVRFTVRV
EVAP-ORVR Fuel Tank Vapor Recirculation
EVAP-OVCV
EVAP Outer Vent Control Valve
EVAP-OWV
EVAP One-Way Valve
EVAP-PCDV
EVAP Purge Control Diaphram Valve
EVAP-PCSV
EVAP Purge Cut-Off Solenoid Valve
EVAP-PFS
EVAP Purge Flow Sensor
EVAP-PFSVVSV
EVAP Purge Flow Switching Valve Vacuum Switching Valve
EVAP-PRRV
EVAP Pressure Relief Rollover Valve
EVAP-PSVVSV
EVAP Pressure Switching Valve Vacuum Switching Valve
EVAP-PSOL
EVAP Purge Solenoid
EVAP-PSSV
EVAP Pressure Switching Solenoid
EVAP-PSVVSV
EVAP Pressure Switching Valve Vacuum Switching Valve
EVAP-PV
EVAP Purge (Frequency) Valve
EVAP-PVS
EVAP Ported Vacuum Switch
EVAP-RV
EVAP Rollover Valve
EVAP-RV/FTPS
EVAP Rollover Valve/Fuel Tank
EVAP-RVSV
EVAP Rollover Vapor Separator Valve
EVAP-SNR
EVAP Canister Sensor
EVAP-SOL
EVAP Solenoid
EVAP-SOV
EVAP Shutoff Valve
EVAP-SSV
EVAP Shut-Off Solenoid Valve
EVAP-SV
EVAP Solenoid Valve
EVAP-TC
EVAP Trap Canister
EVAP-TS
EVAP Temperature Switch
EVAP-TPBPV
EVAP Tank Pressure By-Pass Valve
EVAP-TPCS
EVAP Tank Pressure Control Solenoid
EVAP-TPCV
EVAP Tank Pressure Control Valve
EVAP-TRWV
EVAP Tree-Way Valve
EVAP-TV
EVAP Thermal Valve
EVAP-TVS
EVAP Thermal Vacuum Switch
EVAP-TVV
EVAP Thermal Vacuum Valve
EVAP-TWV
EVAP Two-Way Valve
EVAP-VC
EVAP Vapor Canister
EVAP-VCAT
EVAP Vapor Canister Air Tank
EVAP-VCF
EVAP Vapor Canister Filter
EVAP-VCSV
EVAP Vapor Canister Shut-off Valve
EVAP-VCTV
EVAP Vacuum Control Valve
EVAP-VCV
EVAP Vacuum Canister Valve
EVAP-VCVS
EVAP Vapor Canister Vent Solenoid
EVAP-VM
EVAP Vacuum Motor
EVAP-VPS
EVAP Vapor Pressure Sensor
EVAP-VPSVSV
EVAP Vapor Pressure Sensor Vacuum Switching Valve
EVAP-VS
EVAP Vacuum Sensor
EVAP-VSOL
EVAP Ventilation Solenoid
EVAP-VSOL/LDP
EVAP Ventilation Solenoid/Leak Detection Pump
EVAP-VST
EVAP Vacuum Surge Tank
EVAP-VSV
EVAP Vacuum Switching Valve
EVAP-VV
EVAP Ventilation Valve
EVRS
EGR Vacuum Regulator Solenoid
"F"
FBC
Feedback Carburetor
FCOV
Fuel Change Over Valve
FF
Flex Fuel
FF-CKV
Fuel Fill Check Valve
FF-FCV
Fuel Tank Fuel Cut-Off Valve
FF-FLVV
Fuel Tank Fill Limit Vent Valve

FGOV
Fuel Gravity/Overflow Valve
FGVV
Fuel Gravity Vent Valve
FI
Fuel Injected
FICD
Fast Idle Control Device
FISR
Fast Idle Solenoid Relay
FLV
Fill Limit Valve
FLVV
Fill Limiting Vent Valve
FP-CKV
Fill Pipe Check Valve
FP-RV
Fill Pipe Rollover Valve
FR
Fill Pipe Restrictor
FT-FLVV
Fuel Tank Fill Limit Vent Valve
FT-GVV
Fuel Tank Grade Vent Valve
FT-OPRV
Fuel Tank Over Pressure Vent Valve
FT-PCV
Fuel Tank Pressure Control Valve
FT-VCV
Fuel Tank Vapor Control Valve

FT-VRV
Fuel Tank Vapor Recirculation Valve
FTCV
Fuel Tank Check Valve
FTDPS
Fuel Tank Differential Pressure Sensor
FTEV
Fuel Tank EVAP Valve
FTPS
Fuel Tank Pressure Sensor
FTT
Fuel Tank Temperature Sensor
FTTS
Fuel Tank Temperature Sensor
FTV/LSV
Fuel Tank Vapor/Liquid Seperation Valve
FTVCV
Fuel Tank Vapor Control Valve
FTVPRV
Fuel Tank Ventilation Pressure Retention Valve
FVPS
Fuel Vapor Pressure Sensor
FTVV
Fuel Tank Vent Valve
FVV
Fuel Vapor Valve
"G"
GVWR
Gross Vehicle Weight Rating
"H"
HAC
High Altitude Compensator
HAFS
Heated Air Fuel Ratio Sensor
HAI
Hot Air Intake
HAS
High Altitude System
HC
Hydrocarbons
HCAC-VSV
Hydrocarbon Absorber Catalyst Vacuum Switching Valve
HDC
Heavy Duty Cooling
HDC-CTO
HDC Coolant Temperature Override
HFM-SFI
Hot Film Engine Management SFI
HIC
Hot Idle Compensator
HIM
Heated Intake Manifold
HO
High Output
HO2S
Heated Oxygen Sensor
HP
High Performance
HP
Horsepower
HPCA
Housing Pressure Cold Advance
HSC
High Swirl Combustion
"I"
IAC
Idle Air Control Valve
IACV-SW
IACV Switch
ICOM
Idle Compensator
IDI
Indirect Diesel Injection
IES
Idle Enrichment System
IMCO
Improved Combustion System
"K"
KS
Knock Sensor
"L"
LH-SFI
Hot Wire Sequential Multiport Fuel Injection
LVFD
Liquid/Vapor Fuel Discriminator
LVW
Loaded Vehicle Weight
"M"
MD-TICS
Timing & Injection rate Control System
MDP
Manifold Differential Pressure sensor
ME-SFI
Motor Electronics Sequential Fuel Injection
MFI
Multiport Fuel Injection
MFI-MAF
MFI Mass Airflow Sensor
MFLS
Main Fuel Level Sensor
MI
Mechanical Fuel Injection
MIL
Malfunction Indicator Light
M/T
Manual Transmission
"N"
NAC
Nitrogen Oxides (NOx) Adsorbing Catalyst
NLV
Non-Linear Valve
NOS
NOx Sensor
NOx
NOx Emission Control
NOxC
Nitrogen Oxide Catalyst
NOxS
Nitrogen Oxide Sensor

NOxTWC
NOx adsorptive TWC
NSC
Nitrogen Oxides (NOx) Storage Catalyst
"O"
OBD
On-Board Diagnostic System
PBD (F)/(P)
Full/Partial On-Board Diagnostic
OC
Oxidation Catalytic Converter
OHC
Overhead Cam
ORVR
On-Board Refueling Vapor Recovery
ORVR-COV
ORVR Cut-Off Valve
ORVR-CV
ORVR Control Valve
ORVR-FMV
ORVR Flow Management Valve
ORVR-FTVCV
ORVR Fuel Tank Vapor Control Valve
ORVR-FTVRV
ORVR Fuel Tank Vapor Recirculation Valve
ORVR-LV
ORVR Leveling Valve
ORVR-OCKV
ORVR Overfill Check Valve
ORVR-RCV
ORVR Refueling Control Valve
ORVR-VCV
ORVR Vapor Cut Valve
ORVR-VRV
ORVR Vapor Recirculating Valve
ORVR-VSV
ORVR Vent Shut Valve
ORVR-VV
ORVR Vent Valve
OVCV
Outer Vent Control Valve
O2S
Oxygen Sensor
"P"
PAIR
Pulsed Secondary Air Injection
PAIR-ABV
PAIR Anti-Backfire Valve
PAIR-ACOV
PAIR Air Cut-Off Valve
PAIR-ACS
PAIR Air Control Solenoid
PAIR-ACV
PAIR Air Control Valve
PAIR-AIV
PAIR Air Injection Valve
PAIR-ASCS
PAIR Air Suction Control Solenoid
PAIR-ASOV
PAIR Air Shutoff Valve

PAIR-ASS
PAIR Air Switching Solenoid
PAIR-ASV
PAIR Air Switching Valve
PAIR-ASVL
PAIR Air Suction Valve
PAIR-AVCS
PAIR Air Valve Control Solenoid
PAIR-CSV
PAIR Control Solenoid Valve
PAIR-CKV
PAIR Check Valve
PAIR-DV
PAIR Diverter Valve
PAIR-PAF
PAIR Pulse Air Feeder
PAIR-PAV
PAIR Pulse Air Valve
PAIR-RES
PAIR Resonator
PAIR-RV
PAIR Reed Valve
PAIR-SCSV
PAIR Swirl Control Solenoid Valve
PAIR-SCV
PAIR Swirl Control Valve
PAIR-SOL
PAIR Solenoid
PAIR-VSV
PAIR Vacuum Switching Valve

PCM
Powertrain Control Module
PCV
Positive Crankcase Ventilation
PCV-DOV
PCV Dual Orifice Valve
PCV-HCB
PCV Heated Crankcase Breather
PCV-HE
PCV Heating Element
PCV-PRV
PCV Pressure Regulator Valve
PCV-SOL
PCV Solenoid
PEVR
Power Enrichment Vacuum Regulator
PPM
Parts Per Million
PTOX
Periodic Trap Oxidizer
PURCV
Purge Crankcase Ventilation
PVCS
Ported Valve Control System
PVCS-A
PVCS Actuator
PVCS-CS
PVCS Control Solenoid
PVLCS
Power Valve Control System

"R"
ROV
Rollover Valve
"S"
SAI-SV
Secondary Air Injection Shutoff Valve
SAIR-CV
Secondary Air Injection Control Valve
SC
Supercharged or Super Charger
SC MFI
Supercharged Multiport Fuel Injection
SCR
Selective Catalytic Reduction
SCSV
Swirl Control Solenoid Valve
SCV
Swirl Control Valve
SCV-A
SCV Actuator
SFI
Sequential Multiport Fuel Injection
SFI-MAF
SFI Mass Airflow Sensor
SFLS
Sub-Fuel Level Sensor
SOHC
Single Overhead Cam
SPK
Spark Controls
SPK-AVM
SPK Advance Vacuum Modulator
SPK-BVSV
SPK Bimetal Vacuum Switching Valve
SPK-CC
SPK Computer Controlled
SPK-CKV
SPK Check Valve
SPK-CSSA
SPK Cold Start Spark Advance System
SPK-CSSH
SPK Cold Start Spark Hold System
SPK-CTO
SPK Coolant Temperature Override
SPK-DAVS
SPK Distributor Vacuum Advance Solenoid
SPK-DCKV
SPK Distributor Check Valve
SPK-DCTO
SPK Dual Coolant Temperature Override
SPK-DDD
SPK Dual Diaphragm Distributor
SPK-DMV
SPK Distributor Modulator Valve
SPK-DPD
SPK Dual Point Distributor
SPK-DPVS
SPK Distributor Ported Vacuum Switch
SPK-DRCV
SPK Distributor Retard Control Valve

SPK-DRS
SPK Distributor Retard Solenoid
SPK-DSVMV
SPK Distributor Spark Vacuum Modulator Valve
SPK-DTVS
SPK Distributor Thermal Vacuum Switch
SPK-DTVV
SPK Distributor Thermal Vacuum Valve
SPK-DV
SPK Delay Valve
SPK-DVA
SPK Distributor Vacuum Advance
SPK-DVAS
SPK Distributor Vacuum Advance Solenoid
SPK-DVCS
SPK Distributor Vacuum Control Solenoid
SPK-DVCSW
SPK Distributor Vacuum Controlled Switch
SPK-DVCV
SPK Distributor Vacuum Control Valve
SPK-DVDV
SPK Distributor Vacuum Delay Valve
SPK-DVRS
SPK Distributor Vacuum Retard Switch
SPK-DVRV
SPK Distributor Vacuum Regulating Valve
SPK-DVVV
SPK Distributor Vacuum Vent Valve
SPK-EAVS
SPK Electronically Actuated Vacuum Switch

SPK-EDM
SPK Electronic Distributor Modulator
SPK-EI
SPK Electronic Ignition
SPK-ESA
SPK Electronic Spark Advance
SPK-ESC
SPK Electronic Spark Control (Retard)
SPK-ESS
SPK Electronic Spark Selection
SPK-EST
SPK Electronic Spark Timing
SPK-FDV
SPK Forward Delay Valve
SPK-HPCA
SPK Housing Pressure Cold Advance
SPK-ITCS
SPK Ignition Timing Control System
SPK-ITVS
SPK Ignition Timing Vacuum Switch
SPK-NLVR
SPK Non-Linear Vacuum Regulator
SPK-OSAC
SPK Orifice Spark Advance Control
SPK-PVA
SPK Ported Vacuum Advance
SPK-PVS
SPK Ported Vacuum Switch
SPK-RDO
SPK Retard Delay Orifice

SPK-RDV
SPK Reverse Delay Valve
SPK-RDVD
SPK Reverse Delay Valve (Dual)
SPK-RDVLV
SPK Retard Delay Valve
SPK-RDVS
SPK Reverse Delay Valve (Single)
SPK-RETS
SPK Retard Switch
SPK-SC
SPK Speed Controlled
SPK-SOL
SPK Solenoid
SPK-SRRV
SPK Spark Relay Regulator Valve
SPK-TAVIA
SPK Temperature Activated Vacuum Ignition Advance
SPK-TCS
SPK Transmission Controlled Spark
SPK-TCSYS
SPK Timing Control System
SPK-TIDC
SPK Thermostatic Ignition Distributor Control
SPK-TV
SPK Thermal Valve
SPK-TVS
SPK Thermal Vacuum Switch
SPK-VACTO
SPK Vacuum Advance Coolant Temperature Override

SPK-VAS
SPK Vacuum Advance Solenoid
SPK-VAV
SPK Vacuum Advance Valve
SPK-VR
SPK Vacuum Retard
SPK-VRSW
SPK Vacuum Retard Switch
SPK-VSV
SPK Vacuum Switching Valve
SPK-VTCS
SPK Vacuum Timing Control System
SPL
Smoke Puff Limiter
SRI
Service Reminder Indicator
SSCA
Stepped Speed Control Actuator
SSCS
Stepped Speed Control Solenoid
STS
Service Throttle Soon Light
STVS
Secondary Throttle Valve System
SUB-HO2S
Sub-Heated Oxygen Sensor (after CAT)
SUB-O2S
Sub-Oxygen Sensor
SUB-TWC
Sub Three-Way Catalytic Converter

"T"
TAA
Turbo Air-To-Air
TAA
Throttle Actuator Assembly
TAB
Thermactor Air By-Pass
TAD
Thermactor Air Diverter
TAC
Thermostatic Air Cleaner
TBI
Throttle Body Injection
TBPCS
Throttle By-Pass Control System
TC
Turbo Charger
TCC
Torque Converter Clutch
TCCL
Torque Converter Control
TCD
Throttle Closing Dashpot
TC-DV
TC Delay Valve
TC-TVC
TC Thermal Vacuum Switch
TC-VS
TC Vacuum Switch
TD
Thermactor Diverter
TFT
Tank Fuel Temperature Sensor
THOS2
Third Heated Oxygen Sensor
TICV
Thermal Ignition Control Valve
TIV
Thermal Idle Valve
TK
Throttle Kicker
TLUC
Transmission Lock-Up Converter
TLUC-TVS
TLUC Thermal Vacuum Switch
TLUC-VS
TLUC Vacuum Switch
TM
Throttle Modulator
TOS
Throttle Opener System
TP
Throttle Positioner
TPI
Tuned Port Fuel Injection
TPV
Throttle Poppet Valve
TR
Thermal Reactor
TRC
Throttle Return Control
TRCS
Throttle Return Control Solenoid
TRCTL
Throttle Return Control Throttle Lever Actuator
TRSCV
Throttle Return Solenoid Control Valve
TRTVV
Temperature Regulator Thermal Vacuum Valve
TRVV
Transmission Vacuum Valve
TSOL
Throttle Solenoid
TVISD
Throttle Vacuum Idle Speed Diaphragm
TVM
Transmission Vacuum Modulator
TWC
Three-Way Catalytic Converter
TWC+OC
Three-Way + Oxidation Catalytic Converter
"V"
VA
Vacuum Advance Unit
VAC-AMP
Vacuum Amplifier
VA-CTO
VA Coolant Temperature Override
VCV
Vacuum Cut Valve

VCV-BV
VCV By-Pass Valve
VLFR
Vent Line Flow Restrictor/Anti-Trickle Fill Valve
"W"
WU
Warm-Up Catalyst
WU-OC
Warm-Up Oxidation Converter
WU-TWC
Warm-Up Three-Way Catalytic Converter

Service Manual: FIRING ORDER & CYLINDER IDENTIFICATION
FIRING ORDER & CYLINDER IDENTIFICATION
NOTE: This information is intended as a quick reference for firing order and cylinder
identification only. The information provided covers many vehicles and may include some
information that does not apply to the vehicle you have currently selected.
FIRING ORDER & CYLINDER IDENTIFICATION > H6 ENGINE
Engine Configuation Firing Order Cylinder Identification
Opposed 6 1-6-2-4-3-5
FIRING ORDER & CYLINDER IDENTIFICATION > V6 ENGINE
1-5-3-6-2-4
V6

Question: incorrect firing order
1-3-7-2-6-5-4-8
V8
1-6-3-8-5-10-4-9-2-7
V10
Service Manual: MODE 6 - PORSCHE
INTRODUCTION
Mode 6 is designed to allow access to the results of onboard diagnostic monitoring tests of specific
components/systems that are not continuously monitored. These systems include the catalytic converter,
EVAP system, oxygen sensor, oxygen sensor heater, EGR system, secondary AIR system, and
sometimes misfire.
Mode 6 data is output from the PCM/ECM in hexadecimal form. The $ sign indicates a hexadecimal
number. Depending on the software in the scanner, the output could be displayed in hexadecimal
numbers (no conversion), raw data (conversion to decimal numbers), or measurable values (applying
conversion factor to raw data).
Before reading mode 6 information, ensure that the monitor for the information you are accessing has
run to completion. If the monitor is not complete, the mode 6 data will not be accurate.
MODE 6 DATA 2003-04
Fig 1: Cayenne (9PA) - 2003-04 (1 Of 3)
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Fig 2: Cayenne (9PA) - 2003-04 (2 Of 3)
Fig 3: Cayenne (9PA) - 2003-04 (3 Of 3)
MODE 6 DATA 2005-06

Fig 1: Cayenne (9PA) - 2005-06 (1 Of 3)
Fig 2: Cayenne (9PA) - 2005-06 (2 Of 3)

Fig 3: Cayenne (9PA) - 2005-06 (3 Of 3)
MODE 6 DATA 2008-10
Fig 1: Cayenne (9PA) - 2008-10 (1 Of 3)

Fig 2: Cayenne (9PA) - 2008-10 (2 Of 3)
Fig 3: Cayenne (9PA) - 2008-10 (3 Of 3)
MODE 6 DATA 2011-12

Fig 1: Cayenne (92A) - 2011-12 (1 Of 2)

Fig 2: Cayenne (92A) - 2011-12 (2 Of 2)
MODE 6 DATA 2011-12

Fig 1: Cayenne (92A) - 2013 (1 Of 4)

Fig 2: Cayenne (92A) - 2013 (2 Of 4)

Fig 3: Cayenne (92A) - 2013 (3 Of 4)

Fig 4: Cayenne (92A) - 2013 (4 Of 4)

Service Manual: STATE EMISSION STANDARDS - DIESEL
ARIZONA
NOTE: Because of frequent revisions in state emission standards, the emission standards
listed in this article should only be used as a guide.
ARIZONA EMISSION STANDARDS - PHOENIX & TUCSON AREA (DIESEL OPACITY LOADED
CRUISE TEST)
Opacity (% For 10
Application Altitude (Feet) Seconds)
Light Duty Vehicles (8500 GVWR Or Less)
All Years Less Than 2000 20 Or Less
2001-4000 30 Or Less
Greater Than 4000 40 Or Less
ARIZONA EMISSION STANDARDS - PHOENIX & TUCSON AREA (DIESEL J1667 SNAP IDLE TEST)
Opacity (% For 10
Application Altitude (Feet) Seconds)
Heavy Duty Vehicles (8500 GVWR Or Greater)
1990 & Earlier All 55
1991 & Newer All 40
COLORADO
COLORADO EMISSION STANDARDS - DIESEL OPACITY
Application Opacity %
14,000 GVWR Or Less
Non-Turbo 40
Turbo 35
14,000 GVWR Or More
Non-Turbo 35
Turbo 20
CONNECTICUT
CONNECTICUT EMISSION STANDARDS - DIESEL OPACITY
10,000 GVWR Or Less
1979 & Newer 20
26,000 GVWR Or More
1974 & Earlier 70
1974-90 55
1991 & Newer 40
IDAHO
IDAHO EMISSION STANDARDS - DIESEL OPACITY
All Weight Range
1965-74 70
1975-91 55
1992 & Newer 40
KENTUCKY
KENTUCKY EMISSION STANDARDS - BOONE, CAMPBELL & KENTON COUNTIES (DIESEL
OPACITY)
Application Opacity
18,000 GVWR Or Less
All Years 10% @ Idle
MASSACHUSETTS
MASSACHUSETTS EMISSION STANDARDS - DIESEL OPACITY
Light Duty (8500 GVWR Or Less)
1984 & Newer 20
Light Duty (8501-10,000 GVWR Or Less)
1984 & Newer 40
Heavy Duty Buses (10,000 GVWR Or More)
1984-93 40
1994 & Newer 30
Heavy Duty Trucks (10,000 Or Less GVWR)

1984-90 55
1991 & Newer 40
NEW YORK
NEW YORK EMISSION STANDARDS - DIESEL OPACITY TEST
Heavy Duty Vehicles (8500 GVWR Or More)
1973 & Earlier 70
1974-90 55
1991 & Newer 40
OHIO
OHIO EMISSION STANDARDS - DIESEL OPACITY TEST
Light Duty Diesel 20
RHODE ISLAND
RHODE ISLAND EMISSION STANDARDS - DIESEL OPACITY TEST
All Model Years (8500 GVWR Or Less) 20
UTAH
UTAH EMISSION STANDARDS - DAVIS COUNTY - DIESEL OPACITY TEST
Light Duty Diesel - Turbo (16,000 GVWR Or Less) 30
Light Duty Diesel - Non-Turbo (16,000 GVWR Or Less) 35
Heavy Duty Diesel (16,000 GVWR Or More) 70
UTAH EMISSION STANDARDS - SALT LAKE COUNTY - DIESEL OPACITY TEST
All Model Years - Turbo (16,000 GVWR Or Less) 30
All Model Years - Non-Turbo (16,000 GVWR Or Less) 35
All Model Years (16,000 GVWR Or More) 70
UTAH EMISSION STANDARDS - UTAH COUNTY - DIESEL OPACITY TEST

All Model Years - Turbo (16,000 GVWR Or Less) 30
All Model Years - Non-Turbo (16,000 GVWR Or Less) 35
All Model Years (16,000 GVWR Or More) 70
WASHINGTON
WASHINGTON EMISSION STANDARDS - DIESEL OPACITY TEST
Light Duty Diesel (8500 GVWR Or Less)
All Model Years 20
Heavy Duty Diesel (8500 GVWR Or More)
1991 & Earlier 55
1992 & Newer 40

Service Manual: STATE EMISSION STANDARDS - GAS
ALASKA
NOTE: Because of frequent revisions in state emission standards, the emission standards
listed in this article should only be used as a guide.
NOTE: As of March 1, 2012, Alaska is not testing for tailpipe emissions.
ALASKA EMISSION STANDARDS - ANCHORAGE & FAIRBANKS (2-SPEED IDLE TEST)
Application 2500 RPM HC ppm (CO

Idle HC ppm (CO %) %)
Passenger Cars (1)
1968-71 1000 (5.0) 1000 (4.0)
1972-74 1000 (4.0) 1000 (3.0)
1975-80 1000 (2.0) 1000 (2.0)
1981-83 1000 (1.0) 1000 (1.0)
1984-93 750 (1.0) 750 (1.0)
1994- 200 (0.5) 200 (0.5)
Light & Medium Duty Trucks (1)
1968-72 1000 (5.0) 1000 (4.0)
1973-78 1000 (4.0) 1000 (3.0)
1979-83 1000 (2.0) 1000 (2.0)
1984-93 750 (1.0) 750 (1.0)
1994- 220 (0.5) 220 (0.5)
Heavy Duty Vehicles (2)
1968-73 1000 (5.0) 1000 (5.0)
1974-93 1000 (4.0) 1000 (4.0)
1994- 220 (1.0) 220 (1.0)
(1) 8500 GVWR or less.

(2)
8500 GVWR or more.
ARIZONA
NOTE: Curb idle only test are for vehicles with full-time 4WD, non-defeatable traction
control and motorcycles. Curb idle and loaded cruise tests are performed on 1967-80
light-duty gasoline powered vehicles and all heavy-duty gasoline powered vehicles.
ARIZONA EMISSION STANDARDS - PHOENIX AREA (CURB IDLE & LOADED CRUISE TESTS)
(2)
Loaded/Cruise HC
(1)
Application Idle HC ppm (CO %) ppm (CO %)
1967-71 4-Cyl. Or Less 500 (5.50) 500 (4.20)
1967-71 More Than 4-Cyl. 450 (5.00) 450 (3.75)
1972-74 4-Cyl. Or Less 400 (5.50) 400 (4.20)
1972-74 More Than 4-Cyl. 400 (5.00) 400 (3.75)
1975-78 4-Cyl. Or Less 250 (2.20) 250 (1.65)
1975-78 More Than 4-Cyl. 250 (2.00) 250 (1.50)
1979 4-Cyl. Or Less 220 (2.20) 220 (1.65)
1979 More Than 4-Cyl. 220 (2.20) 220 (1.50)
1980 220 (1.20) 220 (1.20)
1981 & Newer 220 (1.20) .....
Light Duty Trucks (6000 GVWR Or Less)
1967-80 (3) (3)
Light Duty Trucks (6001-8500 GVWR)
1967-74 (3) (3)
1975-78 350 (4.00) 350 (3.00)
1979 4-Cyl. Or Less 220 (2.20) 220 (1.65)
1979 More Than 4-Cyl. 220 (2.00) 220 (1.50)
1980 220 (1.20) 220 (1.20)
1981 & Newer 220 (1.20) .....
Heavy Duty Trucks (Greater Than 8500 GVWR)

(3) (3)
1967-74
1975-78 350 (4.00) 350 (3.00)
1979 & Newer 300 (4.00) 300 (3.00)
Motorcycles
1967 & Newer 1800 (5.50) .....
(1)
4-stroke engines only.
(2) Except AWD, non-defeatable traction control and motorcycles.
(3)
Same as light duty vehicles.
ARIZONA EMISSION STANDARDS - PHOENIX AREA (IM147 TEST)
Application HC gpm (CO gpm) NOx gpm
Light Duty Vehicles
1981-82 3.0 (25.0) 3.5
1983-85 2.4 (20.0) 3.5
1986-89 1.6 (15.0) 2.5
1990-93 1.0 (12.0) 2.5
1994 & Newer 0.8 (12.0) 2.0
Light Trucks (6000 GVWR Or Less)
1981-85 4.0 (40.0) 5.5
1986-89 3.0 (25.0) 4.5
1990-93 2.0 (20.0) 4.0
1994 & Newer 1.6 (20.0) 3.0
1981-85 4.4 (48.0) 7.0
1986-87 4.0 (40.0) 5.5
1988-89 3.0 (25.0) 5.5
1990-93 3.0 (25.0) 5.0
1994 & Newer 2.4 (25.0) 4.0
NOTE: Curb idle test only for 1967-80 light-duty gasoline vehicles, all vehicles with
full-time 4WD and/or non-defeatable traction control and motorcycles. Curb idle and loaded
cruise tests are performed on all 1981 and later vehicles except those with full-time 4WD
and/or non-defeatable traction control.
ARIZONA EMISSION STANDARDS - TUCSON AREA (CURB IDLE & LOADED CRUISE TESTS)
(2) Loaded/Cruise HC
Application (1) Idle HC ppm (CO %) ppm (CO %)

1967-71 4-Cyl. Or Less 500 (5.50) .....
1967-71 More Than 4-Cyl. 450 (5.00) .....
1972-74 4-Cyl. Or Less 400 (5.50) .....
1972-74 More Than 4-Cyl. 400 (5.00) .....
1975-78 4-Cyl. Or Less 250 (2.20) .....
1975-78 More Than 4-Cyl. 250 (2.00) .....
1979 4-Cyl. Or Less 220 (2.20) .....
1979 More Than 4-Cyl. 220 (2.20) .....
1980 220 (1.20) .....
1981 & Newer 220 (1.20) 220 (1.20)

(3) (3)
1967-80

(3) (3)
1967-74
1975-78 350 (4.00) .....
1979 4-Cyl. Or Less 220 (2.20) .....
1979 More Than 4-Cyl. 220 (2.00) .....
1980 220 (1.20) .....
1981 & Newer 220 (1.20) 220 (1.20)
Heavy Duty Trucks (Greater Than 8500 GVWR)
1967-74 (3) (3)
1975-78 350 (4.00) .....
1979-80 300 (4.00) .....
1981 & Newer 300 (4.00) 300 (3.00)
Motorcycles
1967 & Newer 1800 (5.50) .....
(1)
4-stroke engines only.
(2)
Except AWD, non-defeatable traction control and motorcycles.
(3)
Same as light duty vehicles.
CALIFORNIA > CALIFORNIA EMISSION STANDARDS ASM TESTS
Specific vehicle cutpoints are available on the California BAR web site at www.bar.ca.gov under the
Industry tab, then Cutpoints Application.
Fig 1: California Emission Standards - Enhanced & Partially Enhanced Program Areas - Light &
Medium Duty Vehicles (ASM Test)
Fig 2: California Emission Standards - Enhanced & Partially Enhanced Program Areas - Heavy Duty
Vehicles (ASM Test)
CALIFORNIA > LEGEND
ESC - Emission Standard Category
GVWR - Manufacture's Gross Vehicle Weight Rating
LVW - Loaded Vehicle Weight
PC - Passenger Car
LDT1 - Light-Duty Truck up through 3750 LVW and GVWR no greater than 6000 lbs.
LDT2 - Light-Duty Truck greater than 3750 LVW and GVWR no greater than 6000 lbs.
MDV - Medium-Duty Vehicle, GVWR from 6001 to 8500 lbs.
HC - Hydrocarbon, ppm
CO - Carbon Monoxide, %
NO - Nitric Oxide, ppm
CALIFORNIA > PASS/FAIL EMISSION STANDARDS = A+B / VTW
PASS/FAIL STANDARDS - Emission standards used to determine if a vehicle passes the emission
inspection. A vehicle passes if the emission levels are equal to or less than the standards for HC, CO
and NO for ASM 5015 and ASM 2525.
GROSS POLLUTER STANDARDS - Emission standards used to designate a vehicle as a gross polluter.
A vehicle is designated as a gross polluter if the emission levels at the time of the initial inspection,
before repairs are greater than the gross polluter standards for HC, CO or NO for ASM 5015 or ASM
2525.
NOTE: If test data on emission pass/fail rates or gross polluter identification rates indicate
adjustments are required, the emission standards may be increased or decreased by the
bureau by 30% or by the following tolerances, or standards may be set for any specific vehicle
and engine configuration which the bureau determines has excessive errors of commission of
omission, whichever is necessary to comply with Section 44001.5 of the Health and Safety
Code.
COLORADO
COLORADO EMISSION STANDARDS - ENHANCED PROGRAM (IM240)
Application HC gpm CO gpm NOx gpm
Passenger Cars
1982 3.5 45 5.0
1983 3.5 30 4.5
1984 3.0 30 4.5
1985 2.5 20 4.5
1986 2.5 20 4.5
1987 2.5 20 4.0
1988 & 1989 2.0 20 4.0
1990 2.0 20 3.5
1991 1.5 20 3.5
1992 1.5 15 3.5
1993 1.5 15 3.5
1994 1.2 15 3.0
1995 1.2 15 2.5
1996 1.2 15 2.0
1997 1.2 15 2.0
1998 & Newer 1.2 15 1.5
Light Duty Vehicles
1982 6.0 65 6.0
1983 6.0 65 6.0
1984 5.0 55 6.0
1985 4.5 45 6.0
1986 4.0 40 6.0
1987 3.5 30 5.5
1988 & 1989 3.0 25 5.0
1990 3.0 25 5.0
1991 2.5 25 4.5
1992 2.5 25 4.5

1993 2.5 25 4.5
1994 2.0 20 4.0
1995 2.0 20 4.0
1996 1.2 15 3.5
1997 1.2 15 3.0
1998 1.2 15 2.0
1999 & Newer 1.2 15 2.0
COLORADO EMISSION STANDARDS - 2-SPEED IDLE TEST
Application HC ppm CO %
Passenger Cars & Light Duty Trucks
1970 & Earlier 1000 3.5
1971 1000 3.0
1972 1000 3.0
1973 1000 3.0
1974 1000 3.0
1975 600 2.0
1976 600 2.0
1977 400 1.5
1978 400 1.5
1979 400 1.5
1980 400 1.5
1981 & Newer 220 1.2
Heavy Duty Trucks (6000 GVWR Or Greater)
1967 Or Earlier 1500 7.0
1968-69 1200 6.5
1969 1200 6.5
1970 1000 5.5
1971 1000 5.5
1972 1000 5.5
1973 1000 5.5
1974 1000 5.5
1975 1000 5.5

1976 1000 5.5
1977 1000 5.5
1978 1000 5.5
Heavy Duty Trucks (8501 GVWR Or Greater)
1979 800 4.0
1980 800 3.5
1981 600 3.0
1982 600 3.0
1983 600 3.0
1984 600 3.0
1985 600 3.0
1986 & Newer 300 2.0
CONNECTICUT
CONNECTICUT EMISSION STANDARDS - IDLE TEST
Application HC ppm (CO)
10,000 GVWR Or Less
1979 250 (2.1)
1980 225 (2.0)
1981-82 200 (1.2)
1983 175 (1.0)
1984-87 150 (1.0)
1988 & Newer 125 (1.0)
DELAWARE
DELAWARE EMISSION STANDARDS - KENT, NEW CASTLE & SUSSEX COUNTIES (IDLE TEST)
Application HC ppm (CO %)
1968-70 900 (9.0)
1971-74 600 (6.0)
1975-79 400 (4.0)
1980 220 (2.0)
1981 & Newer 220 (1.2)

1970-72 900 (9.0)
1973-78 600 (6.0)
1979-83 400 (4.0)
1984 & Newer 220 (1.2)
DISTRICT OF COLUMBIA
DISTRICT OF COLUMBIA EMISSION STANDARDS - IDLE TEST
Light Duty Vehicles & Trucks (26000 GVWR Or Less)
1968-70 1250 (11.0)
1971-74 1200 (9.0)
1975-79 600 (6.5)
1980 300 (1.5)
1981 & Newer 220 (1.2)
GEORGIA
NOTE: The Georgia program incorporates original U.S. EPA recommended start-up
ASM2525 and ASM5015 standards for 1995 and older model year vehicles. Refer to
appropriate model year range in appropriate table. See U. S. EPA ASM2525 & ASM5015
START-UP EMISSION STANDARDS .
GEORGIA EMISSION STANDARDS - 2-SPEED IDLE TEST
Application (1) HC ppm (CO %)
1979 500 (5.0)
1980 350 (3.5)
1981-83 250 (1.5)
1984 & Newer 220 (1.2)
IDAHO
IDAHO EMISSION STANDARDS - 2-SPEED IDLE TEST
Light Duty Vehicles

8500 GVWR Or Less
1965-74 900 (5.0)
1975-79 700 (3.0)
1980 400 (1.5)
1981 & Newer 220 (1.2)
Heavy Duty Trucks
8501 GVWR Or More
1965-74 900 (6.0)
1975-80 700 (5.0)
1981 & Newer 500 (3.0)
ILLINOIS
ILLINOIS EMISSION STANDARDS - IM240 TEST
Application HC gpm CO gpm
1981-82 2.00 60.0
1983-87 2.00 30.0
1988-95 0.80 15.0
1996 & Newer 0.60 10.0
1981-83 7.50 100.0
1984-87 3.20 80.0
1988-95 1.60 40.0
1996 & Newer (3750 LVW Or More) (1) 0.80 13.0
1996 & Newer (3750 LVW Or Less) (1) 0.60 10.0
1981-83 7.50 100.0
1984-87 3.20 80.0
1988-95 1.60 40.0
1996 & Newer (5750 ALVW Or More) 0.80 15.0
1996 & Newer (5750 ALVW Or Less) 0.80 13.0
(1)
Loaded Vehicle Weight (LVW) is vehicle curb weight plus 300 lbs.
ILLINOIS EMISSION STANDARDS - IDLE TEST

Passenger Vehicles (6000 GVWR Or Less)
1968-71 900 (9.0)
1972-74 800 (8.0)
1975-77 700 (7.0)
1978-79 600 (6.0)
1980 300 (3.0)
1981 & Newer 220 (1.2)
1968-71 900 (9.0)
1972-74 800 (8.0)
1975-78 700 (7.0)
1979-80 600 (6.0)
1981-83 300 (3.0)
1984 & Newer 220 (1.2)
1968-71 1500 (9.5)
1972-78 900 (9.0)
1979-84 700 (7.0)
1985 & Newer 300 (3.0)
INDIANA
INDIANA EMISSION STANDARDS - IM93 TEST
Application HC gpm (CO gpm) NOx (gpm)
Passenger Cars
1981-82 2.0 (60) 3.0
1983-86 2.0 (30) 3.0
1987-90 1.4 (20) 3.0
1991-95 0.8 (15) 2.5
1996 & Newer 0.6 (10) 2.5
1981-83 5.0 (80) 7.0
1984-86 3.2 (70) 7.0

1987-90 2.2 (55) 3.5
1991-95 1.6 (40) 3.0
1996 & Newer 0.8 (20) 3.0
1981-83 5.0 (80) 7.0
1984-86 3.2 (70) 7.0
1987-90 2.2 (55) 5.0
1991-96 1.6 (40) 4.5
1997 & Newer 0.8 (20) 4.5
Heavy Duty Trucks (8501-9000 GVWR)
1981-82 7.5 (100) 8.0
1983-84 6.0 (100) 8.0
1985-86 5.0 (75) 8.0
1987-90 3.0 (60) 8.0
1991-97 2.4 (40) 8.0
1998 & Newer 2.0 (30) 6.0
INDIANA EMISSION STANDARDS - IDLE TEST
Passenger Cars
1976-79 350 (3.5)
1980 250 (2.0)
1981 & Newer 220 (1.2)
1976-78 500 (5.0)
1979-83 350 (3.5)
1984 & Newer 220 (1.2)
Medium Duty Trucks (6001-8500 GVWR)
1976-78 500 (5.0)
1979-83 350 (3.5)
1984 & Newer 220 (1.2)
KENTUCKY
NOTE: Currently, there is no emission testing in Kentucky.
KENTUCKY EMISSION STANDARDS - BOONE, CAMPBELL & KENTON COUNTIES (IDLE TEST)
Application HC ppm (CO)
Passenger Cars (Automobiles)
1968 950 (8.5)
1969 900 (8.5)
1970 850 (8.1)
1972 800 (8.0)
1973 800 (7.8)
1974 800 (7.6)
1975 700 (7.5)
1976 700 (6.5)
1977 650 (6.3)
1978 600 (5.5)
1979 600 (4.5)
1980 250 (2.5)
1981 & Newer 220 (1.2)
1968 1300 (8.0)
1969 1200 (8.0)
1970-71 1100 (8.0)
1972-73 1000 (7.8)
1974 950 (7.8)
1975 900 (7.0)
1976-77 700 (7.0)
1978 700 (6.3)
1979 450 (5.5)
1980 450 (4.0)
1981 350 (1.7)
1982 & Newer 220 (1.2)
Light Duty Trucks (6001-10,000 GVWR)

1969 1500 (9.0)
1970 1100 (8.0)
1971 1000 (8.0)
1972-75 950 (7.5)
1976 900 (7.5)
1977 850 (7.5)
1978 700 (6.0)
1979 650 (5.5)
1980 550 (5.0)
1981 450 (4.0)
1982 400 (2.5)
1983 350 (2.0)
1984 220 (1.5)
1985 & Newer 220 (1.2)
Heavy Duty Trucks (10,001-18,000 GVWR)
1968 1500 (9.0)
1969-70 1300 (8.5)
1971 1200 (8.5)
1972-76 1000 (7.0)
1977-80 900 (6.5)
1982-83 400 (3.0)
1984 & Newer 250 (1.5)
MARYLAND
MARYLAND EMISSION STANDARDS - IM240 TEST
1984-87 1.80 (30.0) 2.8
1988-90 1.40 (30.0) 2.5
1991-93 1.00 (20.0) 2.2
1994-95 0.90 (20.0) 2.1
1984-87 2.80 (80.0) 5.8

1988-90 2.40 (80.0) 3.0
1991-93 2.00 (60.0) 2.7
1994-95 1.80 (60.0) 2.6
1984-87 2.90 (80.0) 6.6
1988-90 2.40 (80.0) 4.2
1991-93 2.00 (60.0) 4.0
1994-95 1.80 (60.0) 3.7
Heavy Duty Trucks (8501-9999 GVWR)
1984 5.80 (100.0) 7.7
1985-86 4.70 (80.0) 7.7
1987 3.00 (80.0) 7.7
1988-90 2.60 (80.0) 7.0
1991-97 2.50 (60.0) 5.5
1998 & Newer 2.20 (60.0) 4.0
MARYLAND EMISSION STANDARDS - IDLE TEST
1977 500 (6.0)
1978 430 (5.5)
1979 400 (4.0)
1980 220 (1.7)
1981 & Newer 220 (1.2)
1977 580 (7.0)
1978 550 (6.7)
1979 470 (5.0)
1980 350 (5.0)
1981 250 (3.0)
1982 220 (2.5)
1983 220 (1.5)
1984 & Newer 220 (1.2)

Heavy Duty Trucks (10,000-26,000 GVWR)
1977-78 650 (7.0)
1979 650 (6.5)
1980-82 500 (6.0)
1983 500 (3.5)
1984-85 440 (3.0)
1986 280 (2.5)
1987 & Newer 220 (1.2)
MASSACHUSETTS
MASSACHUSETTS EMISSION STANDARDS - MA31 TEST
Passenger Cars
1984-90 2.0 (30) 3.0
1991-95 1.2 (20) 2.5
1996 & Newer 0.8 (13) 2.0
1984-87 3.2 (80) 7.0
1988-1990 3.2 (80) 3.5
1991-95 2.4 (60) 3.0
1996 & Newer (3750 LVW (1) Or Less) 0.8 (15) 2.0
1996 & Newer (3751 LVW (1) Or Greater) 1.0 (20) 2.5
1984-87 3.2 (80) 7.0
1988-90 3.2 (80) 5.0
1991-95 2.4 (60) 4.5
1996 & Newer (5750 ALVW (2) Or Less) 1.0 (20) 2.5
1996 & Newer (5751 ALVW (2) Or Greater) 2.4 (60) 4.0
Heavy Duty Trucks (8501-10,000 Or Greater)
1984-87 3.2 (80) 7.0
1988-90 3.2 (80) 5.0
1991-95 2.4 (60) 4.5
1996 & Newer 2.4 (60) 4.0

(1) Loaded Vehicle Weight (LVW).
(2)
Adjusted Loaded Vehicle Weight (ALVW).
MASSACHUSETTS EMISSION STANDARDS - 2-SPEED IDLE TEST
All Vehicles
1984-86 220 (0.80)
1987 & Newer 100 (0.60)
MISSOURI
MISSOURI EMISSION STANDARDS - JEFFERSON, ST. CHARLES & ST. LOUIS COUNTIES - IM240
TEST
1981-82 0.80 (30.0) 2.0
1983-95 0.80 (15.0) 2.0
1996 & Newer 0.60 (10.0) 1.5
1981-83 3.40 (70.0) 4.5
1984-87 1.60 (40.0) 4.5
1988-95 1.60 (40.0) 2.5
1996 & Newer (Less Than 3750 LVW) 0.80 (13.0) 1.8
1996 & Newer (3750 LVW Or Less) 0.60 (10.0) 1.5
1981-83 3.4 (70.0) 4.5
1984-87 1.6 (40.0) 4.5
1988-95 1.60 (40.0) 3.5
1996 & Newer (5750 ALVW Or Less) 0.80 (13.0) 1.8
1996 & Newer (5750 ALVW Or More) 0.80 (15.0) 2.0
MISSOURI EMISSION STANDARDS - FRANKLIN, JEFFERSON, ST. CHARLES & ST. LOUIS
COUNTIES - IDLE TEST
Application (1) HC ppm (CO %)
1971-74 700 (7.0)

1975-79 600 (6.0)
1980 300 (3.0)
1981 & Newer 220 (1.2)
(1)
8500 GVWR or less.
MISSOURI EMISSION STANDARDS - FRANKLIN, JEFFERSON, ST. CHARLES & ST. LOUIS
COUNTIES - REMOTE SENSING CLEAN SCREEN TEST
Application (1) HC ppm (CO %) NOx ppm
All Vehicles (8500 GVWR Or Less)
1971 & Newer 200 (0.5) 2000
(1)
8500 GVWR or less.
NEVADA
NEVADA EMISSION STANDARDS - 2-SPEED IDLE TEST
1968-69 800 (4.0)
1970-74 700 (3.5)
1975-78 500 (2.5)
1979-80 500 (2.0)
1981 & Newer 220 (1.2)
1968-69 1400 (7.0)
1970-78 1400 (6.0)
1979 1000 (5.0)
1980 1000 (4.0)
1981 & Newer 1000 (3.5)
NEW JERSEY
NOTE: The New Jersey program incorporates original U.S. EPA recommended start-up
ASM5015 standards for 1981 and newer model year vehicles. Refer to appropriate model
year range in appropriate table. See U. S. EPA ASM2525 & ASM5015 START-UP EMISSION
STANDARDS .
NEW JERSEY EMISSION STANDARDS - 2-SPEED IDLE TEST
Application Idle HC ppm (CO %) 2500 RPM HC ppm (CO %)
1967 & Earlier 1400 (8.5) .....
1968-70 700 (7.0) .....
1971-74 500 (5.0) .....
1975-80 300 (3.0) .....
1981 & Newer 220 (1.2) 100 (0.5)
Heavy Duty Vehicles (8501 GVWR Or Greater)
1967 & Earlier 1400 (8.5) .....
1968-70 1200 (8.5) .....
1971-74 700 (6.0) .....
1975-78 500 (4.0) .....
1979 & Earlier 300 (3.0) .....
NEW MEXICO
NEW MEXICO EMISSION STANDARDS - 2-SPEED IDLE TEST
Application Idle HC ppm (CO %) 2500 RPM HC ppm (CO %)
1975-78 500 (5.0) 500 (5.0)
1979-80 400 (4.0) 400 (4.0)
1981-85 220 (1.2) 220 (1.2)
1986-90 200 (1.2) 200 (1.2)
1991-95 180 (1.2) 180 (1.2)
1975-78 600 (6.0) 600 (6.0)
1979-80 600 (4.5) 600 (4.5)
1981-82 400 (2.7) 400 (3.0)
1983-88 300 (1.2) 300 (3.0)
1989-95 220 (1.2) 220 (1.2)
Medium Duty Trucks (8001-10,000 GVWR)
1975 & Newer 650 (6.5) 650 (6.5)
NEW YORK
NEW YORK EMISSION STANDARDS - IM240 TEST
HC CO
HC gpmPhase CO gpmPhase NOx
Application gpmComposite 2 gpmComposite 2 gpmBoth
Light Duty Vehicles
1981-82 0.80 0.50 30.0 24.0 2.0
1983-95 0.80 0.50 15.0 12.0 2.0
1996 & Newer 0.60 0.40 10.0 8.0 1.5
1981-83 3.40 2.00 70.0 56.0 4.5
1984-87 1.60 1.00 40.0 32.0 4.5
1988-95 1.60 1.00 40.0 32.0 2.5
1996 & Newer 0.60 0.40 10.0 8.0 1.5

(3750 LVW Or
Less)
1996 & Newer 0.80 0.50 13.0 10.0 1.8

(3751 LVW Or
More)
1981-83 3.40 2.00 70.0 56.0 4.5
1984-87 1.60 1.00 40.0 32.0 4.5
1988-95 1.60 1.00 40.0 32.0 3.5
1996 & Newer 0.80 0.50 13.0 10.0 1.8

(5750 ALVW Or
Less)
1996 & Newer 0.80 0.50 15.0 12.0 2.0

(5751 ALVW Or
More)
NEW YORK EMISSION STANDARDS - IDLE TEST
1978 300 (3.0)
1979-80 300 (2.5)
1981 & Newer 220 (1.2)
1978 600 (4.5)

1979 & Newer 300 (3.0)
NORTH CAROLINA
NORTH CAROLINA EMISSION STANDARDS - IDLE TEST
1977 450 (4.5)
1978-79 350 (3.5)
1980 250 (2.0)
1981 & Newer 250 (1.2)
Heavy Duty Trucks (8501 GVWR Or More)
1977-78 500 (5.0)
1979 & Newer 400 (4.0)
OHIO
NOTE: The Ohio program incorporates original U.S. EPA recommended start-up
ASM2525 standards for all model year vehicles. Refer to appropriate model year range in
appropriate table. See U. S. EPA ASM2525 & ASM5015 START-UP EMISSION
STANDARDS .
OHIO EMISSION STANDARDS - 2-SPEED IDLE TEST
1978 350 (4.0)
1979 275 (3.0)
1980 230 (2.0)
1981 & Newer 220 (1.2)
OREGON
OREGON EMISSION STANDARDS - METROPOLITAN PORTLAND ENHANCED AREA - BAR31
Light Duty Passenger Cars
1981-82 2.0 (64) 3.70
1983-89 2.0 (32) 3.70
1990-95 1.2 (30) 3.00

1996 & Newer OBD-II Test OBD-II Test
1981-83 8.5 (149) 8.32
1984-87 4.0 (85) 8.32
1988-89 4.0 (85) 4.62
1990-95 2.4 (80) 3.75
1981-83 8.5 (149) 8.32
1984-87 4.0 (85) 8.32
1988-89 4.0 (85) 6.47
1990-95 2.4 (80) 5.25
OREGON EMISSION STANDARDS - METROPOLITAN PORTLAND & ROGUE VALLEY AREA BASIC
TEST - 2-SPEED IDLE TEST
2500 RPM HC ppm

Application Idle HC ppm (CO %) (CO %)
Light Duty Passenger Cars (6000 GVWR Or Less)
1975-80 (No Catalyst) 300 (2.5) -
1975-80 (Catalyst) 220 (1.0) -
1981 & Newer (All) 220 (1.0) 220 (1.0)
1975 & Newer (2-Stroke) n/a (7.0) -
1975-78 (All) 350 (2.5) -
1979-80 (No Catalyst) 300 (2.5) -
1979-80 (Catalyst) 220 (1.0) -
1981 & Newer (All) 220 (1.0) 220 (1.0)
1996 & Newer (3750 LVW Or Less) 0.9 (20) 2.25
1975-78 (Carbureted) 500 (4.0) n/a (3.0)
1975-78 (Fuel Injection) 500 (4.0) -
1979-84 (Carbureted) 350 (3.0) n/a (3.0)
1979-84 (Fuel Injection) 350 (3.0) -

1985 & Newer (No Catalyst) 350 (3.0) n/a (3.0)
1985 & Newer (W/Catalyst) 220 (1.0) 220 (1.0)
OREGON EMISSION STANDARDS - METROPOLITAN PORTLAND & ROGUE VALLEY AREA BASIC
TEST - EXHAUST OPACITY TEST
Application Opacity % @ Idle Opacity % @ High Idle
1975 & Newer
2-Cycle Engines 20 .....
Gasoline Engines 0 0
PENNSYLVANIA
NOTE: The Pennsylvania (in Philadelphia area) program incorporates original U.S. EPA
recommended start-up ASM5015 standards for 1981 and newer model year vehicles. Refer to
PENNSYLVANIA EMISSION STANDARDS - PITTSBURGH & OLDER PHILADELPHIA VEHICLES -

IDLE TEST
6000 GVWR Or Less
1975-79 400 (4.0)
1980 300 (3.0)
1981-92 220 (1.2)
1993 & Newer 130 (1.0)
6001-9000 GVWR
1975-78 650 (6.0)
1979 400 (4.0)
1980 300 (3.0)
1981-92 220 (1.2)
1993 & Newer 180 (1.0)
RHODE ISLAND
RHODE ISLAND EMISSION STANDARDS - RI2000 TEST
Light Duty Vehicles

1974 & Earlier 15.92 (132.44) 14.92
1975-76 6.74 (96.21) 9.92
1977-79 6.74 (96.21) 6.59
1980 2.25 (45.48) 6.59
1981-82 2.25 (45.48) 3.25
1983-95 2.25 (23.74) 3.25
1996 & Newer 1.84 (16.50) 2.42
1975 & Earlier 16.94 (175.92) 14.92
1975-78 8.78 (117.95) 9.92
1979-83 7.55 (103.45) 7.42
1984-87 3.88 (59.97) 7.42
1988-90 3.88 (59.97) 4.09
1991-95 3.88 (59.97) 4.09
1996 & Newer (3750 LVW Or Less) 1.84 (16.50) 2.42
1996 & Newer (3751 LVW Or More) 2.25 (20.84) 2.92
1974 & Earlier 16.94 (175.92) 14.92
1975-78 8.78 (117.95) 9.92
1979-83 7.55 (103.45) 7.42
1984-87 3.88 (59.97) 7.42
1989-90 3.88 (59.97) 5.75
1991-95 3.88 (59.97) 5.75
1996 & Newer (5750 LVW Or Less) 2.25 (20.84) 2.92
1996 & Newer (5751 LVW or More) 5.51 (23.74) 3.25
RHODE ISLAND EMISSION STANDARDS - 2-SPEED IDLE TEST
Application Idle (1) HC ppm (CO %)
1967 & Earlier 800 (7.0)
1968-74 700 (6.0)
1975-78 300 (3.0)
1979-80 300 (2.5)
1981 & Newer 220 (1.2)

TENNESSEE
TENNESSEE EMISSION STANDARDS - MEMPHIS - IDLE TEST
1971 & Older 900 (8.9)
1972-74 700 (8.2)
1975-79 600 (7.5)
1980 400 (4.7)
1981 & Newer 220 (1.2)
Heavy Duty Trucks (9001-25,999 GVWR)
1971 & Older 1000 (8.9)
1972-74 1000 (8.2)
1975-79 1000 (8.0)
1980 800 (6.0)
1981 & Newer 400 (4.0)
TENNESSEE EMISSION STANDARDS - DAVIDSON & NASHVILLE COUNTIES - IDLE TEST
1975-77 500 (5.0)
1978-79 400 (4.0)
1980 300 (3.0)
1981 & Newer 220 (1.2)
1975-77 750 (6.5)
1978-79 600 (6.0)
1980 400 (4.5)
1981 & Newer 400 (4.0)
TENNESSEE EMISSION STANDARDS - FOUR COUNTY AREA SURROUNDING NASHVILLE - IDLE

TEST

1975-77 500 (5.0)
1978-79 400 (4.0)
1980 300 (3.0)
1981 & Newer 220 (1.2)
1975-77 750 (6.5)
1978-79 600 (6.0)
1980 400 (4.5)
1981 & Newer 400 (4.0)
TEXAS
NOTE: The Texas program incorporates original U.S. EPA recommended start-up
ASM2525 and ASM5015 standards for 1995 and newer model year vehicles. Refer to
TEXAS EMISSION STANDARDS - 2-SPEED IDLE TEST
1979 600 (6.0)
1980 400 (4.0)
1981 & Newer 220 (1.2)
1979-81 700 (7.0)
1982-84 500 (5.0)
1985 & Newer 300 (3.0)
UTAH
UTAH EMISSION STANDARDS - DAVIS COUNTY - DC98 TEST
1989-90 2.00 (30) 3.0
1991-95 1.2 (20) 2.5

1989-90 3.2 (80) 3.5
1991-95 2.4 (60) 3.0
1989-90 3.2 (80) 5.0
1991-95 2.4 (60) 4.5
UTAH EMISSION STANDARDS - DAVIS COUNTY - 2-SPEED IDLE TEST
1968-69 800 (6.0)
1970-74 700 (5.0)
1975-76 600 (4.0)
1977-79 500 (3.0)
1980 300 (2.0)
1981-95 220 (1.2)
Light Duty Vehicles (6001-8500 GVWR)
1968-69 1500 (7.0)
1970-78 1200 (5.0)
1979 500 (3.0)
1980 300 (2.0)
1981-95 220 (1.2)
1968-69 1500 (7.0)
1970-78 1200 (5.0)
1979-80 1000 (4.0)
1981 & Newer 800 (3.5)
NOTE: The Salt Lake County program incorporates California style ASM2525 and
ASM5015 standards for 1968 and newer model year vehicles; however, actual cutpoints are
unique to this program and current information is not available at this time.
UTAH EMISSION STANDARDS - SALT LAKE COUNTY - 2-SPEED IDLE TEST

1968-69 800 (6.0)
1970-74 700 (5.0)
1975-76 600 (4.0)
1977-79 500 (3.0)
1980 300 (2.0)
1981 & Newer 220 (1.2)
1968-99 800 (6.0)
1970-74 700 (5.0)
1975-76 600 (4.0)
1977-79 500 (3.0)
1980 300 (2.0)
1981 & Newer 220 (1.2)
1968-69 1500 (7.0)
1970-78 1200 (5.0)
1979 500 (3.0)
1980 300 (2.0)
1981 & Newer 220 (1.2)
1968-69 1500 (7.0)
1970-78 1200 (5.0)
1979-80 1000 (4.0)
1981 & Newer 800 (3.5)
UTAH EMISSION STANDARDS - UTAH & WEBER COUNTIES - 2-SPEED IDLE TEST
1968-69 800 (6.0)
1970-74 700 (5.0)
1975-76 600 (4.0)
1977-79 500 (3.0)

1980 300 (2.0)
1981-95 220 (1.2)
1968-99 800 (6.0)
1970-74 700 (5.0)
1975-76 600 (4.0)
1977-79 500 (3.0)
1980 300 (2.0)
1981 & Newer 220 (1.2)
1968-69 1500 (7.0)
1970-78 1200 (5.0)
1979 500 (3.0)
1980 300 (2.0)
1981 & Newer 220 (1.2)
1968-69 1500 (7.0)
1970-78 1200 (5.0)
1979-80 1000 (4.0)
1981 & Newer 800 (3.5)
VIRGINIA
NOTE: The Virginia program incorporates original U.S. EPA recommended start-up
ASM2525 and ASM5015 standards for 1981 and newer model year vehicles. Refer to
VIRGINIA EMISSION STANDARDS - 2-SPEED IDLE TEST
8500 GVWR Or Less
1975-90 400 (4.0)
1980 220 (2.0)
1981-89 220 (1.2)
1990-95 125 (1.0)

1996 & Newer 100 (0.75)
8501-10,000 GVWR
1975-79 400 (4.0)
1980 220 (2.0)
1981-90 220 (1.2)
1991-96 150 (1.0)
1997 & Newer 125 (0.75)
WASHINGTON
WASHINGTON EMISSION STANDARDS - ASM2525 TEST
1980 & Earlier (Light-Duty Vehicles)
1750 GVWR 400 (4.2)
1875 GVWR 380 (4.0)
2000 GVWR 350 (3.8)
2125 GVWR 340 (3.6)
2250 GVWR 320 (3.4)
2375 GVWR 300 (3.2)
2500 GVWR 290 (3.0)
2625 GVWR 270 (2.9)
2750 GVWR 260 (2.8)
2875 GVWR 250 (2.7)
3000 GVWR 240 (2.6)
3125 GVWR 230 (2.5)
3250 GVWR 220 (2.4)
3375 GVWR 220 (2.3)
3500 GVWR 210 (2.2)
3625 GVWR 200 (2.1)
3750 Or Greater GVWR (Passenger Cars Only) 200 (2.1)
3750 Or Greater GVWR (Light Duty Trucks) 300 (2.5)
1981 & Newer (Light-Duty Vehicles)
1750 GVWR 250 (1.8)
1875 GVWR 240 (1.7)

2000 GVWR 220 (1.6)
2125 GVWR 210 (1.5)
2250 GVWR 200 (1.5)
2375 GVWR 190 (1.4)
2500 GVWR 180 (1.3)
2625 GVWR 180 (1.3)
2750 GVWR 171 (1.2)
2875 GVWR 160 (1.2)
3000 GVWR 160 (1.1)
3125 GVWR 150 (1.1)
3250 GVWR 150 (1.0)
3375 GVWR 150 (1.0)
3500 GVWR 150 (1.0)
3625 GVWR 150 (1.0)
3750 Or Greater GVWR (Passenger Cars Only) 150 (1.0)
3750 Or Greater GVWR (Light Duty Trucks) 300 (2.5)
WASHINGTON EMISSION STANDARDS - 2-SPEED IDLE TEST
Application Idle/2500 RPM HC ppm (CO %)
1980 & Earlier 600 (3.0)
1981 & Newer 220 (1.2)
1981 & Newer 400 (3.0)
WISCONSIN
WISCONSIN EMISSION STANDARDS - IM240 TEST
1968-72 7.0 (120) 7.0
1973-74 7.0 (120) 6.0
1975-76 3.0 (65) 6.0
1977-79 3.0 (65) 4.0

1980 2.0 (60) 4.0
1981-82 2.0 (60) 3.0
1983-86 2.0 (30) 3.0
1987-93 0.8 (15) 2.0
1991-95 0.8 (15) 2.0
1996 & Newer 0.6 (10) 1.5
1968-72 7.0 (120) 7.0
1973-74 7.0 (120) 6.0
1975-78 4.0 (80) 6.0
1979-83 3.4 (70) 4.5
1984-86 3.2 (70) 4.5
1987 1.6 (40) 4.5
1988-95 1.6 (40) 2.5
1996 & Newer (3750 LVW Or Less) 0.6 (10) 1.5
1996 & Newer (3751 LVW Or More) 0.8 (13) 1.8
1968-72 7.0 (120) 7.0
1973-74 7.0 (120) 6.0
1975-78 4.0 (80) 6.0
1979-83 3.4 (70) 4.5
1984-86 3.2 (70) 4.5
1988-96 1.6 (40) 3.5
1997 & Newer (5750 ALVW Or Less) 0.8 (13) 1.8
1997 & Newer (5751 ALVW Or More) 0.8 (15) 2.0
Heavy Duty Trucks (8501-10,000 GVWR)
1968-69 20.0 (200) 15.0
1970-73 10.0 (175) 10.0
1974-78 10.0 (150) 10.0
1979-84 7.5 (100) 8.0
1985-86 5.0 (80) 8.0
1987-90 2.0 (40) 6.0
1991-97 2.0 (40) 5.0

1998 & Newer 2.0 (30) 4.0
Heavy Duty Trucks (10,001 GVWR or More)
1968-69 24.0 (250) 30.0
1970-73 13.0 (175) 20.0
1974-78 13.0 (150) 20.0
1979-84 11.5 (150) 16.0
1985-86 10.0 (150) 16.0
1987-90 3.5 (70) 11.0
1991-97 3.5 (70) 9.0
1998 & Newer 3.5 (60) 7.0
WISCONSIN EMISSION STANDARDS - 2-SPEED IDLE TEST
Passenger Cars
1968-71 800 (8.0)
1972-74 550 (7.0)
1975-77 450 (5.5)
1978 350 (4.0)
1979 275 (3.0)
1980 230 (2.0)
1981 & Newer 220 (1.2)
1968-71 800 (8.0)
1972-74 700 (7.0)
1975-77 500 (6.0)
1978 450 (5.0)
1979 300 (3.0)
1980 275 (2.5)
1981-84 250 (2.0)
1985 & Newer 220 (1.2)
1968-69 1450 (9.0)
1970-71 800 (8.0)

1972-74 700 (7.0)
1975-77 550 (6.5)
1978 450 (5.5)
1979 300 (3.0)
1980 275 (2.5)
1981-84 250 (2.0)
1985 & Newer 220 (1.2)
1968-71 1500 (9.5)
1972-78 900 (9.0)
1979-84 700 (7.0)
1985 & Newer 300 (3.0)
U. S. EPA ASM2525 & ASM5015 START-UP EMISSION STANDARDS

U.S. EPA ASM EMISSION STANDARDS - 1968-72 LIGHT DUTY VEHICLES
Test Weight ASM5015 ASM2525
HC ppm (CO
HC ppm (CO %) NOx ppm %) NOx ppm
1750 1118 (8.02) 4990 1098 (9.90) 4990
1875 1052 (7.56) 4990 1034 (9.90) 4990
2000 992 (7.14) 4990 975 (9.90) 4990
2125 938 (6.75) 4990 921 (9.66) 4990
2250 887 (6.40) 4990 872 (9.14) 4990
2375 841 (6.07) 4990 827 (8.67) 4990
2500 800 (5.78) 4990 786 (8.25) 4990
2625 761 (5.51) 4990 748 (7.85) 4990
2750 726 (5.26) 4990 714 (7.50) 4772
2875 695 (5.03) 4892 683 (7.17) 4556
3000 666 (4.83) 4680 654 (6.87) 4359
3125 639 (4.64) 4488 628 (6.60) 4180
3250 615 (4.47) 4311 604 (6.35) 4016
3375 593 (4.31) 4150 583 (6.13) 3866
3500 573 (4.17) 4002 563 (5.92) 3728

3625 554 (4.04) 3867 544 (5.73) 3602
3750 537 (3.91) 3741 527 (5.55) 3485
3875 521 (3.80) 3625 512 (5.39) 3377
4000 506 (3.70) 3517 497 (5.24) 3276
4125 492 (3.60) 3416 484 (5.09) 3182
4250 479 (3.51) 3321 471 (4.96) 3094
4375 467 (3.42) 3230 459 (4.83) 3010
4500 455 (3.34) 3145 447 (4.71) 2930
4625 444 (3.26) 3063 436 (4.60) 2854
4750 433 (3.18) 2983 425 (4.49) 2780
4875 423 (3.11) 2907 415 (4.38) 2709
5000 412 (3.03) 2833 405 (4.28) 2540
5125 402 (2.97) 2760 395 (4.18) 2573
5250 393 (2.90) 2690 386 (4.08) 2507
5375 383 (2.83) 2621 376 (3.98) 2443
5500 374 (2.77) 2554 367 (3.89) 2381
5625 365 (2.70) 2489 359 (3.80) 2321
5750 357 (2.64) 2426 350 (3.71) 2262
5875 348 (2.59) 2366 342 (3.62) 2206
6000 341 (2.53) 2308 334 (3.54) 2152
6125 333 (2.48) 2254 327 (3.47) 2102
6250 326 (2.43) 2204 320 (3.40) 2056
6375 320 (2.39) 2159 314 (3.34) 2014
6500 315 (2.35) 2119 309 (3.28) 1977
6625 310 (2.32) 2087 304 (3.23) 1947
6750 307 (2.29) 2062 301 (3.20) 1924
6875 305 (2.28) 2046 299 (3.17) 1909
7000 304 (2.27) 2040 298 (3.17) 1904
7125 Or More 304 (2.27) 2045 298 (3.17) 1904

HC ppm (CO HC ppm (CO
%) NOx ppm %) NOx ppm
1750 1118 (8.02) 4990 1098 (9.90) 4980
1875 1052 (7.56) 4990 1034 (9.90) 4906
2000 992 (7.14) 4919 975 (9.90) 4838
2125 938 (6.75) 4853 921 (9.66) 4776
2250 887 (6.40) 4792 872 (9.14) 4720
2375 841 (6.07) 4736 827 (8.67) 4668
2500 800 (5.78) 4685 786 (8.25) 4620
2625 761 (5.51) 4639 748 (7.85) 4577
2750 726 (5.26) 4596 714 (7.50) 4374
2875 695 (5.03) 4484 683 (7.17) 4176
3000 666 (4.83) 4290 654 (6.87) 3996
3125 639 (4.64) 4114 628 (6.60) 3832
3250 615 (4.47) 3952 604 (6.35) 3681
3375 593 (4.31) 3804 583 (6.13) 3544
3500 573 (4.17) 3669 563 (5.92) 3418
3625 554 (4.04) 3544 544 (5.73) 3302
3750 537 (3.91) 3429 527 (5.55) 3195
3875 521 (3.80) 3323 512 (5.39) 3096
4000 506 (3.70) 3224 497 (5.24) 3003
4125 492 (3.60) 3131 484 (5.09) 2917
4250 479 (3.51) 3044 471 (4.96) 2836
4375 467 (3.42) 2961 459 (4.83) 2759
4500 455 (3.34) 2883 447 (4.71) 2686
4625 444 (3.26) 2807 436 (4.60) 2616
4750 433 (3.18) 2735 425 (4.49) 2549
4875 423 (3.11) 2665 415 (4.38) 2483
5000 412 (3.03) 2597 405 (4.28) 2420
5125 402 (2.97) 2530 395 (4.18) 2359
5250 393 (2.90) 2466 386 (4.08) 2298
5375 383 (2.83) 2403 376 (3.98) 2240
5500 374 (2.77) 2341 367 (3.89) 2183

5625 365 (2.70) 2282 359 (3.80) 2127
5750 357 (2.64) 2224 350 (3.71) 2074
5875 348 (2.59) 2168 342 (3.62) 2022
6000 341 (2.53) 2116 334 (3.54) 1973
6125 333 (2.48) 2066 327 (3.47) 1927
6250 326 (2.43) 2020 320 (3.40) 1884
6375 320 (2.39) 1979 314 (3.34) 1846
6500 315 (2.35) 1943 309 (3.28) 1813
6625 310 (2.32) 1913 304 (3.23) 1785
6750 307 (2.29) 1890 301 (3.20) 1764
6875 305 (2.28) 1875 299 (3.17) 1750
7000 304 (2.27) 1870 298 (3.17) 1745
7125 Or More 304 (2.27) 1874 298 (3.17) 1745
HC ppm (CO
%) NOx ppm HC ppm (CO %) NOx ppm
1750 774 (3.92) 4990 761 (5.45) 4980
1875 729 (3.70) 4990 717 (5.14) 4906
2000 688 (3.49) 4919 676 (4.85) 4838
2125 650 (3.31) 4853 638 (4.58) 4776
2250 615 (3.13) 4792 604 (4.34) 4720
2375 583 (2.98) 4736 573 (4.12) 4668
2500 554 (2.83) 4685 544 (3.91) 4620
2625 528 (2.70) 4639 518 (3.73) 4577
2750 503 (2.58) 4596 495 (3.56) 4374
2875 481 (2.47) 4484 473 (3.41) 4176
3000 461 (2.37) 4290 453 (3.27) 3996
3125 443 (2.28) 4114 435 (3.14) 3832
3250 426 (2.20) 3952 419 (3.02) 3681
3375 411 (2.12) 3804 404 (2.91) 3544
3500 397 (2.05) 3669 390 (2.82) 3418

3625 384 (1.99) 3544 377 (2.73) 3302
3750 372 (1.93) 3429 365 (2.64) 3195
3875 361 (1.87) 3323 355 (2.57) 3096
4000 351 (1.82) 3224 345 (2.49) 3003
4125 341 (1.77) 3131 335 (2.43) 2917
4250 332 (1.73) 3044 326 (2.36) 2836
4375 323 (1.68) 2961 318 (2.31) 2759
4500 315 (1.64) 2883 310 (2.25) 2686
4625 308 (1.61) 2807 302 (2.19) 2616
4750 300 (1.57) 2735 295 (2.14) 2549
4875 293 (1.53) 2665 288 (2.09) 2483
5000 286 (1.50) 2597 281 (2.04) 2420
5125 279 (1.46) 2530 274 (2.00) 2359
5250 272 (1.43) 2466 267 (1.95) 2298
5375 266 (1.40) 2403 261 (1.90) 2240
5500 259 (1.37) 2341 255 (1.86) 2183
5625 253 (1.34) 2282 248 (1.82) 2127
5750 247 (1.31) 2224 243 (1.78) 2074
5875 241 (1.28) 2168 237 (1.74) 2022
6000 236 (1.25) 2116 232 (1.70) 1973
6125 231 (1.23) 2066 227 (1.66) 1927
6250 226 (1.20) 2020 222 (1.63) 1884
6375 222 (1.18) 1979 218 (1.60) 1846
6500 218 (1.16) 1943 214 (1.57) 1813
6625 215 (1.15) 1913 211 (1.55) 1785
6750 213 (1.14) 1890 209 (1.54) 1764
6875 211 (1.13) 1875 207 (1.52) 1750
7000 211 (1.12) 1870 207 (1.52) 1745
7125 Or More 211 (1.12) 1874 206 (1.52) 1745

HC ppm (CO
1750 774 (3.92) 4990 761 (5.45) 4950
1875 729 (3.70) 4990 717 (5.14) 4655
2000 688 (3.49) 4707 676 (4.85) 4384
2125 650 (3.31) 4441 638 (4.58) 4136
2250 615 (3.13) 4197 604 (4.34) 3909
2375 583 (2.98) 3974 573 (4.12) 3701
2500 554 (2.83) 3771 544 (3.91) 3512
2625 528 (2.70) 3585 518 (3.73) 3339
2750 503 (2.58) 3416 495 (3.56) 3181
2875 481 (2.47) 3261 473 (3.41) 3037
3000 461 (2.37) 3120 453 (3.27) 2906
3125 443 (2.28) 2992 435 (3.14) 2787
3250 426 (2.20) 2874 419 (3.02) 2677
3375 411 (2.12) 2767 404 (2.91) 2577
3500 397 (2.05) 2668 390 (2.82) 2486
3625 384 (1.99) 2578 377 (2.73) 2401
3750 372 (1.93) 2494 365 (2.64) 2323
3875 361 (1.87) 2417 355 (2.57) 2251
4000 351 (1.82) 2345 345 (2.49) 2184
4125 341 (1.77) 2277 335 (2.43) 2122
4250 332 (1.73) 2214 326 (2.36) 2063
4375 323 (1.68) 2154 318 (2.31) 2007
4500 315 (1.64) 2096 310 (2.25) 1953
4625 308 (1.61) 2042 302 (2.19) 1903
4750 300 (1.57) 1989 295 (2.14) 1854
4875 293 (1.53) 1938 288 (2.09) 1806
5000 286 (1.50) 1889 281 (2.04) 1760
5125 279 (1.46) 1840 274 (2.00) 1715
5250 272 (1.43) 1793 267 (1.95) 1672
5375 266 (1.40) 1747 261 (1.90) 1629
5500 259 (1.37) 1703 255 (1.86) 1587

5625 253 (1.34) 1659 248 (1.82) 1547
5750 247 (1.31) 1617 243 (1.78) 1508
5875 241 (1.28) 1577 237 (1.74) 1471
6000 236 (1.25) 1539 232 (1.70) 1435
6125 231 (1.23) 1503 227 (1.66) 1401
6250 226 (1.20) 1469 222 (1.63) 1371
6375 222 (1.18) 1439 218 (1.60) 1343
6500 218 (1.16) 1413 214 (1.57) 1318
6625 215 (1.15) 1391 211 (1.55) 1298
6750 213 (1.14) 1374 209 (1.54) 1283
6875 211 (1.13) 1364 207 (1.52) 1273
7000 Or More 211 (1.12) 1360 207 (1.52) 1269
U.S. EPA ASM EMISSION STANDARDS - 1980 LIGHT DUTY VEHICLES

1750 291 (2.78) 4990 282 (3.64) 4950
1875 275 (2.63) 4990 266 (3.43) 4655
2000 260 (2.48) 4707 252 (3.24) 4384
2125 246 (2.35) 4441 239 (3.06) 4136
2250 234 (2.23) 4197 227 (2.90) 3909
2375 223 (2.12) 3974 216 (2.76) 3701
2500 212 (2.02) 3771 206 (2.62) 3512
2625 203 (1.92) 3585 197 (2.50) 3339
2750 194 (1.84) 3416 189 (2.39) 3181
2875 187 (1.76) 3261 181 (2.29) 3037
3000 180 (1.69) 3120 174 (2.19) 2906
3125 173 (1.63) 2992 168 (2.11) 2787
3250 167 (1.57) 2874 162 (2.03) 2677
3375 162 (1.52) 2767 157 (1.96) 2577
3500 157 (1.47) 2668 152 (1.89) 2486
3625 152 (1.42) 2578 148 (1.84) 2401

3750 148 (1.38) 2492 144 (1.78) 2323
3875 144 (1.34) 2417 140 (1.73) 2251
4000 140 (1.31) 2345 137 (1.68) 2184
4125 137 (1.27) 2277 133 (1.64) 2122
4250 134 (1.24) 2214 130 (1.60) 2063
4375 131 (1.21) 2154 127 (1.56) 2007
4500 128 (1.18) 2096 124 (1.52) 1953
4625 125 (1.15) 2042 122 (1.48) 1903
4750 122 (1.13) 1989 119 (1.45) 1854
4875 120 (1.10) 1938 117 (1.42) 1806
5000 117 (1.08) 1889 114 (1.38) 1760
5125 115 (1.05) 1840 112 (1.35) 1715
5250 112 (1.03) 1793 110 (1.32) 1672
5375 110 (1.01) 1747 107 (1.29) 1629
5500 108 (0.99) 1703 105 (1.26) 1587
5625 106 (0.97) 1659 103 (1.24) 1547
5750 104 (0.94) 1617 101 (1.21) 1508
5875 102 (0.92) 1577 99 (1.18) 1471
6000 100 (0.91) 1539 97 (1.16) 1435
6125 98 (0.89) 1503 95 (1.13) 1401
6250 96 (0.87) 1469 94 (1.11) 1371
6375 95 (0.86) 1439 92 (1.09) 1343
6500 93 (0.84) 1413 91 (1.08) 1318
6625 92 (0.83) 1391 90 (1.06) 1298
6750 91 (0.82) 1374 89 (1.05) 1283
6875 91 (0.82) 1364 89 (1.04) 1273
7000 91 (0.82) 1360 88 (1.04) 1269
7125 Or More 90 (0.81) 1360 88 (1.04) 1269

1750 291 (2.78) 2272 282 (3.64) 2114
1875 275 (2.63) 2181 266 (3.43) 1991
2000 260 (2.48) 2058 252 (3.24) 1877
2125 246 (2.35) 1944 239 (3.06) 1774
2250 234 (2.23) 1839 227 (2.90) 1678
2375 223 (2.12) 1744 216 (2.76) 1592
2500 212 (2.02) 1657 206 (2.62) 1512
2625 203 (1.92) 1577 197 (2.50) 1440
2750 194 (1.84) 1504 189 (2.39) 1374
2875 187 (1.76) 1438 181 (2.29) 1313
3000 180 (1.69) 1378 174 (2.19) 1258
3125 173 (1.63) 1323 168 (2.11) 1208
3250 167 (1.57) 1273 162 (2.03) 1163
3375 162 (1.52) 1227 157 (1.96) 1121
3500 157 (1.47) 1184 152 (1.89) 1082
3625 152 (1.42) 1146 148 (1.84) 1047
3750 148 (1.38) 1110 144 (1.78) 1014
3875 144 (1.34) 1077 140 (1.73) 984
4000 140 (1.31) 1046 137 (1.68) 956
4125 137 (1.27) 1017 133 (1.64) 930
4250 134 (1.24) 990 130 (1.60) 905
4375 131 (1.21) 964 127 (1.56) 882
4500 128 (1.18) 939 124 (1.52) 859
4625 125 (1.15) 916 122 (1.48) 838
4750 122 (1.13) 893 119 (1.45) 818
4875 120 (1.10) 872 117 (1.42) 798
5000 117 (1.08) 850 114 (1.38) 778
5125 115 (1.05) 830 112 (1.35) 760
5250 112 (1.03) 810 110 (1.32) 741
5375 110 (1.01) 790 107 (1.29) 723
5500 108 (0.99) 771 105 (1.26) 706
5625 106 (0.97) 752 103 (1.24) 689
5750 104 (0.94) 734 101 (1.21) 673

5875 102 (0.92) 717 99 (1.18) 657
6000 100 (0.91) 701 97 (1.16) 642
6125 98 (0.89) 685 95 (1.13) 628
6250 96 (0.87) 671 94 (1.11) 615
6375 95 (0.86) 658 92 (1.09) 604
6500 93 (0.84) 647 91 (1.08) 593
6625 92 (0.83) 638 90 (1.06) 585
6750 91 (0.82) 631 89 (1.05) 578
6875 91 (0.82) 626 89 (1.04) 574
7000 91 (0.82) 624 88 (1.04) 573
7125 Or More 90 (0.81) 625 88 (1.04) 573

1750 291 (1.64) 2272 282 (1.83) 2114
1875 275 (1.55) 2181 266 (1.72) 1991
2000 260 (1.47) 2058 252 (1.63) 1877
2125 246 (1.39) 1944 239 (1.54) 1774
2250 234 (1.31) 1839 227 (1.47) 1678
2375 223 (1.26) 1744 216 (1.39) 1592
2500 212 (1.20) 1657 206 (1.33) 1512
2625 203 (1.15) 1577 197 (1.27) 1440
2750 194 (1.10) 1504 189 (1.21) 1374
2875 187 (1.05) 1438 181 (1.16) 1313
3000 180 (1.01) 1378 174 (1.12) 1258
3125 173 (0.98) 1323 168 (1.08) 1208
3250 167 (0.94) 1273 162 (1.04) 1163
3375 162 (0.91) 1227 157 (1.00) 1121
3500 157 (0.88) 1184 152 (0.97) 1082
3625 152 (0.86) 1146 148 (0.94) 1047
3750 148 (0.83) 1110 144 (0.92) 1014

3875 144 (0.81) 1077 140 (0.89) 984
4000 140 (0.79) 1046 137 (0.87) 956
4125 137 (0.77) 1017 133 (0.85) 930
4250 134 (0.75) 990 130 (.83) 905
4375 131 (0.74) 964 127 (0.81) 882
4500 128 (0.72) 939 124 (0.79) 859
4625 125 (0.70) 916 122 (0.77) 838
4750 122 (0.69) 893 119 (0.76) 818
4875 120 (0.67) 872 117 (0.74) 798
5000 117 (0.66) 850 114 (0.73) 778
5125 115 (0.65) 830 112 (0.71) 760
5250 112 (0.63) 810 110 (0.70) 741
5375 110 (0.62) 790 107 (0.68) 723
5500 108 (0.61) 771 105 (0.67) 706
5625 106 (0.59) 752 103 (0.65) 689
5750 104 (0.58) 734 101 (0.64) 673
5875 102 (0.57) 717 99 (0.63) 657
6000 100 (0.56) 701 97 (0.62) 642
6125 98 (0.55) 685 95 (0.61) 628
6250 96 (0.54) 671 94 (0.60) 615
6375 95 (0.53) 658 92 (0.59) 604
6500 93 (0.52) 647 91 (0.58) 593
6625 92 (0.52) 638 90 (0.57) 585
6750 91 (0.51) 631 89 (0.57) 578
6875 91 (0.51) 626 89 (0.56) 574
7000 91 (0.51) 624 88 (0.56) 573
7125 90 (0.51) 625 88 (0.56) 573
7250 Or More 90 (0.50) 625 88 (0.56) 573

1750 224 (1.26) 1819 216 (1.22) 1642
1875 212 (1.19) 1713 205 (1.16) 1547
2000 201 (1.13) 1616 194 (1.09) 1460
2125 191 (1.07) 1527 184 (1.04) 1380
2250 182 (1.02) 1446 175 (0.99) 1307
2375 173 (0.97) 1372 167 (0.94) 1240
2500 166 (0.93) 1304 160 (0.90) 1179
2625 159 (0.89) 1242 153 (0.86) 1123
2750 152 (0.85) 1186 147 (0.82) 1072
2875 146 (0.82) 1134 141 (0.79) 1026
3000 141 (0.79) 1088 136 (0.76) 984
3125 136 (0.76) 1045 132 (0.73) 945
3250 132 (0.73) 1006 127 (0.71) 910
3375 128 (0.71) 970 123 (0.69) 878
3500 124 (0.69) 937 120 (0.67) 848
3625 120 (0.67) 907 117 (0.65) 821
3750 117 (0.65) 879 114 (0.63) 796
3875 114 (0.63) 853 111 (0.61) 773
4000 112 (0.62) 829 108 (0.60) 751
4125 109 (0.60) 807 106 (0.58) 731
4250 107 (0.59) 786 103 (0.57) 712
4375 104 (0.58) 766 101 (0.56) 694
4500 102 (0.57) 747 99 (0.55) 677
4625 100 (0.55) 728 97 (0.54) 661
4750 98 (0.54) 711 95 (0.53) 645
4875 96 (0.53) 694 93 (0.52) 630
5000 94 (0.52) 677 92 (0.51) 615
5125 93 (0.51) 661 90 (0.50) 600
5250 91 (0.50) 646 88 (0.49) 586
5375 89 (0.49) 631 86 (0.48) 573
5500 87 (0.48) 616 85 (0.47) 559
5625 86 (0.47) 601 83 (0.46) 546
5750 84 (0.46) 587 82 (0.45) 534

5875 83 (0.45) 574 80 (0.44) 522
6000 81 (0.44) 561 79 (0.44) 510
6125 80 (0.44) 549 78 (0.43) 499
6250 79 (0.43) 538 76 (0.42) 489
6375 77 (0.42) 528 75 (0.42) 480
6500 76 (0.42) 519 74 (0.41) 473
6625 76 (0.41) 512 74 (0.41) 466
6750 75 (0.41) 507 73 (0.41) 461
6875 75 (0.40) 503 73 (0.40) 458
7000 Or More 74 (0.40) 502 72 (0.40) 457
U.S. EPA ASM EMISSION STANDARDS - 1994 & NEWER + TIER 1 LIGHT DUTY VEHICLES
HC ppm (CO
1750 142 (0.80) 1212 136 (0.77) 1095
1875 134 (0.75) 1142 129 (0.73) 1031
2000 127 (0.71) 1077 123 (0.69) 973
2125 121 (0.68) 1018 116 (0.66) 920
2250 115 (0.64) 964 111 (0.62) 871
2375 109 (0.61) 915 106 (0.59) 827
2500 105 (0.59) 869 101 (0.57) 786
2625 100 (0.56) 828 97 (0.54) 749
2750 96 (0.54) 791 93 (0.52) 715
2875 92 (0.52) 756 89 (0.50) 684
3000 89 (0.50) 725 86 (0.48) 656
3125 86 (0.48) 696 83 (0.46) 630
3250 83 (0.46) 670 80 (0.45) 607
3375 81 (0.45) 647 78 (0.43) 585
3500 78 (0.44) 625 76 (0.42) 566
3625 76 (0.42) 605 74 (0.41) 547
3750 74 (0.41) 586 72 (0.40) 531
3875 72 (0.40) 569 70 (0.39) 515

4000 71 (0.39) 553 68 (0.38) 501
4125 69 (0.38) 538 67 (0.37) 487
4250 67 (0.37) 524 65 (0.36) 475
4375 66 (0.36) 510 64 (0.35) 463
4500 65 (0.36) 498 63 (0.35) 440
4625 63 (0.35) 486 61 (0.34) 440
4750 62 (0.34) 474 60 (0.33) 430
4875 61 (0.34) 463 59 (0.33) 420
5000 60 (0.33) 452 58 (0.32) 410
5125 58 (0.32) 441 57 (0.31) 400
5250 57 (0.32) 431 56 (0.31) 391
5375 56 (0.31) 420 55 (0.30) 382
5500 55 (0.30) 410 54 (0.30) 373
5625 54 (0.30) 401 53 (0.29) 364
5750 53 (0.29) 391 52 (0.29) 356
5875 52 (0.29) 383 51 (0.28) 348
6000 51 (0.28) 374 50 (0.28) 340
6125 50 (0.28) 366 49 (0.27) 333
6250 50 (0.27) 359 48 (0.27) 326
6375 49 (0.27) 352 48 (0.26) 320
6500 48 (0.26) 346 47 (0.26) 315
6625 48 (0.26) 341 46 (0.26) 311
6750 47 (0.26) 338 46 (0.26) 307
6875 47 (0.26) 335 46 (0.25) 305
7000 Or More 47 (0.25) 335 46 (0.25) 305
U.S. EPA ASM EMISSION STANDARDS - 1968-72 LIGHT DUTY TRUCKS (6000 GVWR OR LESS)

1750 1118 (8.02) 4990 1098 (9.90) 4990
1875 1052 (7.56) 4990 1034 (9.90) 4990
2000 992 (7.14) 4990 975 (9.90) 4990

2125 938 (6.75) 4990 921 (9.66) 4990
2250 887 (6.40) 4990 872 (9.14) 4990
2375 841 (6.07) 4990 827 (8.67) 4990
2500 800 (5.78) 4990 786 (8.25) 4990
2625 761 (5.51) 4990 748 (7.85) 4990
2750 726 (5.26) 4990 714 (7.50) 4772
2875 695 (5.03) 4892 683 (7.17) 4556
3000 666 (4.83) 4680 654 (6.87) 4359
3125 639 (4.64) 4488 628 (6.60) 4180
3250 615 (4.47) 4311 604 (6.35) 4016
3375 593 (4.31) 4150 583 (6.13) 3866
3500 573 (4.17) 4002 563 (5.92) 3728
3625 554 (4.04) 3867 544 (5.73) 3602
3750 537 (3.91) 3741 527 (5.55) 3485
3875 521 (3.80) 3625 512 (5.39) 3377
4000 506 (3.70) 3517 497 (5.24) 3276
4125 492 (3.60) 3416 484 (5.09) 3182
4250 479 (3.51) 3321 471 (4.96) 3094
4375 467 (3.42) 3230 459 (4.83) 3010
4500 455 (3.34) 3145 447 (4.71) 2930
4625 444 (3.26) 3063 436 (4.60) 2854
4750 433 (3.18) 2983 425 (4.49) 2780
4875 423 (3.11) 2907 415 (4.38) 2709
5000 412 (3.03) 2833 405 (4.28) 2540
5125 402 (2.97) 2760 395 (4.18) 2573
5250 393 (2.90) 2690 386 (4.08) 2507
5375 383 (2.83) 2621 376 (3.98) 2443
5500 374 (2.77) 2554 367 (3.89) 2381
5625 365 (2.70) 2489 359 (3.80) 2321
5750 357 (2.64) 2426 350 (3.71) 2262
5875 348 (2.59) 2366 342 (3.62) 2206
6000 341 (2.53) 2308 334 (3.54) 2152
6125 333 (2.48) 2254 327 (3.47) 2102

6250 326 (2.43) 2204 320 (3.40) 2056
6375 320 (2.39) 2159 314 (3.34) 2014
6500 315 (2.35) 2119 309 (3.28) 1977
6625 310 (2.32) 2087 304 (3.23) 1947
6750 307 (2.29) 2062 301 (3.20) 1924
6875 305 (2.28) 2046 299 (3.17) 1909
7000 304 (2.27) 2040 298 (3.17) 1904
7125 Or More 304 (2.27) 2045 298 (3.17) 1904
HC ppm (CO
1750 1118 (8.02) 4990 1098 (9.90) 4980
1875 1052 (7.56) 4990 1034 (9.90) 4906
2000 992 (7.14) 4919 975 (9.90) 4838
2125 938 (6.75) 4853 921 (9.66) 4776
2250 887 (6.40) 4792 872 (9.14) 4720
2375 841 (6.07) 4736 827 (8.67) 4668
2500 800 (5.78) 4685 786 (8.25) 4620
2625 761 (5.51) 4639 748 (7.85) 4577
2750 726 (5.26) 4596 714 (7.50) 4374
2875 695 (5.03) 4484 683 (7.17) 4176
3000 666 (4.83) 4290 654 (6.87) 3996
3125 639 (4.64) 4114 628 (6.60) 3832
3250 615 (4.47) 3952 604 (6.35) 3681
3375 593 (4.31) 3804 583 (6.13) 3544
3500 573 (4.17) 3669 563 (5.92) 3418
3625 554 (4.04) 3544 544 (5.73) 3302
3750 537 (3.91) 3429 527 (5.55) 3195
3875 521 (3.80) 3323 512 (5.39) 3096
4000 506 (3.70) 3224 497 (5.24) 3003
4125 492 (3.60) 3131 484 (5.09) 2917

4250 479 (3.51) 3044 471 (4.96) 2836
4375 467 (3.42) 2961 459 (4.83) 2759
4500 455 (3.34) 2883 447 (4.71) 2686
4625 444 (3.26) 2807 436 (4.60) 2616
4750 433 (3.18) 2735 425 (4.49) 2549
4875 423 (3.11) 2665 415 (4.38) 2483
5000 412 (3.03) 2597 405 (4.28) 2420
5125 402 (2.97) 2530 395 (4.18) 2359
5250 393 (2.90) 2466 386 (4.08) 2298
5375 383 (2.83) 2403 376 (3.98) 2240
5500 374 (2.77) 2341 367 (3.89) 2183
5625 365 (2.70) 2282 359 (3.80) 2127
5750 357 (2.64) 2224 350 (3.71) 2074
5875 348 (2.59) 2168 342 (3.62) 2022
6000 341 (2.53) 2116 334 (3.54) 1973
6125 333 (2.48) 2066 327 (3.47) 1927
6250 326 (2.43) 2020 320 (3.40) 1884
6375 320 (2.39) 1979 314 (3.34) 1846
6500 315 (2.35) 1943 309 (3.28) 1813
6625 310 (2.32) 1913 304 (3.23) 1785
6750 307 (2.29) 1890 301 (3.20) 1764
6875 305 (2.28) 1875 299 (3.17) 1750
7000 304 (2.27) 1870 298 (3.17) 1745
7125 Or More 304 (2.27) 1874 298 (3.17) 1745
HC ppm (CO
1750 843 (5.07) 4990 828 (7.26) 4980
1875 794 (4.78) 4990 780 (6.84) 4906
2000 749 (4.51) 4919 736 (6.45) 4838
2125 707 (4.26) 4853 695 (6.10) 4776

2250 669 (4.04) 4792 658 (5.78) 4720
2375 635 (3.83) 4736 624 (5.48) 4668
2500 603 (3.65) 4685 593 (5.21) 4620
2625 574 (3.48) 4639 564 (4.96) 4577
2750 548 (3.32) 4596 539 (4.73) 4374
2875 524 (3.18) 4484 515 (4.53) 4176
3000 502 (3.05) 4290 493 (4.34) 3996
3125 482 (2.93) 4114 474 (4.17) 3832
3250 464 (2.82) 3952 456 (4.01) 3681
3375 447 (2.72) 3804 440 (3.87) 3544
3500 432 (2.63) 3669 424 (3.74) 3418
3625 418 (2.55) 3544 411 (3.62) 3302
3750 405 (2.47) 3429 398 (3.51) 3195
3875 393 (2.40) 3323 386 (3.40) 3096
4000 382 (2.33) 3224 375 (3.31) 3003
4125 371 (2.27) 3131 365 (3.22) 2917
4250 361 (2.21) 3044 355 (3.13) 2836
4375 352 (2.16) 2961 346 (3.05) 2759
4500 343 (2.11) 2883 337 (2.98) 2686
4625 335 (2.06) 2807 329 (2.90) 2616
4750 327 (2.01) 2735 321 (2.83) 2549
4875 319 (1.96) 2665 313 (2.77) 2483
5000 311 (1.92) 2597 305 (2.70) 2420
5125 304 (1.87) 2530 298 (2.64) 2359
5250 296 (1.83) 2466 291 (2.58) 2298
5375 289 (1.79) 2403 284 (2.51) 2240
5500 282 (1.75) 2341 277 (2.46) 2183
5625 276 (1.71) 2282 271 (2.40) 2127
5750 269 (1.67) 2224 264 (2.34) 2074
5875 263 (1.63) 2168 258 (2.29) 2022
6000 257 (1.60) 2116 252 (2.24) 1973
6125 251 (1.57) 2066 247 (2.19) 1927
6250 246 (1.54) 2020 242 (2.15) 1884

6375 242 (1.51) 1979 237 (2.11) 1846
6500 238 (1.48) 1943 233 (2.07) 1813
6625 234 (1.46) 1913 230 (2.04) 1785
6750 232 (1.45) 1890 227 (2.02) 1764
6875 230 (1.44) 1875 225 (2.00) 1750
7000 229 (1.43) 1870 225 (2.00) 1745
7125 Or More 229 (1.43) 1874 225 (2.00) 1745
HC ppm (CO
1750 774 (4.31) 4990 761 (6.06) 4960
1875 729 (4.06) 4990 717 (5.70) 4738
2000 688 (3.83) 4778 676 (5.38) 4535
2125 650 (3.63) 4578 638 (5.09) 4349
2250 615 (3.44) 4395 604 (4.82) 4179
2375 583 (3.26) 4228 573 (4.57) 4024
2500 554 (3.10) 4076 544 (4.35) 3881
2625 528 (2.96) 3936 518 (4.14) 3752
2750 503 (2.83) 3809 495 (3.95) 3579
2875 481 (2.71) 3669 473 (3.78) 3417
3000 461 (2.60) 3510 453 (3.62) 3270
3125 443 (2.50) 3366 435 (3.48) 3135
3250 426 (2.40) 3234 419 (3.35) 3012
3375 411 (2.32) 3113 404 (3.23) 2899
3500 397 (2.24) 3002 390 (3.12) 2796
3625 384 (2.17) 2900 377 (3.02) 2701
3750 372 (2.11) 2806 365 (2.93) 2614
3875 361 (2.05) 2719 355 (2.58) 2533
4000 351 (1.99) 2638 345 (2.77) 2457
4125 341 (1.94) 2562 335 (2.69) 2387
4250 332 (1.89) 2490 326 (2.62) 2320

4375 323 (1.84) 2423 318 (2.55) 2258
4500 315 (1.80) 2359 310 (2.49) 2198
4625 308 (1.76) 2297 302 (2.43) 2140
4750 300 (1.72) 2238 295 (2.37) 2085
4875 293 (1.68) 2180 288 (2.32) 2032
5000 286 (1.64) 2125 281 (2.26) 1980
5125 279 (1.60) 2070 274 (2.21) 1930
5250 272 (1.56) 2017 267 (2.16) 1881
5375 26 (1.53) 1966 261 (2.11) 1833
5500 259 (1.49) 1916 255 (2.06) 1786
5625 253 (1.46) 1867 248 (2.01) 1740
5750 247 (1.43) 1820 243 (1.96) 1697
5875 241 (1.40) 1774 237 (1.92) 1654
6000 236 (1.37) 1731 232 (1.88) 1614
6125 231 (1.34) 1690 227 (1.84) 1577
6250 226 (1.31) 1653 222 (1.80) 1542
6375 222 (1.29) 1619 218 (1.77) 1510
6500 218 (1.27) 1590 214 (1.74) 1483
6625 215 (1.25) 1565 211 (1.72) 1460
6750 213 (1.24) 1546 209 (1.70) 1443
6875 211 (1.23) 1534 207 (1.68) 1432
7000 211 (1.23) 1530 207 (1.68) 1428
7125 Or More 211 (1.22) 1531 206 (1.68) 1428
HC ppm (CO
1750 390 (3.54) 4990 381 (4.85) 4960
1875 368 (3.34) 4990 359 (4.57) 4738
2000 348 (3.16) 4778 339 (4.31) 4535
2125 329 (2.99) 4578 321 (4.08) 4349
2250 312 (2.83) 4395 305 (3.86) 4179

2375 297 (2.69) 4228 290 (3.66) 4024
2500 283 (2.56) 4076 276 (3.48) 3881
2625 270 (2.44) 3936 263 (3.32) 3752
2750 258 (2.33) 3809 252 (3.17) 3579
2875 247 (2.23) 3669 241 (3.03) 3417
3000 237 (2.14) 3510 232 (2.91) 3270
3125 228 (2.06) 3366 223 (2.79) 3135
3250 220 (1.99) 3234 215 (2.69) 3012
3375 213 (1.92) 3113 208 (2.60) 2899
3500 206 (1.86) 3002 201 (2.51) 2796
3625 200 (1.80) 2900 195 (2.43) 2701
3750 194 (1.74) 2806 189 (2.36) 2614
3875 188 (1.69) 2719 184 (2.29) 2533
4000 183 (1.65) 2638 179 (2.22) 2457
4125 179 (1.61) 2562 175 (2.16) 2387
4250 174 (1.56) 2490 170 (2.11) 2320
4375 170 (1.53) 2423 166 (2.06) 2258
4500 166 (1.49) 2359 162 (2.01) 2198
4625 162 (1.46) 2297 159 (1.96) 2140
4750 159 (1.42) 2238 155 (1.91) 2085
4875 155 (1.39) 2180 152 (1.87) 2032
5000 152 (1.36) 2125 148 (1.82) 1980
5125 148 (1.33) 2070 145 (1.78) 1930
5250 145 (1.30) 2017 142 (1.74) 1881
5375 142 (1.27) 1966 139 (1.70) 1833
5500 139 (1.24) 1916 136 (1.66) 1786
5625 136 (1.12) 1867 133 (1.62) 1740
5750 133 (1.19) 1820 130 (1.59) 1697
5875 130 (1.16) 1774 127 (1.55) 1654
6000 127 (1.14) 1731 124 (1.52) 1614
6125 125 (1.11) 1690 122 (1.49) 1577
6250 123 (1.09) 1653 120 (1.46) 1542
6375 120 (1.07) 1619 118 (1.43) 1510

6500 119 (1.06) 1590 116 (1.41) 1483
6625 117 (1.04) 1565 114 (1.39) 1460
6750 116 (1.03) 1546 113 (1.37) 1443
6875 115 (1.02) 1534 113 (1.36) 1432
7000 115 (1.02) 1530 112 (1.36) 1428
7125 Or More 115 (1.02) 1531 112 (1.36) 1428
HC ppm (CO
1750 390 (3.54) 2725 381 (4.85) 2587
1875 368 (3.34) 2649 359 (4.57) 2435
2000 348 (3.16) 2499 339 (4.31) 2295
2125 329 (2.99) 2360 321 (4.08) 2167
2250 312 (2.83) 2232 305 (3.86) 2050
2375 297 (2.69) 2115 290 (3.66) 1943
2500 283 (2.56) 2009 276 (3.48) 1845
2625 270 (2.44) 1912 263 (3.32) 1756
2750 258 (2.33) 1823 252 (3.17) 1675
2875 247 (2.23) 1742 241 (3.03) 1601
3000 237 (2.14) 1668 232 (2.91) 1533
3125 228 (2.06) 1601 223 (2.79) 1471
3250 220 (1.99) 1539 215 (2.69) 1415
3375 213 (1.92) 1483 208 (2.60) 1363
3500 206 (1.86) 1432 201 (2.51) 1316
3625 200 (1.80) 1384 195 (2.43) 1273
3750 194 (1.74) 1340 189 (2.36) 1233
3875 188 (1.69) 1300 184 (2.29) 1195
4000 183 (1.65) 1262 179 (2.22) 1161
4125 179 (1.61) 1227 175 (2.16) 1126
4250 174 (1.56) 1194 170 (2.11) 1098
4375 170 (1.53) 1162 166 (2.06) 1069

4500 166 (1.49) 1132 162 (2.01) 1042
4625 162 (1.46) 1104 159 (1.96) 1015
4750 159 (1.42) 1076 155 (1.91) 990
4875 155 (1.39) 1049 152 (1.87) 966
5000 152 (1.36) 1023 148 (1.82) 942
5125 148 (1.33) 998 145 (1.78) 919
5250 145 (1.30) 974 142 (1.74) 896
5375 142 (1.27) 950 139 (1.70) 874
5500 139 (1.24) 926 136 (1.66) 853
5625 136 (1.12) 904 133 (1.62) 832
5750 133 (1.19) 882 130 (1.59) 812
5875 130 (1.16) 860 127 (1.55) 793
6000 127 (1.14) 840 124 (1.52) 774
6125 125 (1.11) 822 122 (1.49) 757
6250 123 (1.09) 804 120 (1.46) 741
6375 120 (1.07) 788 118 (1.43) 727
6500 119 (1.06) 775 116 (1.41) 714
6625 117 (1.04) 763 114 (1.39) 704
6750 116 (1.03) 755 113 (1.37) 696
6875 115 (1.02) 749 113 (1.36) 691
7000 Or More 115 (1.02) 747 112 (1.36) 689
HC ppm (CO
1750 324 (2.78) 2272 315 (3.64) 2114
1875 306 (2.63) 2181 297 (3.43) 1991
2000 289 (2.48) 2058 281 (3.24) 1877
2125 274 (2.35) 1944 267 (3.06) 1774
2250 260 (2.23) 1839 253 (2.90) 1678
2375 247 (2.12) 1744 241 (2.76) 1592
2500 236 (2.02) 1657 230 (2.62) 1512

2625 225 (1.92) 1577 219 (2.50) 1440
2750 216 (1.84) 1504 210 (2.39) 1374
2875 207 (1.76) 1438 210 (2.29) 1313
3000 199 (1.69) 1378 194 (2.19) 1258
3125 191 (1.63) 1323 186 (2.11) 1208
3250 185 (1.57) 1273 180 (2.03) 1163
3375 179 (1.52) 1227 174 (1.96) 1121
3500 173 (1.47) 1184 169 (1.89) 1082
3625 168 (1.42) 1146 164 (1.84) 1047
3750 163 (1.38) 1110 159 (1.78) 1014
3875 159 (1.34) 1077 155 (1.73) 984
4000 155 (1.31) 1046 151 (1.68) 956
4125 151 (1.27) 1017 147 (1.64) 930
4250 147 (1.24) 990 143 (1.60) 905
4375 144 (1.21) 964 140 (1.56) 882
4500 141 (1.18) 939 137 (1.52) 859
4625 137 (1.15) 916 134 (1.48) 838
4750 134 (1.13) 893 131 (1.45) 818
4875 132 (1.10) 872 128 (1.42) 798
5000 129 (1.08) 850 126 (1.38) 778
5125 126 (1.05) 830 123 (1.35) 760
5250 123 (1.03) 810 120 (1.32) 741
5375 121 (1.01) 790 118 (1.29) 723
5500 118 (0.99) 771 115 (1.26) 706
5625 116 (0.97) 752 113 (1.24) 689
5750 113 (0.94) 734 111 (1.21) 673
5875 111 (0.92) 717 108 (1.18) 657
6000 109 (0.91) 701 106 (1.16) 642
6125 107 (0.89) 685 104 (1.13) 628
6250 105 (.087) 671 102 (1.11) 615
6375 103 (0.86) 658 101 (1.09) 604
6500 102 (0.84) 647 99 (1.08) 593
6625 101 (0.83) 638 98 (1.06) 585

6750 100 (0.82) 631 97 (1.05) 578
6875 99 (0.82) 626 97 (1.04) 574
7000 99 (0.82) 624 96 (1.04) 573
7125 Or More 98 (0.81) 625 96 (1.04) 573
U.S. EPA ASM EMISSION STANDARDS - 1994 + TIER 1 LIGHT DUTY TRUCKS (3750 LVW OR LESS)
HC ppm (CO
1750 142 (0.80) 1212 136 (0.77) 1095
1875 134 (0.75) 1142 129 (0.73) 1031
2000 127 (0.71) 1077 123 (0.69) 973
2125 121 (0.68) 1018 116 (0.66) 920
2250 115 (0.64) 964 111 (0.62) 871
2375 109 (0.61) 915 106 (0.59) 827
2500 105 (0.59) 869 101 (0.57) 786
2625 100 (0.56) 828 97 (0.54) 749
2750 96 (0.54) 791 93 (0.52) 715
2875 92 (0.52) 756 89 (0.50) 684
3000 89 (0.50) 725 86 (0.48) 656
3125 86 (0.48) 696 83 (0.46) 630
3250 83 (0.46) 670 80 (0.45) 607
3375 81 (0.45) 647 78 (0.43) 585
3500 78 (0.44) 625 76 (0.42) 566
3625 76 (0.42) 605 74 (0.41) 547
3750 74 (0.41) 586 72 (0.40) 531
3875 72 (0.40) 569 70 (0.39) 515
4000 71 (0.39) 553 68 (0.38) 501
4125 69 (0.38) 538 67 (0.37) 487
4250 67 (0.37) 524 65 (0.36) 475
4375 66 (0.36) 510 64 (0.35) 463
4500 65 (0.36) 498 63 (0.35) 440
4625 63 (0.35) 486 61 (0.34) 440

4750 62 (0.34) 474 60 (0.33) 430
4875 61 (0.34) 463 59 (0.33) 420
5000 60 (0.33) 452 58 (0.32) 410
5125 58 (0.32) 441 57 (0.31) 400
5250 57 (0.32) 431 56 (0.31) 391
5375 56 (0.31) 420 55 (0.30) 382
5500 55 (0.30) 410 54 (0.30) 373
5625 54 (0.30) 401 53 (0.29) 364
5750 53 (0.29) 391 52 (0.29) 356
5875 52 (0.29) 383 51 (0.28) 348
6000 51 (0.28) 374 50 (0.28) 340
6125 50 (0.28) 366 49 (0.27) 333
6250 50 (0.27) 359 48 (0.27) 326
6375 49 (0.27) 352 48 (0.26) 320
6500 48 (0.26) 346 47 (0.26) 315
6625 48 (0.26) 341 46 (0.26) 311
6750 47 (0.26) 338 46 (0.26) 307
6875 47 (0.26) 335 46 (0.25) 305
7000 Or More 47 (0.25) 335 46 (0.25) 305
U.S. EPA ASM EMISSION STANDARDS - 1994 + TIER 1 LIGHT DUTY TRUCKS (3751 LVW OR
MORE)
HC ppm (CO
1750 224 (1.26) 1819 216 (1.22) 1642
1875 212 (1.19) 1713 205 (1.16) 1547
2000 201 (1.13) 1616 194 (1.09) 1460
2125 191 (1.07) 1527 184 (1.04) 1380
2250 182 (1.02) 1446 175 (0.99) 1307
2375 173 (0.97) 1372 167 (0.94) 1240
2500 166 (0.93) 1304 160 (0.90) 1179
2625 159 (0.89) 1242 153 (0.86) 1123
2750 152 (0.85) 1186 147 (0.82) 1072

2875 146 (0.82) 1134 141 (0.79) 1026
3000 141 (0.79) 1088 136 (0.76) 984
3125 136 (0.76) 1045 132 (0.73) 945
3250 132 (0.73) 1006 127 (0.71) 910
3375 128 (0.71) 970 123 (0.69) 878
3500 124 (0.69) 937 120 (0.67) 848
3625 120 (0.67) 907 117 (0.65) 821
3750 117 (0.65) 879 114 (0.63) 796
3875 114 (0.63) 853 111 (0.61) 773
4000 112 (0.62) 829 108 (0.60) 751
4125 109 (0.60) 807 106 (0.58) 731
4250 107 (0.59) 786 103 (0.57) 712
4375 104 (0.58) 766 101 (0.56) 694
4500 102 (0.57) 747 99 (0.55) 677
4625 100 (0.55) 728 97 (0.54) 661
4750 98 (0.54) 711 95 (0.53) 645
4875 96 (0.53) 694 93 (0.52) 630
5000 94 (0.52) 677 92 (0.51) 615
5125 93 (0.51) 661 90 (0.50) 600
5250 91 (0.50) 646 88 (0.49) 586
5375 89 (0.49) 631 86 (0.48) 573
5500 87 (0.48) 616 85 (0.47) 559
5625 86 (0.47) 601 83 (0.46) 546
5750 84 (0.46) 587 82 (0.45) 534
5875 83 (0.45) 574 80 (0.44) 522
6000 81 (0.44) 561 79 (0.44) 510
6125 80 (0.44) 549 78 (0.43) 499
6250 79 (0.43) 538 76 (0.42) 489
6375 77 (0.42) 528 75 (0.42) 480
6500 76 (0.42) 519 74 (0.41) 473
6625 76 (0.41) 512 74 (0.41) 466
6750 75 (0.41) 507 73 (0.41) 461
6875 75 (0.40) 503 73 (0.40) 458

7000 Or More 74 (0.40) 502 72 (0.40) 457
U.S. EPA ASM EMISSION STANDARDS - 1968-72 LIGHT DUTY TRUCKS (6001 GVWR OR MORE)
HC ppm (CO
1750 1118 (8.02) 4990 1098 (9.90) 4990
1875 1052 (7.56) 4990 1034 (9.90) 4990
2000 992 (7.14) 4990 975 (9.90) 4990
2125 938 (6.75) 4990 921 (9.66) 4990
2250 887 (6.40) 4990 872 (9.14) 4990
2375 841 (6.07) 4990 827 (8.67) 4990
2500 800 (5.78) 4990 786 (8.25) 4990
2625 761 (5.51) 4990 748 (7.85) 4990
2750 726 (5.26) 4990 714 (7.50) 4772
2875 695 (5.03) 4892 683 (7.17) 4556
3000 666 (4.83) 4680 654 (6.87) 4359
3125 639 (4.64) 4488 628 (6.60) 4180
3250 615 (4.47) 4311 604 (6.35) 4016
3375 593 (4.31) 4150 583 (6.13) 3866
3500 573 (4.17) 4002 563 (5.92) 3728
3625 554 (4.04) 3867 544 (5.73) 3602
3750 537 (3.91) 3741 527 (5.55) 3485
3875 521 (3.80) 3625 512 (5.39) 3377
4000 506 (3.70) 3517 497 (5.24) 3276
4125 492 (3.60) 3416 484 (5.09) 3182
4250 479 (3.51) 3321 471 (4.96) 3094
4375 467 (3.42) 3230 459 (4.83) 3010
4500 455 (3.34) 3145 447 (4.71) 2930
4625 444 (3.26) 3063 436 (4.60) 2854
4750 433 (3.18) 2983 425 (4.49) 2780
4875 423 (3.11) 2907 415 (4.38) 2709
5000 412 (3.03) 2833 405 (4.28) 2640

5125 402 (2.97) 2760 395 (4.18) 2573
5250 393 (2.90) 2690 386 (4.08) 2507
5375 383 (2.83) 2621 376 (3.98) 2443
5500 374 (2.77) 2554 367 (3.89) 2381
5625 365 (2.70) 2489 359 (3.80) 2321
5750 357 (2.64) 2426 350 (3.71) 2262
5875 348 (2.59) 2366 342 (3.62) 2206
6000 341 (2.53) 2308 334 (3.54) 2152
6125 333 (2.48) 2254 327 (3.47) 2102
6250 326 (2.43) 2204 320 (3.40) 2056
6375 320 (2.39) 2159 314 (3.34) 2014
6500 315 (2.35) 2119 309 (3.28) 1977
6625 310 (2.32) 2087 304 (3.23) 1947
6750 307 (2.29) 2062 301 (3.20) 1924
6875 305 (2.28) 2046 299 (3.17) 1909
7000 304 (2.27) 2040 298 (3.17) 1904
7125 Or More 304 (2.27) 2045 298 (3.17) 1904
HC ppm (CO
1750 1118 (8.02) 4990 1098 (9.90) 4980
1875 1052 (7.56) 4990 1034 (9.90) 4906
2000 992 (7.14) 4919 975 (9.90) 4838
2125 938 (6.75) 4853 921 (9.66) 4776
2250 887 (6.40) 4792 872 (9.14) 4720
2375 841 (6.07) 4736 827 (8.67) 4668
2500 800 (5.78) 4685 786 (8.25) 4620
2625 761 (5.51) 4639 748 (7.85) 4577
2750 726 (5.26) 4596 714 (7.50) 4374
2875 695 (5.03) 4484 683 (7.17) 4176
3000 666 (4.83) 4290 654 (6.87) 3996

3125 639 (4.64) 4114 628 (6.60) 3832
3250 615 (4.47) 3952 604 (6.35) 3681
3375 593 (4.31) 3804 583 (6.13) 3544
3500 573 (4.17) 3669 563 (5.92) 3418
3625 554 (4.04) 3544 544 (5.73) 3302
3750 537 (3.91) 3429 527 (5.55) 3195
3875 521 (3.80) 3323 512 (5.39) 3096
4000 506 (3.70) 3224 497 (5.24) 3003
4125 492 (3.60) 3131 484 (5.09) 2917
4250 479 (3.51) 3044 471 (4.96) 2836
4375 467 (3.42) 2961 459 (4.83) 2759
4500 455 (3.34) 2883 447 (4.71) 2686
4625 444 (3.26) 2807 436 (4.60) 2616
4750 433 (3.18) 2735 425 (4.49) 2549
4875 423 (3.11) 2665 415 (4.38) 2483
5000 412 (3.03) 2597 405 (4.28) 2420
5125 402 (2.97) 2530 395 (4.18) 2359
5250 393 (2.90) 2466 386 (4.08) 2298
5375 383 (2.83) 2403 376 (3.98) 2240
5500 374 (2.77) 2341 367 (3.89) 2183
5625 365 (2.70) 2282 359 (3.80) 2127
5750 357 (2.64) 2224 350 (3.71) 2074
5875 348 (2.59) 2168 342 (3.62) 2022
6000 341 (2.53) 2116 334 (3.54) 1973
6125 333 (2.48) 2066 327 (3.47) 1927
6250 326 (2.43) 2020 320 (3.40) 1884
6375 320 (2.39) 1979 314 (3.34) 1846
6500 315 (2.35) 1943 309 (3.28) 1813
6625 310 (2.32) 1913 304 (3.23) 1785
6750 307 (2.29) 1890 301 (3.20) 1764
6875 305 (2.28) 1875 299 (3.17) 1750
7000 304 (2.27) 1870 298 (3.17) 1745
7125 Or More 304 (2.27) 1874 298 (3.17) 1745

HC ppm (CO
1750 843 (5.07) 4990 828 (7.26) 4980
1875 794 (4.78) 4990 780 (6.84) 4906
2000 749 (4.51) 4919 736 (6.45) 4838
2125 707 (4.26) 4853 695 (6.10) 4776
2250 669 (4.04) 4792 658 (5.78) 4720
2375 635 (3.83) 4736 624 (5.48) 4668
2500 603 (3.65) 4685 593 (5.21) 4620
2625 574 (3.48) 4639 564 (4.96) 4577
2750 548 (3.32) 4596 539 (4.73) 4374
2875 524 (3.18) 4484 515 (4.53) 4176
3000 502 (3.05) 4290 493 (4.34) 3996
3125 482 (2.93) 4114 474 (4.17) 3832
3250 464 (2.82) 3952 456 (4.01) 3681
3375 447 (2.72) 3804 440 (3.87) 3544
3500 432 (2.63) 3669 424 (3.74) 3418
3625 418 (2.55) 3544 411 (3.62) 3302
3750 405 (2.47) 3429 398 (3.51) 3195
3875 393 (2.40) 3323 386 (3.40) 3096
4000 382 (2.33) 3224 375 (3.31) 3003
4125 371 (2.27) 3131 365 (3.22) 2917
4250 361 (2.21) 3044 355 (3.13) 2836
4375 352 (2.16) 2961 346 (3.05) 2759
4500 343 (2.11) 2883 337 (2.98) 2686
4625 335 (2.06) 2807 329 (2.90) 2616
4750 327 (2.01) 2735 321 (2.83) 2549
4875 319 (1.96) 2665 313 (2.77) 2483
5000 311 (1.92) 2597 305 (2.70) 2420
5125 304 (1.87) 2530 298 (2.64) 2359
5250 296 (1.83) 2466 291 (2.58) 2298

5375 289 (1.79) 2403 284 (2.51) 2240
5500 282 (1.75) 2341 277 (2.46) 2183
5625 276 (1.71) 2282 271 (2.40) 2127
5750 269 (1.67) 2224 264 (2.34) 2074
5875 263 (1.63) 2168 258 (2.29) 2022
6000 257 (1.60) 2116 252 (2.24) 1973
6125 251 (1.57) 2066 247 (2.19) 1927
6250 246 (1.54) 2020 242 (2.15) 1884
6375 242 (1.51) 1979 237 (2.11) 1846
6500 238 (1.48) 1943 233 (2.07) 1813
6625 234 (1.46) 1913 230 (2.04) 1785
6750 232 (1.45) 1890 227 (2.02) 1764
6875 230 (1.44) 1875 225 (2.00) 1750
7000 229 (1.43) 1870 225 (2.00) 1745
7125 Or More 229 (1.43) 1874 225 (2.00) 1745
HC ppm (CO
1750 774 (4.31) 4990 761 (6.06) 4960
1875 729 (4.06) 4990 717 (5.70) 4738
2000 688 (3.83) 4778 676 (5.38) 4535
2125 650 (3.63) 4578 638 (5.09) 4349
2250 615 (3.44) 4395 604 (4.82) 4179
2375 583 (3.26) 4228 573 (4.57) 4024
2500 554 (3.10) 4076 544 (4.35) 3881
2625 528 (2.96) 3936 518 (4.14) 3752
2750 503 (2.83) 3809 495 (3.95) 3579
2875 481 (2.71) 3669 473 (3.78) 3417
3000 461 (2.60) 3510 453 (3.62) 3270
3125 443 (2.50) 3366 435 (3.48) 3135
3250 426 (2.40) 3234 419 (3.35) 3012

3375 411 (2.32) 3113 404 (3.23) 2899
3500 397 (2.24) 3002 390 (3.12) 2796
3625 384 (2.17) 2900 377 (3.02) 2701
3750 372 (2.11) 2806 365 (2.93) 2614
3875 361 (2.05) 2719 355 (2.58) 2533
4000 351 (1.99) 2638 345 (2.77) 2457
4125 341 (1.94) 2562 335 (2.69) 2387
4250 332 (1.89) 2490 326 (2.62) 2320
4375 323 (1.84) 2423 318 (2.55) 2258
4500 315 (1.80) 2359 310 (2.49) 2198
4625 308 (1.76) 2297 302 (2.43) 2140
4750 300 (1.72) 2238 295 (2.37) 2085
4875 293 (1.68) 2180 288 (2.32) 2032
5000 286 (1.64) 2125 281 (2.26) 1980
5125 279 (1.60) 2070 274 (2.21) 1930
5250 272 (1.56) 2017 267 (2.16) 1881
5375 26 (1.53) 1966 261 (2.11) 1833
5500 259 (1.49) 1916 255 (2.06) 1786
5625 253 (1.46) 1867 248 (2.01) 1740
5750 247 (1.43) 1820 243 (1.96) 1697
5875 241 (1.40) 1774 237 (1.92) 1654
6000 236 (1.37) 1731 232 (1.88) 1614
6125 231 (1.34) 1690 227 (1.84) 1577
6250 226 (1.31) 1653 222 (1.80) 1542
6375 222 (1.29) 1619 218 (1.77) 1510
6500 218 (1.27) 1590 214 (1.74) 1483
6625 215 (1.25) 1565 211 (1.72) 1460
6750 213 (1.24) 1546 209 (1.70) 1443
6875 211 (1.23) 1534 207 (1.68) 1432
7000 211 (1.23) 1530 207 (1.68) 1428
7125 Or More 211 (1.22) 1531 206 (1.68) 1428
HC ppm (CO
1750 390 (3.54) 4990 381 (4.85) 4960
1875 368 (3.34) 4990 359 (4.57) 4738
2000 348 (3.16) 4778 339 (4.31) 4535
2125 329 (2.99) 4578 321 (4.08) 4349
2250 312 (2.83) 4395 305 (3.86) 4179
2375 297 (2.69) 4228 290 (3.66) 4024
2500 283 (2.56) 4076 276 (3.48) 3881
2625 270 (2.44) 3936 263 (3.32) 3752
2750 258 (2.33) 3809 252 (3.17) 3579
2875 247 (2.23) 3669 241 (3.03) 3417
3000 237 (2.14) 3510 232 (2.91) 3270
3125 228 (2.06) 3366 223 (2.79) 3135
3250 220 (1.99) 3234 215 (2.69) 3012
3375 213 (1.92) 3113 208 (2.60) 2899
3500 206 (1.86) 3002 201 (2.51) 2796
3625 200 (1.80) 2900 195 (2.43) 2701
3750 194 (1.74) 2806 189 (2.36) 2614
3875 188 (1.69) 2719 184 (2.29) 2533
4000 183 (1.65) 2638 179 (2.22) 2457
4125 179 (1.61) 2562 175 (2.16) 2387
4250 174 (1.56) 2490 170 (2.11) 2320
4375 170 (1.53) 2423 166 (2.06) 2258
4500 166 (1.49) 2359 162 (2.01) 2198
4625 162 (1.46) 2297 159 (1.96) 2140
4750 159 (1.42) 2238 155 (1.91) 2085
4875 155 (1.39) 2180 152 (1.87) 2032
5000 152 (1.36) 2125 148 (1.82) 1980
5125 148 (1.33) 2070 145 (1.78) 1930
5250 145 (1.30) 2017 142 (1.74) 1881
5375 142 (1.27) 1966 139 (1.70) 1833

5500 139 (1.24) 1916 136 (1.66) 1786
5625 136 (1.12) 1867 133 (1.62) 1740
5750 133 (1.19) 1820 130 (1.59) 1697
5875 130 (1.16) 1774 127 (1.55) 1654
6000 127 (1.14) 1731 124 (1.52) 1614
6125 125 (1.11) 1690 122 (1.49) 1577
6250 123 (1.09) 1653 120 (1.46) 1542
6375 120 (1.07) 1619 118 (1.43) 1510
6500 119 (1.06) 1590 116 (1.41) 1483
6625 117 (1.04) 1565 114 (1.39) 1460
6750 116 (1.03) 1546 113 (1.37) 1443
6875 115 (1.02) 1534 113 (1.36) 1432
7000 115 (1.02) 1530 112 (1.36) 1428
7125 Or More 115 (1.02) 1531 112 (1.36) 1428
HC ppm (CO
1750 390 (3.54) 4084 381 (4.85) 4005
1875 368 (3.34) 4054 359 (4.57) 3767
2000 348 (3.16) 3824 339 (4.31) 3548
2125 329 (2.99) 3609 321 (4.08) 3348
2250 312 (2.83) 3411 305 (3.86) 3165
2375 297 (2.69) 3231 290 (3.66) 2998
2500 283 (2.56) 3066 276 (3.48) 2845
2625 270 (2.44) 2916 263 (3.32) 2706
2750 258 (2.33) 2779 252 (3.17) 2579
2875 247 (2.23) 2654 241 (3.03) 2463
3000 237 (2.14) 2539 232 (2.91) 2357
3125 228 (2.06) 2435 223 (2.79) 2260
3250 220 (1.99) 2340 215 (2.69) 2172
3375 213 (1.92) 2253 208 (2.60) 2092

3500 206 (1.86) 2174 201 (2.51) 2018
3625 200 (1.80) 2100 195 (2.43) 1950
3750 194 (1.74) 2033 189 (2.36) 1887
3875 188 (1.69) 1970 184 (2.29) 1829
4000 183 (1.65) 1912 179 (2.22) 1775
4125 179 (1.61) 1857 175 (2.16) 1724
4250 174 (1.56) 1806 170 (2.11) 1677
4375 170 (1.53) 1757 166 (2.06) 1632
4500 166 (1.49) 1711 162 (2.01) 1589
4625 162 (1.46) 1666 159 (1.96) 1548
4750 159 (1.42) 1624 155 (1.91) 1508
4875 155 (1.39) 1583 152 (1.87) 1470
5000 152 (1.36) 1542 148 (1.82) 1433
5125 148 (1.33) 1503 145 (1.78) 1397
5250 145 (1.30) 1465 142 (1.74) 1362
5375 142 (1.27) 1428 139 (1.70) 1327
5500 139 (1.24) 1392 136 (1.66) 1294
5625 136 (1.12) 1357 133 (1.62) 1261
5750 133 (1.19) 1323 130 (1.59) 1230
5875 130 (1.16) 1290 127 (1.55) 1199
6000 127 (1.14) 1259 124 (1.52) 1171
6125 125 (1.11) 1230 122 (1.49) 1144
6250 123 (1.09) 1203 120 (1.46) 1119
6375 120 (1.07) 1179 118 (1.43) 1096
6500 119 (1.06) 1158 116 (1.41) 1077
6625 117 (1.04) 1140 114 (1.39) 1060
6750 116 (1.03) 1127 113 (1.37) 1048
6875 115 (1.02) 1118 113 (1.36) 1040
7000 Or More 115 (1.02) 1115 112 (1.36) 1037

HC ppm (CO
1750 324 (2.78) 3631 315 (3.64) 3532
1875 306 (2.63) 3586 297 (3.43) 3323
2000 289 (2.48) 3383 281 (3.24) 3131
2125 274 (2.35) 3192 267 (3.06) 2955
2250 260 (2.23) 3018 253 (2.90) 2794
2375 247 (2.12) 2859 241 (2.76) 2646
2500 236 (2.02) 2714 230 (2.62) 2512
2625 225 (1.92) 2581 219 (2.50) 2389
2750 216 (1.84) 2460 210 (2.39) 2277
2875 207 (1.76) 2350 210 (2.29) 2175
3000 199 (1.69) 2249 194 (2.19) 2082
3125 191 (1.63) 2157 186 (2.11) 1997
3250 185 (1.57) 2073 180 (2.03) 1920
3375 179 (1.52) 1997 174 (1.96) 1849
3500 173 (1.47) 1926 169 (1.89) 1784
3625 168 (1.42) 1862 164 (1.84) 1724
3750 163 (1.38) 1802 159 (1.78) 1669
3875 159 (1.34) 1747 155 (1.73) 1618
4000 155 (1.31) 1695 151 (1.68) 1570
4125 151 (1.27) 1647 147 (1.64) 1526
4250 147 (1.24) 1602 143 (1.60) 1484
4375 144 (1.21) 1559 140 (1.56) 1444
4500 141 (1.18) 1518 137 (1.52) 1406
4625 137 (1.15) 1479 134 (1.48) 1370
4750 134 (1.13) 1441 131 (1.45) 1336
4875 132 (1.10) 1405 128 (1.42) 1302
5000 129 (1.08) 1369 126 (1.38) 1269
5125 126 (1.05) 1335 123 (1.35) 1237
5250 123 (1.03) 1031 120 (1.32) 1206
5375 121 (1.01) 1269 118 (1.29) 1176
5500 118 (0.99) 1237 115 (1.26) 1147

5625 116 (0.97) 1206 113 (1.24) 1118
5750 113 (0.94) 1176 111 (1.21) 1090
5875 111 (0.92) 1147 108 (1.18) 1064
6000 109 (0.91) 1120 106 (1.16) 1039
6125 107 (0.89) 1094 104 (1.13) 1015
6250 105 (.087) 1070 102 (1.11) 993
6375 103 (0.86) 1049 101 (1.09) 973
6500 102 (0.84) 1030 99 (1.08) 956
6625 101 (0.83) 1014 98 (1.06) 941
6750 100 (0.82) 1003 97 (1.05) 931
6875 99 (0.82) 995 97 (1.04) 924
7000 99 (0.82) 992 96 (1.04) 921
7125 Or More 98 (0.81) 992 96 (1.04) 921
U.S. EPA ASM EMISSION STANDARDS - 1994 + TIER 1 LIGHT DUTY TRUCKS (5750 LVW OR LESS)
HC ppm (CO
1750 224 (1.26) 1819 216 (1.22) 1642
1875 212 (1.19) 1713 205 (1.16) 1547
2000 201 (1.13) 1616 194 (1.09) 1460
2125 191 (1.07) 1527 184 (1.04) 1380
2250 182 (1.02) 1446 175 (0.99) 1307
2375 173 (0.97) 1372 167 (0.94) 1240
2500 166 (0.93) 1304 160 (0.90) 1179
2625 159 (0.89) 1242 153 (0.86) 1123
2750 152 (0.85) 1186 147 (0.82) 1072
2875 146 (0.82) 1134 141 (0.79) 1026
3000 141 (0.79) 1088 136 (0.76) 984
3125 136 (0.76) 1045 132 (0.73) 945
3250 132 (0.73) 1006 127 (0.71) 910
3375 128 (0.71) 970 123 (0.69) 878
3500 124 (0.69) 937 120 (0.67) 848

3625 120 (0.67) 907 117 (0.65) 821
3750 117 (0.65) 879 114 (0.63) 796
3875 114 (0.63) 853 111 (0.61) 773
4000 112 (0.62) 829 108 (0.60) 751
4125 109 (0.60) 807 106 (0.58) 731
4250 107 (0.59) 786 103 (0.57) 712
4375 104 (0.58) 766 101 (0.56) 694
4500 102 (0.57) 747 99 (0.55) 677
4625 100 (0.55) 728 97 (0.54) 661
4750 98 (0.54) 711 95 (0.53) 645
4875 96 (0.53) 694 93 (0.52) 630
5000 94 (0.52) 677 92 (0.51) 615
5125 93 (0.51) 661 90 (0.50) 600
5250 91 (0.50) 646 88 (0.49) 586
5375 89 (0.49) 631 86 (0.48) 573
5500 87 (0.48) 616 85 (0.47) 559
5625 86 (0.47) 601 83 (0.46) 546
5750 84 (0.46) 587 82 (0.45) 534
5875 83 (0.45) 574 80 (0.44) 522
6000 81 (0.44) 561 79 (0.44) 510
6125 80 (0.44) 549 78 (0.43) 499
6250 79 (0.43) 538 76 (0.42) 489
6375 77 (0.42) 528 75 (0.42) 480
6500 76 (0.42) 519 74 (0.41) 473
6625 76 (0.41) 512 74 (0.41) 466
6750 75 (0.41) 507 73 (0.41) 461
6875 75 (0.40) 503 73 (0.40) 458
7000 Or More 74 (0.40) 502 72 (0.40) 457
U.S. EPA ASM EMISSION STANDARDS - 1994 + TIER 1 LIGHT DUTY TRUCKS (5751 LVW OR
MORE)
HC ppm (CO
1750 324 (2.78) 3178 315 (3.64) 3060
1875 306 (2.63) 3117 297 (3.43) 2879
2000 289 (2.48) 2941 281 (3.24) 2713
2125 274 (2.35) 2776 267 (3.06) 2561
2250 260 (2.23) 2625 253 (2.90) 2422
2375 247 (2.12) 2487 241 (2.76) 2295
2500 236 (2.02) 2361 230 (2.62) 2179
2625 225 (1.92) 2246 219 (2.50) 2073
2750 216 (1.84) 2142 210 (2.39) 1976
2875 207 (1.76) 2046 210 (2.29) 1888
3000 199 (1.69) 1959 194 (2.19) 1808
3125 191 (1.63) 1879 186 (2.11) 1734
3250 185 (1.57) 1806 180 (2.03) 1667
3375 179 (1.52) 1740 174 (1.96) 1606
3500 173 (1.47) 1679 169 (1.89) 1550
3625 168 (1.42) 1623 164 (1.84) 1498
3750 163 (1.38) 1571 159 (1.78) 1451
3875 159 (1.34) 1523 155 (1.73) 1407
4000 155 (1.31) 1479 151 (1.68) 1365
4125 151 (1.27) 1437 147 (1.64) 1327
4250 147 (1.24) 1398 143 (1.60) 1291
4375 144 (1.21) 1360 140 (1.56) 1257
4500 141 (1.18) 1325 137 (1.52) 1224
4625 137 (1.15) 1291 134 (1.48) 1193
4750 134 (1.13) 1259 131 (1.45) 1163
4875 132 (1.10) 1227 128 (1.42) 1134
5000 129 (1.08) 1196 126 (1.38) 1106
5125 126 (1.05) 1167 123 (1.35) 1078
5250 123 (1.03) 1138 120 (1.32) 1051
5375 121 (1.01) 1109 118 (1.29) 1025
5500 118 (0.99) 1082 115 (1.26) 1000
5625 116 (0.97) 1055 113 (1.24) 975
5750 113 (0.94) 1029 111 (1.21) 951

5875 111 (0.92) 1004 108 (1.18) 928
6000 109 (0.91) 980 106 (1.16) 906
6125 107 (0.89) 958 104 (1.13) 886
6250 105 (.087) 937 102 (1.11) 867
6375 103 (0.86) 919 101 (1.09) 850
6500 102 (0.84) 902 99 (1.08) 835
6625 101 (0.83) 889 98 (1.06) 823
6750 100 (0.82) 879 97 (1.05) 813
6875 99 (0.82) 872 97 (1.04) 807
7000 99 (0.82) 870 96 (1.04) 805
7125 Or More 98 (0.81) 870 96 (1.04) 805
U. S. EPA REVISED FINAL ASM EMISSION STANDARDS (ASM5015 & ASM2525)
NOTE: EPA has not published a revised final standards for High Altitude, Light Duty
Trucks 2 (6000-8500 GVWR), or vehicles older than 1980 model year. EPA guidance as of
February 2003 states that a program may choose to use combinations of the Original and the
Revised Final Standards.
U.S. EPA REVISED FINAL ASM EMISSION STANDARDS
Application ASM5015 ASM2525
HC ppm (CO
HC ppm (CO %) NOx ppm %) NOx ppm
Passenger Cars
1980 275 8500 500 (2.3) 4750

(1.3)
1981-82 275 3600 500 (2.3) 3500

(1.3)
1983-89 275 3600 500 (1.6) 3500

(1.1)
1990 & 275 3600 300 (1.6) 3500

Newer (1.1)
Light Duty Trucks (Less Than 6000 GVWR)
1980-83 1140 14,145 340 32,200

(9.7) (23.28)
1984-87 537 14,145 160 32,200

(5.4) (12.96)
1988-95 537 7380 160 16,800
(5.4) (12.96)
1996 & 275 6150 82 (4.40) 14,000

Newer (1.1)
U.S. EPA IM240 EMISSION STANDARDS > START-UP STANDARDS
Start-up standards should be used during the first 2 years of program operation. Tier 1 standards are
recommended for all 1996 and newer vehicles and may be used for 1994 and newer vehicles certified to
Tier 1 standards as well.
U.S. EPA IM240 HYDROCARBONS EMISSION START-UP STANDARDS
Application Hydrocarbons (Grams/Mile)
Composite Phase 2
Light Duty Vehicles
1996 & Newer 0.80 0.50
1991-95 1.20 0.75
1983-90 2.00 1.25
1980-82 2.00 1.25
1975-79 7.50 5.00
1968-74 10.0 6.00
High Altitude Light Duty Vehicles
1983-84 2.00 1.25
1982 2.00 1.25
Light Duty Trucks (0-6000 Lbs. GVWR)
1996 & Newer (Less Than 3750 LVW) 0.80 0.50
1996 & Newer (More Than 3750 LVW) 1.00 0.63
1991-95 2.40 1.50
1984-90 3.20 2.00
1979-83 7.50 5.00
1975-78 8.00 5.00
1968-74 10.0 6.00
High Altitude Light Duty Trucks (0-6000 Lbs. GVWR)
1991 & Newer 3.00 2.00
1984-90 4.00 2.50
1982-83 8.00 5.00

1996 & Newer (Less Than 5750 ALVW) 1.00 0.63
1996 & Newer (More Than 5750 ALVW) 2.40 1.50
1991-95 2.40 1.50
1984-90 3.20 2.00
1979-83 7.50 5.00
1975-78 8.00 5.00
1968-74 10.0 6.00
1991 & Newer 3.00 2.00
1984-90 4.00 2.50
1982-83 8.00 5.00
Heavy Duty Trucks (Greater Than 8500 Lbs. GVWR)
1998 & Newer 2.00 1.30
1987-97 3.00 1.90
1985-86 5.00 3.10
1979-84 6.00 3.80
1970-78 10.0 6.30
1969 & Earlier 20.0 12.50
U.S. EPA IM240 CARBON MONOXIDE EMISSION START-UP STANDARDS
Application Carbon Monoxide (Grams/Mile)
Composite Phase 2
Light Duty Vehicles
1996 & Newer 15.0 12.0
1991-95 20.0 16.0
1983-90 30.0 24.0
1980-82 60.0 48.0
1975-79 90.0 72.0
1968-74 150.0 120.0
1983-84 60.0 48.0
1982 75.0 60.0

1991-95 60.0 48.0
1984-90 80.0 64.0
1979-83 100.0 80.0
1975-78 120.0 96.0
1968-74 150.0 120.0
1991 & Newer 70.0 56.0
1984-90 90.0 72.0
1982-83 130.0 104.0
1991-95 60.0 48.0
1984-90 80.0 64.0
1979-83 100.0 80.0
1975-78 120.0 96.0
1968-74 150.0 120.0
1991 & Newer 70.0 56.0
1984-90 90.0 72.0
1982-83 130.0 104.0
1998 & Newer 30.0 24.0
1987-97 60.0 48.0
1985-86 75.0 60.0
1979-84 100.0 80.0
1974-78 150.00 120.0
1970-73 175.00 140.00
1969 & Earlier 200.0 160.0
U.S. EPA IM240 OXIDES OF NITROGEN EMISSION START-UP STANDARDS

Application Oxides Of Nitrogen (Grams/Mile)
Composite Phase 2
Light Duty Vehicles
1996 & Newer 2.0 2.0
1991-95 2.5 2.5
1981-90 3.0 3.0
1977-80 6.0 6.0
1973-76 9.0 9.0
1968-72 10.0 10.0
1982-84 3.0 3.0
1991-95 3.0 3.0
1988-90 3.5 3.5
1979-87 7.0 7.0
1973-78 9.0 9.0
1968-72 10.0 10.0
1991 & Newer 3.0 3.0
1988-90 3.5 3.5
1982-87 7.0 7.0
1991-95 4.5 4.5
1988-90 5.0 5.0
1979-87 7.0 7.0
1973-78 9.0 9.0
1968-72 10.0 10.0

1991 & Newer 4.5 4.5
1988-90 5.0 5.0
1982-87 7.0 7.0
1998 & Newer 4.0 4.0
1991-97 6.0 6.0
1979-90 8.0 8.0
1970-78 10.0 10.0
1969 & Earlier 15.0 15.0
U.S. EPA IM240 EMISSION STANDARDS > FINAL STANDARDS
Final standards are recommended for vehicles tested in calendar years 1997 and later. Tier 1 standards
are recommended for all 1996 and newer vehicles and may be used for 1994 and newer vehicles.
U.S. EPA IM240 HYDROCARBONS EMISSION FINAL STANDARDS
Application Hydrocarbons (Grams/Mile)
Composite Phase 2
Light Duty Vehicles
1996 & Newer 0.60 0.40
1980-95 0.80 0.50
1975-79 3.00 2.00
1968-74 7.00 4.50
1982-84 1.20 0.75
1984-95 1.60 1.00
1979-83 3.40 2.00
1975-78 4.00 2.50
1968-74 7.00 4.50
1988 & Newer 2.00 1.25
1984-87 2.00 1.25

1982-83 4.00 2.50
1984-95 1.60 1.00
1979-83 3.40 2.00
1975-78 4.00 2.50
1968-74 7.00 4.50
1988 & Newer 2.00 1.25
1984-87 2.00 1.25
1982-83 4.00 2.50
1998 & Newer 2.00 1.30
1987-97 2.00 1.30
1985-86 3.00 1.90
1979-84 5.00 3.10
1970-78 10.0 6.30
1969 & Earlier 20.0 12.50
U.S. EPA IM240 CARBON MONOXIDE EMISSION FINAL STANDARDS
Application Carbon Monoxide (Grams/Mile)
Composite Phase 2
Light Duty Vehicles
1996 & Newer 10.0 8.0
1983-95 15.0 12.0
1980-82 30.0 24.0
1975-79 65.0 52.0
1968-74 120.0 96.0
1983-84 30.0 24.0
1982 45.0 36.0

1984-95 40.0 32.0
1979-83 70.0 56.0
1975-78 80.0 64.0
1968-74 120.0 96.0
1988 & Newer 60.0 48.0
1984-87 60.0 48.0
1982-83 90.0 72.0
1984-95 40.0 32.0
1979-83 70.0 56.0
1975-78 80.0 64.0
1968-74 120.0 96.0
1984 & Newer 60.0 48.0
1982-83 90.0 72.0
1998 & Newer 30.0 24.0
1987-97 40.0 32.0
1985-86 50.0 40.0
1979-84 75.0 60.0
1974-78 150.0 120.0
1970-73 175.0 140.0
1969 & Earlier 200.0 160.0
U.S. EPA IM240 OXIDES OF NITROGEN EMISSION FINAL STANDARDS
Application Oxides Of Nitrogen (Grams/Mile)
Composite Phase 2
Light Duty Vehicles

1996 & Newer 1.5 1.5
1981-95 2.0 2.0
1977-80 4.0 4.0
1973-76 6.0 6.0
1968-72 7.0 7.0
1982-84 2.0 2.0
1988-95 2.5 2.5
1979-87 4.5 4.5
1973-78 6.0 6.0
1968-72 7.0 7.0
1988 & Newer 2.5 2.5
1982-87 4.5 4.5
1988-95 3.5 3.5
1979-87 4.5 4.5
1973-78 6.0 6.0
1968-72 7.0 7.0
1988 & Newer 3.5 3.5
1982-87 4.5 4.5
1998 & Newer 4.0 4.0
1991-97 5.0 5.0
1979-90 6.0 6.0
1970-78 10.0 10.0
1969 & Earlier 15.0 15.0

Service Manual: 80 - HEATING -- 92A CAYENNE
WM 802355 REPLACING HEAT EXCHANGER (CAYENNE, CAYENNE GTS, CAYENNE
INFORMATION > INSTALLATION POSITION OF HEAT EXCHANGER
The heat exchanger is located in the heating/fresh-air unit.
Fig 1: Identifying Heat Exchanger Installation Position

PRELIMINARY WORK > PRELIMINARY WORK FOR HEAT EXCHANGER
Information
Make sure that coolant does not soil the passenger compartment.
Protect seats and carpet with protective covers.
1. Remove heating/fresh-air unit → 851519 REMOVING AND INSTALLING

HEATING/FRESH-AIR UNIT .

REMOVING HEAT EXCHANGER
1. Unclip fastening pin -1- from the latch in -direction of arrow A- and pull it out in -direction of
arrow B- .
Fig 1: Removing Heat Exchanger
2. Fold down cover -1- in -direction of arrow A- and pull out heat exchanger -2- in -direction
of arrow B- . The heat exchanger is removed together with the two short coolant pipes. There
are no sealing rings as spare parts for the connection point between the coolant pipe and heat
exchanger.
Fig 2: Pulling Out Heat Exchanger

INSTALLING HEAT EXCHANGER
Information
Make sure not to damage the foam seal on the heat exchanger during installation.
Check that the heat exchanger is seated correctly in the heating/fresh-air unit.
1. Install the heat exchanger in reverse order.

REPLACING HEAT EXCHANGER
Information
Information
The heat exchanger must be replaced together with the two short coolant pipes.
The two coolant pipes must not be disconnected from the heat exchanger. The sealing rings are not
available as spare parts.
1. Replace heat exchanger together with the two short coolant pipes.

SUBSEQUENT WORK > SUBSEQUENT WORK FOR HEAT EXCHANGER
1. Install heating/fresh-air unit → Installing Heating/Fresh-Air Unit .
WM 803619 REMOVING AND INSTALLING PUMP VALVE UNIT > PRELIMINARY WORK
1. Remove left wheel. → 440519 REMOVING AND INSTALLING WHEEL
HOUSING LINER
3. Drain coolant. → 193817 DRAINING AND FILLING IN COOLANT (INCLUDES BLEEDING)
WM 803619 REMOVING AND INSTALLING PUMP VALVE UNIT > REMOVING PUMP
VALVE UNIT
Fig 1: Identifying Pump Valve Unit Installation Position
1. Unscrew two fastening screws -1- on the body.

Fig 2: Identifying Screws On Pump Valve Unit
2. Unscrew one fastening nut -2- on the bracket for the lines on the body.
Fig 3: Identifying Fastening Nut On Bracket For Lines
3. Release and unplug electric plug connection -3- for the pump valve unit.
Fig 4: Removing Electric Connector For Pump Valve Unit
4. Release and unplug electric plug connection -4- for the pump valve unit.
Fig 5: Removing Electric Connector For Pump Valve Unit
5. Loosen two clamps -5- on the hoses and pull out the hoses. Use a suitable container to collect
emerging coolant.
Fig 6: Identifying Pump Valve Unit With Clamps
6. Unscrew two fastening screws -6- on the brackets.
7. Pull the pump valve unit -7- out of the bracket -a- and remove it.
WM 803619 REMOVING AND INSTALLING PUMP VALVE UNIT > INSTALLING PUMP
VALVE UNIT
The pump valve unit is installed in reverse order to removal.
WM 803619 REMOVING AND INSTALLING PUMP VALVE UNIT > SUBSEQUENT

WORK
1. Install left wheel housing liner. → 505619 REMOVING AND INSTALLING FRONT WHEEL
HOUSING LINER
2. Install left wheel. → 440519 REMOVING AND INSTALLING WHEEL
3. Fill in coolant. → 193817 DRAINING AND FILLING IN COOLANT (INCLUDES BLEEDING)
WM 805519 REMOVING AND INSTALLING FRONT FOOTWELL OUTLET VENTS

E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > PRELIMINARY WORK >
PRELIMINARY WORK FOR FRONT FOOTWELL OUTLET VENT ON DRIVER'S SIDE

BRACKET
2. Pull rear footwell outlet vent off the front footwell outlet vent. → 805719 REMOVING AND
INSTALLING REAR FOOTWELL OUTLET VENTS
3. Remove temperature sensor from the footwell outlet vent on the driver's side. → 875819
REMOVING AND INSTALLING TEMPERATURE SENSOR

PRELIMINARY WORK FOR FRONT FOOTWELL OUTLET VENT ON PASSENGER'S
SIDE
DASHBOARD
2. Remove temperature sensor from the footwell outlet vents. → 875819 REMOVING AND
INSTALLING TEMPERATURE SENSOR

E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > REMOVING FRONT FOOTWELL
OUTLET VENTS > REMOVING FRONT FOOTWELL OUTLET VENT ON DRIVER'S SIDE
Fig 1: Identifying Front Footwell Outlet Vents Installation Position
1. Front footwell outlet vent on driver's side
2. Front footwell outlet vent on passenger's side
3. End part of front footwell outlet vent on passenger's side
1. Pull footwell outlet vent on driver's side -1- down off the air guide.
Fig 2: Removing Footwell Outlet Vent

E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > REMOVING FRONT FOOTWELL
OUTLET VENTS > REMOVING FRONT FOOTWELL OUTLET VENT ON PASSENGER'S
SIDE
Fig 1: Identifying Front Footwell Outlet Vents Installation Position
1. Front footwell outlet vent on driver's side
2. Front footwell outlet vent on passenger's side
3. End part of front footwell outlet vent on passenger's side
1. Unclip end part of footwell outlet vent on passenger's side -1- from the bracket -2- and pull it
off the air guide -3- .
Fig 2: Removing End Part Of Footwell Outlet Vent On Passenger's Side
2. Remove glove box. → 681519 REMOVING AND INSTALLING GLOVE BOX
4. Pull rear footwell outlet vent off the front footwell outlet vent. → 805719 REMOVING AND
5. Pull footwell outlet vent on passenger's side -2- down off the air guide.

E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > INSTALLING FRONT FOOTWELL
OUTLET VENTS
The front footwell outlet vents are installed in reverse order to removal.

E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > SUBSEQUENT WORK >
SUBSEQUENT WORK FOR FRONT FOOTWELL OUTLET VENT ON DRIVER'S SIDE
1. Fit rear footwell outlet vent on the front footwell outlet vent. → 805719 REMOVING AND
2. Install temperature sensor. → Installing Temperature Sensor
3. Install dashboard bracket. → Installing Dashboard Support

SUBSEQUENT WORK FOR FRONT FOOTWELL OUTLET VENT ON PASSENGER'S
SIDE
1. Fit rear footwell outlet vent onto the front footwell outlet vent. → 805719 REMOVING AND
2. Install temperature sensor. → Installing Temperature Sensor
DASHBOARD
WM 805719 REMOVING AND INSTALLING REAR FOOTWELL OUTLET VENT

PRELIMINARY WORK FOR REAR FOOTWELL OUTLET VENT ON DRIVER'S SIDE
1. Remove carpet on driver's side. → 704119 REMOVING AND INSTALLING CARPET
2. Remove front seat on driver's side. → 720119 REMOVING AND INSTALLING FRONT SEAT
3. Loosen power distributor. → 978919 REMOVING AND INSTALLING POWER DISTRIBUTOR

PRELIMINARY WORK FOR REAR FOOTWELL OUTLET VENT ON PASSENGER'S
SIDE
1. Remove carpet on passenger's side. → 704119 REMOVING AND INSTALLING CARPET
2. Remove front seat on passenger's side. → 720119 REMOVING AND INSTALLING FRONT
SEAT

E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > REMOVING REAR FOOTWELL
OUTLET VENT
Information
Fig 1: Identifying Rear Footwell Outlet Vent Installation Position
1. Rear footwell outlet vent on driver's side
2. Rear footwell outlet vent on passenger's side
1. Pull rear footwell outlet vent out of the front footwell outlet vent -A- .

E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > INSTALLING REAR FOOTWELL
OUTLET VENT

SUBSEQUENT WORK FOR REAR FOOTWELL OUTLET VENT ON DRIVER'S SIDE
1. Fit carpet on driver's side. → 704119 REMOVING AND INSTALLING CARPET
2. Install front seat on driver's side. → Installing Front Seat
3. Secure power distributor. → Installing Power Distributor

SUBSEQUENT WORK FOR REAR FOOTWELL OUTLET VENT ON PASSENGER'S
SIDE
1. Fit carpet on passenger's side. → 704119 REMOVING AND INSTALLING CARPET
2. Install front seat on driver's side. → Installing Front Seat

Service Manual: 82 - AUXILIARY HEATING -- 92A CAYENNE
WM 820819 REMOVING AND INSTALLING ANTENNA FOR AUXILIARY HEATER
(CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S E-HYBRID,
CAYENNE TURBO, CAYENNE (3.0)) > TECHNICAL VALUES
Screw securing Tightening 2 Nm (1.5 ftlb.)

control unit for torque
auxiliary heater
receiver to roof

CAYENNE TURBO, CAYENNE (3.0)) > INFORMATION > INSTALLATION POSITION
Fig 1: Identifying Control Unit For Auxiliary Heater Receiver Installation Position

CAYENNE TURBO, CAYENNE (3.0)) > PRELIMINARY WORK
1. Detach headliner and lower it at the rear. → 708419 REMOVING AND INSTALLING
HEADLINER
CAYENNE TURBO, CAYENNE (3.0)) > REMOVING CONTROL UNIT FOR AUXILIARY
HEATER RECEIVER

Fig 1: Removing DME Control Unit For Auxiliary Heater Receiver
2. Remove control unit -1- .
3. Release electric plug connections -arrow A- and disconnect them -arrow B- .


CAYENNE TURBO, CAYENNE (3.0)) > INSTALLING CONTROL UNIT FOR AUXILIARY
HEATER RECEIVER
1. Connect electric plug connections -arrows- until they engage securely.

2. Position control unit -1- (-arrow- ).

Fig 2: Securing Control Unit
3. Tighten fastening screws -2- . Tightening torque 2 Nm (1.5 ftlb.)

CAYENNE TURBO, CAYENNE (3.0)) > SUBSEQUENT WORK
1. Install headliner. → Installing Headliner
WM 821819 REMOVING AND INSTALLING CONTROL UNIT FOR AUXILIARY HEATER

CAYENNE TURBO, CAYENNE (3.0)) > PRELIMINARY WORK
1. Remove auxiliary heater. → 822019 REMOVING AND INSTALLING COMPLETE AUXILIARY

HEATING SYSTEM

CAYENNE TURBO, CAYENNE (3.0)) > REMOVING CONTROL UNIT FOR AUXILIARY
HEATER
Fig 1: Identifying Control Unit Components
2. Remove cover -2- from control unit for auxiliary heater -3- .
3. Release electric plug connection -1- and disconnect it -arrow- .

Fig 2: Removing Control Unit For Auxiliary Heater
5. Remove control unit for auxiliary heater -3- .

CAYENNE TURBO, CAYENNE (3.0)) > INSTALLING CONTROL UNIT FOR AUXILIARY
HEATER

CAYENNE TURBO, CAYENNE (3.0)) > SUBSEQUENT WORK
1. Install auxiliary heater. → Installing Complete Auxiliary Heating
WM 822019 REMOVING AND INSTALLING COMPLETE AUXILIARY HEATING

(CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE TURBO,
hose clamps VW tool 3094
assembly pliers Commercially Nr.72-1

available tool

Holder for Tightening 8 Nm (6 ftlb.)

auxiliary heater torque
to body
Holder for Tightening 6 Nm (4.5 ftlb.)

coolant pipes to torque
body
Coolant pipe to Tightening 6 Nm (4.5 ftlb.)

holder torque

CAYENNE (3.0)) > INFORMATION > INSTALLATION POSITION
Fig 1: Identifying Auxiliary Heater Installation Position

CAYENNE (3.0)) > REMOVING AND INSTALLING COMPLETE AUXILIARY HEATING >
PRELIMINARY WORK
1. Disconnect battery ground strap → 978509 LOOSENING AND SECURING GROUND STRAP
FOR BATTERY .
2. Remove the left front wheel → 440519 REMOVING AND INSTALLING WHEEL .
3. Remove front left wheel housing liner → 505619 REMOVING AND INSTALLING FRONT
WHEEL HOUSING LINER .

CAYENNE (3.0)) > REMOVING COMPLETE AUXILIARY HEATING
1. Close off coolant hoses using hose clamps 3094 , loosen spring band clamps -1- on coolant
lines using assembly pliers Nr.72-1 and pull coolant hoses off the coolant pipes.
2. Loosen hose clamp -2- on the fuel line and close off the fuel line. Use a new hose clamp
during installation.
3. Close off coolant hoses using hose clamp 3094 , loosen spring band clamps -6- on coolant
lines using assembly pliers Nr.72-1 and pull coolant hoses off the coolant pipes.
Fig 2: Identifying Exhaust Pipe Holder Clamps
4. Loosen clamp -5- on the exhaust pipe and remove pipe by pulling it downwards.
5. Remove fastening screw -3- and fastening nut -7- and loosen holders for coolant pipes and
exhaust pipe.
Fig 3: Identifying Exhaust Pipe Holder With Screws And Nut
6. Release and disconnect connectors -1, 2 and 3- for auxiliary heating.

Fig 4: Identifying Auxiliary Heating Connectors
7. Loosen fastening screws -1- on the holder -2- .

Fig 5: Identifying Auxiliary Heater Holder With Screws
8. Unhook auxiliary heater holder by lifting it up and carefully remove auxiliary heater.

CAYENNE (3.0)) > INSTALLING COMPLETE AUXILIARY HEATING
2. Tighten auxiliary heater holder to the body using the prescribed tightening torque until secure
Tightening torque 8 Nm (6 ftlb.) .
3. Tighten coolant pipe holder to the body using the prescribed tightening torque until secure
Tightening torque 6 Nm (4.5 ftlb.) .
4. Tighten coolant pipe to holder using the prescribed tightening torque until secure Tightening

CAYENNE (3.0)) > INSTALLING COMPLETE AUXILIARY HEATING > SUBSEQUENT
WORK
1. Connect battery ground strap and carry out work instructions after connecting the battery →
270619 REMOVING AND INSTALLING BATTERY .
2. Install front left wheel housing liner → 505619 REMOVING AND INSTALLING FRONT WHEEL
HOUSING LINER .
3. Fit the left front wheel → 440519 REMOVING AND INSTALLING WHEEL .
4. Bleed the cooling system → 193817 DRAINING AND FILLING COOLANT (INCLUDES
BLEEDING) .
5. Fill fuel line.
1. 5.1. Connect the Porsche System Tester to the vehicle and start the System Tester.
Switch on ignition. Press [F12] to continue.
2. 5.2. Select the vehicle type and start the PIDT.
3. 5.3. Select the Auxiliary heating control unit in the overview .
4. 5.4. Select the Maintenance/repairs menu.
5. 5.5. Line filling must now be selected. Then press [F12] to continue.
6. 5.6. Start the filling process by pressing [F8].
WM 822119 REMOVING AND INSTALLING INTAKE MUFFLER (CAYENNE, CAYENNE

GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE TURBO, CAYENNE (3.0)) >
INFORMATION > INSTALLATION POSITION
Fig 1: Identifying Intake Muffler For Auxiliary Heating Installation Position

REMOVING AND INSTALLING INTAKE MUFFLER > PRELIMINARY WORK
1. Remove auxiliary heater → 822019 REMOVING AND INSTALLING HEATER .

REMOVING INTAKE MUFFLER
1. Loosen clamp -1- on the intake tube for the heater and pull off intake muffler. The clamp must
be replaced.
Fig 1: Identifying Clamp On Intake Tube
2. Loosen tie-wrap -1- on the heater holder.

Fig 2: Identifying Tie-Wrap On Heater Holder
3. Release intake muffler at the fixing clip for the heater housing holder -1- and remove muffler.
Fig 3: Removing Intake Muffler Mounting

INSTALLING INTAKE MUFFLER

INSTALLING INTAKE MUFFLER > SUBSEQUENT WORK
1. Install auxiliary heater. → Installing Complete Auxiliary Heating
WM 825919 REMOVING AND INSTALLING SILENCER (CAYENNE, CAYENNE GTS,

CAYENNE TURBO S, CAYENNE S, CAYENNE TURBO, CAYENNE (3.0)) >
Fig 1: Identifying Auxiliary Heating Silencer Installation Position

CAYENNE TURBO S, CAYENNE S, CAYENNE TURBO, CAYENNE (3.0)) > REMOVING
AND INSTALLING SILENCER FOR AUXILIARY HEATING > PRELIMINARY WORK
WHEEL HOUSING LINER ".
2. Remove cover for centre underbody at the bottom left → 519319 REMOVING AND
INSTALLING COVER FOR CENTRE UNDERBODY .

CAYENNE TURBO S, CAYENNE S, CAYENNE TURBO, CAYENNE (3.0)) > REMOVING
SILENCER FOR AUXILIARY HEATING
Risk of burns
1. Loosen the pipe clamp -5- on the exhaust pipe.

Fig 1: Identifying Exhaust Pipe Holder With Pipe Clamps
2. Loosen fastening screws -4- on the holder -3- and remove the silencer and holder -6- .
Fig 2: Overview Of Silencer For Auxiliary Heating
3. The holder must be converted when replacing the silencer.
1. 3.1. Loosen fastening screws -4- on the holder and remove the holder -6- .

CAYENNE TURBO S, CAYENNE S, CAYENNE TURBO, CAYENNE (3.0)) > INSTALLING
SILENCER
2. Tighten fastening nut securing holder to rubber buffer to the prescribed tightening torque until
secure.
3. Tighten fastening screw securing holder to silencer to the prescribed tightening torque until
secure.

CAYENNE TURBO S, CAYENNE S, CAYENNE TURBO, CAYENNE (3.0)) > INSTALLING
SILENCER > SUBSEQUENT WORK
1. Install cover for centre underbody at the left → 519319 REMOVING AND INSTALLING
HOUSING LINER
WM 826019 REMOVING AND INSTALLING EXHAUST PIPE (CAYENNE, CAYENNE

TECHNICAL VALUES
Holder to Tightening +6 Nm (+4.5

exhaust pipe torque ftlb.)
Clamp securing Tightening +6 Nm (+4.5

exhaust pipe to torque ftlb.)
auxiliary heater

Fig 1: Identifying Exhaust Pipe For Auxiliary Heating Installation Position

REMOVING AND INSTALLING EXHAUST PIPE > PRELIMINARY WORK
1. Remove the complete auxiliary heating system. → 822019 REMOVING AND INSTALLING
COMPLETE HEATER

REMOVING EXHAUST PIPE
Risk of burns
1. Loosen and remove fastening screw -2- on the auxiliary heater holder (figure shows auxiliary
heater installed).
Fig 1: Identifying Exhaust Pipe Holder With Fastening Screw
2. Loosen clamp -1- on the auxiliary heater housing.

Fig 2: Loosening Clamp On Auxiliary Heater Housing
3. Disconnect exhaust pipe at the auxiliary heater connection and remove it carefully.

INSTALLING EXHAUST PIPE
2. Tighten holder to exhaust pipe using the prescribed tightening torque until secure Tightening
torque +6 Nm (+4.5 ftlb.) .
3. Tighten exhaust pipe clamp to auxiliary heater using the prescribed tightening torque until
secure Tightening torque +6 Nm (+4.5 ftlb.) .

INSTALLING EXHAUST PIPE > SUBSEQUENT WORK
1. Install the complete auxiliary heating system. → Installing Complete Auxiliary Heating
WM 827419 REMOVING AND INSTALLING DIRECTIONAL-CONTROL VALVE
E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > TOOLS
hose clamps VW tool 3094

available tool

E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > TECHNICAL VALUES
Screw securing Tightening +4 Nm (+3

directional- torque ftlb.)
control valve to
holder

E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > INFORMATION > INSTALLATION
POSITION OF DIRECTIONAL-CONTROL VALVE
1. Directional-control valve
Fig 1: Overview Of Auxiliary Heater

E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > REMOVING AND INSTALLING
DIRECTIONAL-CONTROL VALVE > PRELIMINARY WORK
1. Disconnect battery ground strap → 978509 LOOSENING AND SECURING GROUND STRAP
FOR BATTERY .
2. Remove front left wheel.

E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > REMOVING DIRECTIONAL-
CONTROL VALVE
Information
Before disconnecting the water lines, it is essential to observe the safety instructions.
Danger of scalding.
The coolant temperature can be over 100 °C when the engine is warm. The cooling system is
pressurized.
Before starting repairs, reduce the pressure and temperature if necessary.
1. Close off coolant hoses with hose clamps 3094 , loosen spring band clamps -4- on the
directional-control valve -2- using assembly pliers Nr.72-1 and pull coolant hoses off the
directional-control valve.
2. Disconnect plug connection -1- from the directional-control valve -2- .

Fig 1: Identifying Plug Connection From Directional-Control Valve
3. Loosen and remove screws -3- from the directional-control valve -2- .

E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > INSTALLING DIRECTIONAL-
CONTROL VALVE
2. Tighten fastening screw securing directional-control valve to holder to the specified tightening
torque Tightening torque +4 Nm (+3 ftlb.) .

E-HYBRID, CAYENNE TURBO, CAYENNE (3.0)) > INSTALLING DIRECTIONAL-
CONTROL VALVE > SUBSEQUENT WORK
1. Connect battery ground strap and carry out work instructions after connecting the battery →
978509 LOOSENING AND SECURING GROUND STRAP FOR BATTERY .
HOUSING LINER .
3. Fit front left wheel.
4. Bleed the cooling system → 193817 DRAINING AND FILLING COOLANT (INCLUDES
BLEEDING) .
5. Teach remote control for auxiliary heater .
WM 828019 REMOVING AND INSTALLING ELECTRIC PASSENGER COMPARTMENT

HEATER (HIGH-VOLTAGE AUXILIARY HEATER) (CAYENNE GTS, CAYENNE TURBO
S, CAYENNE S E-HYBRID) > TOOLS

available tool

S, CAYENNE S E-HYBRID) > TECHNICAL VALUES

S, CAYENNE S E-HYBRID) > INFORMATION > INSTALLATION POSITION OF
ELECTRIC PASSENGER COMPARTMENT HEATER
The electric passenger compartment heater is located in the left wheel housing in front of the A-pillar.
Fig 1: Identifying Electric Passenger Compartment Heater Installation Position

S, CAYENNE S E-HYBRID) > PRELIMINARY WORK > PRELIMINARY WORK FOR
1. Observe warning notes → 2X00IN GENERAL WARNING NOTES FOR WORKING ON THE
documentation → 2X00IN ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM
POWER SUPPLY/STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM (AFES) .
4. Drain coolant → 193817 DRAINING AND FILLING COOLANT .

S, CAYENNE S E-HYBRID) > REMOVING ELECTRIC PASSENGER COMPARTMENT
HEATER
Information
Protect high-voltage plug connections from dampness .

Do not release high-voltage plug connections until you have opened the cooling system .
2. Close off lower coolant hoses in the wheel housing using hose clamp 3094 , loosen spring
band clamps -6- on coolant lines using assembly pliers Nr.72-1 and pull coolant hoses off
the coolant pipes.
Fig 1: Identifying Exhaust Pipe Holder With Clamps
3. Close off upper coolant hoses in the wheel housing using hose clamps 3094 , loosen spring
band clamps -1- on coolant lines using assembly pliers Nr.72-1 and pull coolant hoses off
the coolant pipes.
Fig 2: Identifying Coolant Hoses With Band Clamps
4. Loosen fastening nut and fastening screws -2- for the coolant lines -1- .
Fig 3: Identifying Coolant Lines With Nut And Screws
5. Loosen front coolant hoses at the top of the wheel arch -1- . To do this, loosen spring band
clamps -2- on coolant lines using assembly pliers Nr.72-1 and pull coolant hoses off the
coolant pipes.
Fig 4: Identifying Wheel Arch And Spring Band Clamps
6. Disconnect electric plug connection -2- on electric passenger compartment heater -4- .
Fig 5: Identifying Electric Plug Connection On Electric Passenger Compartment Heater
7. Release and disconnect high-voltage plug connection -3- on electric passenger compartment
heater.
Fig 6: Releasing High-Voltage Connector
1. 7.1. Unclip high-voltage line at the holder.
2. 7.2. Press red release tab -a- .
3. 7.3. Pull orange tab in direction of arrow until you feel a certain amount of resistance
-arrow A- .
4. 7.4. Release black tab -b- and pull off connector -arrow B- .
8. Disconnect ground line on electric passenger compartment heater.
9. Disconnect electric plug connection -1- above the front upper connection point for the coolant
lines.
10. Loosen fastening screws -3 and 7- from the holder -1- .

Fig 8: Identifying Exhaust Pipe Holder With Fastening Screws
11. Remove fastening screws -2- from holder -1- for electric high-voltage battery heater.
1. 11.1. Only loosen fastening nut -3- on the holder -1- .

Fig 9: Identifying Fastening Nut On Holder

Fig 10: Identifying Upper Fastening Screw On Holder For Electric High-Voltage
Battery Heater
12. Remove electric high-voltage heater with holder and coolant lines.
13. Loosen spring band clamps -1- on the electric passenger compartment heater using
assembly pliers Nr.72-1 and pull off coolant hoses -2- .
Fig 11: Identifying Spring Band Clamps
14. Loosen fastening screws -3- securing electric high-voltage battery heater -1- to holder -2- .
Fig 12: Identifying Electric High-Voltage Battery Heater With Screws (1 Of 2)

Fig 13: Identifying Electric High-Voltage Battery Heater With Screws (2 Of 2)

S, CAYENNE S E-HYBRID) > INSTALLING ELECTRIC PASSENGER COMPARTMENT
HEATER
3. Connect high-voltage plug connection -3- to the electric passenger compartment heater -4-
until it engages securely and then lock it.
Fig 1: Identifying Connections For Electric Passenger Compartment Heater
4. Connect electric plug connection -2- on electric passenger compartment heater -4- .
Fig 2: Identifying Connections For Electric Passenger Compartment Heater
5. Tighten fastening screws securing electric passenger compartment heater to holder to the
prescribed tightening torque.
6. Tighten fastening nut securing electric passenger compartment heater holder to the body to
the prescribed tightening torque.
7. Tighten fastening screws securing electric passenger compartment heater holder to the body
to the prescribed tightening torque.
8. Tighten fastening screws securing coolant lines to the body to the prescribed tightening torque.

S, CAYENNE S E-HYBRID) > SUBSEQUENT WORK > SUBSEQUENT WORK FOR
2. Add coolant and bleed the high-temperature cooling system → 193817 DRAINING AND
FILLING COOLANT (INCLUDES BLEEDING) .
3. Start the high-voltage system → 2X00IN ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM
FROM POWER SUPPLY/STARTING HIGH-VOLTAGE ELECTRICAL SYSTEM .
WM 828119 REMOVING AND INSTALLING ELECTRIC HIGH-VOLTAGE BATTERY

HEATER (CAYENNE GTS, CAYENNE TURBO S, CAYENNE S E-HYBRID) > TOOLS
hose clamping Commercially Nr.192

assembly pliers Commercially Nr.72 Pos.1

available tool

HEATER (CAYENNE GTS, CAYENNE TURBO S, CAYENNE S E-HYBRID) >
TECHNICAL VALUES
Fastening screw 6 Tightening 8 Nm (6 ftlb.)

securing holder torque
to body
Connections for electric high-voltage battery heater
Fastening nut 3 Tightening 8 Nm (6 ftlb.)

securing ground torque
cable to electric
high-voltage
battery heater
Connections for electric high-voltage battery heater

securing holder torque ftlb.)
to electric
high-voltage
battery heater

INFORMATION > INSTALLATION POSITION OF ELECTRIC HIGH-VOLTAGE BATTERY
HEATER
The electric high-voltage battery heater is located in front of the high-voltage battery in the luggage
compartment (in direction of travel).
Fig 1: Identifying Electric High-Voltage Battery Heater Installation Position

PRELIMINARY WORK > PRELIMINARY WORK FOR ELECTRIC HIGH-VOLTAGE
BATTERY HEATER
2. Remove luggage compartment cover → 700619 REMOVING AND INSTALLING TRIM PANEL
FOR LUGGAGE COMPARTMENT (LUGGAGE COMPARTMENT COVER) AT THE LOCK
SUPPORT .
3. Drain coolant for the low-temperature cooling system → 193817 DRAINING AND FILLING
COOLANT .

HEATER (CAYENNE GTS, CAYENNE TURBO S, CAYENNE S E-HYBRID) > REMOVING
ELECTRIC HIGH-VOLTAGE BATTERY HEATER
Information
Protect high-voltage plug connections from dampness .
Do not release high-voltage plug connections until you have opened the cooling system .
Information
2. Disconnect coolant hoses -1- at the electric high-voltage battery heater and at the connection
point for the coolant line.
Coolant hoses -1- or connection pieces -3- must not be loosened on the installed high-voltage
battery. Danger of coolant getting into the high-voltage battery and damaging the high-voltage
battery.
Fig 1: Identifying Coolant Hoses On High-Voltage Battery
1. 2.1. Clamp off coolant hoses -1- using hose clamping pliers Nr.192 .
2. 2.2. Loosen spring band clamps -2- on the coolant hoses at the electric high-voltage
battery heater and at the connection point for the coolant line using assembly pliers
Nr.72 Pos.1 .
3. 2.3. Place an absorbent cloth underneath hose connections. Residual coolant can
emerge
4. 2.4. Disconnect coolant hoses from the coolant line and from the connection piece
-3- for the high-voltage battery.
3. Disconnect electric plug connection -2- on electric high-voltage battery heater -5- .
Fig 2: Identifying Connections For Electric High-Voltage Battery Heater
4. Loosen fastening nut -3- for the ground cable on the electric high-voltage battery heater -5- .
5. Release and disconnect high-voltage plug connection -1- on the electric high-voltage battery
heater -5- .
1. 5.1. Press red release tab -a- .
2. 5.2. Pull orange tab in direction of arrow until you feel a certain amount of resistance
-arrow A- .
3. 5.3. Release black tab -b- and pull off connector -arrow B- .
Fig 5: Releasing High-Voltage Connector
6. Loosen fastening screws -6- and remove electric high-voltage battery heater -5- with holder
-4- and coolant hoses to one side.
Fig 6: Identifying Connections For Electric High-Voltage Battery Heater With Screws
7. If the electric high-voltage battery heater has to be replaced, then the holder -4- and the two
coolant hoses -1- must be converted. Tightening torque 10 Nm (7.5 ftlb.)
Fig 7: Identifying Connections For Electric High-Voltage Battery Heater With Screws

INSTALLING ELECTRIC HIGH-VOLTAGE BATTERY HEATER
1. Install electric high-voltage battery heater -5- with holder -4- and coolant hoses and tighten
fastening nuts -6- to the prescribed tightening torque. Tightening torque 8 Nm (6 ftlb.)
Fig 1: Identifying Connections For Electric High-Voltage Battery Heater With Nuts
2. Connect high-voltage plug connection -1- to the electric high-voltage battery heater -5- until it
engages securely and then lock it.
3. Tighten fastening nut -3- on the ground cable at the electric high-voltage battery heater -5- to
the prescribed tightening torque. Tightening torque 8 Nm (6 ftlb.)
4. Plug in electric plug connection -2- at the electric high-voltage battery heater -5- until engages
securely.
5. Fit coolant hose to the electric high-voltage battery heater and high-voltage battery and
position spring band clamps -2- inside the marking on the coolant hose using assembly
pliers Nr.72 Pos.1 .
Hose clamping pliers Nr.192 can then be removed.

Fig 5: Identifying Coolant Hoses On High-Voltage Battery

SUBSEQUENT WORK > SUBSEQUENT WORK FOR ELECTRIC HIGH-VOLTAGE
BATTERY HEATER
1. Install luggage compartment cover → 700619 REMOVING AND INSTALLING TRIM PANEL
FOR LUGGAGE COMPARTMENT (LUGGAGE COMPARTMENT COVER) AT THE LOCK
SUPPORT .
2. Add coolant for the low-temperature cooling system and bleed it → 193817 DRAINING AND
FILLING COOLANT .
Service Manual: 85 - VENTILATION -- 92A CAYENNE
WM 851519 REMOVING AND INSTALLING HEATER/AIR-CONDITIONING UNIT
WORK > PRELIMINARY WORK FOR HEATING/FRESH-AIR UNIT
2. Drain refrigerant. → 870317 DRAINING AND FILLING REFRIGERANT

BRACKET
5. Remove the condenser-evaporator line and compressor-evaporator line at the expansion valve
and close the connections. → 877019 REMOVING AND INSTALLING EXPANSION VALVE

HEATER/AIR-CONDITIONING UNIT
Information
The heat exchanger connection must be closed off using suitable stoppers after disconnecting the
coolant hoses.
Information
Line the driver's footwell with very absorbent material .

Fig 1: Identifying Heater/Air-Conditioning Unit Installation Position
1. Unscrew and remove two fastening screws -1- on the cover on the coolant lines.
Fig 2: Identifying Coolant Lines Cover And Fasteners
2. Remove cover for coolant lines.
3. Release electric plug connection for the servo motors at the heater/air-conditioning unit -a-
and disconnect it -arrow- .
Fig 3: Pulling Off Connector For Servo Motors
4. Pull the retaining clips -2- on the coolant supply line and return line downwards -arrow A- .
Fig 4: Pulling Off Retaining Clips On Coolant Lines
5. Pull the interior carpet away from the coolant lines and place a suitable collecting container in
position.
6. Carefully pull the coolant lines out of the heat exchanger -arrow B- and drain the coolant into
the collecting container.
7. Release the clamp -3- and pull the water drain hose off the heater/air-conditioning unit.
Fig 5: Pulling Off Water Drain Hose
8. Disconnect the center air vents for the footwell and slide them onto the heater/air-conditioning
unit. → 805519 REMOVING AND INSTALLING FRONT FOOTWELL OUTLET VENT
9. Unclip main wire harness and cable duct at the heater/air-conditioning unit at the left and right
-arrows- .
Fig 6: Identifying Main Wire Harness
10. Grasp the heater/air-conditioning unit at the left and right, pull it backwards and remove
completely.

HEATER/AIR-CONDITIONING UNIT
Information
Before the heater/air-conditioning unit is installed again, the following points must be checked:
Check the water drain hose for any cracks, deformities and other damage .
Fig 1: Identifying Water Drain Hose
Check both supports (stars) for the heater/air-conditioning unit on the body for damage. The stars
must be able to turn for installation .
Fig 2: Identifying Supports (Stars) For Heating/Fresh-Air Unit On Body
Both supports for the stars on the heater/air-conditioning unit must not be damaged .
Fig 3: Identifying Supports On Heating/Fresh-Air Unit For Stars

Fig 4: Installing Heater/Air-Conditioning Unit
1. Position the heater/air-conditioning unit in the vehicle with the help of a second person -arrow
A- . Get this person to check that the stars are positioned correctly and turn them if necessary.
2. Slide the heater/air-conditioning unit onto the two mounts (stars) and clip it in at two retaining
points on the left and right. Get a second person to check that the mounts (stars) are
positioned correctly and turn them if necessary.
3. Clip in the main wire harness and cable duct at the heater/air-conditioning unit at the left and
right -arrow B- .
4. Push the water drain hose onto the air-conditioning unit and make sure it is seated correctly.
Slide on the clamp -3- .
Fig 5: Pushing On Water Drain Hose
5. Clip in the main wire harness and cable duct at the heater/air-conditioning unit at the left and
right.
6. Plug in electric plug connection for the servo motors until it engages securely.
Fig 6: Identifying Connector For Servo Motors
7. Insert the center air vents for the footwell and slide them onto the heater/air-conditioning unit.
→ Installing Front Footwell Outlet Vents
Information
1. When installing or replacing the heater/air-conditioning unit, check that the temperature
sensors are fitted in the footwell outlet vents .
2. If the heater/air-conditioning unit has to be replaced, the temperature sensors for the
footwell outlet vents -5 and 6- on the heater/air-conditioning unit are in a park position
and must be moved from there into the fitted footwell outlet vents .
Fig 7: Identifying Temperature Sensors Installation Positions
1. 7.1. Fit temperature sensors into the footwell outlet vents .
Information
1. Always replace O-rings .
8. Insert the coolant supply line and return line into the heat exchanger -arrow B- .
9. Slide on the retaining clips -2- until they engage securely.

Fig 8: Identifying Retaining Clips For Coolant Line
10. Fit cover for coolant lines.

Fig 9: Fitting Cover For Coolant Lines
11. Screw in two fastening screws -1- on the cover.

WORK > SUBSEQUENT WORK FOR HEATING/FRESH-AIR UNIT
2. Install dashboard. → Installing Dashboard
4. Bleed the cooling system. → 190101 CHECKING THE COOLING SYSTEM
5. Fill in refrigerant. → 870317 DRAINING AND FILLING REFRIGERANT
6. Check the heating system for leaks.
WM 851519 REMOVING AND INSTALLING HEATING/FRESH-AIR UNIT (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION > INSTALLATION
POSITION OF HEATING/FRESH-AIR UNIT
Fig 1: Identifying Heater/Air-Conditioning Unit Installation Position

PRELIMINARY WORK FOR HEATING/FRESH-AIR UNIT
2. Drain refrigerant. → 870317 DRAINING AND FILLING REFRIGERANT

BRACKET
5. Remove the condenser-evaporator line and compressor-evaporator line at the expansion valve
and close the connections. → 877019 REMOVING AND INSTALLING EXPANSION VALVE

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING HEATING/FRESH-AIR
UNIT
Information
The heat exchanger connection must be closed off using suitable stoppers after disconnecting the
coolant hoses.
Information
Line the driver's footwell with very absorbent material .
1. Unscrew and remove two fastening screws -1- on the cover on the coolant lines.
Fig 1: Identifying Cover On Coolant Lines With Fastening Screws
2. Remove cover for coolant lines.
3. Release electric plug connection for the servo motors at the heater/air-conditioning unit -a-
and disconnect it -arrow- .
Fig 2: Disconnecting Connector For Servo Motors
4. Pull the retaining clips -2- on the coolant supply line and return line downwards -A- .
Fig 3: Pulling Off Retaining Clips On Coolant Lines
5. Pull the interior carpet away from the coolant lines and place a suitable collecting container in
position.
6. Carefully pull coolant lines out of the heat exchanger -arrow B- and drain coolant into the
collecting container.
7. Loosen spring band clamp -3- and pull the water drain hose off the heating/fresh-air unit.
Fig 4: Pulling Off Water Drain Hose
8. Disconnect the center air vents for the footwell and slide them onto the heating/fresh-air unit.
→ 805519 REMOVING AND INSTALLING FRONT FOOTWELL OUTLET VENT
9. Unclip main wire harness and cable duct at the heating/fresh-air unit at the left and right
-arrows- .
Fig 5: Removing Main Wire Harness
10. Grasp the heating/fresh-air unit at the left and right, pull it backwards and remove completely.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING HEATING/FRESH-AIR
UNIT
Information
Before the heater/air-conditioning unit is installed again, the following points must be checked:
Check both supports (stars) for the heater/air-conditioning unit on the body for damage. The stars
must be able to turn for installation .
Fig 2: Identifying Supports (Stars) For Heating/Fresh-Air Unit On Body
Both supports for the stars on the heater/air-conditioning unit must not be damaged .
Fig 3: Identifying Supports On Heating/Fresh-Air Unit For Stars

Fig 4: Installing Heater/Air-Conditioning Unit
1. Position the heating/fresh-air unit in the vehicle with the help of a second person -arrow A- .
Get this person to check that the stars are positioned correctly and turn them if necessary.
2. Slide the heating/fresh-air unit onto the two supports (stars) and clip it in at two retaining points
on the left and right. Get a second person to check that the supports (stars) are positioned
correctly and turn them if necessary.
3. Clip in the main wire harness and cable duct at the heating/fresh-air unit at the left and right
-arrow B- .
4. Push the water drain hose onto the heating/fresh-air unit and make sure it is seated correctly.
Push on spring band clamp -3- .
Fig 5: Pushing On Water Drain Hose
5. Clip in the main wire harness and cable duct at the heating/fresh-air unit at the left and right.
6. Plug in electric plug connection for the servo motors until it engages securely.
Fig 6: Plugging In Connector For Servo Motors
7. Insert the center air vents for the footwell and slide them onto the heating/fresh-air unit. →
Installing Front Footwell Outlet Vents
Information
1. When installing or replacing the heater/air-conditioning unit, check that the temperature
sensors are fitted in the footwell outlet vents .
2. If the heater/air-conditioning unit has to be replaced, the temperature sensors for the
footwell outlet vents -5 and 6- on the heater/air-conditioning unit are in a park position
and must be moved from there into the fitted footwell outlet vents .
Fig 7: Identifying Installation Positions Of Temperature Sensors
1. 7.1. Fit temperature sensors into the footwell outlet vents .
Information
1. Always replace O-rings .
8. Insert the coolant supply line and return line into the heat exchanger -arrow B- .
9. Slide on the retaining clips -2- until they engage securely.

Fig 8: Sliding On Retaining Clips For Coolant Line
10. Fit cover for coolant lines.

Fig 9: Fitting Cover For Coolant Lines
11. Screw in and tighten two fastening screws -1- on the cover.

SUBSEQUENT WORK FOR HEATING/FRESH-AIR UNIT
4. Bleed the cooling system. → 190101 CHECKING THE COOLING SYSTEM
6. Check the heating system for leaks.
WM 851819 REMOVING AND INSTALLING PARTICLE FILTER (CAYENNE, CAYENNE

OF PARTICLE FILTER
Fig 1: Identifying Installation Position Of Particle Filter

WORK FOR PARTICLE FILTER
Remove cover under the dashboard on the passenger's side. → 702219 REMOVING AND INSTALLING

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING PARTICLE FILTER
guide -3- .
Fig 1: Identifying Footwell Outlet Vent On Passenger's Side From Bracket
Information
Fig 2: Identifying Cover For Particle Filter With Locking Mechanism

Fig 3: Identifying Cover For Particle Filter
the bracket -3- .

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING PARTICLE FILTER
Information

Fig 3: Identifying Footwell Outlet Vent To Air Guide

WORK FOR PARTICLE FILTER
Install cover under the dashboard on the passenger's side. → 702219 REMOVING AND INSTALLING
WM 851819 PARTICLE FILTER: REMOVING AND INSTALLING FILTER ELEMENT

WORK > PRELIMINARY WORK FOR PARTICLE FILTER
Remove cover under the dashboard on the passenger's side. → 702219 REMOVING AND INSTALLING

E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > PARTICLE
FILTER: REMOVING FILTER ELEMENT
Fig 1: Identifying Particle Filter Installation Position
guide -3- .
Information
the bracket -3- .

E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > PARTICLE
FILTER: INSTALLING FILTER ELEMENT
Information


WORK > SUBSEQUENT WORK FOR PARTICLE FILTER
Install cover under the dashboard on the passenger's side. → 702219 REMOVING AND INSTALLING
WM 853019 REMOVING AND INSTALLING HEATING/FRESH-AIR FAN MOTOR

> INSTALLATION POSITION OF HEATING/FRESH-AIR FAN MOTOR
Fig 1: Identifying Installation Position Of Fan Motor

WORK > PRELIMINARY WORK FOR HEATING/FRESH-AIR FAN MOTOR
1. Remove cover in footwell on the passenger's side. → 702219 REMOVING AND INSTALLING

HEATING/FRESH-AIR FAN MOTOR
guide -3- .
2. Unscrew five fastening screws -1- on the fan motor cover -2- .
Fig 2: Identifying Fastening Screws On Fan Motor Cover
3. Unscrew two fastening screws -4- on the fan motor -3- .

Fig 3: Identifying Fastening Screws On Fan Motor
4. Release electric plug connection on the fan motor -a- and disconnect it -A- .
Fig 4: Disconnecting Connector From Fan Motor

HEATING/FRESH-AIR FAN MOTOR > INSTALLING HEATER/FRESH-AIR BLOWER
MOTOR
1. Plug in electric plug connection on the fan motor -A- until the connector engages securely.
Fig 1: Plugging In Connector On Blower Motor
2. Screw in two fastening screws -4- on the fan motor -3- .

3. Screw in five fastening screws -1- on the fan motor cover -2- .

WORK > SUBSEQUENT WORK FOR HEATING/FRESH-AIR FAN MOTOR
1. Install cover in footwell on the passenger's side. → 702219 REMOVING AND INSTALLING
WM 853019 REMOVING AND INSTALLING HEATER/FRESH-AIR BLOWER MOTOR

WORK
1. Remove cover in footwell on the passenger's side. → 702219 REMOVING AND INSTALLING

HEATER/FRESH-AIR BLOWER MOTOR
Fig 1: Identifying Installation Position Of Blower Motor
guide -3- .
2. Unscrew five fastening screws -1- on the blower motor cover -2- .
Fig 3: Identifying Fastening Screws On Blower Motor
3. Unscrew two fastening screws -4- on the blower motor -3- .

4. Release electric plug connection on the blower motor -a- and pull it off -A- .
Fig 5: Removing Connector From Blower Motor

HEATER/FRESH-AIR BLOWER MOTOR
1. Plug in electric plug connection on the blower motor -A- until the connector engages securely.
Fig 1: Plugging In Connector On Blower Motor
2. Screw in two fastening screws -4- on the blower motor -3- .

3. Screw in five fastening screws -1- on the blower motor cover -2- .

WORK
1. Install cover in footwell on the passenger's side. → 702219 REMOVING AND INSTALLING
WM 853419 REMOVING AND INSTALLING AIR GUIDE (CAYENNE, CAYENNE GTS,

OF AIR GUIDE
Fig 1: Overview Of Air Guides
1. Bracket for end part
2. End part of air guide
3. Centre part of air guide
4. Front part of air guide

Information
Depending on vehicle equipment and on the required air guide, all interior components must be
removed .
The removal and installation described provides information about routing and the connection or
fastening points .
The air guide auxiliary guide (rear four-zones) can be found under Removing and installing
auxiliary air conditioning air guide. → 883419 REMOVING AND INSTALLING AUXILIARY AIR
CONDITIONING AIR GUIDE

WORK FOR AIR GUIDE

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING AIR GUIDE
1. Pull bracket for end part -1- up and remove it -A- .
2. Pull end part of air guide -2- out of the center part -3- (-B- ).
Fig 1: Removing End Part Of Air Guide
3. Pull center part -3- and front part -4- of air guide down out of the dashboard -C- .
Fig 2: Removing Centre Part And Front Part Of Air Guide

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING AIR GUIDE
The rear air guide is installed in reverse order to removal.

WORK FOR AIR GUIDE
WM 855319 REMOVING AND INSTALLING CENTRE AIR NOZZLE (CAYENNE,


unlocking tool Special tool 9827

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING CENTRE AIR NOZZLE
Information
Fig 1: Identifying Centre Air Nozzle Installation Position
1. Release air vent using unlocking tool 9827 .
1. 1.1. Release the metal clip above the second vane from the bottom at the outside
using the unlocking tool. Pull the air vent out slightly at the same time.
2. 1.2. Release the metal clip below the second vane from the top at the outside using
the unlocking tool. Pull the air vent out slightly at the same time.
2. Pull center air vent -1- out completely -A- .

Fig 2: Removing Centre Air Nozzle
3. Unplug electrical plug connection -A- .

Fig 3: Disconnecting Plug Connection At Centre Air Nozzle

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING CENTRE AIR NOZZLE
WM 855319 REMOVING AND INSTALLING CENTRE AIR VENT (EXCEPT CAYENNE,


unlocking tool Special tool 9827

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING CENTRE AIR VENT
Information
Fig 1: Identifying Centre Air Nozzle Installation Position
1. Release air vent using unlocking tool 9827 .
1. 1.1. Release the metal clip above the second vane from the bottom at the outside
using the unlocking tool. Pull the air vent out slightly at the same time.
2. 1.2. Release the metal clip below the second vane from the top at the outside using
the unlocking tool. Pull the air vent out slightly at the same time.
2. Pull center air vent -1- out completely -A- .

Fig 2: Removing Centre Air Nozzle
3. Unplug electrical plug connection -A- .

Fig 3: Disconnecting Plug Connection At Centre Air Nozzle

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING CENTRE AIR VENT >
INSTALLING CENTRE AIR NOZZLE
WM 855719 REMOVING AND INSTALLING REAR CENTRE AIR VENT (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR CENTRE AIR
VENT
Information
Information
1. Insert a plastic spatula at the sides of the air vent -1- and lever the air vent out of the center
console -2- (-arrow- ).
Fig 1: Removing Air Vent
2. Unplug electric plug connection -2- on the air vent -1- (-arrow- ).
Fig 2: Identifying Electric Plug Connection On Air Vent
3. Remove air vent.
WM 855719 REMOVING AND INSTALLING REAR CENTRE AIR VENT (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR CENTRE AIR
VENT
WM 855919 REMOVING AND INSTALLING AIR VENT FOR DOOR WINDOW

> INSTALLATION POSITION OF AIR VENT FOR DOOR WINDOW
Fig 1: Identifying Air Nozzle For Door Window Installation Position

WORK
Remove cover at side of dashboard.

AIR NOZZLE FOR DOOR WINDOW > REMOVING AIR VENT FOR DOOR WINDOW
Information

Fig 1: Removing Air Vent For Door Window
2. Pull out air vent -A- .
3. Disconnect electric plug connection -A- .

Fig 2: Disconnecting Plug Connection At Centre Air Vent

AIR NOZZLE FOR DOOR WINDOW
The air nozzle for the door window is installed in reverse order to removal.

WORK
Install cover at side of dashboard.
WM 856519 REMOVING AND INSTALLING VENTILATION COVER (CAYENNE,

POSITION OF VENTILATION COVER
Fig 1: Identifying Ventilation Cover Installation Position

PRELIMINARY WORK FOR VENTILATION COVER

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING VENTILATION COVER
Information
1. Insert a plastic wedge in between the vehicle body and the bottom of the ventilation cover.
Fig 1: Inserting Plastic Wedge
2. Pull the lower edge of the ventilation cover outwards.

Fig 2: Pulling Lower Edge Of Ventilation Cover Outwards
3. Remove ventilation cover.

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING VENTILATION COVER
Information
1. Position the ventilation cover at the top and press it in until the locking lugs engage securely.
Check that the seal is seated securely.
Fig 1: Pressing In Ventilation Cover

SUBSEQUENT WORK FOR VENTILATION COVER

Service Manual: 87 - AIR CONDITIONING -- 92A CAYENNE
WM 870101 CHECKING AIR-CONDITIONING SYSTEM (CAYENNE, CAYENNE GTS,

CAYENNE S DIESEL, CAYENNE (3.0)) > TROUBLESHOOTING THE AIR
CONDITIONING SYSTEM FOLLOWING COMPLAINTS ABOUT COOLING OUTPUT
Information
If it is not possible to clearly detect a leak using a leak detector, then only the leak detector additive
supplied by SPEKTRONICS may be used. Leak detector additive: Traserline TP 3860 in dissolved
form .
This leak detector additive is available from service equipment providers (e.g. Waeco).
For filling this Traser additive, special adapter kits are required, which are also available from service
equipment providers (e.g. Waeco).
Information on how to use the air conditioning system and the procedure for filling it can be found in the
operating instructions for the adapter kits.
Information
The troubleshooting steps shown must be used if complaints are received about the cooling output of
the air conditioning system.
Status Specification OK Specification not OK
1) Check the cooling output, Specified air flow and Insufficient air flow from the
temperature and air flow.Check the temperature is reached.Air exhaust vents. Continue with
air distribution by making distribution is working.Continue Step 3) .Required temperature
adjustments to the air-conditioning with Step 2) . is not reached. Continue with
control panel.Start the vehicle and
check the air conditioning system
for the prescribed nominal
Step 2) .
temperature values. → 870101
FUNCTION CHECK ON AIR
CONDITIONING
No fault memory stored, air flow

and temperature complies with
specified nominal
Fault present:Work through fault
2) Perform on-board diagnosis on values.Function OK. No further
memory in accordance with
all control units. PIWIS Tester II action required .No fault
"Guided Fault Finding".Continue
9818 memory stored and the
with Step 1) .
temperature does not reach the
specified nominal values.
Continue with Step 4) .
3) Check the following points one

Replace activated
after the other. Replace if
charcoal/particle filter if
necessary.Remove activated
necessary.Check mechanical
charcoal/particle filter and check
operation (air distribution) of the
for dirt and dust particles.→ Fan motor and activated charcoal
servo motors/flaps and repair
85181900 REMOVING AND filter OK.Continue with Step 4) .
them if necessary, e.g.→ 872019
INSTALLING PARTICLE
REMOVING AND INSTALLING
FILTERCheck fan motor for correct
SERVO MOTOR Following
operation and control. Use wiring
repairs, continue with Step 1) .
diagram if necessary.
4) Connect air-conditioning service High pressure too high, continue

device, measure high and low with Step 5) .High pressure too
High and low pressure
pressure and compare with low, continue with Step 6) .Low
OK.Function OK. No further
nominal values.→ 870101 pressure too high, continue with
action required .
FUNCTION CHECK ON AIR Step 7) .Low pressure too low,
CONDITIONING continue with Step 8) .
5) High pressure too high. Check

the following points one after the Clean the condenser.Repair
other:Check condenser for dirt/dust condenser fan activation
particles and damage.Check mechanism. Use wiring
electrical operation, condenser fan diagram.Fill the air conditioning
activation.Drain refrigerant, system with the prescribed
measure and document the amount of refrigerant.→ 8X00IN
amount of refrigerant removed. >> TECHNICAL DATA FOR
Too much refrigerant.→ 87031700 AIR-CONDITIONING
DRAINING AND FILLING SYSTEMContinue with Step 1) .
REFRIGERANT
6) High pressure too low. Check >> If the amount of refrigerant is Repair air-conditioning
the following points one after the correct, remove the expansion compressor activation
other:Check electrical operation, valve and check for foreign mechanism. Use wiring
air-conditioning compressor bodies (e.g. chips, abrasion).→ diagram.>> If there is not enough
activation.Drain refrigerant, 87701900 REMOVING AND refrigerant, fill the air conditioning
measure and document the INSTALLING EXPANSION system according to
amount of refrigerant. VALVE → 87031700 DRAINING specifications. → 8X00IN
TECHNICAL DATA FOR
AIR-CONDITIONING
AND FILLING SYSTEMCheck refrigerant circuit
REFRIGERANT Replace and connection points using a
expansion valve if leak detector. >> Once you have
necessary.Continue with Step 1) determined the cause of
refrigerant loss, replace seal or
spare part.Continue with Step 1)
If the amount of refrigerant is

correct, remove the expansion
7) Low pressure too high. Check
valve and check for foreign >> If there is too much
the following points one after the
bodies (e.g. chips, abrasion).→ refrigerant, fill the air conditioning
other:Drain refrigerant, measure
87701900 REMOVING AND system according to
and document the amount of
INSTALLING EXPANSION specifications. → 8X00IN
refrigerant. >> Too much
VALVE → 87031700 DRAINING TECHNICAL DATA FOR
refrigerant. → 87031700
AND FILLING AIR-CONDITIONING
DRAINING AND FILLING
REFRIGERANT Replace SYSTEMContinue with Step 1)
REFRIGERANT
expansion valve if
necessary.Continue with Step 1)
8) Low pressure too low. Check Fill the air conditioning system
the following points one after the If the amount of refrigerant is with the prescribed amount of
other:Drain refrigerant and correct, remove the expansion refrigerant.→ 8X00IN
measure the amount of refrigerant. valve and check for foreign TECHNICAL DATA FOR
>> Not enough refrigerant.→ bodies (e.g. chips, abrasion).→ AIR-CONDITIONING
87031700 DRAINING AND 87701900 REMOVING AND SYSTEMCheck refrigerant circuit
FILLING REFRIGERANT Loosen INSTALLING EXPANSION and connection points using a
lines on the air conditioning VALVE → 87031700 DRAINING leak detector. >> Once you have
compressor and check for foreign AND FILLING determined the cause of
bodies (e.g. chips, abrasion).→ REFRIGERANT Replace refrigerant loss, replace seal or
873419 REMOVING AND expansion valve if spare part.Replace air
INSTALLING AIR CONDITIONING necessary.Continue with Step 1) conditioning compressor if
COMPRESSOR necessary.Continue with Step 1)

CAYENNE S DIESEL, CAYENNE (3.0)) > TROUBLESHOOTING THE AIR
CONDITIONING SYSTEM FOLLOWING COMPLAINTS ABOUT NOISES
Information
The troubleshooting steps shown must be used if complaints are received about noises in the
air-conditioning system.
Information
If it is not possible to clearly detect a leak using a leak detector, then only the leak detector additive
supplied by SPEKTRONICS may be used. Leak detector additive: Traserline TP 3860 in dissolved
form .
This leak detector additive is available from service equipment providers (e.g. Waeco).
For filling this Traser additive, special adapter kits are required, which are also available from service
equipment providers (e.g. Waeco).
Information on how to use the air-conditioning system and the procedure for filling it can be found in the
operating instructions for the adapter kits.
Status Specification OK Specification not OK
No unusual operating
Noises coming from the air conditioning
1) Check for noises from noises can be heard
system.>> Mechanical noises, continue with
around the compressor.Start from the air
Step 3) If you have already carried out Step 3)
the engine and switch on air conditioning
, continue with Step 5) >> Squeaking noises,
conditioning. system.Continue with
continue with Step 4)
Step 2) .
2) Start the vehicle and check Nominal values OK

the air conditioning system for and no noises from
Nominal values not OK, proceed according to
the prescribed nominal the air conditioning
"Troubleshooting the air conditioning system
temperature values.→ 870101 system.Function OK.
following complaints about cooling output".
FUNCTION CHECK ON AIR No further action
CONDITIONING required .
Replace drive belt if necessary.If pulley is

3) Check the following points
damaged and there is bearing clearance,
one after the other:Remove
replace air conditioning compressor. → 873419
drive belt and check
REMOVING AND INSTALLING AIR
condition.Check the bearing
CONDITIONING COMPRESSOR Fill the air
clearance of the pulley.Check
conditioning system with the prescribed amount
refrigerant level. Drain
of refrigerant. → 8X00IN TECHNICAL DATA
refrigerant and measure the
FOR AIR-CONDITIONING SYSTEMCheck
amount of refrigerant. >> Not
refrigerant circuit and connection points using a
enough refrigerant.→ 87031700
leak detector. >> Once you have determined
DRAINING AND FILLING
the cause of refrigerant loss, replace seal or
REFRIGERANT
spare part.Continue with Step 1)
Systematically
4) Remove drive belt and broaden the check to
Replace drive belt if necessary.Continue with
check for signs of wear or determine if there are
Step 1)
damage. noises coming from
other components.
5) Replace air conditioning

compressor. → 873419 Function OK. No
REMOVING AND INSTALLING further action
AIR CONDITIONING required .
COMPRESSOR
WM 870101 FUNCTION TEST ON AIR CONDITIONING (CAYENNE, CAYENNE GTS,

CAYENNE S DIESEL, CAYENNE (3.0)) > FUNCTION TEST ON AIR CONDITIONING >
GENERAL INFORMATION
Information
The air outlet temperatures at the center vent on the dashboard and the high pressure in the
air-conditioning system must not be higher or lower than the specified tolerance ranges after a
running time of 7 minutes (high-pressure measurement) .

CAYENNE S DIESEL, CAYENNE (3.0)) > FUNCTION TEST ON AIR CONDITIONING >
PROCEDURE AND GENERAL REQUIREMENTS FOR TESTING
Information
The safety regulations must be observed during all work on the refrigerant system! → 8X00IN
SAFETY REGULATIONS FOR WORKING ON AIR-CONDITIONED VEHICLES AND DEALING
WITH REFRIGERANT R134A , → 8X00IN SAFETY REGULATIONS FOR EXTRACTION AND
FILLING SYSTEMS .
Information
If the specified nominal values are not reached, the air conditioning must be checked for leaks and
repaired .
Information
Check condensed water drain tubes: Must not be blocked by wax or underbody protection or
otherwise dirty. Condensate must be able to drain away freely .
Check fresh-air intake system: Water must not be allowed to run into the air conditioner. Must be
completely dirt-free .
Check that there is sufficient ventilation in the outside-temperature sensor area .
Do not allow heat from the warm engine to build up near the outside-temperature sensor .
Check particle filter: Must be dry and not excessively dirty .
Condenser must be dirt-free .
Make sure that all servo motors/flaps move to their end positions .
Switch on MONO mode or SYNC mode using the button on the front air conditioning control panel
.
1. Connect air conditioning service unit. → 870317 DRAINING AND FILLING REFRIGERANT .
2. Measure outside temperature with a thermometer.
3. Open all air outlet vents on the dashboard, center console and B-pillar (direct the blower near
the test person if necessary).
4. Insert sensor of the temperature measuring device approx. 4 cm into the middle of the
left center vent .
5. Check stopwatch and keep an eye on the relevant temperature and high pressure on the air
conditioning service unit.
7. Hybrid vehicles: Check battery temperature of HV battery. Temperature must be < 35 °C
.
8. Open driver's and passenger's side windows and close sliding roof.
9. Press A/C Max button.
10. Start the engine and leave it running at idlespeed (do not rev engine unnecessarily after
starting!).
Hybrid vehicles: Establish driving readiness (with or without combustion engine running).
11. Operate air conditioning for five minutes at idle speed.
12. Increase engine speed depending on engine type and maintain a constant engine speed
for two minutes . Start the time measurement immediately.
1. 12.1. Increase engine speed on V6 petrol vehicles to 2, 000 rpm .
2. 12.2. Increase engine speed on V8 petrol vehicles to 1, 900 rpm .
3. 12.3. Increase engine speed on diesel vehicles to 1, 500 rpm .
4. 12.4. Hybrid vehicles: Not necessary. Continue with Step 13.
13. Note center vent temperature and pressure values after two minutes.
14. Compare values (center vent temperature and pressure values) with the specified tolerances.

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > CENTRE VENT
TEMPERATURE DEPENDING ON OUTSIDE TEMPERATURE - 2-ZONE AIR
CONDITIONING
Fig 1: Centre Vent Temperature Graph
blue - Upper limit
TA - Outside temperature (°C)
TMi - Centre vent temperature (°C)

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > HIGH PRESSURE IN
REFRIGERANT CIRCUIT DEPENDING ON OUTSIDE TEMPERATURE - 2-ZONE AIR
CONDITIONING
Fig 1: High Pressure Refrigerant Circuit Graph
blue - Upper limit
red - Lower limit
p - High pressure in refrigerant circuit (bar)

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > CENTRE VENT
TEMPERATURE DEPENDING ON OUTSIDE TEMPERATURE - 4-ZONE AIR
CONDITIONING
Fig 1: Centre Vent Temperature Graph
blue - Upper limit
TMi - Centre vent temperature (°C)

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > HIGH PRESSURE IN
REFRIGERANT CIRCUIT DEPENDING ON OUTSIDE TEMPERATURE - 4-ZONE AIR
CONDITIONING
Fig 1: High Pressure In Refrigerant Circuit Graph
blue - Upper limit
red - Lower limit
p - High pressure in refrigerant circuit (bar)
WM 870317 DRAINING AND FILLING REFRIGERANT (CAYENNE, CAYENNE GTS,

Air-conditioning Commercially
recycling unit available tool

Low-pressure Nominal value 3 bar

gauge reading

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > PRELIMINARY WORK
1. Hybrid only: Isolate high-voltage system from power supply → 2X00IN ISOLATION FROM
SUPPLY PRIOR TO PERFORMING MAINTENANCE TASKS ON HYBRID VEHICLES →
2X00IN ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER

CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > SERVICING
EQUIPMENT
Air-conditioning recycling unit

CAYENNE S DIESEL, CAYENNE (3.0)) > DRAINING AND FILLING REFRIGERANT >
ASSEMBLY WORK INVOLVING THE REFRIGERANT SYSTEM
Information
During all work on the air-conditioning system which necessitates opening the refrigerant system, the
system contents must first be disposed of in accordance with regulations!
Dirt and moisture must be kept out of the air-conditioning system's pipe system!
Thorough cleanliness must be ensured during all work!
System components must never be cleaned on the inside with hot steam!
Use only nitrogen for cleaning purposes!
When replacing a component, all openings must be closed off using suitable stoppers immediately after
opening the system!

CAYENNE S DIESEL, CAYENNE (3.0)) > DRAINING AND FILLING REFRIGERANT >
GENERAL ASSEMBLY SEQUENCE
1. Screw off the protection caps on the charging valves.

Fig 1: Removing Protection Caps On Charging Valves

Before connecting the high-pressure and low-pressure lines to the vehicle, remove any
refrigerant remaining in the lines by suction.
Fig 2: Connecting High-Pressure And Low-Pressure Lines On Air-Conditioning Unit
2. Connect the high-pressure and low-pressure lines on the air-conditioning unit
Information
In the case of servicing equipment with a transparent oil separator, read and take note of the
oil level before removing the refrigerant.
Do not carry out this step on empty air-conditioning systems (pressure gauge approx. 0 bar)
because if you do, air will get into the refrigerant bottle.
If the vehicle is cold, it may be necessary to repeat the suction procedure until all refrigerant
has been removed from the air-conditioning system. This step is carried out automatically with
some units.
1. 2.1.
2. 2.2. Let the engine run for a short while with the air-conditioning on, then connect the
high-pressure and low-pressure lines of the air-conditioning unit.
3. 2.3. Open the valves of the high-pressure and low-pressure lines.

3. Remove refrigerant by suction.
1. 3.1. If the vehicle is cold, it may be necessary to repeat the suction procedure until all
refrigerant has been removed from the air-conditioning system. This step is carried
out automatically with some units.
2. 3.2. Wait for approx. 2 minutes after the servicing equipment has switched itself off. If
the pressure gauge reading rises above 0 bar, repeat the suction process.
3. 3.3. The vehicle air-conditioning system is now completely empty. Necessary repairs,
such as removing and installing the desiccator, can now be carried out.
4. 3.4. The open air-conditioning system should not be left open unnecessarily, but
must be closed off using suitable stoppers immediately after being opened.
5. 3.5. Drain the extracted refrigerant oil into a measuring cup on the service unit and
determine the volume.
4. Carry out repairs.
Information
The desiccator must be replaced in the following situations:
1. Refrigerant circuit is open for > 20 minutes .
2. Amount of refrigerant extracted is < 30% of the required quantity .
3. Refrigerant circuit has been open for an indefinite period of time (gradual leak, stone
damage to condenser) .
4. Air-conditioning compressor has become blocked .
5. Dryer cartridge is damaged .
6. After opening the packaging and line connections (on a new desiccator), the desiccator
must be installed within 20 minutes at the latest and the refrigerant circuit must be
closed, evacuated and filled .
The desiccator must not be replaced in the following situations:
1. If the components are closed off using stoppers immediately after opening the refrigerant
circuit and the refrigerant circuit is closed and evacuated within 20 minutes at the latest .
1. 4.1. Before closing off the refrigerant circuit, check whether the desiccator needs to
be replaced.
2. 4.2. If necessary, re-connect high-pressure and low-pressure lines.
5. Evacuate the system and check it for leaks.
1. 5.1. If the air-conditioning system has been opened, evacuation should last at least
20 minutes so that the moisture can evaporate and be removed by suction.
2. 5.2. If the air-conditioning system has been open for a long time, evacuation can be
carried out for up to 120 minutes.
3. 5.3. Observe the pressure gauge for approx. 2 minutes. If the pressure rises, air is
entering the vehicle's air-conditioning system. The leak must be located and
repaired. If the pressure remains constant, add refrigerant oil.
Information
Only ND8 refrigerant oil must be used.
6. Add refrigerant oil.
1. 6.1. For units without oil filling system:
2. 6.2. Start the vacuum pump. At the start of this vacuum phase, add the measured
quantity of refrigerant oil using an oil injector or a hose disconnected from the
servicing equipment. Re-connect the hose to the servicing equipment immediately
after adding the oil.
3. 6.3. For units with oil filling system: Add the measured quantity of refrigerant oil and
wait for it to be taken in.
4. 6.4. Do not allow any air to be taken in, otherwise Step 5 must be repeated.
7. Evacuate the system.
3. 7.3. For units with an integrated oil filling system, add refrigerant oil now.
8. Fill the air-conditioning system
1. 8.1. Using the service unit, add the refrigerant quantity stated in the manual into the
air-conditioning lines. → Technical data for air-conditioning system
2. 8.2. As refrigerant usually flows instead of being pumped, it may not be possible -
especially if the vehicle is warm and the servicing equipment is cold - to add the
entire quantity. If this is the case, switch the engine and air conditioning on. Wait for
the suction pressure to fall below 2 bar. Now open the low-pressure valve on the unit
slowly and carefully until the remaining quantity has been added.
NOTE: Excessively high pressure in refrigerant circuit
1. Risk of damage to air-conditioning compressor
→ Do not allow the low-pressure gauge to exceed → Nominal value: 3 bar at any
time.
3. 8.3.
9. Add refrigerant from both connection hoses to the air-conditioning system in the vehicle.
1. 9.1. The refrigerant in the high-pressure and low-pressure lines is part of the filling
capacity of the refrigerant in the air-conditioning system in the vehicle.
2. 9.2. Close the valve on the high-pressure line and disconnect it from the vehicle.
3. 9.3. Start the engine and air-conditioning system. When the pressure on both
pressure gauges falls below 2 bar, close the valve on the low-pressure line and
disconnect it from the vehicle.
Information
After filling the air-conditioning system, the valve on the high-pressure and low-pressure
connection must be checked using a leak detector.
The protection caps must not be fitted.
Position the leak detector at a specified distance (see operating instructions for each leak
detector) above the valves and check the valves for signs of any leaks.
10. If there are no leaks in the high-pressure and low-pressure connection valves, fit the caps.

2. Connect high-voltage system to power supply → 2X00IN ISOLATION FROM SUPPLY PRIOR
TO PERFORMING MAINTENANCE TASKS ON HYBRID VEHICLES → 2X00IN ISOLATING
WM 870317 ADDING REFRIGERANT AND REMOVING BY SUCTION (CAYENNE,

Air-conditioning Commercially
recycling unit available tool

Low-pressure Nominal value 3 bar

gauge reading

1. Hybrid only: Isolate high-voltage system from power supply → 2X00IN ISOLATION FROM
SUPPLY PRIOR TO PERFORMING MAINTENANCE TASKS ON HYBRID VEHICLES →
2X00IN ISOLATING HIGH-VOLTAGE ELECTRICAL SYSTEM FROM POWER

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL VALUES > SERVICING
EQUIPMENT
Air-conditioning recycling unit

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > DRAINING AND FILLING
REFRIGERANT > ASSEMBLY WORK INVOLVING THE REFRIGERANT SYSTEM
Information
During all work on the air-conditioning system which necessitates opening the refrigerant system, the
system contents must first be disposed of in accordance with regulations!
Dirt and moisture must be kept out of the air-conditioning system's pipe system!
Thorough cleanliness must be ensured during all work!
System components must never be cleaned on the inside with hot steam!
Use only nitrogen for cleaning purposes!
When replacing a component, all openings must be closed off using suitable stoppers immediately after
opening the system!

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > DRAINING AND FILLING
REFRIGERANT > GENERAL ASSEMBLY SEQUENCE
1. Screw off the protection caps on the charging valves.

Fig 1: Removing Protection Caps On Charging Valves
Before connecting the high-pressure and low-pressure lines to the vehicle, remove any
refrigerant remaining in the lines by suction.
Fig 2: Connecting High-Pressure And Low-Pressure Lines To Vehicle
2. Connect the high-pressure and low-pressure lines on the air-conditioning unit
Information
In the case of servicing equipment with a transparent oil separator, read and take note of the
oil level before removing the refrigerant.
Do not carry out this step on empty air-conditioning systems (pressure gauge approx. 0 bar)
because if you do, air will get into the refrigerant bottle.
If the vehicle is cold, it may be necessary to repeat the suction procedure until all refrigerant
has been removed from the air-conditioning system. This step is carried out automatically with
some units.
1. 2.1.
2. 2.2. Let the engine run for a short while with the air-conditioning on, then connect the
high-pressure and low-pressure lines of the air-conditioning unit.
3. 2.3. Open the valves of the high-pressure and low-pressure lines.
3. Remove refrigerant by suction.

1. 3.1. If the vehicle is cold, it may be necessary to repeat the suction procedure until all
refrigerant has been removed from the air-conditioning system. This step is carried
out automatically with some units.
2. 3.2. Wait for approx. 2 minutes after the servicing equipment has switched itself off. If
the pressure gauge reading rises above 0 bar, repeat the suction process.
3. 3.3. The vehicle air-conditioning system is now completely empty. Necessary repairs,
such as removing and installing the desiccator, can now be carried out.
4. 3.4. The open air-conditioning system should not be left open unnecessarily, but
must be closed off using suitable stoppers immediately after being opened.
5. 3.5. Drain the extracted refrigerant oil into a measuring cup on the service unit and
determine the volume.
4. Carry out repairs.
Information
The desiccator must be replaced in the following situations:
Refrigerant circuit is open for > 20 minutes .
Amount of refrigerant extracted is < 30% of the required quantity .
Refrigerant circuit has been open for an indefinite period of time (gradual leak, stone damage
to condenser) .
Air-conditioning compressor has become blocked .
Dryer cartridge is damaged .
After opening the packaging and line connections (on a new desiccator), the desiccator must
be installed within 20 minutes at the latest and the refrigerant circuit must be closed,
evacuated and filled .
The desiccator must not be replaced in the following situations:
1. If the components are closed off using stoppers immediately after opening the refrigerant
circuit and the refrigerant circuit is closed and evacuated within 20 minutes at the latest .
1. 4.1. Before closing off the refrigerant circuit, check whether the desiccator needs to
be replaced.
2. 4.2. If necessary, re-connect high-pressure and low-pressure lines.
5. Evacuate the system and check it for leaks.
3. 5.3. Observe the pressure gauge for approx. 2 minutes. If the pressure rises, air is
entering the vehicle's air-conditioning system. The leak must be located and
repaired. If the pressure remains constant, add refrigerant oil.
Information
Only ND8 refrigerant oil must be used.
6. Add refrigerant oil.
1. 6.1. For units without oil filling system:
2. 6.2. Start the vacuum pump. At the start of this vacuum phase, add the measured
quantity of refrigerant oil using an oil injector or a hose disconnected from the
servicing equipment. Re-connect the hose to the servicing equipment immediately
after adding the oil.
3. 6.3. For units with oil filling system: Add the measured quantity of refrigerant oil and
wait for it to be taken in.
4. 6.4. Do not allow any air to be taken in, otherwise Step 5 must be repeated.
7. Evacuate the system.
1. 7.1. If the air-condi@tioning system has been opened, evacuation should last at least
3. 7.3. For units with an integrated oil filling system, add refrigerant oil now.
8. Fill the air-conditioning system
1. 8.1. Using the service unit, add the refrigerant quantity stated in the manual into the
air-conditioning lines. → Technical data for air-conditioning system
2. 8.2. As refrigerant usually flows instead of being pumped, it may not be possible -
especially if the vehicle is warm and the servicing equipment is cold - to add the
entire quantity. If this is the case, switch the engine and air conditioning on. Wait for
the suction pressure to fall below 2 bar. Now open the low-pressure valve on the unit
slowly and carefully until the remaining quantity has been added.
NOTE: Excessively high pressure in refrigerant circuit
1. Risk of damage to air-conditioning compressor
→ Do not allow the low-pressure gauge to exceed → Nominal value: 3 bar at any
time.
3. 8.3.
9. Add refrigerant from both connection hoses to the air-conditioning system in the vehicle.
1. 9.1. The refrigerant in the high-pressure and low-pressure lines is part of the filling
capacity of the refrigerant in the air-conditioning system in the vehicle.
2. 9.2. Close the valve on the high-pressure line and disconnect it from the vehicle.
3. 9.3. Start the engine and air-conditioning system. When the pressure on both
pressure gauges falls below 2 bar, close the valve on the low-pressure line and
disconnect it from the vehicle.
Information
After filling the air-conditioning system, the valve on the high-pressure and low-pressure
connection must be checked using a leak detector.
The protection caps must not be fitted.
Position the leak detector at a specified distance (see operating instructions for each leak
detector) above the valves and check the valves for signs of any leaks.
10. If there are no leaks in the high-pressure and low-pressure connection valves, fit the caps.

2. Connect high-voltage system to power supply → 2X00IN ISOLATION FROM SUPPLY PRIOR
TO PERFORMING MAINTENANCE TASKS ON HYBRID VEHICLES → 2X00IN ISOLATING
WM 871419 REMOVING AND INSTALLING SUN SENSOR (CAYENNE, CAYENNE GTS,

OF SUN SENSOR
Fig 1: Identifying Sun Sensor Installation Position

WORK FOR SUN SENSOR
Remove cover for dashboard (defroster trim). → 702019 REMOVING AND INSTALLING COVER FOR
DASHBOARD (DEFROSTER TRIM)

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING SUN SENSOR
1. Release electric plug connection on the sun sensor -a- and disconnect it -A- .
Fig 1: Disconnecting Connector On Sun Sensor

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING SUN SENSOR
The sun sensor is installed in reverse order to removal.

WORK FOR SUN SENSOR
Install cover for dashboard (defroster trim). → 702019 REMOVING AND INSTALLING COVER FOR
DASHBOARD (DEFROSTER TRIM)
WM 872019 REMOVING AND INSTALLING SERVO MOTOR FOR DEFROSTER


VALUES
Servo motor for Tightening 1.2 Nm (1

air conditioning torque ftlb.)
Bracket for Tightening 8 Nm (6 ftlb.)

front-end torque
electronics
control unit

WORK
1. Remove dashboard. → Removing Dashboard

SERVO MOTOR FOR DEFROSTER
NOTE: Voltage peaks
Fig 1: Identifying Servo Motors Installation Position
1 - Servo motor for fresh air/recirculated air
2 - Servo motor for defroster
3 - Servo motor for front left footwell
4 - Servo motor for front right footwell
7 - Servo motor for left center vent
8 - Servo motor for right center vent
9 - Servo motor for front left temperature valve
10 - Servo motor for front right temperature valve
11 - Servo motor for left side vent
12 - Servo motor for right side vent

Fig 2: Identifying Servo Motors In Dashboard Installation Position
5 - Servo motor for top left center vent
6 - Servo motor for top right center vent
1. Detach bracket -3- from the front-end electronics control unit. The control unit remains
attached to the bracket.
Fig 3: Detaching Bracket From Front-End Electronics Control Unit
1. 1.1. Unscrew two fastening screws -4- .
2. 1.2. Lift bracket -3- up and remove it -arrow- .
2. Before removing the servo motor, mark the position of the air flap on the housing.
Fig 4: Identifying Servo Motor With Mounting Screw
3. Unscrew two fastening screws -2- on the servo motor -1- .

Fig 5: Removing Servo Motor For Defroster
4. Remove servo motor for defroster -1- (-A- ).

Fig 6: Removing Connector On Servo Motor For Defroster

SERVO MOTOR FOR DEFROSTER
1. The servo motor is installed in reverse order to removal.
2. Set air flap to the marked position.
3. Tighten two fastening screws on the servo motor to → Tightening torque: 1.2 Nm (1 ftlb.) .
4. Tighten two fastening screws on the bracket for the front-end electronics control unit to →
Fig 1: Identifying Fastening Screws On Bracket For Front-End Electronics Control Unit

SERVO MOTOR
Information
The servo motors only need to be taught if a servo motor is replaced.
1. PIWIS Tester II 9818 must be connected. Then teach the servo motors.
1. 1.1. Select vehicle.
2. 1.2. Select "Air conditioning" control unit.
3. 1.3. Select "Maintenance and repairs".
4. 1.4. Select and start "Teach: LIN automatic addressing".
5. 1.5. Select and start "Alignment drive for LIN servo motors".
6. 1.6. Shut down and disconnect PIWIS Tester II.

WORK
WM 872019 REMOVING AND INSTALLING SERVO MOTOR FOR FRESH

AIR/RECIRCULATED AIR (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE
TOOLS

TECHNICAL VALUES


PRELIMINARY WORK
DASHBOARD

REMOVING SERVO MOTOR FOR FRESH AIR/RECIRCULATED AIR
NOTE: Voltage peaks

Fig 3: Identifying Servo Motor With Screw

Fig 4: Removing Servo Motor For Fresh Air/Recirculated Air
3. Remove servo motor for fresh air/recirculated air -1- (-A- ).

Fig 5: Removing Connector On Servo Motor For Fresh Air/Recirculated Air

INSTALLING SERVO MOTOR FOR FRESH AIR/RECIRCULATED AIR
1. The servo motor for fresh air/recirculated air is installed in reverse order to removal.

INSTALLING SERVO MOTOR FOR FRESH AIR/RECIRCULATED AIR > TEACHING
SERVO MOTOR
Information


SUBSEQUENT WORK
DASHBOARD
WM 872019 REMOVING AND INSTALLING SERVO MOTOR FOR FRONT LEFT

FOOTWELL (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE
S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TOOLS

S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL
VALUES

front-end torque
electronics
control unit

S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) >
PRELIMINARY WORK

S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING
SERVO MOTOR FOR FRONT LEFT FOOTWELL
NOTE: Voltage peaks



Fig 5: Removing Servo Motor For Front Left Footwell
4. Remove servo motor for front left footwell -1- (-A- ).

Fig 6: Removing Connector On Servo Motor For Front Left Footwell

S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING
SERVO MOTOR FOR FRONT LEFT FOOTWELL
Fig 1: Identifying Fastening Screws On Bracket

SERVO MOTOR FOR FRONT LEFT FOOTWELL > TEACHING SERVO MOTOR
Information

SUBSEQUENT WORK

TEMPERATURE VALVE (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE
TOOLS

TECHNICAL VALUES


front-end torque
electronics
control unit

PRELIMINARY WORK
1. Remove dashboard. → Removing Dashboard .

REMOVING SERVO MOTOR FOR FRONT LEFT TEMPERATURE VALVE
NOTE: Voltage peaks


Fig 5: Identifying Fastening Screws On Servo Motor
4. Remove servo motor for front left temperature valve -1- (-A- ).

Fig 6: Removing Connector On Servo Motor For Front Left Temperature Valve

INSTALLING SERVO MOTOR FOR FRONT LEFT TEMPERATURE VALVE

INSTALLING SERVO MOTOR FOR FRONT LEFT TEMPERATURE VALVE > TEACHING
SERVO MOTOR
Information

SUBSEQUENT WORK
1. Install dashboard. → Installing Dashboard .
WM 872019 REMOVING AND INSTALLING SERVO MOTOR FOR FRONT RIGHT

S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TOOLS

S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TECHNICAL
VALUES


PRELIMINARY WORK
1. Remove glove box. → 681519 REMOVING AND INSTALLING GLOVE BOX

S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING
SERVO MOTOR FOR FRONT RIGHT FOOTWELL
NOTE: Voltage peaks

Fig 3: Identifying Servo Motor Screws

Fig 4: Removing Servo Motor For Front Right Footwell
3. Remove servo motor for front right footwell -1- (-A- ).

Fig 5: Removing Connector On Servo Motor For Front Right Footwell

SERVO MOTOR FOR FRONT RIGHT FOOTWELL

S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > TEACHING
SERVO MOTOR
Information


SUBSEQUENT WORK
1. Install glove box. → 681519 REMOVING AND INSTALLING GLOVE BOX

TOOLS

TECHNICAL VALUES

PRELIMINARY WORK
1. Remove dashboard. → Removing Dashboard .

REMOVING SERVO MOTOR FOR FRONT RIGHT TEMPERATURE VALVE
NOTE: Voltage peaks

Fig 3: Identifying Servo Motor Screws

Fig 4: Removing Servo Motor For Front Right Temperature Valve
3. Remove servo motor for front right temperature valve -1- (-A- ).

Fig 5: Removing Connector On Servo Motor For Front Right Temperature Valve

INSTALLING SERVO MOTOR FOR FRONT RIGHT TEMPERATURE VALVE

INSTALLING SERVO MOTOR FOR FRONT RIGHT TEMPERATURE VALVE >
TEACHING SERVO MOTOR
Information


SUBSEQUENT WORK
WM 872019 REMOVING AND INSTALLING SERVO MOTOR FOR LEFT CENTRE VENT
VALUES

front-end torque
electronics
control unit
WORK
SERVO MOTOR FOR LEFT CENTRE VENT
NOTE: Voltage peaks



Fig 5: Identifying Servo Motor For Centre Vent
4. Remove servo motor for left center vent -1- (-A- ).

Fig 6: Removing Connector On Servo Motor For Left Centre Vent
SERVO MOTOR FOR LEFT CENTRE VENT
Fig 1: Identifying Bracket On Screws
SERVO MOTOR FOR LEFT CENTRE VENT > TEACHING SERVO MOTOR
Information

WORK
WM 872019 REMOVING AND INSTALLING SERVO MOTOR FOR LEFT SIDE VENT
VALUES


front-end torque
electronics
control unit
WORK
SERVO MOTOR FOR LEFT SIDE VENT
NOTE: Voltage peaks


Fig 5: Identifying Fastening Screws On Servo Motor
4. Remove servo motor for left side vent -1- (-A- ).

Fig 6: Removing Connector On Servo Motor For Left Side Vent
SERVO MOTOR FOR LEFT SIDE VENT
SERVO MOTOR FOR LEFT SIDE VENT > TEACHING SERVO MOTOR
Information

WORK
WM 872019 REMOVING AND INSTALLING SERVO MOTOR FOR RIGHT CENTRE

VENT (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S

VALUES


WORK

SERVO MOTOR FOR RIGHT CENTRE VENT
NOTE: Voltage peaks

Fig 3: Identifying Servo Motor With Screws

Fig 4: Removing Servo Motor For Right Centre Vent
3. Remove servo motor for right center vent -1- (-A- ).

Fig 5: Removing Connector On Right Centre Vent

SERVO MOTOR FOR RIGHT CENTRE VENT

SERVO MOTOR
Information


WORK
WM 872019 REMOVING AND INSTALLING SERVO MOTOR FOR RIGHT SIDE VENT
VALUES

WORK
SERVO MOTOR FOR RIGHT SIDE VENT
NOTE: Voltage peaks


Fig 4: Removing Servo Motor For Right Side Vent
3. Remove servo motor for right side vent -1- (-A- ).

Fig 5: Removing Connector On Servo Motor For Right Side Vent
SERVO MOTOR FOR RIGHT SIDE VENT
Tighten two fastening screws on the servo motor to → Tightening torque: 1.2 Nm (1 ftlb.) .
SERVO MOTOR FOR RIGHT SIDE VENT > TEACHING SERVO MOTOR
Information

WORK
WM 872019 REMOVING AND INSTALLING SERVO MOTOR FOR TOP LEFT CENTRE
VALUES

WORK
PCM 3.1 DISPLAY AND OPERATOR CONTROL UNIT
SERVO MOTOR FOR TOP LEFT CENTRE VENT
NOTE: Voltage peaks
Information
The fresh-air flaps must be closed.
Before starting work, adjust the ventilation regulator so that the center vent is closed .
Information
The linkage must remain on the servo motor during removal. Mark the position of the linkage on the
servo motor.

1. Unclip servo motor linkage -1- from the adjustment flap linkage -2- using a screwdriver.
Fig 3: Disconnecting Servo Motor Linkage

Fig 4: Removing Servo Motor
3. Remove servo motor -2- with linkage -A- and mark the installation position of the linkage on
the servo motor.

Fig 5: Disconnecting Connector From Servo Motor
SERVO MOTOR FOR TOP LEFT CENTRE VENT
1. Plug in electric plug connection -A- .

Fig 1: Plugging In Connector For Servo Motor
2. Fit servo motor -2- with linkage at the marked installation position -A- .
Fig 2: Installing Servo Motor
3. Tighten two fastening screws -1- on the servo motor -2- to → Tightening torque: 1.2 Nm (1
ftlb.) .
4. Clip servo motor linkage -1- into the adjustment flap linkage -2- (-A- ).
Fig 3: Connecting Linkage
SERVO MOTOR FOR TOP LEFT CENTRE VENT > TEACHING SERVO MOTOR
Information

WORK
Control Unit
WM 872019 REMOVING AND INSTALLING SERVO MOTOR FOR TOP RIGHT CENTRE
VALUES

WORK
SERVO MOTOR FOR TOP RIGHT CENTRE VENT
NOTE: Voltage peaks
Information
The fresh-air flaps must be closed.
Before starting work, adjust the ventilation regulator so that the center vent is closed .
Information
The linkage must remain on the servo motor during removal. Mark the position of the linkage on the
servo motor.

1. Unclip servo motor linkage -1- from the adjustment flap linkage -2- using a screwdriver.
Fig 3: Disconnecting Servo Motor Linkage

3. Remove servo motor -2- with linkage -A- and mark the installation position.

Fig 5: Disconnecting Connector From Servo Motor
SERVO MOTOR FOR TOP RIGHT CENTRE VENT
1. Plug in electric plug connection -A- .

Fig 1: Plugging In Connector For Servo Motor
2. Fit servo motor -2- with linkage at the marked installation position -A- .
Fig 2: Installing Servo Motor
3. Tighten two fastening screws -1- on the servo motor -2- to → Tightening torque: 1.2 Nm (1
ftlb.) .
4. Clip servo motor linkage -1- into the adjustment flap linkage -2- (-A- ).
Fig 3: Connecting Linkage
SERVO MOTOR FOR TOP RIGHT CENTRE VENT > TEACHING SERVO MOTOR
Information

WORK
Control Unit
WM 872019 REMOVING AND INSTALLING SERVO MOTOR FOR LEFT SIDE AIR VENT
Fastening screws 2 Tightening 1.2 Nm (0.5

securing servo torque ftlb.)
motor to
heating/fresh-air
unit
Fastening screws 4 Tightening 8 Nm (6 ftlb.)

for bracket for torque
front-end
electronics control
unit
CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION >
INSTALLATION POSITION OF SERVO MOTOR FOR LEFT SIDE AIR VENT
11 - Servo motor for left side air vent
12 - Servo motor for right side air vent

PRELIMINARY WORK FOR SERVO MOTOR FOR LEFT SIDE AIR VENT
CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING SERVO
MOTOR FOR LEFT SIDE AIR VENT
NOTE: Voltage peaks
1. Detach bracket -3- for front-end electronics control unit. The control unit remains attached to
the bracket.
Fig 1: Detaching Bracket For Front-End Electronics Control Unit

Fig 3: Removing Servo Motor For Left Side Air Vent
4. Remove servo motor for left side air vent -1- (-A- ).

Fig 4: Disconnecting Connector On Servo Motor For Left Side Air Vent
CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING SERVO
MOTOR FOR LEFT SIDE AIR VENT
3. Tighten two fastening screws for the servo motor to the prescribed tightening torque.
Tightening torque 1.2 Nm (0.5 ftlb.)
4. Tighten two fastening screws on the bracket for the front-end electronics control unit to the
prescribed tightening torque. Tightening torque 8 Nm (6 ftlb.)
Fig 1: Installing Servo Motor For Left Side Air Vent
CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING SERVO
MOTOR FOR LEFT SIDE AIR VENT > TEACHING SERVO MOTOR
Information
6. 1.6. PIWIS Tester II must then be shut down and disconnected.

SUBSEQUENT WORK FOR SERVO MOTOR FOR LEFT SIDE AIR VENT
WM 8720IN OVERVIEW OF SERVO MOTORS FOR FRONT HEATER/AIR-

CONDITIONING UNIT (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S,
INFORMATION > COMPONENT INFORMATION
Information
The servo motors for the air conditioning system are described in individual service information. This
information merely provides an overview of the installation positions of the installed servo motors.

WM 8720IN OVERVIEW OF FRONT HEATER/AIR-CONDITIONING UNIT

SERVOMOTORS (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S,
CAYENNE (3.0)) > INFORMATION > COMPONENT INFORMATION
Information
The servo motors for the air conditioning system are described in individual service information. This
information merely provides an overview of the installation positions of the installed servo motors.

WM 872219 REMOVING AND INSTALLING AIR QUALITY SENSOR (CAYENNE,


securing water torque
drip pan to DME
control unit
bracket

POSITION OF AIR QUALITY SENSOR
Fig 1: Identifying Air Quality Sensor Installation Position

PRELIMINARY WORK FOR AIR QUALITY SENSOR
Remove right cover flap on the cowl panel cover. → 664419 REMOVING AND INSTALLING COWL
PANEL COVER

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING AIR QUALITY SENSOR
NOTE: Voltage peaks
1. Loosen left fastening screw -1- (in direction of travel) on DME control unit bracket and remove
water drip pan -2- .
Fig 1: Identifying DME Control Unit Bracket With Screws
2. Turn air quality sensor -1- (-B- ) and move it to the rear to remove it.
Fig 2: Removing Air Quality Sensor
3. Release electric plug connection in order to release the locking mechanism using a
screwdriver -a- and slide circlip -1- in direction of arrow -b- , then disconnect the connector
-A- .
Fig 3: Disconnecting Connector From Air Quality Sensor

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING AIR QUALITY SENSOR
1. The air quality sensor is installed in reverse order to removal.
2. Insert water drip pan -2- and tighten fastening screw -1- to the prescribed tightening torque.
Tightening torque 8 Nm (6 ftlb.)
Fig 1: Identifying Water Drip Pan With Screws

SUBSEQUENT WORK FOR AIR QUALITY SENSOR
Install right cover flap on the cowl panel cover. → 664419 REMOVING AND INSTALLING COWL PANEL
COVER
WM 873419 REMOVING AND INSTALLING ELECTRIC AIR-CONDITIONING

COMPRESSOR (CAYENNE GTS, CAYENNE TURBO S, CAYENNE S E-HYBRID) >
TOOLS


TECHNICAL VALUES
Fastening screw 1 Tightening 20 Nm (15 +/-3 Nm (+/- 2

securing torque ftlb.) ftlb.)
low-pressure
refrigerant line to
air-conditioning
compressor
Bottom front Tightening 25 Nm (19

securing
air-conditioning
compressor to
engine bracket
Bottom rear 7 Tightening 25 Nm (19

securing
air-conditioning
compressor to
engine bracket
Top front fastening 10 Tightening 25 Nm (19

air-conditioning
compressor to
engine bracket
Fastening screw 5 Tightening 20 Nm (15 +/-3 Nm (+/- 2

securing torque ftlb.) ftlb.)
high-pressure
refrigerant line to
air-conditioning
compressor
Fastening screw 3 Tightening 12 Nm (9 ftlb) +/-1.5 Nm (+/-1
low-pressure
refrigerant line to
low-pressure
refrigerant line at
connection point in
engine
compartment
Fastening nut for 1 Tightening 8 Nm (6 ftlb.)

holding clamp on torque
low-pressure
refrigerant line
Fastening screw 3 Tightening 12 Nm (9 ftlb.) +/-1.5 Nm (+/-1

refrigerant line
from evaporator
(chiller) to
low-pressure
refrigerant line
Oil filler screw, -B- Tightening 26 Nm (19

M10 torque ftlb.)

INFORMATION > INSTALLATION POSITION OF AIR-CONDITIONING COMPRESSOR
Fig 1: Identifying Electric Air-Conditioning Compressor Installation Position

PRELIMINARY WORK
3. Remove power electronics. → 279119 REMOVING AND INSTALLING POWER

ELECTRONICS
4. Remove high-voltage line for electric air-conditioning compressor. → 279319 REMOVING AND

6. Draw off and dispose of refrigerant in accordance with regulations. → 870317 DRAINING AND
FILLING REFRIGERANT
HOUSING LINER

REMOVING ELECTRIC AIR-CONDITIONING COMPRESSOR
WARNING: Refrigerant
Danger of freezing
→ Avoid contact with refrigerant.
→ Observe the safety regulations for working on air-conditioned vehicles and dealing with refrigerant.
→ Observe the safety regulations for extraction and filling systems.
→ Observe the instructions for repairing air conditioning systems and storing spare parts.
1. Open the holding clamp on the low-pressure refrigerant line in the engine compartment.
1. 1.1. Unscrew M6 fastening nut -1- .
2. 1.2. Open the holding clamp -2- and bend it up carefully.

Fig 1: Opening Holding Clamp On Low-Pressure Air-Conditioning Line

evaporator.
suitable stoppers.
2. Unscrew M8 fastening screw -3- on the low-pressure refrigerant line -4- and pull off the line.
Close off the lines immediately using suitable stoppers.
Fig 2: Opening Low-Pressure Air-Conditioning Line
3. Disconnect refrigerant line from the evaporator (Chiller) -1- at the low-pressure refrigerant line
-2- .
1. 3.1. Loosen fastening screw -3- and disconnect refrigerant line from the evaporator
-1- .


evaporator.
suitable stoppers.
Close off the refrigerant line and air-conditioning compressor connection immediately using
suitable stoppers.
Fig 3: Identifying Refrigerant Line From Evaporator On Low-Pressure Line
4. Unscrew M8 fastening screw -5- for the high-pressure refrigerant line -6- on the electric
air-conditioning compressor and pull off the refrigerant line.


evaporator.
suitable stoppers.
Close off the refrigerant line and air-conditioning compressor connection immediately using
suitable stoppers.
Fig 4: Opening High-Pressure Air-Conditioning Line On Air-Conditioning Compressor

5. Release and disconnect electric plug connection at the air-conditioning compressor.
Fig 5: Disconnecting Electric Plug Connection For Air-Conditioning Compressor
6. Unscrew the bottom M8 fastening screw -7- used to secure the electric air-conditioning
compressor to the engine at the rear .
Accessible via front left wheel housing.

Fig 6: Identifying Air-Conditioning Compressor To Engine Screws (Bottom Rear)
7. Unscrew the bottom M8 fastening screw -8- used to secure the electric air-conditioning
compressor to the engine at the front .
For easier access to the screw, press the hose -9- down slightly with the tool.

Fig 7: Identifying Air-Conditioning Compressor To Engine Screws (Bottom Front)
8. Unscrew the top M8 fastening screw -10- used to secure the electric air-conditioning
compressor to the engine.
Accessible via top of engine compartment.

Fig 8: Identifying Air-Conditioning Compressor To Engine Screws (Top)
9. Turn the air-conditioning compressor slightly to the right and guide it forward as far as the
radiator.
Fig 9: Turning Air-Conditioning Compressor Towards Radiator
10. Turn the air-conditioning compressor approx. 90 degrees to the right and remove it by pulling it
up at the front side first.
Fig 10: Turning Air-Conditioning Compressor

REPLACING ELECTRIC AIR-CONDITIONING COMPRESSOR
NOTE: Fill level too low
Risk of damage to components.
→ Do not start the engine.
→ Do not tow the vehicle.
Information
If the air-conditioning compressor is blocked or seized up, then additional steps must be carried
out to ensure that the air-conditioning system is working. See section on WORK STEPS FOR
BLOCKED OR SEIZED UP AIR-CONDITIONING COMPRESSOR
Information
New air-conditioning compressors are pressurized and filled with the required amount of oil for the
refrigerant circuit .
The remaining oil quantity in the individual components must therefore be taken into account!
Refrigerant oil from the compressor or refrigerant oil removed by suction from a previously run
air-conditioning system may no longer be used (special-category waste)!
1. Unscrew M8 fastening screw -11- used to secure the low-pressure refrigerant line -4- to the
electric air-conditioning compressor.
1. 1.1. Replace O-ring on low-pressure refrigerant line and coat it with refrigerant oil.
2. 1.2. Tighten fastening screw -11- used to secure the low-pressure refrigerant line -4-
to the electric air-conditioning compressor to the prescribed tightening torque.
Tightening torque 20 Nm (15 ftlb.) +/-3 Nm (+/-2 ftlb.)
Fig 1: Identifying Low-Pressure Air-Conditioning Line On Air-Conditioning
Compressor
2. Open the cap on the high-pressure side and relieve the pressure from the air-conditioning
compressor.
3. Open the oil filler screw on the air-conditioning compressor.
4. Drain approx. 70 cm3 of refrigerant oil out of the air-conditioning compressor and into a
measuring glass. The remaining quantity of oil (approx. 80 cm3 ) remains in the air-conditioning
compressor.
5. Always replace the sealing ring for the oil filler screw.
6. Use fastening screws from the new air-conditioning compressor. Replace O-rings and coat
new O-rings with refrigerant oil.
7. Tighten oil filler screw to the prescribed tightening torque. Tightening torque 26 Nm (19 ftlb.)

INSTALLING ELECTRIC AIR-CONDITIONING COMPRESSOR
1. Clamp the high-pressure refrigerant line -6- under the longitudinal member -Z- for installing
the air-conditioning compressor.
Fig 1: Removing High-Pressure Line Under Longitudinal Member
2. Install electric air-conditioning compressor.
1. 2.1. Pre-position the air-conditioning compressor with the rear side first and turned
approx. 90 degrees to the right.
Fig 2: Installing Electric Air-Conditioning Compressor
3. Lower the air-conditioning compressor at the front and turn it slightly to the left. Guide the
air-conditioning compressor to the rear onto the engine and position it.
Fig 3: Guiding Air-Conditioning Compressor To Rear Onto Engine
4. Fit and screw in the top front M8 fastening screw -10- used to secure the electric
air-conditioning compressor to the engine bracket. Do not tighten the screw yet .
Fig 4: Identifying Air-Conditioning Compressor To Engine Screw (Top)
5. Tighten the bottom front M8 fastening screw -8- used to secure the electric air-conditioning
compressor to the engine to the prescribed tightening torque. Tightening torque 25 Nm (19
ftlb.)
For easier access to the screw, press the hose -9- down slightly with the tool.

Fig 5: Identifying Air-Conditioning Compressor To Engine Screw (Bottom Front)
6. Tighten the bottom rear M8 fastening screw -7- used to secure the electric air-conditioning
compressor to the engine to the prescribed tightening torque. Tightening torque 25 Nm (19
ftlb.)

Fig 6: Identifying Air-Conditioning Compressor To Engine Screw (Bottom Rear)
7. Tighten the top front M8 fastening screw -10- used to secure the electric air-conditioning
compressor to the engine bracket to the prescribed tightening torque. Tightening torque 25
Nm (19 ftlb.)
Fig 7: Identifying Air-Conditioning Compressor To Engine Screw (Top)
8. Secure the high-pressure refrigerant line to the electric air-conditioning compressor.
1. 8.1. Remove stoppers.
2. 8.2. Replace O-ring and coat with refrigerant oil.
3. 8.3. Tighten M8 fastening screw -5- used to secure the high-pressure refrigerant line
-6- to the electric air-conditioning compressor to the prescribed tightening torque.
Tightening torque 20 Nm (15 ftlb.) +/-3 Nm (+/-2 ftlb.)
Fig 8: Installing High-Pressure Air-Conditioning Line On Air-Conditioning Compressor
9. Connect low-pressure refrigerant line at the connection point in the engine compartment and
secure it.
3. 9.3. Tighten M8 fastening screw -3- used to secure the low-pressure refrigerant line
to the low-pressure refrigerant line at the connection point in the engine compartment
to the prescribed tightening torque. Tightening torque 12 Nm (9 ftlb) +/-1.5 Nm
(+/-1 ftlb.)
Counter at the low-pressure refrigerant line connection point using an open-ended

wrench (a/f 22).
Fig 9: Connection Point For Low-Pressure Air-Conditioning Line In Engine
Compartment
10. Close the holding clamp on the low-pressure refrigerant line -2- and tighten M6 fastening nut
-1- to the prescribed tightening torque. Tightening torque 8 Nm (6 ftlb.)
Fig 10: Holding Clamp On Low-Pressure Air-Conditioning Line
11. Secure refrigerant line from evaporator to the low-pressure refrigerant line.
3. 11.3. Tighten fastening screw -3- used to secure the refrigerant line from the
evaporator (chiller) -1- to the low-pressure refrigerant line -2- to the prescribed
tightening torque. Tightening torque 12 Nm (9 ftlb.) +/-1.5 Nm (+/-1 ftlb.)
Fig 11: Identifying Refrigerant Line From Evaporator On Low-Pressure Line
12. Plug in electric connector for the air-conditioning compressor until it engages securely.
Fig 12: Plugging In Electric Connector For Air-Conditioning Compressor

INSTALLING ELECTRIC AIR-CONDITIONING COMPRESSOR > WORK STEPS FOR
BLOCKED/SEIZED UP AIR-CONDITIONING COMPRESSOR
1. Remove desiccator from the condenser. 875555 REPLACING DESICCATOR
2. Check the desiccator for wear/chips.
If there is wear/chips:
3. Remove the refrigerant line between the compressor and condenser. → 874319 REMOVING
AND INSTALLING COMPRESSOR/CONDENSER LINE
4. Replace the refrigerant line between the compressor and condenser.
5. Replace the condenser with desiccator. → 875019 REMOVING AND INSTALLING

CONDENSER
6. Install the new refrigerant line between the compressor and condenser. → 874319
REMOVING AND INSTALLING COMPRESSOR/CONDENSER LINE
7. Remove air-conditioning compressor. → 873419 REMOVING AND INSTALLING
If there is no wear/chips:
Replace the desiccator. → 875555 REPLACING DESICCATOR

SUBSEQUENT WORK
2. Install left wheel housing liner. → 505619 REMOVING AND INSTALLING FRONT WHEEL
HOUSING LINER
3. Fill in refrigerant in accordance with regulations. → 870317 DRAINING AND FILLING

REFRIGERANT
4. Install high-voltage line for electric air-conditioning compressor. → 279319 REMOVING AND
1. 4.1. Dry and clean plug connection and angled plug socket on the air-conditioning
compressor.
2. 4.2. Spray plug connection and angled plug socket on the air-conditioning
compressor completely with cavity preservation .
5. Install power electronics. → 279119 REMOVING AND INSTALLING POWER ELECTRONICS
8. If the air-conditioning compressor has been replaced, an air-conditioning compressor

run-in must be carried out using PIWIS Tester II 9818 .
1. 8.1. Select [Air-conditioning system] control unit
2. 8.2. [Drive links/checks] must now be selected.
3. 8.3. [General] can now be selected.
4. 8.4. [Reset compressor run-in] must now be selected and started.
5. 8.5. Start the engine.
6. 8.6. [Compressor run-in] must be selected and started.
9. Check the cooling performance using the front blower outlet sensor.
1. 9.1. Open the air outlet vents on the dashboard and set the fan to at least 75%.
10. Switch off the air-conditioning system again. Do not drive until the air-conditioning system has
been filled.
WM 874319 REMOVING AND INSTALLING AIR-CONDITIONING

COMPRESSOR/CONDENSER LINE (CAYENNE, CAYENNE GTS, CAYENNE TURBO S,
Refrigerant line to Fastening screw Tightening 12 Nm (9 ftlb.)

condenser - 3- torque
Refrigerant line to Fastening screw Tightening 20 Nm (15

air-conditioning -1- torque ftlb.)
compressor
Engine speed Engine speed 1, 500 1/min

CAYENNE (3.0)) > PRELIMINARY WORK > PRELIMINARY WORK FOR REMOVING
AND INSTALLING AIR-CONDITIONING COMPRESSOR/CONDENSER LINE
1. Drain the air conditioning system. → 870317 ADDING REFRIGERANT AND REMOVING BY
SUCTION
3. Loosen front wheel housing liner at the left. → 505619 REMOVING AND INSTALLING FRONT
WHEEL HOUSING LINER

CAYENNE (3.0)) > REMOVING AIR-CONDITIONING COMPRESSOR/CONDENSER LINE
Danger of freezing

1. Remove the refrigerant lines at the compressor.

Fig 1: Identifying Refrigerant Lines On Air-Conditioning Compressor
1. 1.1. Loosen the fastening screws -1- for the refrigerant lines -3- .
2. 1.2. Pull out the line -3- at the air-conditioning compressor and close off the
connections with suitable stoppers.
2. Remove the line -1- from the air-conditioning compressor to the condenser -2- .
Fig 2: Identifying Line From Air-Conditioning Compressor To Condenser
1. 2.1. To do this, unscrew the fastening screw -3- for the line -1- at the condenser -2-
.

CAYENNE (3.0)) > INSTALLING AIR-CONDITIONING COMPRESSOR/CONDENSER
LINE
1. Replace the sealing rings -1, 2- on the coolant line -3- from the air-conditioning compressor to
the condenser.
Fig 1: Identifying Sealing Rings On Lines
2. Fit the coolant line -1- from the air-conditioning compressor to the condenser -2- .
line.
Fig 2: Identifying Line From Air-Conditioning Compressor To Condenser
1. 2.1. Position the refrigerant line -1- on the condenser -2- and fit the fastening screw
-3- . → Tightening torque: 12 Nm (9 ftlb.)
3. Position the refrigerant line on the air-conditioning compressor.
Make sure that the guide pin on the air-conditioning compressor fits into the mounting for the
refrigerant line.
4. Fit the fastening screws -1- for the refrigerant lines -3- . → Tightening torque: 20 Nm (15
ftlb.) .
Fig 3: Identifying Refrigerant Lines On Air-Conditioning Compressor With Screws

CAYENNE (3.0)) > SUBSEQUENT WORK > SUBSEQUENT WORK FOR REMOVING
AND INSTALLING AIR-CONDITIONING COMPRESSOR/CONDENSER LINE
1. Fill the air conditioning system with refrigerant. → 870317 ADDING REFRIGERANT AND
REMOVING BY SUCTION
2. Fit engine guard. → 108019 REMOVING AND INSTALLING ENGINE GUARD
3. Open air outlet vents on the dashboard and set fan to at least 75 %.
4. After allowing the system to stabiles at idle speed (approx. 5 sec.), switch on air conditioning
and allow the engine to run uninterrupted for at least 2 minutes at an engine speed of less than
→ Engine speed: 1, 500 1/min .
5. Switch off the air conditioning again. Do not drive until the air conditioning system has been
filled.
WM 874419 REMOVING AND INSTALLING CONDENSER/EVAPORATOR LINE
VALUES
Fastening screw Item 3 Tightening 12 Nm (9 ftlb.) +/-1.5 Nm (+/- 1

refrigerant line to
expansion valve

on water drip torque
pan
Refrigerant line Tightening 12 Nm (9 ftlb.)

to condenser torque
Engine speed Engine speed 1500 rpm

WORK > PRELIMINARY WORK FOR REMOVING AND INSTALLING
CONDENSER/EVAPORATOR LINE AT THE FRONT
2. Remove left air cleaner housing. → 242519 REMOVING AND INSTALLING AIR CLEANER
HOUSING
3. Remove right cross panel. → 508119 REMOVING AND INSTALLING CROSS PANEL
4. Remove brake booster. → 477019 REMOVING AND INSTALLING BRAKE BOOSTER
5. Remove alarm siren. → 966519 REMOVING AND INSTALLING ALARM SIREN
6. Remove vacuum line for brake booster. → 477719 REMOVING AND INSTALLING BRAKE
BOOSTER VACUUM LINE
7. Disconnect hydraulic fluid reservoir and set it aside. → 489719 REMOVING AND INSTALLING
RESERVOIR
8. Vehicles with PDCC:
Disconnect PDCC reservoir and set it aside. → 430955 REPLACING RESERVOIR (PDCC)
SUCTION
10. Remove the brake lines from the brake master cylinder to the hydraulic unit.

Danger of freezing
Information
Always replace the sealing rings on the refrigerant lines.
Fig 1: Identifying Refrigerant Line From Condenser To Expansion Valve
1. Loosen the fastening screw -1- on the top refrigerant line -2- at the condenser.
Fig 2: Identifying Refrigerant Line - Condenser
2. Loosen the fastening nut -1- on the holder -2- for the refrigerant line and remove the
refrigerant line -3- from the holder.
Fig 3: Identifying Front Refrigerant Line Holder With Nut
3. Remove the refrigerant line from the compressor to the connection point. → 874519
REMOVING AND INSTALLING COMPRESSOR/EVAPORATOR LINE
4. Unclip refrigerant lines -1, 2- from the holder -3- on the left wheel housing.
Fig 4: Identifying Refrigerant Line Holder On Left Wheel Housing
5. Pull the refrigerant lines -1, 2- together with the rubber boot -3- up -arrow out of the
bulkhead -4- .
Fig 5: Removing Rubber Boot On Refrigerant Lines
6. Unclip the refrigerant line from the holders in the plenum panel.
Fig 6: Removing Refrigerant Line Holders In Plenum Panel
1. 6.1. Unclip vacuum line -1- from the upper parts of the holders -2, 3- .
2. 6.2. Open the upper parts of the holders -2, 3- using a suitable tool and bend them
up -arrows- .
3. 6.3. Remove refrigerant line -4- from the lower parts of the holders -5, 6- .
7. Unscrew inner fastening screw -1- on the DME control unit bracket and remove water drip pan
-2- .
Fig 7: Identifying Water Drip Pan With Fastening Screws
8. Remove front part of refrigerant line from the compressor to the evaporator from the vehicle.
9. Unscrew the two fastening screws -3- for the refrigerant lines -4- on the expansion valve -5- .
Fig 8: Identifying Refrigerant Lines, Expansion Valve And Screws
10. Pull the two refrigerant lines -4- out of expansion valve -5- and move them up/down to keep
them out of the way.
11. Take the refrigerant line out of the vehicle.

Information
1. Fit the refrigerant line in the vehicle.
2. Position the refrigerant lines -4- on the expansion valve -5- and press them into place. Do not
tilt.
Fig 1: Identifying Refrigerant Lines, Expansion Valve And Screws
3. Tighten the two fastening screws -3- used to secure the refrigerant lines to the expansion
valve -5- to → Tightening torque: 12 Nm (9 ftlb.)+/-1.5 Nm (+/-1 ftlb.) .
4. Fit water drip pan -2- and tighten fastening screws -1- to → Tightening torque: 8 Nm (6
ftlb.) .
5. Clip refrigerant lines into the holders in the plenum panel.

Fig 3: Removing Refrigerant Line Holders In Plenum Panel
1. 5.1. Insert refrigerant line -4- into the lower parts of the holders -5, 6- .
2. 5.2. Close upper parts of holders -2, 3- (-arrows- ) and clip them in.
3. 5.3. Clip vacuum line -1- into the upper parts of the holders -2, 3- .
6. Insert the refrigerant lines -1, 2- together with the rubber boot -3- from above -arrow- into the
bulkhead -4- .
Check that the rubber boot -3- is seated correctly.

Fig 4: Installing Rubber Boot On Refrigerant Lines
7. Clip refrigerant lines -1, 2- into the holder -3- on the left wheel housing.
Fig 5: Identifying Refrigerant Line Holder On Left Wheel Housing With Screws
8. Position refrigerant line -3- with the holder -2- at the front and fit the fastening nut -1- .
Fig 6: Identifying Front Refrigerant Line Holder With Nut
9. Fit the top refrigerant line -1- on the condenser.
Check that the guide sleeve is seated correctly.
Tighten the fastening screw -2- securing the refrigerant line -1- to the condenser to →
Fig 7: Identifying Refrigerant Line Screws - Condenser
10. Fit the refrigerant line from the compressor to the connection point. → 874519 REMOVING
AND INSTALLING COMPRESSOR/EVAPORATOR LINE

WORK > SUBSEQUENT WORK FOR REMOVING AND INSTALLING
1. Fill the air conditioning system with refrigerant. → 870317 ADDING REFRIGERANT AND
REMOVING BY SUCTION
2. Open air outlet vents on the dashboard and set fan to at least 75 %.
→ Engine speed: 1500 rpm .
filled.
5. Vehicles with PDCC:
Fit PDCC reservoir. → 430955 REPLACING RESERVOIR (PDCC)
6. Fit hydraulic fluid reservoir. → Installing Reservoir
7. Fit the brake lines from the brake master cylinder to the hydraulic unit.
8. Install vacuum line for the brake booster. → 477719 REMOVING AND INSTALLING BRAKE
BOOSTER VACUUM LINE
9. Fit alarm siren. → 966519 REMOVING AND INSTALLING ALARM SIREN
10. Fit the brake booster. → Installing Brake Booster
11. Install right cross panel. → Installing Cross Panel
12. Install left air cleaner housing. → Installing Air Cleaner Housing
WM 874519 REMOVING AND INSTALLING COMPRESSOR/EVAPORATOR LINE

VALUES
Line to Tightening 20 Nm (15

compressor torque ftlb.)
Mounting for Tightening 16 Nm (12

refrigerant line torque ftlb.)
connection point
Engine speed Engine speed 1, 500 rpm

WORK > PRELIMINARY WORK FOR REMOVING AND INSTALLING
COMPRESSOR/EVAPORATOR LINE
SUCTION
3. Loosen front wheel housing liner at the left. → 505619 REMOVING AND INSTALLING FRONT
WHEEL HOUSING LINER

Danger of freezing
1. Remove the refrigerant line -4- at the compressor.

Fig 1: Identifying Refrigerant Lines, Air-Conditioning Compressor And Fastening Screws
1. 1.1. Loosen the fastening screw -2- for the refrigerant lines -4- .
2. 1.2. Pull out the line -4- at the air-conditioning compressor and close off the
connections with suitable stoppers.
2. Loosen the fastening screw -1- for the refrigerant line -2- at the front left longitudinal member
-3- .
Fig 2: Identifying Front Left Refrigerant Line With Fastening Screws
3. Remove front part of refrigerant line from the compressor to the evaporator from the vehicle.

NOTE: Too much refrigerant oil in new air-conditioning compressor.
Risk of damage to air-conditioning components.
→ Do not start engine.

Information
1. Replace the sealing rings -1, 2- on the refrigerant line -3- from the air-conditioning
compressor to the front left connection point.
Fig 1: Identifying Sealing Rings On Air-Conditioning Line
2. Position the refrigerant line on the air-conditioning compressor.
Make sure that the guide pin on the air-conditioning compressor fits into the mounting for the
refrigerant line.
3. Tighten the fastening screw -2- securing the refrigerant lines -4- to the air-conditioning
compressor to → Tightening torque: 20 Nm (15 ftlb.) .
Fig 2: Identifying Refrigerant Lines, Air-Conditioning Compressor With Screws
4. Position front part of refrigerant line -2- from the compressor to the evaporator at the
longitudinal member -3- at the left.
line.
Tighten fastening screw -1- to → Tightening torque: 16 Nm (12 ftlb.) .

Fig 3: Identifying Front Left Refrigerant Line With Screws

WORK > SUBSEQUENT WORK FOR REMOVING AND INSTALLING
1. Fill the air-conditioning system with refrigerant. → 870317 ADDING REFRIGERANT AND
REMOVING BY SUCTION
2. Fit engine guard. → 108019 REMOVING AND INSTALLING ENGINE GUARD
3. Secure front wheel housing liner at the left. → 505619 REMOVING AND INSTALLING FRONT
WHEEL HOUSING LINER
4. Open air outlet nozzles on the dashboard, and set fan to at least 75 %.
→ Engine speed: 1, 500 rpm .
filled.
WM 875019 REMOVING AND INSTALLING CONDENSER (CAYENNE, CAYENNE GTS,

OF CONDENSER
Fig 1: Identifying Condenser Installation Position

1. Remove refrigerant by suction. → 870317 DRAINING AND FILLING REFRIGERANT
2. Vehicles with turbocharging: Remove charge-air cooler at the left in direction of travel. →
213019 REMOVING AND INSTALLING CHARGE-AIR COOLER
3. Remove center air guide. → 192419 REMOVING AND INSTALLING CENTRE AIR GUIDE

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING CONDENSER
Danger of freezing
1. Remove strut -3- under the radiator at the left. To do this, unscrew and remove the two
fastening screws -1+2- .
Fig 1: Identifying Strut With Screws
2. Unscrew and remove fastening screw for the refrigerant lines at the condenser. Disconnect
refrigerant lines and close them off so that they are air-tight.
Fig 2: Identifying Screws On Air-Conditioning Lines To Condenser
3. Loosen fastening screw -4- securing ATF thermostat to radiator.

Fig 3: Removing Front Lines
4. Lift up both locks -6- for the cooler and air-conditioning condenser with a screwdriver and
push them down.
Fig 4: Identifying Power-Steering Cooler
5. Loosen fastening screw for the clamp on the hydraulic lines at the radiator -arrow B- .
Fig 5: Disconnecting Hoses
6. Disengage power-steering cooler -7- from the plastic frame and secure it to prevent it from
falling down. Make sure that the lines are not deformed.
7. Disengage condenser from the plastic frame and remove it in a downward direction.
Fig 6: Disengaging Condenser From Plastic Frame

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING CONDENSER
Information
Before re-installing the component, check the O-rings of the refrigerant lines for damage and replace
them if necessary.
Wet the O-rings of the refrigerant lines with refrigerant oil.
Close off all lines and connections using suitable stoppers during removal.
Do not open the stoppers for the lines and connections until shortly before installation.
1. Slide the condenser -5- into the plastic frame -8- with the ATF cooler -9- from below.
Fig 1: Sliding Condenser Into Plastic Frame
2. Tighten fastening screw for the clamp on the hydraulic lines at the radiator -arrow B- .
Fig 2: Installing Hydraulic Lines
3. Engage the condenser -5- in the plastic frame -8- .
4. Position the plastic frame -8- on the cooler and clip in the two locks -6- .
Fig 3: Identifying Power-Steering Cooler With Screws
5. Tighten fastening screw -3- securing ATF thermostat to radiator.

Fig 4: Installing ATF Thermostat
6. Tighten fastening screws -4- used to secure the refrigerant lines to the condenser to the
prescribed tightening torque.
Fig 5: Identifying Air-Conditioning Lines To Condenser Screws
7. Secure the strut -3- with the side fastening screw -1- .
Fig 6: Identifying Strut With Fastening Screws
Secure the strut -3- with the fastening screw -2- .

WORK FOR CONDENSER
1. Install center air guide. → 192419 REMOVING AND INSTALLING CENTRE AIR GUIDE
2. Vehicles with turbocharging: Install charge-air cooler at the left in direction of travel. → 213019
REMOVING AND INSTALLING CHARGE-AIR COOLER
WM 875319 REMOVING AND INSTALLING FAN FOR CONDENSER (EXCEPT

AND INSTALLING FAN FOR CONDENSER > INFORMATION ON CONDENSER FAN
Information
As of model year 2011, the condenser fan and electric fan are the same component.
1. If the condenser fan is defective, the electric fan must be replaced.
WM 875555 REPLACING DESICCATOR (CAYENNE, CAYENNE GTS, CAYENNE

DIESEL, CAYENNE (3.0)) > INFORMATION > INSTALLATION POSITION OF
DESICCATOR
Fig 1: Identifying Desiccator Installation Position

DIESEL, CAYENNE (3.0)) > PRELIMINARY WORK > PRELIMINARY WORK FOR
DESICCATOR
FRONT LOCK SUPPORT

DIESEL, CAYENNE (3.0)) > REMOVING DESICCATOR
Danger of freezing
1. Unscrew stopper -1- on the condenser and remove it in an upward direction.

Fig 1: Opening Stopper
2. Use pliers to pull the desiccator -2- up out of the condenser.

Fig 2: Identifying Desiccator

DIESEL, CAYENNE (3.0)) > INSTALLING DESICCATOR
Danger of freezing
Information
The desiccator must be replaced in the event of malfunctions in the system (e.g. accident damage
or air conditioning system is depressurized)!
Used refrigerant oil extracted from a previously run air conditioning unit must not be re-used!
1. Replace both O-rings -3- on the stopper -1- and coat them with refrigerant oil.
Fig 1: Identifying O-Rings On Stopper
2. Slide desiccator -2- into the condenser.

Fig 2: Identifying Desiccator
3. Place stopper -1- on the condenser and tighten it.

Fig 3: Tightening Stopper

DIESEL, CAYENNE (3.0)) > SUBSEQUENT WORK > SUBSEQUENT WORK FOR
DESICCATOR
FRONT LOCK SUPPORT
WM 875819 REMOVING AND INSTALLING TEMPERATURE SENSOR (CAYENNE GTS,

CAYENNE S DIESEL, CAYENNE (3.0)) > INFORMATION > COMPONENT OVERVIEW
Fig 1: Identifying Temperature Sensors Installation Positions
1. Temperature sensor in left side vent
2. Temperature sensor in right side vent
3. Temperature sensor for intake air temperature (described under 875919 Outside temperature
sensor)
4. Temperature sensor for evaporator
5. Temperature sensor in left footwell outlet vent
6. Temperature sensor in right footwell outlet vent

WORK FOR TEMPERATURE SENSOR IN SIDE VENTS
1. Remove dashboard cover. → 701619 REMOVING AND INSTALLING DASHBOARD COVER

WORK FOR TEMPERATURE SENSOR IN FOOTWELL OUTLET VENTS
1. Remove PCM 3.1 display and operator control unit. → 911019 REMOVING AND INSTALLING
WORK FOR EVAPORATOR TEMPERATURE SENSOR
1. Remove footwell outlet vent at the front right. → 805519 REMOVING AND INSTALLING
FRONT FOOTWELL OUTLET VENT

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING TEMPERATURE SENSOR >
REMOVING TEMPERATURE SENSOR IN SIDE VENTS
Information
1. Turn the temperature sensor -1- by 90° and remove it.

Fig 1: Removing Temperature Sensor In Side Vents

2. Release electric plug connection on temperature sensor -1- (-a- ) and pull it off -A- .

REMOVING TEMPERATURE SENSOR IN FOOTWELL OUTLET VENTS
Information

Fig 1: Removing Temperature Sensor In Footwell Outlet Vents

REMOVING EVAPORATOR TEMPERATURE SENSOR
Fig 1: Removing Evaporator Temperature Sensor

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING TEMPERATURE SENSOR >
INSTALLING TEMPERATURE SENSOR IN SIDE VENTS
The temperature sensor in the side vents is installed in reverse order to removal.

INSTALLING TEMPERATURE SENSOR IN FOOTWELL OUTLET VENTS
The temperature sensor in the footwell outlet vents is installed in reverse order to removal.

INSTALLING TEMPERATURE SENSOR FOR EVAPORATOR
The evaporator temperature sensor is installed in reverse order to removal.

WORK FOR TEMPERATURE SENSOR IN SIDE VENTS
1. Install dashboard cover. → 701619 REMOVING AND INSTALLING DASHBOARD COVER

WORK FOR TEMPERATURE SENSOR IN FOOTWELL OUTLET VENTS
1. Install PCM 3.1 display and operator control unit. → Installing PCM 3.1 Display And Operator
Control Unit

WORK FOR EVAPORATOR TEMPERATURE SENSOR
1. Install footwell outlet vent at the front right. → 805519 REMOVING AND INSTALLING FRONT
FOOTWELL OUTLET VENT
WM 876055 REPLACING EVAPORATOR (CAYENNE GTS, CAYENNE TURBO S,

CAYENNE (3.0)) > INFORMATION > INSTALLATION POSITION OF EVAPORATOR
Fig 1: Identifying Evaporator Installation Position

CAYENNE (3.0)) > PRELIMINARY WORK > PRELIMINARY WORK FOR EVAPORATOR
Information
1. Remove heating/fresh-air unit → 851519 REMOVING AND INSTALLING

HEATING/FRESH-AIR UNIT .

CAYENNE (3.0)) > REMOVING EVAPORATOR
1. Remove expansion valve.
2. Disconnect electric plug connection on the evaporator temperature sensor -2- .

Fig 1: Identifying Evaporator Temperature Sensor And Expansion Valve
3. Disconnect wiring harness -2- in the colored area and set it aside.
1. 3.1. Disconnect electric plug connections on the servo motors.
2. 3.2. Disconnect wiring harness -2- from the brackets on the heating/fresh-air unit -1-
.
Fig 2: Identifying Wiring Harness From Brackets On Heating/Fresh-Air Unit
4. Remove upper part of evaporator housing -2- .

Fig 3: Identifying Upper Part Of Evaporator Housing (Rear)
1. 4.1. Remove foam seal -2- .

Fig 4: Loosening Locating Pin On Upper Part Of Housing
2. 4.2. Unclip locating pin -1- (-arrow A- ) and pull it out -arrow B- .
Fig 5: Loosening Locating Pin On Upper Part Of Housing
3. 4.3. Loosen fastening screws -3- and -4- .


Fig 7: Identifying Upper Part Of Evaporator Housing (Front)
4. 4.4. Loosen clamps -7- carefully. The clamps are not available as spare parts and
must be re-used.
5. 4.5. Loosen clips -5- and -6- .

Fig 9: Identifying Upper Part Of Evaporator Housing Clips (Rear)

Fig 10: Identifying Upper Part Of Evaporator Housing Clips (Front)
5. Remove evaporator -2- from lower part of evaporator housing -1- (-arrow A- ).
Fig 11: Removing Evaporator From Lower Part Of Evaporator Housing

CAYENNE (3.0)) > INSTALLING EVAPORATOR
Information
Make sure not to damage the foam seal on the evaporator during installation .
The seal on the evaporator cannot be replaced separately. It must only be replaced together with
the evaporator .
Check that the evaporator is fitted correctly in the heating/fresh-air unit .
2. When installing the upper part of the housing, make sure that the three guide pins on the lower
part of the housing are inserted into the openings on the upper part of the housing.

CAYENNE (3.0)) > SUBSEQUENT WORK > SUBSEQUENT WORK FOR EVAPORATOR
1. Install heating/fresh-air unit → 851519 REMOVING AND INSTALLING HEATING/FRESH-AIR
UNIT .
WM 877019 REMOVING AND INSTALLING EXPANSION VALVE (CAYENNE, CAYENNE


securing torque
expansion valve
to evaporator
Fastening screw Item 3 Tightening 12 Nm (9 ftlb.) +/-1.5 Nm (+/- 1

refrigerant line
to expansion
valve

securing water torque
drip pan to DME
control unit
bracket

OF EXPANSION VALVE
Fig 1: Identifying Expansion Valve Installation Position

WORK FOR EXPANSION VALVE
2. Remove right cover flap on the cowl panel cover. → 664419 REMOVING AND INSTALLING
COWL PANEL COVER

CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING EXPANSION VALVE
Danger of freezing
Information
The refrigerant connections must be closed off immediately using suitable stoppers once the refrigerant
lines have been removed.
1. Unscrew left fastening screw -1- (in direction of travel) on DME control unit bracket and
remove water drip pan -2- .
Fig 1: Identifying Water Drip Pan With Fastening Screws
2. Unscrew and remove both fastening screws -3- for the refrigerant lines -4- on the expansion
valve -5- .
Fig 2: Pulling Refrigerant Lines Out Of Expansion Valve
3. Pull both refrigerant lines -4- out of the expansion valve -5- and move them up/down to keep
them out of the way.
4. Unscrew both fastening screws -6- for the expansion valve and remove expansion valve -5- .
Fig 3: Identifying Expansion Valve With Fastening Screws

CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING EXPANSION VALVE
Information
Before the expansion valve is re-installed, the O-rings of the refrigerant lines must be checked for
damage and replaced if necessary .
Wet the O-rings of the refrigerant lines with refrigerant oil .
1. Carefully slide the expansion valve -5- onto the refrigerant lines from the evaporator. Do not
tilt.
Fig 1: Identifying Expansion Valve With Screws
2. Tighten both fastening screws -6- on the expansion valve to the prescribed tightening torque.
Tightening torque 5.5 Nm (4 ftlb.)
3. Fit refrigerant lines -4- on the expansion valve -5- and press into place. Do not tilt.
Fig 2: Identifying Refrigerant Lines On Expansion Valve
4. Tighten both fastening screws -3- securing refrigerant lines to the expansion valve -5- to the
prescribed tightening torque. Tightening torque 12 Nm (9 ftlb.) +/-1.5 Nm (+/-1 ftlb.)
5. Insert water drip pan -2- and tighten fastening screws -1- to the prescribed tightening torque.
Tightening torque 8 Nm (6 ftlb.)

WORK FOR EXPANSION VALVE
1. Install right cover flap on the cowl panel cover. → 664419 REMOVING AND INSTALLING
COWL PANEL COVER
WM 877819 REMOVING AND INSTALLING BLOWER REGULATOR (CAYENNE,

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING AND INSTALLING
BLOWER REGULATOR > INFORMATION ON BLOWER REGULATOR
Information
The condenser fan and electric fan are the same component.
1. If the blower regulator is faulty, the fan motor must be replaced → 853019 REMOVING AND
INSTALLING HEATING/FRESH-AIR FAN MOTOR .
WM 878319 REMOVING AND INSTALLING PRESSURE SWITCH (CAYENNE,

POSITION OF PRESSURE SWITCH
Fig 1: Identifying Pressure Switch Installation Position

PRELIMINARY WORK FOR PRESSURE SWITCH
Remove right cover flap on the cowl panel. → 664419 REMOVING AND INSTALLING COWL PANEL
COVER

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING PRESSURE SWITCH
Danger of freezing
Information
Support the refrigerant line with your hand close to the pressure switch when screwing the pressure
switch on and off.
1. Loosen the left fastening screw (in direction of travel) -1- and remove the water drip pan -2- .
Fig 1: Identifying DME Control Unit Bracket With Screws

Fig 2: Removing Pressure Switch
3. Unscrew pressure switch -1- .

TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING PRESSURE SWITCH >
INSTALLING PRESSURE SWITCH
1. Replace O-ring on the pressure switch and coat it with refrigerant oil.
Information
Support the refrigerant line with your hand close to the pressure switch when screwing the
pressure switch on and off.
2. Screw on pressure switch -1- and tighten to the prescribed tightening torque.
Fig 1: Installing Pressure Switch
3. Connect electric plug connection on the pressure switch -A- until the connector engages
securely.
4. Fit water drip pan -2- and tighten fastening screw -1- to the prescribed tightening torque.
Fig 2: Identifying Water Drip Pan With Fastening Screw

SUBSEQUENT WORK FOR PRESSURE SWITCH
1. Install right cover flap on the cowl panel. → 664419 REMOVING AND INSTALLING COWL
PANEL COVER
Service Manual: 88 - AUXILIARY AIR CONDITIONING SYSTEM -- 92A CAYENNE
WM 881019 REMOVING AND INSTALLING ADDITIONAL AIR CONDITIONER
(CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE TURBO, CAYENNE S


available tool


securing torque
refrigerant lines
to expansion
valve
Fastening 2 Tightening 9 Nm (6.5 ftlb.)

additional air
conditioner to
body
DIESEL, CAYENNE (3.0)) > INFORMATION > INSTALLATION POSITION OF
ADDITIONAL AIR CONDITIONER
On vehicles with four-zone air conditioning (2+2), the additional air conditioning system is located behind
the left rear side section cover.
Fig 1: Identifying Additional Air Conditioner Installation Position

DIESEL, CAYENNE (3.0)) > PRELIMINARY WORK > PRELIMINARY WORK FOR
3. Disconnect battery ground strap. → 2X00IN WORK INSTRUCTIONS AFTER

4. Remove center part and left side panel of luggage compartment cover. → 700619 REMOVING
COMPARTMENT COVER)
5. Remove left side trim panel for rear luggage compartment. → 700319 REMOVING AND
DIESEL, CAYENNE (3.0)) > REMOVING ADDITIONAL AIR CONDITIONER
NOTE: Danger of slipping due to emerging coolant
The emerging coolant will make the floor of the workshop slippery and may cause
people to slip and fall over.
→ Collect emerging coolant in a suitable pan.
Information
Before re-installing the component, check the O-rings of the refrigerant lines for damage and replace
them if necessary.
Wet the O-rings of the refrigerant lines with refrigerant oil.
Close off all lines and connections using suitable stoppers during removal.
Do not open the stoppers for the lines and connections until shortly before installation.
1. Unscrew and remove fastening screws -1- for refrigerant lines at the expansion valve.
Fig 1: Identifying Fastening Screws For Refrigerant Lines
2. Pull refrigerant lines out of the expansion valve and close off using stoppers.
3. Disconnect electric plug connection -1- above the additional air conditioner.
Fig 2: Disconnecting Additional Air Conditioner
4. Unscrew fastening screws -2- on the additional air conditioner.

5. Carefully unclip locking lugs for the air guide -3- on the additional air conditioner.
Fig 4: Loosening Locking Lugs For Air Guide
6. Carefully tilt additional air conditioner to the right and be careful with the flexible coolant hoses.
7. Clamp off coolant hoses -1- using hose clamping pliers Nr.192 .
Fig 5: Clamping Off Coolant Hoses On Additional Air Conditioner
NOTE: Danger of scalding
1. Coolant can be very hot.
2. Coolant may be pressurized.
→ Only remove the heater when the cooling system has cooled down.
→ By carefully opening the catch on the reservoir, make sure that the cooling system is
depressurized.
8. Disconnect coolant hoses -1- at the heat exchanger.
1. 8.1. Loosen spring band clamps -2- at the heat exchanger using assembly pliers
Nr.72 Pos.1 and disconnect coolant hoses.
Fig 6: Identifying Coolant Hoses From Heat Exchanger For Additional Air Conditioner
9. Lift up additional air conditioner -1- and disconnect water drain hose -2- .
10. Remove additional air conditioner.

DIESEL, CAYENNE (3.0)) > INSTALLING ADDITIONAL AIR CONDITIONER
Information
Before re-installing the additional air conditioner, always check the following points:
1. The additional air conditioner is installed in reverse order.
2. Position the additional air conditioner and connect water drain hose. Make sure that the water
drain hose remains connected to the drain when fitting the additional air conditioner.
3. Tighten fastening screws securing refrigerant lines to the expansion valve to the prescribed
tightening torque. Tightening torque 12 Nm (9 ftlb.)
4. Tighten fastening screws securing additional air conditioner to the body to the prescribed
tightening torque. Tightening torque 9 Nm (6.5 ftlb.)

DIESEL, CAYENNE (3.0)) > SUBSEQUENT WORK > SUBSEQUENT WORK FOR
1. Fit left side trim panel for rear luggage compartment. → 700319 REMOVING AND
2. Fit center part and left side panel of luggage compartment cover. → 700619 REMOVING AND
INSTALLING LUGGAGE COMPARTMENT TRIM PANEL (LUGGAGE COMPARTMENT
COVER)
3. Connect ground strap for battery. → 2X00IN WORK INSTRUCTIONS AFTER

WM 881119 REMOVING AND INSTALLING REAR AIR-CONDITIONING SYSTEM

REGULATOR (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S,

PRELIMINARY WORK FOR REMOVING AND INSTALLING REAR AIR-CONDITIONING
SYSTEM REGULATOR
1. If the rear air-conditioning system regulator has to be replaced, the values/data must be read
out prior to removal using PIWIS Tester II 9818 .
2. Remove air vents in rear center console. → 855719 REMOVING AND INSTALLING REAR
CENTRE AIR VENT

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > REMOVING REAR
Information
Information
The ignition must be switched off and the ignition key removed before the control unit for the
auxiliary air conditioning system can be removed .
Information
1. Unscrew screws -2- on the rear air-conditioning system regulator -1- from the center console
-3- .
Fig 1: Removing Rear Air-Conditioning System Regulator
2. Unclip fixing clips -4- from the center console -3- using a suitable tool.
3. Release electric plug connection -2- for heated seats -a- and pull it off the air-conditioning
system regulator -arrow- .
4. Release electric plug connection -3- for air-conditioning system regulator -b- and pull it off the
air-conditioning system regulator -arrow- .
Fig 2: Identifying Electric Plug Connections Of Air-Conditioning System Regulator

CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) > INSTALLING REAR
1. The rear air-conditioning system regulator is installed in reverse order to removal.

SUBSEQUENT WORK FOR REMOVING AND INSTALLING REAR AIR-CONDITIONING
SYSTEM REGULATOR
1. Install rear center air jet. → 855719 REMOVING AND INSTALLING REAR CENTRE AIR JET
2. If the rear air-conditioning system regulator was replaced, the values/data must be loaded
using PIWIS Tester II 9818 .
WM 882019 REMOVING AND INSTALLING SERVO MOTOR (CAYENNE, CAYENNE

GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE TURBO, CAYENNE (3.0)) > TOOLS

INFORMATION > INSTALLATION POSITION OF SERVO MOTORS
1. Servo motor for right air flow
2. Servo motor for left air flow
3. Servo motor for left temperature mixing flap
4. Servo motor for right temperature mixing flap

PRELIMINARY WORK > PRELIMINARY WORK FOR SERVO MOTOR
COMPARTMENT COVER)

REMOVING SERVO MOTOR > REMOVING SERVO MOTOR FOR RIGHT AIR FLOW
NOTE: Voltage peaks


4. Remove servo motor for right air flow.

REMOVING SERVO MOTOR > REMOVING SERVO MOTOR FOR LEFT AIR FLOW
NOTE: Voltage peaks
1. Disconnect connector -1- above the additional air conditioner.

5. The servo motor for the left air flow -1- is removed in the same way as the servo motor for the
right air flow.
Fig 3: Removing Servo Motor On Additional Air Conditioner

REMOVING SERVO MOTOR > REMOVING SERVO MOTOR FOR RIGHT
TEMPERATURE MIXING FLAP
NOTE: Voltage peaks
2. Carefully disengage the linkage -4- at the servo motor -1- . The linkage is not available as a
spare part .
Fig 1: Removing Servo Motor For Temperature Mixing Flap

4. Unscrew three fastening screws -2- on the servo motor -1- .

5. Remove servo motor for right temperature mixing flap.

REMOVING SERVO MOTOR > REMOVING SERVO MOTOR FOR LEFT TEMPERATURE
MIXING FLAP
NOTE: Voltage peaks
1. Disconnect connector -1- above the additional air conditioner.

5. The servo motor for the left temperature mixing flap -1- is removed in the same way as the
servo motor for the right temperature mixing flap.

INSTALLING SERVO MOTOR
1. The relevant servo motors are installed in reverse order to removal.
3. Tighten fastening screws for the relevant servo motor to the prescribed tightening torque.

INSTALLING SERVO MOTOR > TEACHING SERVO MOTOR
Information
6. 1.6. PIWIS Tester II must then be shut down and disconnected.

SUBSEQUENT WORK > SUBSEQUENT WORK FOR SERVO MOTOR
INSTALLING TRIM PANEL FOR LUGGAGE COMPARTMENT (LUGGAGE COMPARTMENT
COVER)

TURBO S, CAYENNE S, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0)) >
TOOLS


available tool

TECHNICAL VALUES
Fastening 2 Tightening 9 Nm (6.5 ftlb.)

additional air
conditioner to
body
Fastening screw Tightening 1.2 Nm (1.0

securing servo torque ftlb.)
motor to heat
exchanger

INFORMATION > INSTALLATION POSITION OF HEAT EXCHANGER
Fig 1: Identifying Heat Exchanger Installation Position

PRELIMINARY WORK > PRELIMINARY WORK FOR HEAT EXCHANGER
COMPARTMENT COVER)

REMOVING HEAT EXCHANGER
NOTE: Danger of slipping due to emerging coolant
The emerging coolant will make the floor of the workshop slippery and may cause
people to slip and fall over.
→ Collect emerging coolant in a suitable pan.
Information
1. Disconnect electric plug connection -1- above the additional air conditioner.
Fig 1: Disconnecting Additional Air Conditioner Connector
3. Lift up additional air conditioner -1- and pull off water drain hose -2- .
5. Clamp off coolant hoses -1- using hose clamping pliers Nr.192 .
Fig 4: Clamping Off Coolant Hoses On Additional Air Conditioner
NOTE: Danger of scalding
1. Coolant can be very hot.
2. Coolant may be pressurized.
→ Only remove the heater when the cooling system has cooled down.
→ By carefully opening the catch on the reservoir, make sure that the cooling system is
depressurized.
6. Disconnect coolant hoses at the heat exchanger.
1. 6.1. Loosen spring band clamps -1- at the heat exchanger using assembly pliers
Nr.72 Pos.1 and disconnect coolant hoses.
7. Disconnect electric plug connection -3- at the servo motor -1- and move wiring harness -4-
above the heat exchanger aside.
8. Loosen upper fastening screw -2- on the servo motor -1- .

9. Loosen fastening screws -2- on the cover -1- of the heat exchanger and remove cover.
Fig 7: Removing Heat Exchanger Cover
10. Remove heat exchanger.

INSTALLING HEAT EXCHANGER
Information
Before re-installing the additional air conditioner, always check the following points:
Information
1. The heat exchanger is installed in reverse order.

2. Tighten fastening screw securing servo motor to additional air conditioner to the prescribed
tightening torque. Tightening torque 1.2 Nm (1.0 ftlb.)
3. Tighten fastening screws securing additional air conditioner to the body to the prescribed
tightening torque. Tightening torque 9 Nm (6.5 ftlb.)

SUBSEQUENT WORK > SUBSEQUENT WORK FOR HEAT EXCHANGER
INSTALLING LUGGAGE COMPARTMENT TRIM PANEL (LUGGAGE COMPARTMENT
COVER)
WM 883419 REMOVING AND INSTALLING AIR GUIDE FOR ADDITIONAL AIR

CONDITIONING (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S,
Fig 1: Identifying Air Guide Of Additional Air Conditioning Installation Position
1. Air duct in wheel housing
2. Rear air duct

3. Air duct in tunnel, left
4. Air duct in tunnel, right
5. Air distributor with servo motor, left
6. Air distributor with servo motor, right
7. Air duct in B-pillar, bottom left
8. Air duct in B-pillar, bottom right
9. Air duct in footwell, rear left
10. Air duct in footwell, rear right
11. Air duct in B-pillar, left
12. Air duct in B-pillar, right
13. Side vent, left
14. Side vent, right

REMOVING AND INSTALLING AIR DUCT IN WHEEL HOUSING > PRELIMINARY
WORK
AND INSTALLING LUGGAGE COMPARTMENT TRIM (LUGGAGE COMPARTMENT COVER)
2. Remove side trim panel for rear left luggage compartment. → 700319 REMOVING AND
3. Remove temperature sensor. → 885419 REMOVING AND INSTALLING TEMPERATURE

SENSOR

REMOVING AND INSTALLING AIR DUCT IN WHEEL HOUSING > REMOVING AIR
DUCT IN WHEEL HOUSING
2. Carefully remove the air guide -1- .

Fig 2: Removing Air Guide In Wheel Housing

REMOVING AND INSTALLING AIR DUCT IN WHEEL HOUSING > INSTALLING AIR
DUCT IN WHEEL HOUSING

REMOVING AND INSTALLING AIR DUCT IN WHEEL HOUSING > SUBSEQUENT
WORK
1. Install temperature sensor. → 885419 REMOVING AND INSTALLING TEMPERATURE

SENSOR
2. Install side trim panel for rear left luggage compartment. → 700319 REMOVING AND
3. Install center part and left side panel of luggage compartment cover. → 700619 REMOVING

REMOVING AND INSTALLING REAR AIR DUCT > PRELIMINARY WORK
2. Remove side trim panel for rear left luggage compartment. → 700319 REMOVING AND
3. Remove rear seat completely.
→ 724819 REMOVING AND INSTALLING 2/3-SPLIT FOLDING REAR SEAT

REMOVING AND INSTALLING REAR AIR DUCT > REMOVING REAR AIR DUCT
1. Loosen the screw -1- on the left support for the luggage compartment cover and remove the
support -2- .
Fig 1: Removing Support From Luggage Compartment Cover
2. Carefully detach the air guide -2- from the studs at the fastening points -15- and remove it.
Fig 2: Removing Rear Air Duct

REMOVING AND INSTALLING REAR AIR DUCT > INSTALLING REAR AIR DUCT

REMOVING AND INSTALLING REAR AIR DUCT > SUBSEQUENT WORK
1. Install rear seat completely.
2. Install side trim panel for rear left luggage compartment. → 700319 REMOVING AND
3. Install center part and left side panel of luggage compartment cover. → 700619 REMOVING

REMOVING AND INSTALLING AIR DUCT IN TUNNEL > PRELIMINARY WORK
1. Remove rear seat completely.

REMOVING AND INSTALLING AIR DUCT IN TUNNEL > REMOVING AIR DUCT IN
TUNNEL
1. Carefully loosen the air duct -3- from the air distributor and remove it.
Fig 1: Removing Air Duct From Tunnel

REMOVING AND INSTALLING AIR DUCT IN TUNNEL > INSTALLING AIR DUCT IN
TUNNEL

REMOVING AND INSTALLING AIR DUCT IN TUNNEL > SUBSEQUENT WORK
2. Install rear seat completely.

REMOVING AND INSTALLING AIR DISTRIBUTOR WITH SERVO MOTOR >
PRELIMINARY WORK

REMOVING AND INSTALLING AIR DISTRIBUTOR WITH SERVO MOTOR > REMOVING
AIR DISTRIBUTOR WITH SERVO MOTOR
1. Move front seat forward and up.
2. Release and pull off the connector -a- on the servo motor at the air distributor -5- .
Fig 1: Removing Air Duct With Servo Motor
3. Loosen fastening screw -A- .

4. Carefully remove the air distributor -5- .

INSTALLING AIR DISTRIBUTOR WITH SERVO MOTOR

SUBSEQUENT WORK

REMOVING AND INSTALLING AIR DUCT IN BOTTOM OF B-PILLAR > PRELIMINARY
WORK
1. Remove B-pillar trim. → 706719 REMOVING AND INSTALLING B-PILLAR TRIM

REMOVING AND INSTALLING AIR DUCT IN BOTTOM OF B-PILLAR > REMOVING AIR
DUCT IN BOTTOM OF B-PILLAR
1. Loosen the air duct -7- at the stud -15- and remove it carefully.
Fig 1: Removing Air Duct From B-Pillar

REMOVING AND INSTALLING AIR DUCT IN BOTTOM OF B-PILLAR > INSTALLING
AIR DUCT IN BOTTOM OF B-PILLAR

REMOVING AND INSTALLING AIR DUCT IN BOTTOM OF B-PILLAR > SUBSEQUENT
WORK
1. Install B-pillar trim. → 706719 REMOVING AND INSTALLING B-PILLAR TRIM

REMOVING AND INSTALLING AIR DUCT IN TOP OF B-PILLAR > REMOVING AIR
DUCT ON UPPER B-PILLAR
Information
The air duct on the upper B-pillar cannot be removed separately. It is part of the B-pillar trim panel.
1. Remove B-pillar trim panel. → 706719 REMOVING AND INSTALLING UPPER PART OF
B-PILLAR TRIM PANEL

REMOVING AND INSTALLING AIR DUCT IN TOP OF B-PILLAR > INSTALLING AIR
DUCT IN TOP OF B-PILLAR

REMOVING AND INSTALLING AIR DUCT IN REAR FOOTWELL > PRELIMINARY
WORK
1. Remove air vent under the front seat. → 887519 REMOVING AND INSTALLING AIR VENT

REMOVING AND INSTALLING AIR DUCT IN REAR FOOTWELL > REMOVING AIR
DUCT IN REAR FOOTWELL
1. Loosen the air duct -9- at the studs -15- and remove it carefully.
Fig 1: Removing Air Duct From Rear Footwell

REMOVING AND INSTALLING AIR DUCT IN REAR FOOTWELL > INSTALLING AIR
DUCT IN REAR FOOTWELL

CAYENNE S E-HYBRID, CAYENNE TURBO, C

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Porsche Cayenne

Service Manual: 01 - SALES CHECK -- 92A CAYENNE

Designation Type Number Description

PIWIS Tester II Special tool 9818

WM 0101IN DIAGNOSTIC SYSTEM: PERFORMING VEHICLE HANDOVER (CAYENNE,

Location Description Type Basic value Tolerance 1 Tolerance 2

Current rating Nominal value 40 A

WM 0101IN DIAGNOSTIC SYSTEM: PERFORMING VEHICLE HANDOVER (CAYENNE,

NOTE: Voltage drop

Risk of irreparable damage to control unit

Risk of damage to control unit

Fault entries in the control unit

Coding in the control unit is aborted

Malfunctions in control unit, even during programming

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

2. Select the vehicle.

4. Select the Vehicle handover function, then press [F12].

5. When Remove transport protection is displayed, press [F12] to continue.

6. Create vehicle handover log , then press [F12].

7. Write service interval, then press [F8] (Yes).

9. Write maintenance interval , then press [F12].

WM 010100 SALES CHECK (CAYENNE TIP, CAYENNE TIP (3.0), CAYENNE S,

WARNING: High voltage at the high-voltage system on hybrid vehicles

Danger of electric shock from live parts

Risk of serious burns or death

Health risks for persons with medical devices/life-support systems.

Work instruction for order no.

Remove transport locks, transport protection → 0X01IN REMOVING TRANSPORT

Electrical equipment, warning and indicator lights: Check operation

Mobile roofs: Check operation → 0X01IN MOBILE ROOFS: CHECKING OPERATION

Check wheel mounting → 440519 REMOVING AND INSTALLING WHEEL

Visual inspection for leaks: oils, fluids

Exterior equipment and paint finish: Visual inspection for damage

Glazing: Visual inspection for damage

Interior equipment: Visual inspection for damage and soiling

Alarm system: Check operation of monitoring devices

Transmission: Check operation

Check vehicle for unusual handling behaviour, vibrations and noise

Diagnostic system: Read out and erase fault memory

Stamp of Official Porsche Centre

WARNING: Working on electric components

Risk of short circuit or fire.

→ Only replace cables in a dry environment.

Fig 1: Identifying Porsche Universal Charger (AC) Components

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

B. Power plug (connector for connecting to main power supply)

Risk of damage to charging equipment.

WM 0940IN PORSCHE UNIVERSAL CHARGER (AC) (HIGH-VOLTAGE CHARGING

A. Power plug (connector for connecting to main power supply)

B. Control unit display

C. Vehicle plug (plug connection for the vehicle)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Final switch-off due Dry the vehicle

Control unit display

Switch-off due to Continuous

Control unit display

Charging current Place control unit

Control unit display

Place control unit