Porsche Cayenne S 2006 (Completo) ENG

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PORSCHE CAYENNE 2003 2004 2005 2006 REPAIR MANUAL

CAYENNE,CAYENNE S,CAYENNE TURBO,CAYENNE TURBO S
WARNUNG
Gefahr des Verlusts der Text-Bild-Zuordnung beim Ausdruck.
z Aus technischen Gründen kann derzeit nicht ausgeschlossen werden, dass trotz
einwandfreier Darstellung auf dem Bildschirm beim Ausdruck der Zusammenhang von
Text und zugehörigem Bild verloren geht.
z Wird der Fehler nicht bemerkt, besteht die Gefahr, daß Arbeiten nicht korrekt
durchgeführt werden und es dadurch zu Personen- und Sachschäden kommt.
→ Vergleichen Sie deshalb nach dem Druckvorgang unbedingt die Ausdrucke mit der
Bildschirmdarstellung. Korrigieren Sie die Ausdrucke im Fehlerfall so, daß der Inhalt der
Bildschirmdarstellung zutreffend wiedergegeben wird.
WARNING
Danger of losing text-figure correspondence when printing out.
z For technical reasons, it can currently not be ruled out that the correspondence between
text and associated figure can be lost when it is printed out, even though the display on
the screen is correct.
z If the fault is not noticed, there is the danger that work will not be performed correctly
which can cause injury and damage.
→ Therefore, always compare printouts with the screen display after printing them out. Correct the
printouts if they are faulty so that the content of the screen display matches that on the printouts.
AVERTISSEMENT
Risque de perte de la correspondance texte-illustration lors de l'impression papier.
z Pour des raisons techniques, il ne peut pas être exclu à l'heure actuelle que, même en
cas d'affichage correct à l'écran, la correspondance entre le texte et l'illustration puisse
être erronée sur l'impression papier.
z Si l'erreur passe inaperçue, on court le risque d'exécuter certaines opérations de
manière incorrecte pouvant conduire à des dommages corporels et matériels.
→ Comparez impérativement pour cette raison les impressions papier avec l'affichage à l'écran.
Corrigez-les en cas d'erreur de manière à reproduire correctement l'affichage à l'écran.
ATTENZIONE
Pericolo di perdita dell'abbinamento testo-immagine nella stampa.
z Per motivi tecnici non è escluso che, nonostante la rappresentazione sullo schermo
risulti perfetta, durante la stampa venga persa la corrispondenza fra testo e relativa
immagine.
z Se tale difetto non viene rilevato vi è il pericolo che i lavori non siano eseguiti
correttamente; ciò può avere come conseguenza lesioni e danneggiamenti.
→ Per questo motivo, dopo la stampa è assolutamente necessario confrontare le stampe con la
rappresentazione sullo schermo. In caso di errore si prega di correggere le stampe, così da
garantire la riproduzione esatta della rappresentazione sullo schermo.
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ADVERTENCIA
Al imprimir se corre el riesgo de perder la correcta asignación de las figuras al texto.
z Por motivos técnicos, por el momento no se puede descartar que, aun siendo correcta la
imagen que aparezca en la pantalla, al imprimir se pierda la correlación entre el texto y la
figura correspondiente.
z Si este error pasara desapercibido, existe el riesgo de que los trabajos no se ejecuten de
forma correcta y, por tanto, se produzcan daños personales y materiales.
→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con
la imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se
correspondan con el contenido de la imagen de la pantalla.
01 01 00 Sales check - as of MY 2003

- Information
Information
Note
z ♦ 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.
Workshop no.
Vehicle Ident. No.
OK 1) Not OK 2)
Check conformity of vehicle Ident. No. on vehicle, data bank, vehicle registration
documents and on-board literature
→ Checking Vehicle Ident. No. for conformity [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ Checking Vehicle Ident. No. for conformity [9PAAJ1]
Removing transport locks, transport protection
→ Removing transport protection [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→
Removing transport protection [9PAAJ1]
→ Main switch for power supply (removing battery disconnect switch) [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Main switch for power supply (removing
battery disconnect switch) [9PAAJ1]
Battery: check battery charging condition (bear in mind transport and idle period)
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→ Battery: checking charging condition [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]

→ Battery: checking charging condition [9PAAJ1]
Diagnosis system: read out and erase fault memory, activate systems
→ Diagnosis system: reading out fault memory and activating systems [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Diagnosis system: reading out fault memory
and activating systems [9PAAJ1]
Windscreen washer/headlight cleaning system: check operation, fluid level and nozzle
settings, pay attention to antifreeze protection in the winter months
→ Windscreen washer/headlight cleaning system: checking operation, nozzle
settings [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Windscreen
washer/headlight cleaning system: checking operation, nozzle settings [9PAAJ1]
Vehicle lights: check operation All headlights: check adjustment. Horn and clock: check
operation
→ Check the function of the vehicle's lights [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ Check the function of the vehicle's lights [9PAAJ1]
Electrical equipment, warning and indicator lights: check operation
→ Checking the function of electrical equipment, indicator and warning lights [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Checking the function of electrical equipment,
indicator and warning lights [9PAAJ1]
Mobile roofs: check operation
→ Mobile roofs: checking operation [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→
Mobile roofs: checking operation [9PAAJ1]
Check engine-oil level
→ 170117 Engine oil and oil filter change [9PAAD1 9PAAD7]→ 170117 Engine oil and
oil filter change [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]
Check tyre pressure
→ Running gear maintenance: Tyres and spare wheel: checking condition
and... [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Running gear maintenance:
Tyres and spare wheel: checking condition and... [9PAAJ1]
Wheels, tyres: visual inspection for damage
→ Running gear maintenance: Tyres and spare wheel: checking condition
Tyres and spare wheel: checking condition and... [9PAAJ1]
Check wheel mounting → Checking wheel mounting [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ Checking wheel mounting [9PAAJ1]
Brake hoses and lines: visual inspection for damage in wheel area → Running gear
maintenance: Visual inspection - brake lines/brake ... [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ Running gear maintenance: Visual inspection - brake
lines/brake ... [9PAAJ1]
Check brake fluid level → Running gear maintenance: checking brake fluid level
checking brake fluid level and... [9PAAJ1]
Visual inspection for leaks: oils, fluids
Exterior equipment and paint finish: visual inspection for damage
→ Checking exterior equipment and paintwork [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ Checking exterior equipment and paintwork [9PAAJ1]
Glazing: visual inspection for damage
→ Checking glazing [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Checking
glazing [9PAAJ1]
Interior equipment: visual inspection for damage and soiling
→ Interior equipment: visual inspection for damage and soiling [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ Interior equipment: visual inspection for damage and
soiling [9PAAJ1]
Door and lid locks: check operation
→ Checking lids and doors [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→
Checking lids and doors [9PAAJ1]
Alarm system: check operation of monitoring devices
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→ Alarm system: checking operation of monitoring devices [9PAAD1 9PAAD7

9PAAE1 9PAAE7 9PAAF1]→ Alarm system: checking operation of monitoring
devices [9PAAJ1]
Complete vehicle and check that all equipment is present
→ Checking vehicle equipment for completeness [9PAAJ1]→ Checking vehicle
equipment for completeness [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]
→ Sales check: Fitting mobile phone console [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ Sales check: Fitting mobile phone console [9PAAJ1]
Test drive OK 1) Not OK 2)
Foot and parking brakes, clutch, steering, automatic speed control, ParkAssist,
heating, air-conditioning system and instruments: check operation
→ Test drive: sales check
Transmission: check operation
Check vehicle for unusual handling behaviour, vibration and noise
Diagnosis system: read out and erase fault memory
→ Diagnosis system: Reading out fault memory and activating systems [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Diagnosis system: Reading out fault memory
and activating systems [9PAAJ1]
1) OK = functioning correctly
2) Not OK = not functioning correctly
Stamp of Official Porsche Centre
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
01 01 01 Battery: checking charging condition - as of MY 2003

- Battery: checking charging condition
Tools
Designation Type Number Explanation

Rapid-start battery charger special tool 44
Battery: checking charging condition
Checking charge state with battery tester
Note
z Follow the instructions for the Tester, topic: charge state/functional state.
z The tester must be connected directly to the battery.
1. Remove battery cover.
2. Connect battery tester to vehicle battery and check the battery charge state according to the operating
instructions for the tester. Rapid-start battery charger 44
Evaluating the test results and further procedures:

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– Open-circuit voltage: 12.7 - 12.5 V
– 1. Charge state: 100-80 %
– 2. Charge state OK
– 1. Charge state: 80 - 50 %
– 2. Battery charge state reduced, recharge battery and observe an inactive period for two hours after charging.
→ 2706 Battery
– 1. Charge state: 50 - 10 %
– 2. Battery flat; recharge battery and observe an inactive period for two hours after charging. → General
information and on vehicle battery [9PAAE1 9PAAE7 9PAAF1]→ General information and on vehicle
battery [9PAAD1 9PAAD7]
– Open-circuit voltage: below 11.6 V
– 1. Charge state: below 10 %
– 2. Battery totally discharged; replace battery
9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
01 01 01 Alarm system: Checking operation of indicators - as of

MY 2003
- Checking indicators
Checking indicators
check operation of indicators
Vehicle must be unlocked and the sales check item - Diagnosis system: systems activated and fault memory read
out - must be performed.
1. Lock vehicle with the remote control. Shortly after locking, no warning tone must be emitted by the alarm
system horn. If a warning tone is emitted, check exterior covers, glove compartment cover, centre console
cover and all doors; open and close these items in turn.
2. As soon as the vehicle is locked, the LED - in the middle of the driver's door trim panel - must flash quickly
for 2 seconds and then flash slowly.
Fault display:
3. 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. → "Rep. Gr. 96 Alarm system diagnosis manual "
Alarm system: checking operation of indicators
Vehicle must be unlocked and the sales check item - Diagnosis system: systems activated and fault memory read
out - must be performed.
1. Lock vehicle with the remote control. Shortly after locking, no warning tone must be emitted by the alarm
system horn. If a warning tone is emitted, check exterior covers, glove compartment cover, centre console
cover and all doors; open and close these items in turn.
2. As soon as the vehicle is locked, the LED - in the middle of the driver's door trim panel - must flash quickly
for 2 seconds and then flash slowly.
Fault display:
3. 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. → "Rep. Gr. 96 Alarm system diagnosis manual "
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as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
01 01 23 Sales check: Fitting mobile phone console - as of MY

2003
- E-box
- Fitting mobile phone console
E-box
Note
z The E-box components are not included in the mobile phone console delivery package.
z If the customer already has an E-box, this can be installed on the mobile phone console.
z If the customer does not yet have an E-box, an E-box that can be used with the mobile phone to be fitted
must be purchased on the open market.
Overview of E-box
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1 - Cover for interface box

2 - Interface box
3 - VDA interface and antenna
4 - Mobile phone-specific cradle
Fitting mobile phone console
Note
z An assembly kit for the mobile phone console is supplied in the vehicle along with the I No. for the mobile
phone console.
z Before delivery to the customer, this console must be fitted with whichever E-box matches the customer's
mobile phone.
z The E-box to be fitted must be agreed with the customer and purchased on the open market, if required.
Overview of the single parts in the mobile phone console
Installation Location:
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Overview of installation of mobile phone console
1. On the upper part -E- , mark the fixing variant of the relevant
interface box, drill as required, push the wiring through and position
correctly using the fastening screws -1- .
Fastening holes in interface box

2. Fit the upper part -E- loosely to the outer part -D- and lay the VDA interface lead and antenna lead in the
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Assembly C, D, E
outer part -D- and the cable duct -C- .
3. Make sure that the wires are not pinched.
4. Engage the cable duct -C- in the outer part -D- .
5. Lift the assembled components -C, D, E- onto the centre console

support, engage the cable duct at the lower edge of the centre
console and push the components -C, D, E- onto the centre console
support.
6. Place the clamp -B- on the outer part and secure with the three
fastening screws -2- . → Tightening torque: 1.5 ftlb.
Pushing components onto centre

console support
7. Engage the inner part -A- with the outer part -D- , then clip into the
outer part and secure with the fastening screw -3- . → Tightening
torque: 0.4 ftlb.
Installing inner part

8. Screw in the fastening screws -4- for the interface box support from the upper part -E- .
9. Engage the upper part -E- in das inner-outer part -A-D- and secure with the fastening screw -4- . →
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Screwing interface box onto upper part

Tightening torque: 0.4 ftlb.
10. Screw in the fastening screws -1- for the interface box support into
the upper part -E- . → Tightening torque: 0.4 ftlb.
Screwing on support for interface box

11. Push the interface box onto the cradle from below until the interface
box engages.
12. Move/position the passenger seat all the way up and forwards.
Pushing interface box into cradle

13. The line for the VDA interface and antenna line is located under the
seat. Guide this line with the connector under the left seat rail and lay
it up along the seat.
Routing line for the VDA interface and

antenna line
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14. Connect wiring for the VDA interface and antenna leads
G - Centre console
F - Seat
Connecting line for the VDA interface

and antenna line
15. Press the carpet at the lower edge of the side part of the centre console down and push/press the wiring
under the centre console.
16. Move the seat to the position required by the customer.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
01 01 IN Diagnostic system: reading out fault memory and

activating systems - as of MY 2003
Tools

PIWIS Tester special tool 9718
Performing vehicle handover
WARNING
Sudden voltage interruption of the power supply to the control unit.
z Risk of irreparable damage to the control unit.
→ During vehicle handover, 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 external power supply.
1. PIWIS Tester 9718 must be connected to the vehicle, then start the System Tester. Switch on ignition.
Press >> to continue.
2. Select Special functions using the cursor keys.
3. In the Special functions menu, select Cayenne handover and continue with >> .
4. Follow the instructions on the Tester (vehicle handover). Press >> to continue.
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5. Switch on the ignition and start the function by pressing F8 .
6. The Tester runs the functions and displays the confirmation message Functions ended. Press >> to
continue.
7. Enter Vehicle Ident. No. and press >> . Compare Vehicle Ident. No. and if it is OK, confirm with F7 .
7.1. Read out all fault memories.
8. Exit the Special functions menu and select the Cayenne menu.
9. Carry out an automatic search for control units.
10. Read out the fault memory and then erase the fault memory for all control units for which a fault was
recorded.
11. For vehicles with the navigation system, insert the navigation DVD into the navigation unit (DVD) under the
passenger’s seat and switch on PCM.
11.1. Switch on the PCM in clear surroundings (to load GPS almanac). The almanac is loaded as soon as four
satellites are identified.
11.2. Message on PCM >>Loading navigation DVD<< - do not interrupt loading operation.
12. Print out vehicle handover log and place it in vehicle documents folder.
13. Test-drive the vehicle and read out the fault memory. Check faults in accordance with diagnosis if necessary
and erase fault memory before delivering the vehicle.
Activating systems
Note
z The work procedure is menu-driven; the Tester instructions have the highest priority, additional operation is
specified using the arrow icons, e.g. >> .
1. Connect the Porsche System Tester to the vehicle and start the
System Tester. Switch on ignition. Press >> to continue.
2. Select the Special functions menu using the cursor keys.
3. Switch to Cayenne analysis and start it. Analysis is performed. Print

out analysis log and assign it to the vehicle process.
4. →| Select vehicle type. Switch to Cayenne handover .
5. Observe instructions on the Tester and code >> using F8 .
6. Enter the required chassis number >> .

Connecting Porsche System Tester to
7. Wait until the Tester displays the message All functions run and the vehicle
PCM/CDR was activated. >> . Continue with Read out fault
memory
Reading out fault memory

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Porsche System Tester connected to vehicle and System Tester started. Ignition switched on.
1. Select vehicle type. >>
Note
z All control units are automatically read out in turn.
2. Faulty control units are flagged as such with an asterisk before their name >> * DME.
3. Select these control units, then select Read out fault memory.
4. Fault memory can now be deleted in the Erase fault memory menu. If PCM is installed, continue with Load
navigation .
The fault memory must be read out again or erased after the test drive. If the same faults are present again,
proceed in accordance with Rep.-Gr. 20 — 97 Diagnosis Manual.
Loading navigation
Note
z Only vehicles with PCM.
1. Insert navigation CD into PCM and switch on PCM.
2. Navigation CD is loaded.
3. Disconnect Tester on vehicle.
Reading out and erasing fault memory
The PIWIS Tester 9718 is connected to the vehicle via a diagnostic socket. The diagnosis socket is located inside
the vehicle in the vicinity of the driver's A-pillar below the instrument panel.
1. Open the cover of the diagnostic socket and plug in the plug
connection for the PIWIS Tester.
2. Start the PIWIS Tester 9718 and follow the instructions on the
Tester.
3. Select vehicle type, press >> and start the automatic control unit
search.
4. If an asterisk appears in front of the relevant control unit, read out the
fault memory and follow the instructions on the Tester.
Connecting Porsche System Tester to

the vehicle
Selecting voice recognition language
Note
As of model year '06, voice recognition will be offered as additional equipment.
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The scope of delivery contains a voice recognition CD.
The voice recognition CD can be used to select the desired language.
After vehicle handover is done with the PIWIS tester, voice recognition is active in German.
Selecting voice recognition language
1. Insert speech recognition CD in the PCM.
2. After the voice recognition CD is read, Select language appears on the PCM screen.
3. Select desired language and confirm.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
01 01 Checking Vehicle Ident. No. for conformity - as of MY 2003

- Check Vehicle Ident. No. for conformity.
Check Vehicle Ident. No. for conformity.
Checking Vehicle Ident. No. for conformity
Note
z The adhesive label for the on-board literature is located on the data bank affixed to the rear left of luggage
compartment.
Check whether the following vehicle identification numbers are identical, and then affix the enclosed data-bank
adhesive label to the on-board literature (guarantee and maintenance booklet).
– Check Vehicle Ident. No. on lower left of windscreen.
– Vehicle Ident. No. stamped on bodyshell, in the rear right of luggage compartment
– Vehicle Ident. No. on the data-bank adhesive label in rear left of luggage compartment.
– Vehicle Ident. No. in the vehicle registration documents.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
01 53 Removing transport protection - as of MY 2003
Removing external transport protection

– Installation location: Body
– 1. Material: Plastic film, white (complete protective cover)
– Installation location: Windscreen
– 1. Material: Adhesive tape, white
– Installation location: Doors
– 1. Material: Styrodur strips with adhesive film
– Installation location: Front bumper
– 1. Material: Styrodur block with adhesive film
– Installation location: Wheel rims
– 1. Material: Self-adhesive rim protection
Removing internal transport protection

– Installation location: Seats (front)
– 1. Material: Fleece
– Installation location: Inner sill
– 1. Material: Transparent film, red
– Installation location: Inner side member
– 1. Material: Fleece
– Installation location: Lower door trim panel
– 1. Material: Transparent film, red

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– Installation location: Footwell
– 1. Material: Cardboard protection
– Installation location: Inner door handle
– 1. Material: Cardboard protection
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
01 01 Checking lid and doors - as of MY 2003

- Checking lid and doors
Checking lid and doors
Checking lid lock, front and rear

– Check that the lid locks engage when the lids (front and rear) are closed by engaging the lock upper parts
and that they disengage again when the lid releases are activated.
Checking safety hook, 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.
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).
Functional check of tank cap lock

– Lock vehicle.
– Check tank cap is locked by the tank cap lock in the closed position.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
01 01 Mobile roofs: Checking operation - as of MY 2003
Checking sliding roof

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.
Teaching the panorama roof the limit position
Note
z When the maximum duration of operation (> 40 s) is exceeded, the fault code 0409 can be stored in the
control module.
z Initialisation must be completed fully as otherwise the roof cannot be operated electrically.
z If initialisation is interrupted or terminated, the entire procedure must be repeated.
1. Turn on ignition and turn rotary switch to the position "Close roof fully".
2. Wait until the roof remains in any position.
3. Keep the rotary switch pressed until the sun blind and the roof are completed closed.
4. Relieve the seals from strain by briefly opening and then closing the roof again.
5. Read out the fault memory with the Porsche System Tester and remedy any faults.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
01 01 Checking exterior equipment and paintwork - as of MY 2003

- Checking exterior equipment and paintwork
Checking exterior equipment and paintwork
Note
z 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.
Checking exterior equipment

1. Check vehicle for secure fit of accessories such as trim strips, doors mirrors, front and rear spoilers.
2. Check underbody for noticeable areas where undersealing material is missing (e.g. scrapes).
3. Check lower side member of body flange for deformation of jacking points.
4. Check outer shell of vehicle for noticeable soiling by cavity sealing wax.
Checking paintwork
1. Check outer shell of vehicle for noticeable sheetmetal damage such as dents and bulges.
2. Check painted surfaces of vehicle for noticeable defects such as scores, scratches, notches, scrapes, pores,
bubbles or signs that the bodywork is coming through the paint.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
01 01 Checking glazing - as of MY 2003
Check glazing
Note
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.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
01 IN Checking vehicle equipment for completeness - as of MY

2003
- Tools
- Vehicle key
Check that the items listed below are in the vehicle.
Designation Number Limitations Position in the vehicle

Warning triangle 1x Standard Luggage compartment (stowage
compartment on right-hand side)
Emergency kit 1x Standard Luggage compartment (stowage
compartment on right-hand side)
Tool kit 1x Standard Luggage compartment (under the
loadspace floor)
Vehicle key set 1x Dependent on equipment version
Car jack 1x Standard Luggage compartment (under the
loadspace floor)
On-board folder containing 1x Standard Glove compartment
technical information 1)
Driver's Manual for vehicle,
PCM/CDR manual,
Guarantee and
Maintenance Booklet 2) 3)
1x Optional extra Luggage compartment (under the
Emergency spare wheel
loadspace floor)
Spare wheel 1x Optional extra fitted externally
2x Standard Luggage compartment (under the
Folding wedges
loadspace floor)
1x Vehicles with trailer hitch Luggage compartment (under the
Ball head for trailer hitch
loadspace floor)
1x Vehicles without spare wheel Luggage compartment (under the
Sealant bottle for tyres
loadspace floor)
1x Vehicles with spare wheel or Tire Luggage compartment (under the
Compressor Fit (except for vehicles with air loadspace floor)
suspension)
1x Vehicles with air suspension Oddments tray under the right-hand
Tyre inflation hose
seat
Torch and torch holder 1x only Japan
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Number plate bracket, front 1x USA only Luggage compartment

4)
Wiper blades, front 5) 2x Luggage compartment
1) Except for German-speaking countries, the on-board information folder containing technical information (Driver's Manual and Guarantee and
Maintenance booklet) must be supplied by the dealer or importer.
2) The PCM/CDR manual must be supplied by the dealer or importer in all non-German-speaking countries.
3) The navigation CD must be supplied by the dealer or importer in the U.S.
4) Only in USA states that require a number plate at the front of the vehicle → 668323 Installing number plate trim [9PAAD1 9PAAD7 9PAAE1
9PAAE7]→ 668323 Installing number plate trim [9PAAF1].

5) Replace the one-way wiper blades with the enclosed wiper blades → 922719 Removing and installing wiper blade.
Tools
Designation Number Limitations Position in the vehicle

Wheel wrench 1x
Open-ended wrench 1x
Towing eye 1x 1)
Screwdriver 1x
Gloves 1x Luggage compartment (under the
Standard
Socket wrench 1x loadspace floor)
Assembly pin 1x
Puller hook 1x
Socket for security wheel 1x
bolts
Allen key for emergency 1x Vehicles with sliding or panorama Centre armrest front (upper
operation of sliding roof roof compartment)
panel
1) 2x in vehicles with Off-Road Technical or Off-Road Design package
Vehicle key
Designation Number Limitations

Keyring 1x Standard
Key fob 1x Standard
Emergency key 1x Standard
1)
Radio remote control 2x Standard

Control element 1x Only vehicles with Porsche Entry & Drive
1) Emergency key no longer included as of model year 05.

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as of MY 2003
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ADVERTENCIA
01 01 Interior trim: visual inspection for damage and soiling - as

of MY 2003
- Checking seat belts
Check interior equipment
Note
component joints or under seals.
2. Check interior equipment of vehicle for noticeable damage such as scores, scratches, notches and scrapes.
3. Check interior equipment of vehicle for soiling.
Checking seat belts
Functional Check
Note
z The following requirements must be met when fitting the seat belt
z If one of the requirements listed below is not met, the seat belt or the buckle must be replaced.
It must be possible to unroll the belt strap smoothly from the belt retractor via the deflector fitting by pulling evenly.
The tongue of the seat belt must engage audibly in the buckle.
An abrupt pull on the belt strap must lock the belt retractor.
Condition inspection
Visually inspect the belt strap for damage by unrolling it completely.

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If it displays evidence of damage in the form of cuts, fraying, seam tears etc., the seat belt must be replaced.
as of MY 2003
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ADVERTENCIA
01 IN Test drive - sales check - as of MY 2003

- Test drive - sales check
Test drive - sales check
Note
z The following test items are included in the test drive.
– Check foot- and handbrake 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 air-conditioning system when engine is running.
– Check operation of instruments.
as of MY 2003
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ADVERTENCIA
01 01 Mobile roofs: checking operation - as of MY 2003

- Teaching control unit
- Checking operation
Teaching control unit
Teaching the panorama roof the limit positions
WARNING
Danger of injury! Risk of material damage!
→ Do not reach into the moving area of the mechanism when opening and closing the roof assembly.
→ Anti-crushing protection is deactivated in emergency operation mode.
→ If there is danger, release the rotary switch immediately or activate it in the opposite direction, or switch off
the ignition.
→ Never open the roof assembly without having initialised the limit position of the motors. Danger of collision
for the two rear roof segments!
Note
z When the maximum duration of operation (> 40 seconds) is exceeded, the fault code 0409 (Rotary switch
emergency button signal is permanently displayed) can be stored in the control unit.
z Initialisation must be completed fully as otherwise the roof cannot be operated electrically.
z If initialisation is interrupted or terminated, the entire procedure must be repeated.
1. Switch on ignition and turn rotary switch to the position "Close roof fully". Wait until the roof remains in any
position.
2. Hold the rotary switch in this position -arrow- . The closing operation starts after approx. 5 seconds. Keep
the rotary switch pressed until the sun blind and the roof are closed. First the sun blind is closed; then the lid
of the roof assembly is closed, opened briefly, and closed again. The rear lid of the roof assembly closes
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only after the rotary switch is released -arrow- .
3. Relieve the seals from strain by briefly opening and then closing the roof again.
4. Read out the fault memory with the Porsche System Tester and remedy any faults.
Checking operation
Checking sliding roof/panorama roof

1. By operating the control switch, return to original tilting, opening and closing positions. During operation,
check for malfunctions and noises.
2. In vehicles with a sunroof: Fully open and close sliding roof lining by hand. During operation, check for
noises and stiffness.
as of MY 2003
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ADVERTENCIA
03 24 00 Minor maintenance - as of MY 2003, until MY 2003

- Minor maintenance
Minor maintenance
Note
z The engine oil and oil filter must be changed every 10,000 km (6,000 mls) in vehicles which are operated in
countries where leaded fuel is used.
z If the mileage for scheduled maintenance is not reached, minor maintenance must be carried out after 2, 6,
10...... years.
z The terms "inspect" and "check" include all necessary subsequent work such as adjustments, readjustments,
corrections and replenishment. They do not include the repair, replacement or overhaul of components or
assemblies.
z The maintenance item > Replacing spark plugs < depends on the engine type. Please refer to the "Additional
maintenance" chapter → 287055 Replacing spark plugs.
Minor maintenance after: OK

30,000, 90,000, 150,000, 210,000 km etc./
20,000, 60,000, 100,000, 140,000 mls etc.
Diagnosis system: read out fault memory → Diagnostic maintenance: diagnostic system and
maintenance inter...
Vehicle underside and engine compartment: visual inspection for leaks (oils and other fluids)
Engine compartment: visual inspection for damage
Underside panels: visual inspection for completeness, secure installation and damage
Change engine oil and oil filter → 170117 Engine oil and oil filter change
Check drive belt → 137801 Checking drive belt
Radiators and air inlets: visual inspection for external contamination and blockage; check coolant
level → 190101 Checking cooling system
Brake system: visual inspection of brake pads and brake discs for wear → Running gear
maintenance: visual inspection - brake lines/brake pads/brake discs
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Brake hoses and lines: visual inspection for damage, routing and corrosion → Running gear
Drive shafts: visual inspection of boots for leaks and damage → Running gear maintenance: axle
joints/drive shafts
Front cardan shaft: visual inspection of air bellows for damage (up to and including '03 model) →
Cardan shaft maintenance
Rear cardan shaft: visual inspection of centre bearing for damage (up to and including '03 model) →
Check threaded connections of suspension adjustment system at front and rear are secure (applies
to the first service only) → Cardan shaft maintenance
Exterior of tyres and spare wheel: check condition and tyre pressure → Running gear maintenance:
tyres and spare wheel - checking condition and tyre pressure
Panorama roof system: teach control unit → Panorama roof system control unit
Windscreen wiper/washer system, headlight washer: checking operation, fluid level and nozzle
settings, pay attention to antifreeze protection in winter months; check wiper blades → Electrics
maintenance: windscreen wiper and washer system, ...
All headlights: check adjustment. Horn: checking operation → Electrics maintenance: checking
operation of vehicle lights
Battery and vent hose: check condition → Battery maintenance: checking condition of battery and
vent hose
Test drive:
remote control, front seats, foot and parking brakes (also actuation travel), engine, clutch, steering,
transmission, ParkAssist, automatic speed control, PSM switch, heating, air-conditioning system and
instruments: check operation → Test drive - maintenance
Oils, fluids: visual inspection for leaks
9PAAE1, 9PAAE7, 9PAAF1
as of MY 2003, until MY 2003

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WARNUNG
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ADVERTENCIA
03 24 00 Minor maintenance - as of MY 2003

- Minor maintenance
Minor maintenance
Note
z If the mileage for scheduled maintenance is not reached, minor maintenance must be carried out after 2, 6,
10...... years.
assemblies.
maintenance" chapter → 287055 Replacing spark plugs [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]→ 287055
Replacing spark plugs [9PAAD1 9PAAD7].
Minor maintenance after: OK

30,000, 90,000, 150,000, 210,000 km etc./
20,000, 60,000, 100,000, 140,000 mls etc.
Diagnostic system: read out fault memory → Diagnostic maintenance: diagnostic system and
maintenance inter... [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Diagnostic maintenance:
diagnostic system and maintenance inter... [9PAAJ1]
Vehicle underbody and engine compartment: visual inspection for leaks (oils and other fluids)
Underbody panels: visual inspection for completeness, secure installation and damage
Change engine oil and oil filter → 170117 Engine oil and oil filter change [9PAAD1 9PAAD7]
→ 170117 Engine oil and oil filter change [9PAAE1 9PAAE7 9PAAF1 9PAAJ1] (the oil change
service plan applies for the Cayenne V6) → Oil change service [9PAAD1 9PAAD7]→ Oil change
service [9PAAE1 9PAAE7 9PAAF1 9PAAJ1])
Check drive belt → 137801 Checking drive belt [9PAAD1 9PAAD7]→ 137801 Checking drive
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belt [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]

Radiators and air inlets: visual inspection for external contamination and blockage; check coolant
level → 190101 Checking cooling system
maintenance: visual inspection - brake lines/brake pads/brake discs [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ Running gear maintenance: visual inspection - brake lines/brake pads/brake
discs [9PAAJ1]
discs [9PAAJ1]
joints/drive shafts [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Running gear maintenance: axle
joints/drive shafts [9PAAJ1]
Front cardan shaft: visual inspection of air bellows for damage (up to '03 model) → Cardan shaft
maintenance [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Cardan shaft maintenance [9PAAJ1]
Rear cardan shaft: visual inspection of centre bearing for damage (up to '03 model) → Cardan shaft
maintenance [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Cardan shaft maintenance [9PAAJ1]
Check screw connections of the suspension adjustment system at front and rear are secure (applies
to first service only) → Running gear maintenance: running gear adjustment/mounting of
assemblies [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Running gear maintenance: running
gear adjustment/mounting of assemblies [9PAAJ1]
tyres and spare wheel - checking condition and tyre pressure [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ Running gear maintenance: tyres and spare wheel - checking condition and tyre
pressure [9PAAJ1]
Panorama roof system: teach control unit → Teaching control unit of Panorama roof system
All headlights: check adjustment. Horn: check operation → Electrics maintenance: windscreen wiper
and washer system, ...
vent hose
Test drive:
instruments: check operation → Test drive - maintenance [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ Test drive - maintenance [9PAAJ1]
as of MY 2003
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WARNUNG
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ADVERTENCIA
03 26 00 Major maintenance - as of MY 2003, until MY 2003

- Major maintenance
Major maintenance
Note
z If the mileage for scheduled maintenance is not reached, major maintenance must be carried out after 4, 8,
12...... years.
assemblies.
maintenance" chapter → 287055 Replacing spark plugs.
Major maintenance after OK

60,000, 120,000, 180,000, 240,000 km etc./
40,000, 80,000, 120,000, 160,000 mls etc.
Diagnosis system: read out fault memory → Diagnostic maintenance: diagnostic system and
maintenance inter...
Change engine oil and oil filter → 170117 Engine oil and oil filter change
Particle filter: replace filter insert → 851519 Particle filter: replacing filter insert
Check drive belt → 137801 Checking drive belt
Steering gear: visual inspection of bellows for damage → Running gear maintenance: steering gear
- fluid level...
Track rod joints: check the play and dust bellows → Running gear maintenance: axle joints/drive
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shafts
Power steering: check fluid level → Running gear maintenance: steering gear - fluid level...
Fuel lines and connections: visual inspection
Radiators and air inlets: visual inspection for external contamination and blockage; Coolant: check
the level and antifreeze protection → 190101 Checking cooling system
Foot-operated parking brake: check free play → Running gear maintenance: checking free play of
foot-operated parking brake
joints/drive shafts
Axle joints: check the play and visually inspect the dust bellows for damage → Running gear
maintenance: axle joints/drive shafts
Exhaust system: visual inspection for leaks and damage, check mounts
tyres and spare wheel - checking condition and tyre pressure
Lubricate door arrester and fastening pins → Checking lid and doors
Windscreen wiper/washer system, headlight washer: check operation, fluid level and nozzle settings,
pay attention to antifreeze protection in winter months; check wiper blades → Electrics maintenance:
windscreen wiper and washer system, ...
Seat belts: checking operation and condition → Checking seat belts
All headlights: check adjustment; horn: check operation → Electrics maintenance: checking
operation of vehicle lights
vent hose
Trailer hitch: check operation → Trailer hitch maintenance: checking operation
Airbag system: check operation and condition (see Additional maintenance) → Occupant protection
maintenance: inspecting airbag system
Test drive:
instruments: check operation → Test drive - maintenance

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WARNUNG
WARNING
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ATTENZIONE
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ADVERTENCIA
03 26 00 Major maintenance - as of MY 2003

- Major maintenance
Major maintenance
Note
z If the mileage for scheduled maintenance is not reached, major maintenance must be carried out after 4, 8,
12...... years.
assemblies.
maintenance" chapter → 287055 Replacing spark plugs [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]→ 287055
Replacing spark plugs [9PAAD1 9PAAD7].
Major maintenance after OK

60,000, 120,000, 180,000, 240,000 km etc./
40,000, 80,000, 120,000, 160,000 mls etc.
Diagnostic system: read out fault memory → Diagnostic maintenance: diagnostic system and
maintenance inter... [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Diagnostic maintenance:
diagnostic system and maintenance inter... [9PAAJ1]
Change engine oil and oil filter → 170117 Engine oil and oil filter change [9PAAD1 9PAAD7]
→ 170117 Engine oil and oil filter change [9PAAE1 9PAAE7 9PAAF1 9PAAJ1] (the oil change
service plan applies for the Cayenne V6) → Oil change service [9PAAD1 9PAAD7]→ Oil change
service [9PAAE1 9PAAE7 9PAAF1 9PAAJ1])
Particle filter: replace filter insert → 851519 Particle filter: replacing filter insert
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Check drive belt → 137801 Checking drive belt [9PAAD1 9PAAD7]→ 137801 Checking drive
belt [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]
Steering gear: visual inspection of bellows for damage → Running gear maintenance: steering gear
- fluid level... [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Running gear maintenance: steering
gear - fluid level... [9PAAJ1]
Tie rod joints: check the play and dust bellows → Running gear maintenance: axle joints/drive
shafts [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Running gear maintenance: axle joints/drive
shafts [9PAAJ1]
Power steering: check fluid level → Running gear maintenance: steering gear - fluid
level... [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Running gear maintenance: steering gear -
fluid level... [9PAAJ1]
Fuel lines and connections: visual inspection
Radiators and air inlets: visual inspection for external contamination and blockage; Coolant: check
the level and antifreeze protection → 190101 Checking cooling system
Foot-operated parking brake: check free play → Running gear maintenance: checking free play of
foot-operated parking brake [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Running gear
maintenance: checking free play of foot-operated parking brake [9PAAJ1]
discs [9PAAJ1]
discs [9PAAJ1]
joints/drive shafts [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Running gear maintenance: axle
joints/drive shafts [9PAAJ1]
Cardan shaft maintenance [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Cardan shaft
maintenance [9PAAJ1]
Cardan shaft maintenance [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Cardan shaft
maintenance [9PAAJ1]
Axle joints: check the play and visually inspect the dust bellows for damage → Running gear
maintenance: axle joints/drive shafts [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Running gear
maintenance: axle joints/drive shafts [9PAAJ1]
Hydraulically disengagable off-road stabilizer: check fluid level and operation → Hydraulically
disengagable off-road stabilizer- checking fluid level and operation
Exhaust system: visual inspection for leaks and damage, check mounts
tyres and spare wheel - checking condition and tyre pressure [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ Running gear maintenance: tyres and spare wheel - checking condition and tyre
pressure [9PAAJ1]
Lubricate door arrester and fastening pins → Checking lid and doors
Seat belts: check operation and condition → Checking seat belts [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ Checking seat belts [9PAAJ1]
All headlights: check adjustment; horn: check operation → Electrics maintenance: checking operation
of vehicle lights
vent hose
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Trailer hitch: check operation → Trailer hitch maintenance: checking operation [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ Trailer hitch maintenance: checking operation [9PAAJ1]
Airbag system: check operation and condition (see Additional maintenance) → Occupant protection
maintenance: inspecting airbag system
Test drive:
instruments: check operation → Test drive - maintenance [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ Test drive - maintenance [9PAAJ1]
as of MY 2003
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ADVERTENCIA
03 35 00 Diagnosis maintenance: resetting diagnostic system and

maintenance interval - as of MY 2004
- Reading out fault memory
- Resetting maintenance interval
The Porsche System Tester is connected to the vehicle via a 16-pin
Connector on diagnostic socket

diagnosis socket. The diagnostic socket is located inside the vehicle below the dashboard near to the driver (left-
hand drive vehicles) or the passenger (right-hand drive vehicles) -arrow- .
1. Start Porsche System Tester (PST) and follow the instructions on the Tester.
2. Select vehicle type with >> and perform the automatic control unit search.
3. If a # star appears in front of the relevant control unit, read out the fault memory. Follow the instructions of
the PST.
4. → Resetting maintenance interval
Resetting maintenance interval

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Resetting maintenance interval
Note
If the engine oil is replaced at a service, the maintenance interval must be reset.
1. In the Porsche System Tester, select Instrument cluster, then press >> .
2. Select the Coding menu, then press >> .
3. Select Reset Service Interval Display menu, then press >> .
Note
Depending on the country, additional items are checked in the case of the V6 model. These items must be
selected on a country-specific basis.
4. Select Reset menu and confirm with F8 .
5. Quit menu, shut down PST and disconnect from vehicle.
as of MY 2004
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ADVERTENCIA
03 39 01 Passenger protection maintenance: inspecting airbag

system - as of MY 2003
- Information
- checking
Information
Information
Note
z The inspection must be carried out every 60,000 km (40,000 miles) in the first 10 years.
z After the first 10 years, the inspection must be carried out every 2 years, regardless of the mileage.
checking
Visual inspection
1. Check airbag units visually:
1.1. Check that no trim or stickers are attached to the airbag units (driver's, passenger's, side, head airbag).
1.2. Visual inspection of the components for damage and deformation.
1.3. The system check must be certified in the stamp spaces provided in the Guarantee and Maintenance
booklet.
Checking airbag warning light

1. Function test of airbag warning light in instrument cluster:
1.1. Switch on ignition.

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Note
z The airbag warning light must light up for approx. 3 seconds. If the warning light does not light up, check the
light unit and power supply.
1.2.
2. Function test of airbag warning light in centre console:
DANGER
Danger of serious or fatal injuries from passenger's airbag!
z If the PASSENGER AIRBAG warning light does not light up when
the ignition is switched on, there may be a fault in the system.
→ Read out fault memory and correct the malfunction.
2.1.
2.2. Use the vehicle key to deactivate the passenger's airbag at the key-operated switch (cover of right fuse
carrier).
2.3. Switch position ON - airbag active.
2.4. Switch position OFF - airbag deactivated.
2.5. Switch on the ignition; the warning light must light up continuously.
Function test of the airbag system

1. Function test of the airbag system:
1.1. Move the driver's seat back and up as far as possible.
1.2. Unclip front cover of driver's seat subframe.
1.3. Connect and switch on the Porsche System Tester.
1.4. Switch on ignition.
1.5. Establish communication with the airbag control unit.
1.6. Read out fault memory: No fault stored.
WARNING
Performing the drive link test when vehicle is in motion!
z Danger of injury if the drive link test is carried out when the vehicle is in motion! The following
conditions must be satisfied when carrying out the drive link test:
→ Never carry out the drive link test when the vehicle is in motion.
→
The drive link test must always be carried out on a stationary vehicle in a workshop with adequate
commercially available tools. The cutoff relay must be activated again following the drive link test. Only then
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can the engine be restarted (see warning note below).
1.7.
1.8. Start the engine and activate central locking system with the switch in the door trim panel.
1.9. Start the Drive links menu.
Note
z When you perform the drive link test:
z The cutoff relay is activated. The cutoff relay must be activated again. To activate the cutoff relay: Press on
the coloured area of cutoff relay (located in power distributor).
z The engine is switched off.
z The hazard warning lights are activated.
z The central locking system is opened.
1.10.
1.11. Read out and erase fault memory for the DME control module and airbag control unit.
1.12. Switch off ignition and disconnect battery.
ATTENTION
Danger of injury and material damage if airbag units are not handled correctly! Always observe the safety
regulations for handling airbag units. → 69 Safety regulations for vehicles with airbag and belt tensioner.
Remove ignition key. Disconnect battery . Route or isolate ground strap so that all contact with a ground
carrier (e.g. body, seat frame) is avoided. → 90 Work instructions after disconnecting the battery . After
the battery is disconnected, always wait one minute before disconnecting the airbag connectors.
1.13.
2. Simulate the fault:
2.1. Simulate the fault using the side airbag, for example. Move seat all
the way forward.
Note
z To check the operation of the airbag system, a plug connection is
disconnected from an airbag unit. A fault code - Static fault - must
then be stored in the Porsche System Tester.
2.2.
2.3. Fold up retainer on plug socket -1- -A- , press lock -B- on airbag connector -2- and pull out connector -C- .
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2.4. Connect the battery and switch on ignition.
2.5. Read out fault memory. Static fault present.
3. Correct the fault:
3.1. Switch off ignition, disconnect the battery and wait one minute.
3.2. Fold up retainer -A- on plug socket -1- and insert connector -2- -B-
until it is felt to engage.
4. Read out and delete faults:

4.1. Connect the battery, switch on ignition and read out the fault
memory with the Porsche System Tester.
Note
z Fault memory shows a sporadic fault.
4.2.
4.3. Erase fault memory.
Carry out work instruction after disconnecting the battery. → 90 Work instructions after disconnecting the battery.
as of MY 2003
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ADVERTENCIA
03 81 00 Additional spark plug maintenance - as of MY 2003

- Additional maintenance, replacing spark plugs
Additional maintenance, replacing spark plugs
Note
Additional maintenance, replacing spark plugs → 287055 Replacing spark plugs [9PAAE1 OK
9PAAE7 9PAAF1 9PAAJ1]→ 287055 Replacing spark plugs [9PAAD1 9PAAD7]
Replace spark plugs in Cayenne every 60,000 km/40,000 mls or every 4 years
Replace spark plugs in Cayenne S every 90,000 km/60,000 mls or every 4 years
Replace spark plugs in Cayenne Turbo every 60,000 km/40,000 mls or every 4 years
as of MY 2003
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ADVERTENCIA
03 85 00 Additional maintenance after 120,000 km/80,000 mls - as

of MY 2003
- Additional maintenance every 120,000 km/80,000 mls or every 4 years
Additional maintenance every 120,000 km/80,000 mls or every 4 years
Note
Additional maintenance every 120,000 km/80,000 mls OK

Air cleaner: replace filter insert → 242455 Replacing air cleaner element [9PAAF1 9PAAJ1]
→ 242455 Replacing air cleaner element [9PAAE1 9PAAE7]→ 242455 Replacing air cleaner
element [9PAAD1 9PAAD7]
as of MY 2003
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WARNUNG
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ADVERTENCIA
03 95 00 Additional maintenance after 240,000 km/160,000 mls - as

of MY 2003
- Additional maintenance every 240,000 km/160,000 mls or every 16 years
Additional maintenance every 240,000 km/160,000 mls or every 16 years
Additional maintenance every 240,000 km/160,000 miles or every 16 years
Note
Additional maintenance every 240,000 km/160,000 mls or every 16 years OK

All-wheel final drive: change oil. → 399055 Changing oil for all-wheel final drive
Rear final drive: change oil. → 399055 Changing oil for rear final drive
Transfer box: change oil. → 399055 Changing oil for transfer box
Manual transmission: change oil. → 340155 Changing transmission oil [9PAAD7 9PAAE7]→ 340155
Changing transmission oil [9PAAD1 9PAAE1 9PAAF1 9PAAJ1]
Tiptronic transmission: change ATF and ATF filter:
→ 370255 Changing ATF [9PAAF1 9PAAJ1]→ 370255 Changing ATF [9PAAD1 9PAAE1]→ 370255
Changing ATF [9PAAD7 9PAAE7]
→ 375819 Removing and installing ATF filter [9PAAD1 9PAAE1 9PAAF1 9PAAJ1]→ 375819 Removing and
installing ATF filter [9PAAD7 9PAAE7]
as of MY 2003
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WARNUNG
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AVERTISSEMENT
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03 01 Checking operation of vehicle lights - as of MY 2003

- Checking operation of vehicle lights
- Adjusting main headlight
Tools

flexible screwdriver special tool 9703
Checking operation of vehicle lights
Check lighting
Turn on ignition, switch on all vehicle lights one after another and check that the individual lights are working.
Lights to be checked:
z Main headlights
z Fog lights
z Side direction indicator light
z Tail light
z Number plate light
z Additional brake light
Checking Xenon headlights

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-1- - Bulb for direction indicator light PY 21 W, 12 V (yellow bulb).

-2- - Bulb for auxiliary high beam headlight. H7 (12 V, 55 W).
-3- - Bulb for cornering light. H3 (12 V, 55 W).
-4- - Installing bulb for parking light H6W (12V, 6W).
-5- - 5 Xenon gas discharge lamp for dipped beam and high beam. D1S
(12 V, 35 W).
Overview of bulbs
Checking rear light
-A- - Brake light. P 21 W.

-B- - Direction indicator. P 21 W.
-C- - Reverse light. P 21 W.
-D- - Rear fog light and tail light. P 21/4 W.
-E- - Tail light P 21/5 W.
Overview of bulbs
Checking horn function
Press horn actuation on steering wheel and check the function and sound of horn.
Checking the clock
Check current time, adjust if necessary.
1. The clock is set in the multi-function display.
2. Press clock button on instrument cluster.
3. Set the time using the rocker switch on the wiper switch.
4. Press reset switch on the wiper switch.
Compare time displayed in instrument cluster with time displayed in PCM (if available) and adjust the time in PCM
also if necessary.
Adjusting main headlight
Adjusting main headlights

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The vehicle must be on a horizontal surface!
Make the adjustment with the regulator switch set to 0 (headlight beam adjustment)!
Use a flexible screwdriver 9703 with a hexagon bit to adjust the headlights.
Using a headlight adjustment unit, make the adjustment with the vehicle ready for driving (fuel tank full, driver's
seat occupied by a person or loaded with → Mass: 75 kg ; tyre pressures must correspond to specified values).
1. Press down cover -1- in engine compartment and remove it.
2. Turn on the ignition, turn on dipped beam and high beam headlights.
3. Check setting and adjust if necessary.
Adjusting:
Set headlight adjustment unit to 10 cm/10 m (1%)!
With this alignment, preference must be given to the central zone around
the salient point of the light/dark limit!
Note
z The distance between the headlights and the adjustment unit should be as small as possible!
z It should not exceed 30 cm, because at greater distances it is no longer possible to define the formation of
the light/dark limit in the adjustment unit clearly!
The vertical/side adjustment of the dipped beam/high beam highlight is

made first: adjustment -A- and -B- .
4. To do this, line up the light/dark borderline running upwards at an

angle on the right-hand side with the dotted 15° line of the
adjustment unit.
5. The dipped beam headlight is then adjusted horizontally: adjustment

-A- and -B- .
To do this, line up the left, horizontal section of the light/dark limit (when driving on the right) with the dotted
horizontal line of the adjustment unit.
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6. Check auxiliary high beam

headlight and, if necessary,
adjust the side setting using
-A- and -B- .
7. In the case of Xenon

headlights, the ignition must
be switched off and on after
the adjustment has been
made with the lights switched
on.
8. After this, the adjustment

must be checked again.
9. Fit cap again.
Adjusting the main headlights, USA version

– Vertical and horizontal adjustment must be carried out with a headlight adjustment unit.
as of MY 2003
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03 01 Checking electrical equipment such as control and warning

lights for functionality. - as of MY 2003
- Checking electrical equipment
Checking electrical equipment
Checking electrical equipment

– Turn ignition key and check function of warning and indicator lights (visual inspection).
– Actuate power windows and check operation.
– Check that rear window heater is in working order.
– Adjust heater blower and fans to high and low and check the air vents for air throughput.
– Check operation of front seats.
– Check audio function.
– Check operation of door mirror, check adjustment options.
– Check operation of orientation lights.
– Actuate central locking and check operation.
– Operate cigarette lighter and check that it is in working order.
as of MY 2003
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03 Entire vehicle -General - as of MY 2003

- General warning notes
General warning notes
Lifting the vehicle
DANGER
Risk of injury due to vehicles slipping or tilting off lifting platforms.
z Risk of injury due to vehicles slipping or tilting off lifting platforms may be caused by improper
alignment of the lifting platform arms or support plates, and by raising, supporting or removing units
on raised vehicles.
→ Align the vehicle evenly between the lifting platform columns.

→ Lift the vehicle only at the take-up points provided.
→ Check the correct seating of the support plates by raising the vehicle slightly and conducting a visual
inspection.
→ In order to ensure that the vehicle is not lifted off the support plates during assembly work, the vehicle must
be secured on the lifting platform, or the shift in the centre of gravity must be offset by a corresponding load
in the vehicle, when units are removed or supported.
→ In addition, the guidelines of the lifting platform manufacturers and the legal accident prevention regulations
and those of the mutual indemnity association (VGB 14) must be observed.
ATTENTION
Danger of material damage if the vehicle is raised incorrectly.
z Lifting or supporting the vehicle at unsuitable take-up points can lead to material damage on the
vehicle.
z Raising the vehicle in the sill area will lead to the deformation of body parts and to leakage in the
underbody area.
→ Lift the vehicle only at the approved take-up points.

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Note
For Cayenne vehicles with air suspension/level control, the following work must also be performed before raising
the vehicle:
z Adjusting car to normal level
z Switching off level control
After ending the repair or maintenance work, perform the steps for the following activity:
z Switch on level control
Note
When driving onto the lifting platform, bear in mind the work to be carried out. 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.
Position the vehicle.
Mounting point for raising Cayenne

vehicles
Adjusting car to normal level
Note
If air suspension accumulators of the air suspension are filled, only the ignition has to be switched on. If air
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pressure in accumulators is too low, compressor comes on and loads battery. In this case, a constanter (charging
unit) must be connected or the engine must be started.
– Stop vehicle and apply brake.
– Close vehicle doors
Note
When the normal vehicle position has been reached, the middle indicator light next to the rocker switch is
permanently on. If a further indicator light should come on, a different level is adjusted.
– Tap the right-hand rocker switch on the center console in the appropriate direction until vehicle has reached
normal level.
Switching off level control

– Adjust car to normal level.
– Switch on ignition.
Note
The message Car may now be lifted appears in the variable control display of the instrument panel.
– Push → time value: 5 s +5 s forwards.
Switch on level control
Note
Level control comes on automatically when setting off with the vehicle. As an alternative, the following steps can
be performed.
as of MY 2003
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03 IN Test drive - maintenance - as of MY 2003

- Test drive - maintenance
Test drive - maintenance
Note
z The following test items are included in the test drive.
– Actuate remote control of central locking and check operation.
– Seats: check operation of adjustments.
– Check 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 air-conditioning system when engine is running.
– Check operation of instruments.

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as of MY 2003
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03 Running gear maintenance: axle joints/drive shafts - as of MY

2004
- Tie rod joints: checking the play and dust bellows
- Axle joints: checking the play and dust bellows
- Drive shafts: visual inspection of the boots
Tie rod joints: checking the play and dust bellows
Tie rod joints: checking play and dust boots

1. Lift vehicle → 40 Lifting the vehicle.
Note
z 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.
z 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 play and dust boots.
3. Check that dust boots, bellows and joints are functioning correctly and not leaking.
Axle joints: checking the play and dust bellows
Axle joints: checking play and dust boots

1. Check play.
2. Visually inspect the dust boots for damage.
Note
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z When doing so, the rubber dust boots should be pressed down with the fingers to reveal hidden cracks.
z 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.
3. Inspect the dust boots of the axle joints (ball joints) on the wheel suspension (front and rear) as follows:
z Place the vehicle on a lifting platform with the steering lock disengaged.
z Perform a visual inspection after cleaning.
Note
z Over a small area in the vicinity of the brake cover panels, no visual inspection is possible.
z Check this area by touch.
The procedure for the front axle is as follows:
z Turn the front wheels as far as they will go

z Perform a visual inspection of the visible surfaces on the left and right
z After turning the front wheels to the other steering stop, check the other half of each rubber dust boot.
Drive shafts: visual inspection of the boots
Drive shafts: visual inspection of boots

– Perform a visual inspection of the boots for leaks and damage.
as of MY 2004
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03 Trailer hitch maintenance: checking operation - as of MY 2004

- Checking operation of the trailer hitch socket
- Checking electrically retractable trailer hitch (AHK)
Information - trailer hitch maintenance: check operation
Note
z To perform this check, a trailer with no faults in the wiring and lights,
or a trailer test cable VAS 1537 A is required.
z Please note that, if a VAS 1537 A trailer test cable is used, only
vehicles with a 13-pin plug can be checked.
z The test cable can be attached to 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. Test cable VAS 1537 A:
Item Designation Source Explanation

Socket tester V.A.G. 1537 A → "See Workshop
Equipment Manual,
Chapter 3.0"
Checking operation of the trailer hitch socket
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.
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Test procedure
Note
z The LED for permanent positive -9- is lit for the entire duration of the test.
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Illustration showing the marking on the test equipment, direction indicator light, stop light + with designation 1 - 13
at top and A - D below
1. Switch on the ignition and switch through the following loads in turn:
Switch on left -1- or right direction indicator -4- : the direction indicator and direction indicator pilot light for the
trailer in the instrument cluster light up. Press the relevant key -B- for left or -C- right: during flashing, the LEDs -1-
or -4- and the direction indicator in the instrument cluster should not now light up.
2. Actuate brake pedal - LEDs -6- should light up.
3. Switch on parking light - LEDs -5, 7- should light up.
4. Switch on parking light and rear fog light. Switch on parking 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 back-up light on the vehicle must light up.
General:
-10- Charge positive
-11- Ground for charge positive
-12- Trailer detection
-13- Depending on the load (heat build-up) in the test equipment (the more LEDs that are lit up), the tester will
switch off and this is indicated by this LED lighting up. Disconnect the test equipment and let it cool for at least 20
minutes.
Checking electrically retractable trailer hitch (AHK)

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Checking electrically retractable trailer hitch
Note
z 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.
z 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 hitch ball.
z Make sure that no persons, animals or obstacles are in the movement range of the hitch ball.
z To interrupt the swivel action of the hitch ball in the event of danger, touch the rocker switch again.
→ Never swivel the hitch ball when a trailer is coupled or when, for example, bicycle racks are mounted or
supported on the hitch ball.
→ Only use the trailer coupling when the hitch ball is extended fully.
→ Never insert tools of any kind into the hitch ball swivel mechanism. This could damage the locking
mechanism; safe operation of the trailer hitch can then no longer be assured.
→ Check that the hitch ball locks into position correctly before every journey.
Overload protection
Note
z The vehicle must be stationary.
z Rear lid or rear window must be open.
z Trailer must be unhitched.
z Connectors (and any adapters) must be removed from the socket.
z There must not be any accessories on the hitch ball (e.g. ball protection cap, bicycle rack, etc.).
1. Swivelling out the trailer coupling

1.1. Requirements:
Note
1.2.
1.3. To swivel out:

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1.4. Touch rocker switch -A- .
1.5. >> The hitch ball moves automatically into operating position.
1.6. The red LED in the rocker switch flashes until the operating position is reached.
2. Retracting the trailer hitch
2.1. Requirements:
Note
z Trailer must be unhitched.
z Connectors (and any adapters) must be removed from the socket.
z There must not be any accessories on the hitch ball (e.g. ball protection cap, bicycle rack, etc.).
2.2.
2.3. To retract:
2.4. Touch rocker switch -A- .
2.5. >> The hitch ball moves automatically into operating position.
2.6. The red LED in the rocker switch flashes until the operating position is reached.
as of MY 2004
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03 Running gear maintenance: checking the brake fluid level and

changing the brake fluid - as of MY 2004
- Checking brake fluid level
- Changing the brake fluid
Checking brake fluid level
Note
z The brake fluid level must not exceed the MAX mark.
z Observe brake fluid quality. Use only new DOT 4 brake fluid.
z This brake fluid is available under the following part numbers:

container quantity 1 litre = 000.043.203.66; container quantity 30
litres = 000.043.203.67.
Visually inspect brake fluid level. The brake fluid level must be between
the MAX and MIN markings. The brake fluid reservoir is located under the
left plenum panel cover -arrow- .
Changing the brake fluid

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Note
z The brake fluid change interval is two years using Super DOT 4 brake fluid.
z This brake fluid is available under the following part numbers: container quantity 1 litre = 000.043.203.66;
container quantity 30 litres = 000.043.203.67.
z Drain brake fluid from every brake caliper at both bleeder valves.
z Bleed the outer bleeder valve first.
1. Open threaded cover of brake fluid reservoir -arrow- .
2. Connect a bleeding device to the brake fluid reservoir.
3. Switch on the bleeding device. Bleeding pressure is approx. 2.0 bar.
4. Continue changing the brake fluid at the brake callipers. Do so in the

following sequence: rear right/rear left/front left/front right.
5. Open every bleeder valve until clear, bubble-free brake fluid emerges
and until the corresponding change quantity per brake caliper is
reached (approx. 250 cm3).
6. Use a transparent hose and a collecting bottle to check the escaping brake fluid accurately for cleanliness,
freedom from air bubbles and to determine the brake fluid used.
7. Tighten the bleeder valves to the specified tightening torque and remove the bleeder hoses → 47 Tightening
torques for brake hydraulic system.
8. Switch off bleeding device and remove the adapter on the brake fluid
reservoir. The brake fluid level in the brake fluid reservoir must be
between the MIN and MAX markings once the vehicle has been filled
and bled. Adjust the brake fluid level if necessary.
as of MY 2004
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03 IN Additional maintenance - as of MY 2003

- Additional maintenance
Additional maintenance
Maintenance every 2 years
Note
Maintenance every 2 years OK

Change brake fluid (use only original Porsche brake fluid) → 470855 Changing brake fluid
Prepare status report - long-life guarantee
Form WKD 444 010 02 Germany
Form WKD 444 020 02 English
Form WKD 444 021 02 US English
Form WKD 444 030 02 French
Form WKD 444 031 02 French-Canadian
Form WKD 444 040 02 Italian
Form WKD 444 050 02 Spanish
Form WKD 444 091 02 Dutch
Maintenance every 4 years
Note
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Maintenance every 4 years OK

Replace tyre sealant
Maintenance after 4 then every 2 years
Note
Maintenance after 4 then every 2 years OK

Check tyre pressure monitoring system battery → Wheel electronics: reading out battery service
life [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Wheel electronics: reading out battery service
life [9PAAJ1]
Maintenance after 10 then every 2 years
Note
Maintenance after 10 then every 2 years OK

Inspect airbag system (see Major maintenance) → Occupant protection maintenance: inspecting
airbag system
as of MY 2003
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03 Checking wheel mounting - as of MY 2004
Checking wheel mounting
Note
Use a suitable commercially available tool (wrench size 19 mm) together with a tested torque wrench, cover a
range of 30-150 ftlb. Never use an impact bolter.
– Do not undo the wheel bolts to check whether they are secure.
– Re-tighten the wheel bolts and check they fit securely. → Tightening torque: 118 ftlb.
as of MY 2004
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03 Cardan shaft maintenance - as of MY 2004

- Visual inspection of rollers (front cardan shaft)
- Visual inspection of centre bearing (rear cardan shaft)
Note
z The air bellows of the cardan shafts may be damaged by external influences e.g. during off-road use or
similar operation.
z Consequence: loss of a large amount of grease, ingress of dirt into the universal joint.
z Premature replacement of the cardan shaft may be necessary.
1. Maintenance of cardan shafts
Visual inspection of rollers (front cardan shaft)

1. Remove engine guard → 108019 Removing and installing engine guard - chapter on "Removing".
2. Inspect air bellows of front cardan shaft for damage. To do this, rotate the cardan shaft in steps through
180°.
3. Install engine guard → 108019 Removing and installing engine guard - chapter on "Installing".
Visual inspection of centre bearing (rear cardan shaft)

1. Inspect air bellows of centre bearing for damage. To do this, rotate the cardan shaft in steps through 180°.
as of MY 2004
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03 Running gear maintenance: Tyres and spare wheel: checking

condition and tyre pressure - as of MY 2004
- Checking condition
- Cold tyre pressures (at approx. 20° C)
Checking condition
Checking condition
Tyres 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 accident if the air pressure in the tyres 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).
z Modified handling behaviour 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.
→ A visual inspection of the tyres (for cracks, pricks, bulges in the sidewall and/or foreign bodies) must be
carried out.
Note
z For vehicles with a tyre pressure monitoring system, which can be
identified by aluminium valves, the tyre pressure should be adjusted
according to the filling information in the multi-function display. To do
this, in the >> Main menu >> Tyre pressure >>
-Settings- << adjust the deviation values so that they are from
0.0 bar to +0.1 bar. Fill the tyres according to the display using the
tyre-inflating device. Example: If the tyre-pressure display shows
>> Settings << - 0.2 bar, then 0.2 bar must be added.
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z Due to the pressure and temperature relationship (0.1 bar/10° C), the
actual pressures displayed in the -Basic tyre pressure screen- in
the multifunction display, or on the pressure gauge of the tyre-
inflating device, may deviate from the required pressure specification
at 20° C on the tyre pressure plate. This is particularly the case if the
tyre air temperature is significantly above (higher values) or
significantly below (lower values) 20° C. Changes in the tyre pressure
are displayed for up to 1 minute in the >> Settings <<.
z For vehicles with the tyre pressure monitoring system, always use
plastic valve caps. They protect the valve from dust, dirt, and
moisture and therefore from damage (corrosion, etc.).
1. Check condition and tyre pressure.
Valve caps protect the valve from dust and dirt and therefore from damage.
2. Always screw on valve caps tightly and replace missing valve caps.
Cold tyre pressures (at approx. 20° C)
Cold tyre pressures (at approx. 20° C)
Tyre pressures apply to all-season, all-terrain, summer and winter tyres. They also apply only to tyres approved
by Porsche.
Partial load: The tyre pressure is specified for a load of up to 3 people + 21 kg of luggage.
The collapsible spare wheel, or alternatively the spare wheel, is an option (standard: tyre sealant)
The spare wheel on the carrier is inflated to 3.4 bar gauge pressure max. During operation, tyres are to be
adjusted to the gauge pressure specified for the particular vehicle axle and load condition.
Tyre pressure - vehicle partially loaded
Values in bar gauge
Partial load Cayenne Cayenne S Cayenne

17/18/19/20-inch 18/19/20- Turbo
inch 18/19/20-
inch
Front axle 2.6 bar 2.6 bar 2.6 bar
Rear axle 2.9 bar 2.9 bar 2.9 bar
Collapsible spare wheel, 3.5 bar
17/18-inch front/rear
Tyre pressure - vehicle fully loaded
Values in bar gauge

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Full load Cayenne Cayenne S Cayenne

17/18/19/20-inch 18/19/20- Turbo
inch 18/19/20-
inch
Front axle 2.6 bar 2.6 bar 2.6 bar
Rear axle 3.4 bar 3.4 bar 3.4 bar
Collapsible spare wheel, 3.5 bar
17/18-inch front/rear
as of MY 2004
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03 Wheel electronics: reading out battery service life - as of MY

2004
Wheel electronics: reading out battery service life
The remaining service life of the wheel electronics can be read out with the Porsche System Tester. Before
scheduled maintenance and/or changing a tyre, it is recommended to read out the remaining service life of the
wheel electronics (due to battery capacity). It is always advisable to replace the wheel electronics if the expected
remaining service life of the wheel electronics is shorter than that of the tyre. The battery for the wheel electronics
cannot be replaced separately.
1. Connect the -Porsche System Tester- . Read out the respective

battery service life of the wheel electronics, FL, FR, RL, RR in
months in the menu >> RDK >> Actual values >>
Battery service life <<.
2. If necessary, replace the -wheel electronics A- → 443219

Removing and installing wheel electronics.

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as of MY 2004
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03 Running gear maintenance: visual inspection - brake

lines/brake pads/brake discs - as of MY 2004
- Brake hoses and lines
- Brake system: visual inspection of the brake pads and brake discs for wear
- Technical data, wear limits
Brake hoses and lines
Brake hoses and lines

– Carry out visual inspection for leaks, damage, routing and corrosion.
Brake system: visual inspection of the brake pads and brake discs for wear
Brake system: visual inspection of brake pads and brake discs for wear
WARNING
Risk of accident if brake pads and brake discs are not replaced in time.
z 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.
Note
z If brake pad wear is indicated by the warning light, the warning contact (sender including line and plug
connection) must also be replaced.
z Replacement of the warning contact can be avoided by replacing the brake pads no later than when the pad
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thickness is approx. 2.5 mm -arrows- .
z Warning contacts must be replaced if the core of the line is worn.
z However, if only the plastic part of the warning contact is worn, there
is no need to replace it.
1. To check the brake pads, remove the wheels.
2. Visually inspect the brake pads for wear. → 03 TW Maintenance of

running gear: visual inspection - brake lines/brake pads/brake discs -
chapter on "Technical values"
3. Carry out visual inspection of the brake discs for wear → 03

TW Maintenance of running gear: visual inspection - brake
lines/brake pads/brake discs - chapter on "Technical values"
Technical data, wear limits
Technical data, wear limits
Designation Note, dimensions Wear limit

Pad thickness front approx. 10.5 mm 2 mm
rear approx. 11.5 mm 2 mm
Brake disc thickness, new front 34 mm 2 mm
rear 28 mm 2 mm
as of MY 2004
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03 Running gear maintenance: steering gear - fluid level and

bellows - as of MY 2004
- Checking
Checking
Power steering: Checking fluid level
ATTENTION
Increased risk of accident and material damage if too much Pentosin CHF 11 S is filled in or if Pentosin
CHF 11 S comes into contact with the coolant hoses when filling or topping up.
z Overfilling of the system with consequent overflow of Pentosin CHF 11 S onto coolant hoses and
other components may occur.
→ Before inspecting the fluid level, run the engine for approx. 20 seconds. Multiple steering operations
(manoeuvring) will alter the fluid level in the reservoir! Check the fluid level.
→ If coolant hoses come into contact with Pentosin, thoroughly clean them with water IMMEDIATELY.
→ Replace visibly swollen coolant hoses.
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 on turning the steering to full lock or foam formation in the reservoir indicate a shortage of oil
and/or the absorption of air. Before filling the reservoir, any existing leaks must be eliminated . In this case the oil
level in the reservoir 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, then there is air in the hydraulic system. The system must then be bled
→ 48 Test and assembly work on power steering.
The reservoir is located in the engine compartment, front left under the engine compartment cover -arrow- .
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
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level with a cold engine (approx. 20

°C)!
Note
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

Dipstick and power-steering reservoir Power-steering reservoir (engine
the lid of the engine
compartment, left plenum panel)
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.
Checking bellows on steering gear
Note
z The bellows on the steering gear can be damaged by outside influences, for example by stone damage or
during assembly work.
z The steering gear can start to leak if dirt or moisture enters a leaky bellows.
– Visually inspect the bellows for damage.
as of MY 2004
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
03 Checking seat belts - as of MY 2004

- Checking condition
Checking operation
Functional Check
Note
z The following requirements must be met when fitting the seat belt
z If one of the requirements listed below is not met, the seat belt or the buckle must be replaced.
It must be possible to unroll the belt strap smoothly from the belt retractor via the deflector fitting by pulling evenly.
The tongue of the seat belt must engage audibly in the buckle.
An abrupt pull on the belt strap must lock the belt retractor.
Checking condition
Condition inspection
Visually inspect the belt strap for damage by unrolling it completely.
If it displays evidence of damage in the form of cuts, fraying, seam tears etc., the seat belt must be replaced.
as of MY 2004
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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03 Running gear maintenance: running gear adjustment/storage

of assemblies - as of MY 2004
- Running gear adjustment (wheel alignment values)
- Storage of assemblies and running gear
Running gear adjustment (wheel alignment values)
Running gear adjustment (wheel alignment values)

– Check that the screw connections of the running gear adjustment facility (wheel alignment values) at front
and rear are secure.
Storage of assemblies and running gear
Storage of assemblies and running gear

– Visual inspection of all rubber mountings for damage.
as of MY 2004
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
03 Running gear maintenance: checking free play of foot-operated

parking brake - as of MY 2004
- Foot-operated parking brake: checking free play
- Adjusting the foot-operated parking brake
Tools

piston resetting fixture commercially NR.144
(replaces P83) available tool
Foot-operated parking brake: checking free play
Foot-operated parking brake: Checking free play
The foot-operated parking brake, hereafter referred to as the FPB, is equipped with asbestos-free brake pads.
The FPB pedal module is located on the left in the driver's footwell.
Note
z An FPB that is equipped with asbestos-free brake pads must never be adjusted in such a way that the pad
has to grind free during operation!
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z Adjustment must only be done at the two adjustment devices on the rear wheels. Do not make adjustments
at the pedal module or at the Z deflector on the centre console.
z Ensure that the FPB cables are routed correctly.
Check free play at the pedal module:
To do this, measure from the left seat rail up to the lower edge of the pedal plate of the FPB.
2. Depress pedal 40 mm (+ 5 mm). When this dimension is reached, the wheels must be able to turn without
grinding the brake pads.
3. Depress pedal 75 mm (+ 5 mm). When this dimension is reached, the wheels must be fixed. If the wheels
can still turn, the FPB must be adjusted!
Adjusting the foot-operated parking brake
The rear wheels must be removed to gain access to the adjustment device → 440519 Removing and installing
wheel - chapter on "removing".
In the event of unfavourable tolerances, the brake pads may prevent the
brake disc from turning freely. If this happens, the brake pads must be
(evenly) pressed back a little with the piston resetting fixture (replaces
P83) NR.144, see Workshop Equipment Manual, Chapter 2.4
-direction arrow- !
1. Release the FPB pedal so that the wheels and brake discs can turn
freely.
The wheels may still grind slightly even then! If this happens, loosen the
rear brake cables by moving them to and fro gently!
2. Remove rear wheels → 440519 Removing and installing wheel -

chapter on "removing".
3. Adjust the brake shoes (on both wheels). To do this, unscrew the
plug -arrow- and turn the brake disc with the opening towards the
adjustment device position. Using a screwdriver, adjust the
adjustment device until the wheel can no longer be turned. Then
unscrew by 6 teeth (wheels must be free to turn).
4. Check the free play on the pedal module once again.
5. Position disc brake pads by operating the brake several times.

6. Fit rear wheels → 440519 Removing and installing wheels - chapter
on "installing" .
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as of MY 2004
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
03 01 Windscreen washer/headlight cleaning system: Checking

operation, nozzle settings - as of MY 2003
- Windscreen washer/headlight washer system: Checking operation and nozzle settings
- Adjusting spray nozzles
- Information
Windscreen washer/headlight washer system: Checking operation and nozzle

settings
Checking headlight washer
ATTENTION
Danger of material damage if headlights are cleaned incorrectly!
→ 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 cloths, paper towels or insect-removal sponges that are dry or just
damp!
Note
z The headlight washer nozzles are pre-set!
z Generally, it is not necessary to adjust them!
– Check function, fluid levels and nozzle settings.
Adjusting spray nozzles

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Note
z The angle of the spray nozzle can be adjusted by hand.
z The recommended spraying range is in the central position.
z Sharp objects must not be placed in the nozzle bore as there is a risk of damaging the spray nozzle!
The bonnet must be closed.
-arrow- Spray nozzle adjustment.
Information
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
as of MY 2003
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AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
03 01 Battery maintenance: checking condition of battery and

battery vent hose - as of MY 2003
- Preliminary work
- Checking condition of battery and battery vent hose
Preliminary work
Preliminary work - Battery maintenance: Checking condition of battery and battery vent hose
Switch off all loads and remove ignition key.
Observe the warning notes and safety regulations for hydrocyanic acid batteries.
1. Move backrest all the way forward. Move front seat all the way up and all the way forward.
2. Release the covers -arrows A- and remove rear seat rail cover caps
-arrows B- .
3. Move front left seat back and up as far as possible. Move backrest
fully forward.
4. Unclip the front seat trim forwards -A- .
5. Fold the carpet sections forward and unscrew both fastening screws -1- .
6. Fold the seat back as far as possible. With the seat in its folded position, move the seat forward again using
the fore-and-aft adjustment.
7. Open the four tension hooks on the battery case cover using a screwdriver.
8. Remove the battery case cover with ventilation channel.
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Cut-out relay
Checking condition of battery and battery vent hose
Check maintenance-free battery
Note
z The maintenance-free battery has an inspection glass.
z The charge state and acid level of the battery can be checked through
the inspection glass -B- .
z If a battery is more than 5 years old and the indicator of the inspection
glass is colourless, replace the battery.
Vent hose A + connections and

inspection glass B
z If the battery has been charged, air bubbles can form under the
inspection glass. Before carrying out a visual inspection, tap carefully
on the inspection glass with something like the handle of a
screwdriver.
Three different colour indications are possible:
Maintenance-free battery
Colour indication Charge state
Green The battery is charged sufficiently.
Black The battery is not charged or the charge is too low.
Colourless or yellow Critical acid level.
=> Replace battery.
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Check low-maintenance battery
WARNING
Improper handling of batteries.
z Risk of injury and damage to the environment
→ The accident prevention regulations must be strictly observed when handling battery acids.
→ Wear suitable protective clothing and protective glasses.
→ Only use a torch to illuminate the inside of the battery. Never illuminate the inside of the battery with a naked
flame.
→ Do not handle a naked flame or lighted cigarettes near batteries.
→ Observe the disposal regulations for batteries and sulphuric acid when disposing of batteries.
Note
z Use a commercially available battery filling bottle.
z The correct acid level of the battery is an important factor for a long service life of the battery.
z When the acid level is too low, a capacity loss (performance loss) of the battery occurs, which is caused by
the cell plates drying out. If the cell plates are not surrounded by electrolyte (battery acid), it will lead to
corrosion of the lead plates, the plate bridges and the cell connectors. The result of the corrosion is that
battery functioning cannot be guaranteed. The battery will become useless.
z If the acid level is too high, damage can occur by the battery acid (sulphuric acid/water mixture) leaking out of
the battery.
1. Unscrew battery plugs.
2. Shine a torch into the battery. The electrolyte level of the battery must be at the protruding " lug" .
2.1. If the acid level is too low, refill with distilled water using the battery filling bottle.
3. Screw in battery plugs again and ensure that they are seated correctly.
Checking battery vent hose
Note
z Make sure the vent hose -A- is not kinked or damaged. If in doubt, replace it.
z Vent hose -A- must be inserted in the battery and in the battery box.
Checking battery vent hose under the driver's seat

1. Replace the battery box cover carefully. The ventilation channel must be mounted properly.
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Central venting
2. Attach the four tension hooks in the battery case cover and close using the screwdriver.
ATTENTION
Risk of material damage to screw connections for seat and seat frame!
→ The fastening screws for seat and seat frame are coated and must be replaced after being unscrewed.
→ Before screwing in the new fastening screws, clean the thread holes with an M10 x 1.5 tap!
3. Move the seat in its folded position towards the rear and then tip forward.
4. Screw in fastening screws -1- and put back the carpet sections. →
Tightening torque: 33 ftlb.
5. Clip in front seat trim -C- .
Battery
6. Push rear cover caps onto seat rails -arrows A- and press down the covers -arrows B- until these engage
audibly.
Checking battery vent hose of the auxiliary battery
Note
z The battery is located in the luggage compartment under the loadspace floor.
z If the vehicle contains a subwoofer or collapsible spare wheel, the relevant component must be removed
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before the auxiliary battery is removed.
1. Remove collapsible spare wheel:
1.1. Remove twist grip -A- and position it on the bolt -B- .
1.2. Unscrew the bolt and remove it together with the collapsible spare
wheel.
2. Removing subwoofer fastening:
2.1. Remove tyre sealant -1- if it is present.
2.2. Unscrew both fastening screws -2- .
2.3. Unscrew the fastening screw -3- .
3. Disconnect electrical plug connection and remove subwoofer:
3.1. Remove plug connection from retaining bracket on the subwoofer

and disconnect the plug connection.
3.2. Lift subwoofer up and out.
4. Remove battery case cover:

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4.1. Unscrew the four fastening nuts -A- .
4.2. Unclip the four fastening clips -B- with a screwdriver.
4.3. Remove the cover for the housing by pulling it up.
4.4. Check vent hose.
5. Position battery case cover and screw it on:
5.1. Put on the battery case cover, position it and clip in the four
fastening clips -A- onto the cover.
5.2. Push the restraining straps across the four fastening bolts on the
body floor and screw on the four fastening nuts -B- . → tightening
torque: 4.5 ftlb.
6. Installing subwoofer:
6.1. Position the subwoofer over the battery case.
6.2. Push the electrical plug connections together until the plug is felt to
engage.
6.3. Position electrical plug connection on subwoofer.
7. Fastening subwoofer:
Note
z If the vehicle contains a subwoofer or collapsible spare wheel the
relevant component must be re-installed.
7.1.
7.2. Insert fastening screw -3- with washer and tighten. → tightening
torque: 3.5 ftlb.
7.3. Position both tightening nuts -2- and tighten them. → tightening torque: 1.5 ftlb.
7.4. If present, place tyre sealant -1- in tray.
8. Install collapsible spare wheel:
Note
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8.1.
8.2. Insert collapsible spare wheel.
8.3. Screw in screw B -B- .
8.4. Position twist grip -A- and tighten fastening screw -B- hand tight.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
10 01 19 Removing and installing V8 4.5 l engine - as of MY 2003

- Tools and materials
- Preliminary work
- Removing V8 4.5 l engine
- Installing V8 4.5 l engine
- Subsequent work
Tools

Suspending device special tool 3033
Porsche System Tester ll special tool 9588
Filling device special tool 9696

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Transport eyebolt special tool 9700
Circlip pliers for spring band commercially NR.72-1

clamps, Cayenne hose available tool
connections
Flexible screwdriver a/f 7 commercially NR.73-1

available tool
Tools and materials
Required tools
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The following tools are described in the Workshop Equipment Manual, Chapter 3.0.13 "WE 1206" (exceptions are
noted).
Lifting platform

-A- Assembly mandrel Height can be adjusted; used for
mounting in the engine cross member;
equipped with a locking screw to
prevent engine from tipping.
-B- Wheel hub holder Secures the axles against falling out
-C- Assembly mandrel 1/11 Height can be adjusted; for mounting at
the front of the front-axle carrier.
-D- Oil pan support Secures the engine against tipping
after the transmission has been
disconnected. Do not mount at the
beginning of removal
-E- Steering knuckle bracket In conjunction with -B- it protects the
axles and spring struts from damage.
-F- Assembly mandrel For mounting on the rear front-axle
carrier
-G- Assembly mandrel Positioning guide of the elevating
platform into the body
-H- Assembly mandrel For mounting on the transmission
cross member
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Tools overview

-A- Oil pan support Prevents the engine tipping backwards.
The support is mounted in the direction
of travel towards the rear.
-B- Wheel hub support Prevents the spring struts from tipping
to the side, thereby damaging the
axles.
-1/11- Front mounting on front-axle Mounted on the base carrier at position
carrier 1.
-1a- Mounting with height adjustment Screwed into part 1/11.
-2- Lateral mounting mandrel for
engine carrier
-2a- Mounting with height adjustment Screwed into part 2.
-2b- Protection against tipping Screwed into part 2a. Prevents the
engine from tipping forward.
-3- Rear front-axle carrier mounting Mounted on the base carrier at position
3.
-4- Mounting in body Mounted on the base carrier at position
4.
-5- Mounting for transmission cross Mounted on the base carrier at position
member 5
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Tools overview

-A- Suspending device 3033 See Workshop Equipment
Manual 2.2.3
-B- Transport eyebolt 9700 See Workshop Equipment
Manual 2.2.2
-C- Flexible screwdriver a/f 7 See Workshop Equipment
NR.73-1 Manual 2.4
-D- Antifreeze testing device See Workshop Equipment Combined tool for testing antifreeze
Manual, Chapter 3.0.6 "WE and electrolytes
1036"
-E- Circlip pliers for spring band See Workshop Equipment
clamps, Cayenne hose Manual 2.4
connections NR.72-1
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-F- Filling device 9696 See Workshop Equipment Used for vacuum filling of the cooling
Manual 2.2.2 system
-G- Porsche System Tester ll 9588 See Workshop Equipment
Manual 2.2.2
-H- Lifting platform Can be found in Workshop
Equipment Manual, 3.0.13
"WE 1206"
Preliminary work
Preliminary work
Special equipment-specific features are described in the notes.
z If the engine is to be replaced by a new one, make sure the air conditioner is evacuated and the existing air-
conditioning compressor removed during removal of the engine as the replacement engine is delivered with
the new compressor mounted. → 873419 Removing and installing air-conditioning compressor - chapter on
"Removing"
z Fix steering wheel with wheels in straight-ahead position (engage steering column lock or clamp steering
wheel in centre position with steering wheel holder)! If this is not done, the airbag contact unit will have to be
put in centre position after installation of the steering gear! → 945019 Removing and reinstalling steering-
column switch
z Position the vehicle at the take-up points provided on a lifting platform. → Lifting the vehicle [9PAAE1
9PAAE7 9PAAF1]→ Lifting the vehicle [9PAAJ1]
z Put on the protective covers.
z Produce the OBD II log.
z Move the Tiptronic's selector lever to position N.
z Remove ignition key.
z Disconnect battery . → Work instructions after disconnecting the battery
z Remove front wheels. → 440519 Removing and reinstalling wheel - chapter on "Removing"
z Remove the front wheel-housing liners. → 505619 Removing and reinstalling front wheel-housing liner -
chapter on "Removing"
z Remove engine compartment covers. → 700219 Removing and reinstalling front cover (engine compartment)
- chapter on "Removing"
z Allow engine to cool down.
Removing V8 4.5 l engine
Removing engine
Special features that are required for the equipment or relate to the Cayenne Turbo (M48/50) are described
in the notes.
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V8 engine
1. Remove engine guard with transverse strut. → 108019 Removing and installing engine guard - chapter on
"Removing"
2. Drain coolant → 193817 Draining and filling coolant (includes

bleeding).
3. Remove both wiper arms → 922519 Removing and installing wiper
arm - chapter on "Removing".
Note
z The air quality sensor is located on the cover of the radiator tank. This
must be unclipped.
Coolant drain plug

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4. Loosen the 4 bayonet screws -A- on the plenum panel cover. Then lift
the cover in the middle, release left and right and remove from the
vehicle.
Plenum chamber cover

5. Disconnect the engine wire harness on the right-hand side of the
vehicle. To do this, unplug the control unit and disconnect the ground
point.
Engine wire harness

6. Open the cover of the central electrical system on the left side of the
vehicle. To do this, loosen the four Torx screws.
7. Disconnect the connectors from the engine wire harness (white, red,
black and brown). Remove the wiring harness from the retaining clips
and lay it down on the engine.
Torx screws for cover of central

electrical system
8. Disconnect B+ transfer point at the left of the engine compartment.
B+ transfer point
9. Pull the cover of the throttle body up and off.
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Throttle adjuster electric connection Throttle body cover

10. Separate the electric connection from the throttle adjuster. To do this, press on the plug at the top and bottom
and, at the same time, pull it off. Unclip the cable from the sheetmetal holder.
Fastening bolts on the throttle body
Note
z In the Cayenne Turbo (M48/50), the boost pressure sensor must also
be disconnected.
11. Release the fastening bolts on the throttle body. To do this, twist both
bolts through 45° in an anti-clockwise direction. The dot on the bolt
must appear as illustrated in the figure.
Boost-pressure sensor
12. Remove the fastening bolts. To do this, take hold of the bolt by the
rubber ring with pliers and pull it out.
13. Pull off the Y-shaped pipe from the throttle body.
Pull out fastening bolt with pliers

14. Disconnect the mass air flow connections. To do this, loosen the hose clamps to the left and right on the
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Mass air flow connections

bellows and pull the bellows off the mass air flow (in the Cayenne Turbo, pull them off the pressure pipes).
Note
z If the engine is to be subsequently transported by crane, the right-hand design cover on cylinder row 5 - 8
should be removed at this point. → 108319 Removing and installing engine cover - chapter on "Removing"
z To do this, loosen the 4 fastening screws. Unclip the design cover from
the intake system and slide out at an angle towards the front.
Design cover of cylinder row 5 - 8

15. Loosen the clamps on the air cleaner housing.
Air cleaner housing clamps
Note
z In vehicles with air suspension, the suction line of the compressor must also be removed on the right air
cleaner cover. To do this, unclip the green cap, press circlip -1- inwards and pull off adapter -2- .
16. Remove the air cleaner covers on the right and left. → 242519 Removing and installing air cleaner housing -
chapter on "Removing" [9PAAF1 9PAAJ1]→ 242519 Removing and installing air cleaner housing - chapter
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Air cleaner cover Circlip and adapter

on "Removing" [9PAAE1 9PAAE7]
17. Remove the filter elements.
Filter elements
18. Disconnect the 2 respective oxygen sensor connectors (brown, black)
at the left and right of the water splash panel and unclip the cable from
the supports.
Oxygen sensor connector
Note
z In the Cayenne Turbo (M48/50), the support for the vacuum pump
must also be undone. To do this, unscrew the two fastening screws
and press the pump forward slightly.
Fastening screws for vacuum pump

19. Disconnect the 2 coolant lines and vacuum line on the right side of the engine compartment.
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WARNING
Servo oil is aggressive!
z Possible danger of injury or damage (swollen hoses, skin
irritation, danger of slipping, etc.)
→ Before lines are opened, place a cloth underneath them!

→ Components that come into contact with servo oil must be cleaned
IMMEDIATELY with water!
→ Take suitable protective measures (e.g. gloves, safety goggles, oil
binding material) Coolant lines and vacuum line
20. Empty the servo oil reservoir with a syringe. Next, remove the hose
from the reservoir. Close the open connections with plugs.
Servo oil reservoir

21. Loosen the torque support. To do this, remove the screw on the
engine and loosen the screw on the body. Then pivot up the torque
support.
Torque converter support
DANGER
Fuel can escape when fuel line is disconnected.
z Risk of fatal injury!
z Damage to skin
→ Do not work on fuel system if engine is hot!

→ Do not smoke, avoid fire and naked flames!
→ Wear fuel-resistant protective gloves and goggles.
→ Attach warning sign to vehicle in a clearly visible position.
Fuel line and carbon canister line
22. Disconnect fuel line -1- and line -2- from the carbon canister on the plenum panel splash panel.
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Fastening screws for spring struts

23. Loosen the 3 fastening screws on the left and right spring struts. The screws are loosened from inside the
engine compartment. Of the 3 screws per spring strut, one is in the plenum panel. Replace screws.
24. Disconnect the coolant feed and return lines from the radiator. To do
this, pull out the securing clip and pull off the connection. The clips
should be mounted again immediately so that they are not confused.
Note
z The drive belt must be slackened so that the air-conditioning
compressor can be removed later.
z If at all possible, the air-conditioning system should not be opened.
z If the engine is to be replaced by a new one, make sure the air

conditioner is evacuated and the existing air-conditioning compressor Securing clip on connection for coolant
removed during removal of the engine as the replacement engine is feed and return lines
delivered with the new compressor mounted. → 873419 Removing and installing air-conditioning compressor -
25. Slacken the drive belt (a/f 30) and remove from the tensioning roller.
Drive belt tensioning pulley
Note
z In the Cayenne Turbo (M48/50), the control lines of the ambient air valves on the T-piece should be pulled off.
Note
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z In the case of vehicles with air

suspension, the compressed
air line on the spring strut must
also be disconnected. Loosen
the line carefully and allow the
remaining pressure to escape.
Loosen the threaded joint
completely only when the line is
fully depressurised.
Compressed air line on spring strut Control lines of the ambient air valves
z The electric plug connection of the height sensor must be
disconnected in vehicles with air suspension or automatic headlight
levelling system.
Electric plug connection for height

sensor
26. Disconnect electric plug -1- on the spring struts in the wheel housing.
Then unclip the support -2 and 3- . Tie the cable on the spring strut.
Electric plug on the spring struts in the

wheel housing
27. Disconnect the brake lines in the wheel well to the left and right.
28. Disconnect the ground point on the right side member.
WARNING
ATF!
z Possible danger of injury or damage (swollen hoses, skin irritation, danger of slipping, etc.)
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→ Before lines are opened, place

a cloth underneath them!
→ Components that come into
contact with ATF must be
cleaned IMMEDIATELY with
water!
→ Take suitable protective
measures (e.g. gloves, safety
goggles, oil binding material)
→ Collect emerging ATF!
Ground point of right side member Brake lines in the wheel housing
29. Disconnect the ATF lines on the cooler. To do this, loosen the
fastening screw and pull off the line. Seal open lines with a plug.
ATF lines on cooler

30. Remove the heat protection shield on the steering gear connection.
To do this, loosen the 2 fastening screws.
Note
z In the case of vehicles with Servotronic, an electric plug must also be
removed from the steering gear.
Heat protection shield on steering gear

connection
31. Loosen the clamping screw from the steering column on the steering
gear and remove it. The screw must not be re-used. Force the
steering column up and off the steering gear.
32. Disconnect the electric plug on the steering gear (Servotronic only).
Clamping screw on steering column

33. Disconnect the heat exchanger coolant lines in the left wheel housing below. Approx. 2 litres of coolant will
flow out when you do this.
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Heat exchanger coolant lines in the left

wheel housing
34. Remove the complete exhaust system from the connection point on the catalytic converter to the tailpipes
→ 260119 Removing and installing exhaust system - chapter on "Removing".
35. Remove rear cardan shaft → 393519 Removing and installing rear cardan shaft [9PAAE1 9PAAE7 9PAAF1]
→ 393519 Removing and installing rear cardan shaft [9PAAJ1].
36. Disconnect electrical connections -1,2 and 3- on the transmission and

unclip the wiring harness.
Electric connections on the

transmission
Connections on transfer box

37. Remove the heat shield on the left transmission side. To do so, loosen the 3 fastening screws and take out
the heat protection shield.
Note
z Do not loosen nut.
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Selector lever cable on the Fastening screws for heat protection

transmission shield
38. Detach the selector lever cable on the transmission. To do this, press the ball socket away from the
transmission. Then pull out top sheetmetal clip -A- and remove the cable in an upward direction.
Note
z If the transmission is to be separated from the engine after removal, the two lower fastening screws on the
transmission housing and front cardan shaft should be removed at this point, since access to the lifting
platform will be impaired.
WARNING

→ Components that come into contact with servo oil must be cleaned IMMEDIATELY with water!
→ Take suitable protective measures (e.g. gloves, safety goggles, oil binding material)
39. Disconnect the lower line on the servo oil cooler.
Lower line on servo oil cooler
Note
z On the Cayenne Turbo (M48/50), the hose connections on the turbochargers must also be loosened. To do
this, pull out locking spring -1- on the turbocharger adapter. Then loosen hose clamp -2- of the pressure pipe
on the turbocharger.
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z Disconnect the connection on

the charge air cooler. To do
this, remove locking clip -1- and
pull off the line. Line -2- of the
ambient air valve must also be
disconnected on the right-hand
side of the vehicle. To do this,
remove the spring band clamp
and pull off the line.
Note
Locking clip and line of ambient air Locking spring on turbocharger
z It is easier to remove the air- valve adapter and hose clamp of
conditioning compressor from
turbocharger pressure pipe
its installation position when the engine has already been lowered a
little.
z The air-conditioning compressor lines must not be kinked or twisted.
z The lines of the air-conditioning compressor remain mounted, so the refrigerant does not need to be
evacuated.
"Removing"
40. Loosen the 3 fastening screws and disconnect the electric plug from
the air-conditioning compressor. Set the air-conditioning compressor
aside.
Fastening screws and electric

connector of air-conditioning
compressor
41. The air-conditioning compressor must be secured with a piece of wire.
Note
z For installation, it is a good idea to mark the installation position of the
front axle carrier diagonally at 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).
Air-conditioning compressor
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Mark installation position of the front-

axle carrier
42. Mark the installation position of the front axle carrier diagonally at at least two places on the body.
Note
z Because of the high loosening torque, the 6 fastening screws on the front-axle carrier can now be loosened.
Loosen the screws by a maximum of one turn.
43. Place the elevating platform under the engine and raise it. When you
do this, ensure that the positioning guides of the elevating platform are
inserted into the body.
Elevating platform
44. Secure the spring struts. 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 elevating platform.
Securing the spring struts

45. Loosen the transmission cross member. To do this, loosen the 4 fastening screws -A- .
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Fastening screws for transmission

cross member
46. Secure the engine/transmission combination. Then secure the mounting mandrels on the engine transverse
bar with locking screws.
47. Loosen the 4 fastening screws on the front-axle carrier and the 2
fastening screws on the engine transverse bar.
Note
When lowering the engine, make sure that cables or lines do not get
mounted accidentally between engine and body. Thus a second person
should make sure that the cables and lines do not get caught.
48. Lower the lifting platform slowly. When this is done, a second person
should ensure that there is sufficient clearance around the engine
compartment and wheel housings.
Fastening screws for front-axle carrier
and fastening screws for engine
transverse bar
Installing V8 4.5 l engine
Installing engine
in the notes.
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Overview of V8 engine
1. Suspend the engine at the jacking points provided on a workshop

crane and set down on the front-axle carrier.
2. Secure the engine against tipping. To do this, attach the locks on the
engine cross member and raise the support under the oil pan until it
touches the oil pan.
3. Fit the transmission onto the engine. → 373527 Removing and

mounting the transmission - section on "Mounting" [9PAAE1 9PAAF1
9PAAJ1]→ 373527 AG Removing and mounting the transmission -
section on "Mounting" [9PAAE7] or → 343527 Removing and
mounting the transmission - section on "Mounting" [9PAAE7]
→ 343527 AG Removing and mounting the transmission - section on
"Mounting" [9PAAE1 9PAAF1 9PAAJ1] Lifting the engine with a workshop
crane
4. Install pre- and main catalytic converters. → 267619 Removing and installing primary catalytic converter -
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section on "Removing" [9PAAE1 9PAAE7]→ 267619 Removing and installing primary catalytic converter -
section on "Removing" [9PAAF1 9PAAJ1]
5. Tighten the fastening screw on the catalytic converter support. →

Tightening torque: 23 (17 ftlb.) Nm
6. Bolt the main catalytic converter supports onto the transmission cross
member. For details see → 267319 Removing and installing (main)
catalytic converter - section on "Installing"
7. Remove the support from under the oil pan and remove the tipping
protection from the engine cross member.
Catalytic converter support

8. Clip the oxygen sensor cable of the rear oxygen sensors into the
supports and place the connector on the engine.
9. Pre-fit the drive belt. Mount the drive belt on the pulleys as far as
possible.
10. Position the lifting platform under the body.
11. Raise the body to a comfortable working height with the platform lift.
Note
z When moving the unit into the body, ensure that the shift cable is on Oxygen sensor cable for the rear
the transmission. oxygen sensors
z When moving the unit into the body, put the air-conditioning compressor into installation position.

conditioner is evacuated before removing the engine and the new air-
conditioning compressor is connected during installation of the engine
as the replacement engine is delivered with the new compressor
mounted. → 873419 Removing and installing air-conditioning
compressor - chapter on "Installing"
Note
z Position the front-axle carrier back in the original, marked installation
position and be careful not to damage adjacent parts.
12. Raise the engine/transmission combination into the body with the lifting platform. Ensure sufficient clearance.
The insertion guides on the lifting platform must fit into the holes in the body.
13. Tighten the 6 new front-axle carrier engine carrier screws. For details, see → 400619 Removing and installing
front axle carrier - section on "Installing" [9PAAJ1]→ 400619 Removing and installing front axle carrier -
section on "Installing" [9PAAE1 9PAAE7 9PAAF1] → Initial tightening: 120 (89 ftlb.) Nm → Final
tightening - torque angle: 180 °
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Fastening screws for front-axle carrier Guiding the engine/transmission

and engine carrier combination into the body with the
lifting platform

cross member
14. Install transmission cross member. For details see → 396519 Removing and installing transfer box - section
on "Installing" -A- .
15. Loosen the lateral supports on the wheel hubs.
16. Lower the lifting platform slowly and remove.
Support of wheel hub

17. Connect electric connector -1, 2 and 3- on the transmission and clip in
the wiring harness.
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18. Mount selector lever cable. For Connector to transmission

details see → 371519
Removing and installing
selector lever cable - section
on "Installing" [9PAAE1
9PAAF1 9PAAJ1]→ 371519
23 Removing and installing
selector lever cable - section
on "Installing" [9PAAE7].
Connector to transfer box
Note
z In the Cayenne Turbo (M48/50), the hose connections on the
turbochargers must also be fastened. To do this, connect pressure
pipe -2- and tighten the hose clamp. Then fit the lead of the charge air
cooler. The connection piece must engage audibly. Ensure that
sheetmetal clip -1- is fitted correctly.
Hose clamp and sheetmetal clip

z Connect the hose line on the left charge air cooler. Ensure that locking
clip -1- is mounted correctly. Then connect the line to the ambient air
valve -2- and fit the spring-band clamp.
Locking clip and line to ambient air

valve
19. Push the servo oil line onto the oil cooler and mount the spring band
clamp.
Note
z For vehicles with Servotronic, the electric connector on the steering
gear must also be connected.
Spring band clamp on servo line

20. Fit the steering column onto the steering gear. For details see → 489019 Removing and installing steering
gear - section on "Installing".
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Steering column on steering gear

21. Fit the heat protection shield on the steering gear by means of 2
fastening screws. → Tightening torque: 10 (7.5 ftlb.) Nm
Fastening screws for heat protection

shield to steering gear
22. Slide the heater coolant lines on the left side member and mount the
clips.
Heater coolant lines on the left side

member
23. Push on the coolant connection piece on the lower left on the radiator.
The connection piece must engage audibly.
Coolant connection piece

24. Connect the ATF lines to the radiator. Remove the plugs and mount the lines. For details see → 386219
Removing and installing the line for ATF cooling - section on "Installing" [9PAAE1 9PAAF1 9PAAJ1]
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ATF lines
→ 386219 23 Removing and installing the line for ATF cooling - section on "Installing" [9PAAE7].
25. Mount the ground point of the generator on the right side member. →
Generator ground point

26. Tighten the catalytic converter fastening on the body. For details see
→ 267319 Removing and installing (main) catalytic converter - section
on "Installing"
Catalytic converter on elbow

27. Install cardan shaft. → 393519 Removing and installing rear cardan
shaft - section on "Installing" [9PAAE1 9PAAE7 9PAAF1]→ 393519
23 Removing and installing rear cardan shaft - section on "Installing"
[9PAAJ1]
Installing cardan shaft

28. Install the exhaust system. Move the exhaust system to its installation position using a transmission jack.
→ 260119 Removing and installing exhaust system - section on "Installing"
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Exhaust system on transmission jack

29. Install the front transverse strut under the radiators. To do this, tighten
the four fastening screws. → Tightening torque: 23 (7.5 ftlb.) Nm
Fastening screws of front transverse

strut
30. Screw the front apron onto the transverse strut. → Tightening
torque: 5 (3.5 ftlb.) Nm
31. Lower the vehicle halfway.
Front apron fastening screw on

transverse strut
Note
z In the case of vehicles with air suspension, the compressed air lines
must also be screwed on.
Compressed air line

z Then connect the headlight levelling system sensor.
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32. Tighten the brake lines on the

left and right in the wheel
housings.
Brake lines in the wheel housings Sensor for headlight levelling system
33. Fit the electric connections of the spring struts. To do this, connect
cable -1- and then fasten supports -2 and 3- .
34. Lower the vehicle.
Electric connections of the spring

struts
35. Mount the three fastening screws on the left and right spring struts
from above (engine compartment side). -arrows- → Tightening
torques for front axle
Mounting the fastening screws of the

spring struts
36. Mount B+ transfer point on left spring dome. → Tightening torque: 23 (17 ftlb.) Nm
37. Connect the servo line to the reservoir and mount the spring band clamp. Then fill the container with Pentosin.
38. Connect the line from carbon canister -2- to the plenum panel splash panel until it audibly engages and
tighten fuel line -1- . → Tightening torque: 35 (26 ftlb.) Nm
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B+ transfer point on left spring dome
Spring strut view from the wheel

housing
Spring band clamp on servo line to

reservoir
Plug connections for oxygen sensors Line from carbon canister and fuel line
39. On the left and right of the plenum panel splash panel, connect the oxygen sensor plug connections in front of
and behind the catalytic converter and lay the cables so they are not subject to chafing.
Note
z In the Cayenne Turbo, the support for the vacuum pump must also be
screwed into position. → Tightening torque: 7.5 ftlb.
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support
Vacuum line and lines on coolant

reservoir
40. Connect the vacuum line to the right spring dome and mount the spring band clamp. Then mount the 2 lines
on the coolant reservoir and secure with spring band clamps.
41. Lay the engine wire harness into the plenum panel. Mount the rubber
sleeve into the middle opening. Then guide the control unit connector
to the right. Connect the control unit, connector, and ground point. →
Tightening torque: 10 (7.5 ftlb.) Nm
Control unit, connector, and ground

point
42. Plug in the 4 connectors (red, brown, white and black) in the left-hand
central electrical system box. Then mount the cover using 4 Torx
screws.
43. Check whether the wiring harness is laid correctly. Close all fixing
clips.
Fastening screws for the central

electrical system box
44. Mount the plenum chamber cover. Do not forget the electric connector for the air-quality sensor. Mount the 4
bayonet screws -A- .
45. Position and tighten drive belt on all pulleys → 137819 Removing and installing drive belt - section on
"Installing" [9PAAF1 9PAAJ1]→ 137819 Removing and installing drive belt - section on "Installing" [9PAAE1
9PAAE7].
46. Connect the upper left coolant connection piece to the radiator. The connection piece must engage audibly.
47. Mount the torque support with new lock nuts. → Tightening torque: 60 (44 ftlb.) Nm → Tightening torque:
60 (44 ftlb.) Nm
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Drive belt Bayonet screws for plenum chamber

cover
Upper left coolant connection piece

48. Insert the air-cleaner element.
Note
z In the case of vehicles with air suspension, the line of the air
compressor must also be connected on the left air cleaner cover.
Air-cleaner element
49. Mount both air cleaners with cover. Insert the air cleaners in the housings and slide on the covers from the top
downwards. Then close the two respective sheetmetal clips. The coolant overflow hose must also be clipped
onto the air cleaner housing of cylinder bank 1-4. Connect the electric connectors of the hot film mass air flow
sensors.
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Note
z In the Cayenne Turbo
(M48/50), the control lines of
the ambient air valve on the T-
piece must also be connected.
Control lines of the ambient air valves Air cleaner with cover
on T-piece
Note
z Clip on the leads when mounting the Y-shaped pipe on the bottom.
Clipping in lines
50. Attach the vacuum line to the underside of the Y-shaped pipe.
Vacuum line
51. Fit the Y-shaped pipe to the left and right and tighten the hose clamps.
Hose clamps on the Y-shaped pipe
Note
z In the Cayenne Turbo (M48/50), the boost pressure sensor -3- must also be connected.
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52. Slide the Y-shaped pipe onto the throttle adjuster. Then insert the left
and right fastening bolts. Turn both bolts 45° clockwise.
Fastening bolt Y-shaped pipe on

throttle adjuster
53. Connect the throttle adjuster. The connector must engage audibly.
Clip the connecting cable into the sheetmetal holder.
Connecting cable to throttle adjuster

54. Press the 4 rubber elements in the cover onto the 4 ball head
supports. The mounts must be felt to engage.
Rubber elements in cover on ball head

support
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Subsequent work
Subsequent work
1. Fill and bleed the cooling system. → 193817 Draining and filling in coolant (includes bleeding) - chapter on
"Filling in"
2. Bleed brake system. → 470107 Bleeding brake system - chapter on "Bleeding"
3. Connect battery. → Work instructions after disconnecting the battery
4. Mount the wiper arms. → 922519 Removing and reinstalling wiper arm - chapter on "Installing".
5. Mount engine compartment covers. → 700219 Removing and reinstalling front cover (engine compartment) -
chapter on "Installing"
6. Check ATF level. → Test and assembly work on power steering
7. Bleed power-assisted steering. → Test and assembly work on power steering
8. Bleed offroad stabiliser if necessary. → 402607 Bleeding the Offroad Stabilisator System (ORS) - chapter on
"Adjusting and bleeding" [9PAAJ1]→ 402607 Bleeding the Offroad Stabilisator System (ORS) - chapter on
"Adjusting and bleeding" [9PAAE1 9PAAE7 9PAAF1]
9. Mount front wheels. → 440519 Removing and reinstalling wheel - chapter on "Installing"
10. If the engine has been replaced by a new one, the air conditioner must be filled in accordance with the
instructions as a result of the change of air conditioning compressor. → 873419 Removing and reinstalling air-
conditioning compressor - chapter on "Installing" and → 870317 Evacuating and filling in refrigerant - chapter
on "filling"
11. Perform suspension alignment. → Suspension alignment, complete
12. Fit engine guard. → 108019 Removing and installing engine guard -
chapter on "installing"
13. Perform a test drive with the vehicle. Check the fluid level in the
reservoir after the coolant circuit has cooled again and, if necessary,
fill up to the max marking with coolant.
14. Check engine oil level.
Engine guard
9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
10 01 21 Removing engine - as of MY 2003

- Preliminary work
- Removing engine
Tools


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connections

available tool
Tools and materials
Required tools
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noted).
Lifting platform

-C- Assembly mandrel 1/11 Height can be adjusted; for mounting at
the front of the front-axle carrier.
carrier
cross member
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Tools overview

-A- Oil pan support Prevents the engine tipping backwards.
The support is mounted in the direction
of travel towards the rear.
axles.
-1/11- Front mounting on front-axle Mounted on the base carrier at position
carrier 1.
engine carrier
-3- Rear front-axle carrier mounting Mounted on the base carrier at position
3.
-4- Mounting in body Mounted on the base carrier at position
4.
-5- Mounting for transmission cross Mounted on the base carrier at position
member 5
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Tools overview

Manual 2.2.3
Manual 2.2.2
NR.73-1 Manual 2.4
1036"
connections NR.72-1
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Manual 2.2.2 system
Manual 2.2.2
"WE 1206"
Preliminary work
Preliminary work
"Removing"
wheel in centre position with steering wheel holder)! If this is not done, the airbag contact unit will have to be
put in centre position after installation of the steering gear! → 945019 Removing and reinstalling steering-
column switch
z Remove engine compartment covers. → 700219 Removing and reinstalling front cover (engine compartment)
- chapter on "Removing"
Removing engine
Removing engine
in the notes.
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V8 engine
1. Remove engine guard with transverse strut. → 108019 Removing and installing engine guard - chapter on
"Removing"

bleeding).
3. Remove both wiper arms → 922519 Removing and installing wiper
arm - chapter on "Removing".
Note
z The air quality sensor is located on the cover of the radiator tank. This
must be unclipped.
Coolant drain plug

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4. Loosen the 4 bayonet screws -A- on the plenum panel cover. Then lift
the cover in the middle, release left and right and remove from the
vehicle.
Plenum chamber cover

5. Disconnect the engine wire harness on the right-hand side of the
vehicle. To do this, unplug the control unit and disconnect the ground
point.
Engine wire harness

6. Open the cover of the central electrical system on the left side of the
vehicle. To do this, loosen the four Torx screws.
7. Disconnect the connectors from the engine wire harness (white, red,
black and brown). Remove the wiring harness from the retaining clips
and lay it down on the engine.

electrical system
8. Disconnect B+ transfer point at the left of the engine compartment.
B+ transfer point
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Throttle adjuster electric connection Throttle body cover

10. Separate the electric connection from the throttle adjuster. To do this, press on the plug at the top and bottom
and, at the same time, pull it off. Unclip the cable from the sheetmetal holder.
Fastening bolts on the throttle body
Note
z In the Cayenne Turbo (M48/50), the boost pressure sensor must also
be disconnected.
11. Release the fastening bolts on the throttle body. To do this, twist both
bolts through 45° in an anti-clockwise direction. The dot on the bolt
must appear as illustrated in the figure.

14. Disconnect the mass air flow connections. To do this, loosen the hose clamps to the left and right on the
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bellows and pull the bellows off the mass air flow (in the Cayenne Turbo, pull them off the pressure pipes).
Note
z If the engine is to be subsequently transported by crane, the right-hand design cover on cylinder row 5 - 8
should be removed at this point. → 108319 Removing and installing engine cover - chapter on "Removing"
z To do this, loosen the 4 fastening screws. Unclip the design cover from
the intake system and slide out at an angle towards the front.
Design cover of cylinder row 5 - 8

Air cleaner housing clamps
Note
z In vehicles with air suspension, the suction line of the compressor must also be removed on the right air
cleaner cover. To do this, unclip the green cap, press circlip -1- inwards and pull off adapter -2- .
16. Remove the air cleaner covers on the right and left. → 242519 Removing and installing air cleaner housing -
chapter on "Removing" [9PAAF1 9PAAJ1]→ 242519 Removing and installing air cleaner housing - chapter
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Air cleaner cover Circlip and adapter

on "Removing" [9PAAE1 9PAAE7]
Filter elements
18. Disconnect the 2 respective oxygen sensor connectors (brown, black)
at the left and right of the water splash panel and unclip the cable from
the supports.
Oxygen sensor connector
Note
z In the Cayenne Turbo (M48/50), the support for the vacuum pump
must also be undone. To do this, unscrew the two fastening screws
and press the pump forward slightly.

19. Disconnect the 2 coolant lines and vacuum line on the right side of the engine compartment.
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WARNING

→ Components that come into contact with servo oil must be cleaned
→ Take suitable protective measures (e.g. gloves, safety goggles, oil
binding material) Coolant lines and vacuum line
20. Empty the servo oil reservoir with a syringe. Next, remove the hose
from the reservoir. Close the open connections with plugs.
Servo oil reservoir

engine and loosen the screw on the body. Then pivot up the torque
support.
DANGER
z Damage to skin

Fuel line and carbon canister line
22. Disconnect fuel line -1- and line -2- from the carbon canister on the plenum panel splash panel.
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23. Loosen the 3 fastening screws on the left and right spring struts. The screws are loosened from inside the
engine compartment. Of the 3 screws per spring strut, one is in the plenum panel. Replace screws.
24. Disconnect the coolant feed and return lines from the radiator. To do
this, pull out the securing clip and pull off the connection. The clips
should be mounted again immediately so that they are not confused.
Note
z If at all possible, the air-conditioning system should not be opened.

conditioner is evacuated and the existing air-conditioning compressor Securing clip on connection for coolant
removed during removal of the engine as the replacement engine is feed and return lines
delivered with the new compressor mounted. → 873419 Removing and installing air-conditioning compressor -
25. Slacken the drive belt (a/f 30) and remove from the tensioning roller.
Note
z In the Cayenne Turbo (M48/50), the control lines of the ambient air valves on the T-piece should be pulled off.
Note
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z In the case of vehicles with air

suspension, the compressed
air line on the spring strut must
also be disconnected. Loosen
the line carefully and allow the
remaining pressure to escape.
Loosen the threaded joint
completely only when the line is
fully depressurised.
Compressed air line on spring strut Control lines of the ambient air valves
disconnected in vehicles with air suspension or automatic headlight
levelling system.

sensor
26. Disconnect electric plug -1- on the spring struts in the wheel housing.
Then unclip the support -2 and 3- . Tie the cable on the spring strut.

wheel housing
WARNING
ATF!
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→ Before lines are opened, place

a cloth underneath them!
→ Components that come into
contact with ATF must be
cleaned IMMEDIATELY with
water!
→ Take suitable protective
measures (e.g. gloves, safety
goggles, oil binding material)
Ground point of right side member Brake lines in the wheel housing
ATF lines on cooler

30. Remove the heat protection shield on the steering gear connection.
To do this, loosen the 2 fastening screws.
Note
z In the case of vehicles with Servotronic, an electric plug must also be
removed from the steering gear.

connection
31. Loosen the clamping screw from the steering column on the steering
gear and remove it. The screw must not be re-used. Force the
steering column up and off the steering gear.

33. Disconnect the heat exchanger coolant lines in the left wheel housing below. Approx. 2 litres of coolant will
flow out when you do this.
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wheel housing
34. Remove the complete exhaust system from the connection point on the catalytic converter to the tailpipes
→ 260119 Removing and installing exhaust system - chapter on "Removing".
35. Remove rear cardan shaft → 393519 Removing and installing rear cardan shaft [9PAAE1 9PAAE7 9PAAF1]
→ 393519 Removing and installing rear cardan shaft [9PAAJ1].
36. Disconnect electrical connections -1,2 and 3- on the transmission and

unclip the wiring harness.

transmission

37. Remove the heat shield on the left transmission side. To do so, loosen the 3 fastening screws and take out
the heat protection shield.
Note
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Selector lever cable on the Fastening screws for heat protection

transmission shield
38. Detach the selector lever cable on the transmission. To do this, press the ball socket away from the
transmission. Then pull out top sheetmetal clip -A- and remove the cable in an upward direction.
Note
z If the transmission is to be separated from the engine after removal, the two lower fastening screws on the
transmission housing and front cardan shaft should be removed at this point, since access to the lifting
platform will be impaired.
WARNING

Lower line on servo oil cooler
Note
z On the Cayenne Turbo (M48/50), the hose connections on the turbochargers must also be loosened. To do
this, pull out locking spring -1- on the turbocharger adapter. Then loosen hose clamp -2- of the pressure pipe
on the turbocharger.
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z Disconnect the connection on

the charge air cooler. To do
this, remove locking clip -1- and
pull off the line. Line -2- of the
ambient air valve must also be
disconnected on the right-hand
side of the vehicle. To do this,
remove the spring band clamp
and pull off the line.
Note
Locking clip and line of ambient air Locking spring on turbocharger
z It is easier to remove the air- valve adapter and hose clamp of
conditioning compressor from
its installation position when the engine has already been lowered a
little.
z The air-conditioning compressor lines must not be kinked or twisted.
evacuated.
"Removing"
40. Loosen the 3 fastening screws and disconnect the electric plug from
the air-conditioning compressor. Set the air-conditioning compressor
aside.

compressor
Note
z For installation, it is a good idea to mark the installation position of the
front axle carrier diagonally at 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).
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axle carrier
Note
z Because of the high loosening torque, the 6 fastening screws on the front-axle carrier can now be loosened.
Loosen the screws by a maximum of one turn.
43. Place the elevating platform under the engine and raise it. When you
do this, ensure that the positioning guides of the elevating platform are
inserted into the body.
Elevating platform
44. Secure the spring struts. 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 elevating platform.

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cross member
46. Secure the engine/transmission combination. Then secure the mounting mandrels on the engine transverse
bar with locking screws.
Note
mounted accidentally between engine and body. Thus a second person
should make sure that the cables and lines do not get caught.
48. Lower the lifting platform slowly. When this is done, a second person
should ensure that there is sufficient clearance around the engine
compartment and wheel housings.
transverse bar
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g g g
ADVERTENCIA
10 01 23 Installing engine. - as of MY 2003

- Installing engine
- Subsequent work
Tools


g g g

connections

available tool
Tools and materials

g g g
Required tools
noted).
Lifting platform

-C- Assembly mandrel 1/11 Height can be adjusted; for mounting
at the front of the front-axle carrier.
carrier
cross member
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Tools overview

-A- Oil pan support Prevents the engine tipping
backwards. The support is mounted in
the direction of travel towards the rear.
axles.
-1/11- Front mounting on front-axle Mounted on the base carrier at
carrier position 1.
engine carrier
-3- Rear front-axle carrier mounting Mounted on the base carrier at
position 3.
-4- Mounting in body Mounted on the base carrier at
position 4.
-5- Mounting for transmission cross Mounted on the base carrier at
member position 5
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Tools overview

Manual 2.2.3
Manual 2.2.2
NR.73-1 Manual 2.4
1036"
connections NR.72-1
g g g
Manual 2.2.2 system
Manual 2.2.2
"WE 1206"
Installing engine
Installing engine
in the notes.
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2. Secure the engine against tipping. To do this, attach the locks on the
engine cross member and raise the support under the oil pan until it
touches the oil pan.

mounting the transmission - section on "Mounting" [9PAAE1 9PAAF1
9PAAJ1]→ 373527 AG Removing and mounting the transmission -
section on "Mounting" [9PAAE7] or → 343527 Removing and
mounting the transmission - section on "Mounting" [9PAAE7]
→ 343527 AG Removing and mounting the transmission - section on
"Mounting" [9PAAE1 9PAAF1 9PAAJ1] Lifting the engine with a workshop
crane
4. Install pre- and main catalytic converters. → 267619 Removing and
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installing primary catalytic converter - section on "Removing"

[9PAAE1 9PAAE7]→ 267619 Removing and installing primary
catalytic converter - section on "Removing" [9PAAF1 9PAAJ1]

6. Bolt the main catalytic converter supports onto the transmission

cross member. For details see → 267319 Removing and installing
(main) catalytic converter - section on "Installing"
7. Remove the support from under the oil pan and remove the tipping
protection from the engine cross member.

possible.

11. Raise the body to a comfortable working height with the platform lift.
Note
z When moving the unit into the body, ensure that the shift cable is on
the transmission. Oxygen sensor cable for the rear
oxygen sensors

conditioner is evacuated before removing the engine and the new air-
conditioning compressor is connected during installation of the engine
as the replacement engine is delivered with the new compressor
mounted. → 873419 Removing and installing air-conditioning
compressor - chapter on "Installing"
Note
z Position the front-axle carrier back in the original, marked installation
position and be careful not to damage adjacent parts.
12. Raise the engine/transmission combination into the body with the lifting platform. Ensure sufficient clearance.
The insertion guides on the lifting platform must fit into the holes in the body.
13. Tighten the 6 new front-axle carrier engine carrier screws. For details, see → 400619 Removing and
installing front axle carrier - section on "Installing" [9PAAJ1]→ 400619 Removing and installing front axle
carrier - section on "Installing" [9PAAE1 9PAAE7 9PAAF1] → Initial tightening: 120 (89 ftlb.) Nm → Final
tightening - torque angle: 180 °
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Fastening screws for front-axle carrier Guiding the engine/transmission

and engine carrier combination into the body with the
14. Install transmission cross lifting platform
member. For details see
→ 396519 Removing and
installing transfer box -
section on "Installing" -A- .

cross member

17. Connect electric connector -1, 2 and 3- on the transmission and clip
in the wiring harness.
Connector to transmission
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18. Mount selector lever cable. For details see → 371519 Removing and installing selector lever cable - section
on "Installing" [9PAAE1 9PAAF1 9PAAJ1]→ 371519 23 Removing and installing selector lever cable -
section on "Installing" [9PAAE7].
Note
turbochargers must also be fastened. To do this, connect pressure
pipe -2- and tighten the hose clamp. Then fit the lead of the charge
air cooler. The connection piece must engage audibly. Ensure that
sheetmetal clip -1- is fitted correctly.

z Connect the hose line on the left charge air cooler. Ensure that
locking clip -1- is mounted correctly. Then connect the line to the
ambient air valve -2- and fit the spring-band clamp.

valve
19. Push the servo oil line onto the oil cooler and mount the spring band clamp.
Note
z For vehicles with Servotronic, the electric connector on the steering gear must also be connected.
20. Fit the steering column onto the steering gear. For details see → 489019 Removing and installing steering
gear - section on "Installing".
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Steering column on steering gear Spring band clamp on servo line

21. Fit the heat protection shield on the steering gear by means of 2 fastening screws. → Tightening torque: 10
(7.5 ftlb.) Nm
22. Slide the heater coolant lines on the left side member and mount the
clips.

member
23. Push on the coolant connection piece on the lower left on the
radiator. The connection piece must engage audibly.
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24. Connect the ATF lines to the Coolant connection piece

radiator. Remove the plugs
and mount the lines. For
details see → 386219
Removing and installing the
line for ATF cooling - section
on "Installing" [9PAAE1
9PAAF1 9PAAJ1]→ 386219
23 Removing and installing
the line for ATF cooling -
section on
"Installing" [9PAAE7].
ATF lines
25. Mount the ground point of the generator on the right side member. →

26. Tighten the catalytic converter fastening on the body. For details see
→ 267319 Removing and installing (main) catalytic converter -
section on "Installing"

27. Install cardan shaft. → 393519 Removing and installing rear cardan
shaft - section on "Installing" [9PAAE1 9PAAE7 9PAAF1]→ 393519
23 Removing and installing rear cardan shaft - section on "Installing"
[9PAAJ1]

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Fastening screws of front transverse Exhaust system on transmission jack

strut
29. Install the front transverse strut under the radiators. To do this, tighten the four fastening screws. →

transverse strut
Note
z In the case of vehicles with air suspension, the compressed air lines
must also be screwed on.
Compressed air line

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Sensor for headlight levelling system
Brake lines in the wheel housings

32. Tighten the brake lines on the left and right in the wheel housings.
33. Fit the electric connections of the spring struts. To do this, connect
cable -1- and then fasten supports -2 and 3- .

struts
35. Mount the three fastening screws on the left and right spring struts
from above (engine compartment side). -arrows- → Tightening

spring struts
37. Connect the servo line to the reservoir and mount the spring band clamp. Then fill the container with
Pentosin.
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housing

reservoir
Line from carbon canister and fuel line
38. Connect the line from carbon canister -2- to the plenum panel splash panel until it audibly engages and
tighten fuel line -1- . → Tightening torque: 35 (26 ftlb.) Nm
39. On the left and right of the plenum panel splash panel, connect the oxygen sensor plug connections in front
of and behind the catalytic converter and lay the cables so they are not subject to chafing.
Note
z In the Cayenne Turbo, the support for the vacuum pump must also be screwed into position. → Tightening
torque: 7.5 ftlb.
40. Connect the vacuum line to the right spring dome and mount the spring band clamp. Then mount the 2 lines
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Fastening screws for vacuum pump Plug connections for oxygen sensors
support

reservoir
on the coolant reservoir and secure with spring band clamps.
41. Lay the engine wire harness into the plenum panel. Mount the rubber
sleeve into the middle opening. Then guide the control unit connector
to the right. Connect the control unit, connector, and ground point. →

point
42. Plug in the 4 connectors (red, brown, white and black) in the left-hand central electrical system box. Then
mount the cover using 4 Torx screws.
43. Check whether the wiring harness is laid correctly. Close all fixing clips.
44. Mount the plenum chamber cover. Do not forget the electric connector for the air-quality sensor. Mount the 4
bayonet screws -A- .
"Installing" [9PAAF1 9PAAJ1]→ 137819 Removing and installing drive belt - section on "Installing" [9PAAE1
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Bayonet screws for plenum chamber Fastening screws for the central
cover electrical system box
Drive belt
9PAAE7].
46. Connect the upper left coolant connection piece to the radiator. The
connection piece must engage audibly.

47. Mount the torque support with new lock nuts. → Tightening torque:
60 (44 ftlb.) Nm → Tightening torque: 60 (44 ftlb.) Nm

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Note
Air-cleaner element
49. Mount both air cleaners with cover. Insert the air cleaners in the
housings and slide on the covers from the top downwards. Then
close the two respective sheetmetal clips. The coolant overflow hose
must also be clipped onto the air cleaner housing of cylinder bank 1-
4. Connect the electric connectors of the hot film mass air flow
sensors.
Air cleaner with cover
Note
z In the Cayenne Turbo (M48/50), the control lines of the ambient air
valve on the T-piece must also be connected.
Control lines of the ambient air valves

on T-piece
Note
z Clip on the leads when mounting the Y-shaped pipe on the bottom.
Clipping in lines
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Hose clamps on the Y-shaped pipe Vacuum line
Note
z In the Cayenne Turbo (M48/50), the boost pressure sensor -3- must
also be connected.
and right fastening bolts. Turn both bolts 45° clockwise.

throttle adjuster

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support
54. Press the 4 rubber elements in the cover onto the 4 ball head supports. The mounts must be felt to engage.
Subsequent work
Subsequent work
"Filling in"
5. Mount engine compartment covers. → 700219 Removing and reinstalling front cover (engine compartment) -
8. Bleed offroad stabiliser if necessary. → 402607 Bleeding the Offroad Stabilisator System (ORS) - chapter on
"Adjusting and bleeding" [9PAAJ1]→ 402607 Bleeding the Offroad Stabilisator System (ORS) - chapter on
"Adjusting and bleeding" [9PAAE1 9PAAE7 9PAAF1]
instructions as a result of the change of air conditioning compressor. → 873419 Removing and reinstalling
air-conditioning compressor - chapter on "Installing" and → 870317 Evacuating and filling in refrigerant -
chapter on "filling"
12. Fit engine guard. → 108019 Removing and installing engine guard - chapter on "installing"
13. Perform a test drive with the vehicle. Check the fluid level in the reservoir after the coolant circuit has cooled
again and, if necessary, fill up to the max marking with coolant.

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Engine guard
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
10 01 29 Cleaning the engine (washing the engine) - as of MY 2003

- Notes on washing the engine
Notes on washing the engine
DANGER
Hot water under high pressure!
z Risk of damage for engine components.
z Incoming washer-fluid in electric components.
→ Only wash the engine when it is cold.

→ Only wash the engine when engine is switched off (electric shock through the ignition system).
→ Protect the oxygen sensor connectors from moisture.
→ Maintain a minimum clearance of 50 cm between the cleaning lance and engine component.
→ Protect the brake fluid reservoir from moisture.
Note
z The engine should be washed only if this is absolutely essential for repair work.
z Components sensitive to moisture must be adequately protected. Cover them, if necessary.
z Cleaning agents or water should never be applied directly to components that are sensitive to moisture, such
as electric connectors.
z When using high-pressure cleaning apparatus, maintain a minimum clearance of 50 cm between the
cleaning lance and the engine component.
z Never wash the engine when the engine is warm.
z For environmental reasons, the engine may only be washed in workshops in which oils are separated from
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waste water.
1. Open the bonnet.
2. Protect components sensitive to moisture, possibly by covering them with plastic sheeting. Oxygen sensor
connectors must not get wet.
3. Remove any maintenance labels (e.g. oil change schedule tag) and replace after the work is completed.
4. Pre-clean very dirty engines with pure water.
5. Spray engine components to be cleaned with an appropriate engine cleaning agent and allow it to work in.
6. Clean the engine. Ensure that a minimum clearance of 50 cm is maintained between the cleaning lance and
engine component. The water temperature must not exceed 80 °C. Remove persistent dirt with a non-
abrasive sponge.
7. Moving components in the engine compartment, such as the hook for the bonnet, must be re-greased.
8. Carry out a test drive after washing the engine.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
10 01 37 Disassembling and assembling engine - as of MY 2003

- Technical values
- Preliminary work
- Disassembling engine
- Preliminary work
- Assembling engine
- Subsequent work
Tools

piston ring restraining strap for special tool 57
944 - S2 and Boxster and 911
Carrera (996)
centring pins special tool 9321
mounting elements special tool 9590

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holding bridges special tool 9677
engine support special tool P 9676
Tools and materials
Required special tools
Note
z The special tools that are required are described in the chapter → (Special) tools required for repairing the
M48/00 and M48/50 engines or in the corresponding individual chapters.
Technical values
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Technical values
Note
z For information on all tightening torques, see → Tightening torques for Cayenne S (M48/00) and Cayenne
Turbo (M48/50) [9PAAF1 9PAAJ1]→ Tightening torques for Cayenne S (M48/00) and Cayenne Turbo
(M48/50) [9PAAE1 9PAAE7] or the corresponding individual chapters.
Preliminary work
Preliminary work for disassembling engine
1. Remove engine. → 100119 Removing and installing V8 4.5 l engine - section on "Removing"
2. Remove engine from transmission. → 343527 Removing and refitting the transmission [9PAAE7]→ 343527
Removing and refitting the transmission [9PAAE1 9PAAF1 9PAAJ1] or → 373527 Removing and refitting
the transmission [9PAAE1 9PAAF1 9PAAJ1]→ 373527 Removing and refitting the transmission [9PAAE7]
Note
z The engine must be disassembled in accordance with the detailed
descriptions in the Technical Manual!
z This chapter does not provide details or further information. Further

details can be found in the relevant individual descriptions.
3. Secure engine support P 9676 on engine → Crankcase on engine

support (shown with lower part of crankcase) . To do this, use the
four screws for mounting elements 9590 and tighten them slightly.
Secure engine on engine support. To do this, carefully guide the Crankcase on engine support (shown
engine support axle into the take-up bore on the engine support and with lower part of crankcase)
secure it.
4. Remove wire harness for engine. → 975219 Removing and installing wire harness for engine - section on
"Removing" [9PAAE1 9PAAE7]→ 975219 Removing and installing wire harness for engine - section on
"Removing" [9PAAF1 9PAAJ1]
5. Remove the generator. → 272219 Removing and installing generator - section on "Removing" [9PAAE1
9PAAE7]→ 272219 Removing and installing generator - section on "Removing" [9PAAF1 9PAAJ1]
6. Remove power-steering pump. → 489819 Removing and installing hydraulic pump (Cayenne
Turbo/Cayenne S) - section on "Removing"
7. Remove left additional assembly bracket -2- and right engine carrier -8- . There are also two dowel sleeves
(not shown) on the additional assembly bracket.
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Removing and installing engine support
1- Nut → Tightening torque: 75 (56 ftlb.) Nm

2- Additional assembly bracket, left
3- Screw x 10 → Tightening torque: 65 (48 ftlb.) Nm
4- Hydraulic mount, left
5- Engine carrier
7- Hydraulic mount, right
8- Engine carrier
Disassembling engine
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1. Remove starter. → 276019 Removing and installing starter - section on "Removing" [9PAAE1 9PAAE7
9PAAF1]→ 276019 21 Removing and installing starter - section on "Removing" [9PAAJ1]
2. Remove knock sensors. → 287219 Removing and installing knock sensor - section on "Removing"
3. Remove cylinder heads. → 157021 Removing cylinder head
4. Remove water pump. → 195019 Removing and installing coolant pump - section on "Removing"
5. Remove coolant regulator. → 195819 Removing and installing coolant regulator (thermostat) - section on
"Removing"
6. Remove guide and tensioning rails. → 154756 21 Replacing guide and tensioning rails - section on
"Removing"
7. Remove crankshaft. → 134819 Removing and installing crankshaft - section on "Removing"
8. Remove oil spray jets on turbo engine and cap on naturally aspirated engine. → 101321 Removing oil spray
jets for piston cooling [9PAAF1 9PAAJ1]→ 101321 Removing oil spray jets for piston cooling [9PAAE1
9PAAE7]
Preliminary work
Preliminary work for engine assembly

1. The crankcase must be prepared for installation (dowel sleeves, caps and pins screwed in).
Note

2. Attach top section of crankcase to engine support. To do this, use the

four screws for mounting elements 9590 and tighten them slightly.
Crankcase on engine support
Assembling engine
Assembling engine
ATTENTION
Leaks due to components being at too low a temperature or at different temperatures!
z If components that are cold or at different temperatures are sealed together by the application of
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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.
Note

Note
z Four oil spray nozzle are installed in the M48/50 engine instead of the Caps and oil spray nozzles
caps used in the M48/00 engine.
1. Fit caps on crankcase. When doing so, make sure that new O-rings are fitted. Tighten the → Tightening
torque: 10 (7.5 ftlb.) Nm .
Inserting the bearing shells
Note
z The bearing shells are available in various tolerance classes. The
classes are indicated by the colour marking on the outside. The
colour marking must match the corresponding colour dot on the
crankshaft. Further details: → Removing and installing crankshaft
2. Insert the bearing shells with the lubricating groove into the upper
part of the crankcase → Inserting the bearing shells . Make sure the
twist locks are positioned correctly. Then lightly oil the bearing
locations.
Colour marking on bearing shell
3. Insert the sickle-shaped washer (make sure of axial bearing play). To do this, insert the two sickle-shaped
washers to the left and right on crankshaft bearing no. 3. Apply some grease (000.043.204.17) between the
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Inserting the sickle-shaped washers

crankshaft bearing and the sickle washers so that the sickle washers do not fall down. Each of the lubricating
grooves of the sickle-shaped washers must face outwards → Inserting the sickle-shaped washers .
WARNING
The crankshaft is heavy!
z There is a danger of hands being crushed when inserting the
crankshaft.
→ Hold the very outside of the crankshaft.

→ Wear gloves.
4. Insert crankshaft. The connection flange must point towards the back
of the engine. Then secure the crankshaft from falling down using Crankshaft holding bridges
holding bridges 9677. Attach the holding bridges at bearing
locations 3 and 5 → Crankshaft holding bridges . Then screw the
fastening screw of the front pulley into the crankshaft until they just
make contact.
5. Turn crankcase by 180° on the assembly support.
Note
z The pistons must already be pre-fitted (pistons, piston rings,
connecting rods and fastening material) before performing the next
step.
z The required bearing shells must be inserted in the connecting rods.
z The connecting rod is symmetrical and can be fitted either on the

piston so that the number on the connecting rod is facing outwards or
inwards, or the tolerance class designation of the piston does not
have to be on the same side as the connecting rod code. The Turning the crankshaft
direction of travel arrow is on the same side as the connecting rod
code -A- as is evident on the piston shown. This can be installed as standard on one cylinder bank side on
the same side as shown here, and on the other cylinder bank side, the connecting rod code is on the
opposite side. The connecting rod code is installed to the exhaust side as standard.
z When installing the piston in the crankcase, the direction of travel arrow must point in the direction of travel.
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z For further information, see → 131019 Removing and installing

pistons
Connecting rod code and direction of

travel arrow
z The code on the connecting-rod big end and connecting-rod bearing
cap must be on the same side and at the exhaust side.
6. Install piston. To do this, turn the crankshaft with a wrench (a/f 27)
until the corresponding lift pin is pointing straight downwards.
7. Lightly oil cylinder and piston.
Connecting rod code "A"

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

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

Sliding in the piston
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Twist lock on bearing shells Push piston in using the handle of a

hammer, if necessary.
10. Push the piston downwards until the connecting-rod bearing is sitting on the lift pin. Then fit connecting-rod
bearing cap with bearing shell. The connecting rod numbers must face each other. Screw in con-rod bolts by
hand. Make sure the twist locks and connecting rod code are positioned correctly during assembly.
11. Fit the opposite piston (e.g. 1 and 4).
12. Fit other pistons in accordance with the step above.
13. Turn crankcase on the assembly support until the crankshaft is on

top.
Note
z Con-rod bolts must always be replaced.
14. Tighten con-rod bolts that have been replaced. See → 131019 View of connecting rod numbers
Removing and installing pistons - section on "Installing"
15. holding bridges 9677 must be removed from the crankshaft.
16. Screw the two thin centring pins 9321 into the outer fastening bores
on the upper part of the crankcase -Arrows- (crankshaft not fitted in
illustration).
Centring pin
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17. Insert the bottom bearing shells into the bottom section of the crankcase (bed plate) and lightly oil running
surfaces. Pay attention to the twist locks when doing so.
18. Make sure the crankcase is ready to be screwed in. Check that the sickle discs are positioned correctly.
Degrease parting surfaces between top and bottom section of crankcase. A totally grease-free product (e.g.
brake cleaner) must be used for this. Then insert a new O-ring at the front of the parting surface.
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Bottom section of crankcase (bed plate)
1- Crankcase, bottom section

2- Cylindrical pin used to centre the lower part of the crankcase on the crankcase
3- Sealing ring; replace
4- Application of sealant; Loctite 5970 liquid sealant (000.043.300.39) must be applied and the screws screwed
in within five minutes and without interruption
5- Thrust-bearing screw, M12 x 1.5 x 132
6- Thrust-bearing screw, M10 x 117
7- Fastening screw, M8 x 70
10 - Dowel sleeve
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Note
z Liquid sealant must be applied and screws tightened immediately and without interruption.
z The threads and head contact surface of the bearing seat screws (M10 x 1.5 and M12 x 1.5) must be oiled.
19. Apply Loctite 5970 liquid sealant - 000.043.300.39 (status 11/2005, for details of current sealant, see Parts
Catalogue) to the lower part of the crankcase as shown. The surfaces marked -A- must be cleaned after
fitting.
Applying sealant to bottom section of crankcase
20. Place bottom section of crankcase into position. When doing so, make sure that the sealing bead is not
destroyed.
21. For details of the tightening sequence for the bottom section of the crankcase and tightening torques, see
→ 134819 Removing and installing crankshaft - section on "Installing".
22. Then tighten the four fastening screws on the clutch side →
Tightening torque: 23 (17 ftlb.) Nm -Arrows- .
Bottom section of crankcase (clutch

side)
23. Fit chain drive sprocket on the crankshaft. Unscrew fastening screw on belt pulley. Check that the feather
keys are fitted correctly and push on the chain sprocket with the oil pump drive chain. The double-tooth row
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Chain drive wheel
must be facing forwards.
24. Install oil pump. → 172019 Removing and installing oil pump -
25. Fit guide rail -9- and tensioning rail -6- for the oil pump drive. Push
the tensioning rail over the fastening pin and engage the guide rail in
the bottom section of the crankcase as shown in the illustration.
Oil pump
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Oil pump components
26. Fit timing chain cover on oil pump. Tighten the → Tightening
27. Turn engine 180° on the assembly support.
Timing chain cover on oil pump

28. Install starter → 276019 Removing and installing starter - section on "Installing" [9PAAE1 9PAAE7 9PAAF1]
→ 276019 23 Removing and installing starter - section on "Installing" [9PAAJ1].
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29. Fit knock sensors. Align the

knock sensors as shown in
the illustration and tighten the
→ Tightening torque: 23 (17
ftlb.) Nm .
Figure shows knock sensor on bank 1 Installing starter

-4
30. Install thermostat housing. Fit a new O-ring at the water pump inlet
and then insert the thermostat housing. Tighten the two →
Tightening torque: 10 (7.5 ftlb.) Nm .
31. Mount cylinder heads. To do this, turn the engine on the assembly
support so that the required cylinder bank is pointing vertically
upwards.
Figure shows knock sensor on bank 5

-8
32. Fit new cylinder-head gasket. The gasket designation is shown on
the back and is legible from above when fitted correctly.
Cylinder bank 1 - 4
33. Fit cylinder head. The fastening screws must be tightened in the
sequence shown below. The tightening sequences and step-by-step
tightening torques must be observed! For details, see → 157023
Removing and installing cylinder head.
Cylinder bank 5 - 8
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Tightening sequence for cylinder head
34. Fit camshaft housing. Apply a bead of Loctite 5970 liquid sealant - 000.043.300.39 (status 11/2005, for
details of current sealant, see Parts Catalogue) -A- as shown. Then screw two thin centring pins 9321 into
two opposing blind holes in the cylinder head. Insert the O-ring -B- into the oil duct. Wipe off any sealant -C-
that emerges as a result of screwing.
Sealant application
35. Position camshaft housing and then unscrew the two centring pins.
36. Tighten the camshaft housing screws in the sequence shown. Don't forget the two hexagon socket head
bolts at the front of the camshaft housing. For details, see → 150323 Removing and installing camshaft
housing.
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Tightening sequence for camshaft housing
Note
z The bearing locations of the camshafts must be lightly oiled.
z Place the camshafts in such a way that the cams are positioned as
shown below!
37. Install camshafts. → 150523 Installing camshafts
Screws at the front
Positioning camshafts
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1- Cam position cylinder 6

2- Cam position cylinder 2 (A) and cylinder 3 (B)
D- Cam position cylinder bank 5 – 8 exhaust side
C- Cam position cylinder bank 5 – 8 inlet side
B- Cam position cylinder bank 1 – 4 inlet side
A- Cam position cylinder bank 1 – 4 exhaust side
38. Fit oil return line to camshaft housing 5 - 8. Fit oil return line -1- with a new O-ring -2- . Tighten the four →
Tightening torque: 10 (7.5 ftlb.) Nm -3 and 4- (camshaft housing, cylinder head, crankcase and oil pan).
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Oil return line
39. Position oil feed housing of inlet camshaft and tighten → Tightening torque: 10 (7.5 ftlb.) Nm .
Note
z If the camshaft timing gears and camshaft adjusters are removed completely, the diamond washers and
fastening screws must be replaced!
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Diamond washer
40. Replace the diamond washer and fastening screw located underneath the camshaft adjuster and camshaft
timing gear.
41. Fitting deflection rail -4- . → 154756 23 Replacing guide and tensioning rails – section on "Installing"
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Deflection rail
ATTENTION
Damage to the camshaft switch-over valve!
z Malfunction.
→ Do not turn camshaft switch-over valve.
42. Install camshaft switch-over valves → Tightening torque: 10 (7.5

ftlb.) Nm . Figure → Fastening screw for camshaft switch-over valve
shows procedure with timing-case cover fitted.
Fastening screw for camshaft switch-
43. Fit timing drive mechanism. Fit guide rail of cylinder bank 5 - 8. over valve
Tighten the leaf spring of the oil pump tensioning rail at the same
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time. → 154756 23 Replacing guide and tensioning rails – section on

"Installing"
44. Fit tensioning rail to cylinder bank 1 - 4.
45. Install timing chain. Position the chain on the crankshaft gear wheel
and then fit it over all four camshaft timing gears. To do this, use both
hands to carefully insert the camshaft adjuster and camshaft timing
gear into the timing chain. Screw in fastening screws of the timing
gears loosely to half a turn. Figure → Installing timing chain shows
procedure with timing-case cover fitted. Screw in fastening screws of
the timing gears loosely to half a turn.→ 153523 Installing timing
chain
46. Fit U-rail. Insert the U-rail into the timing drive mechanism from
above. Tighten the four fastening screws.
Installing timing chain

47. Fit the short guide rails between the camshaft timing gears. Figure
→ Guide rails shows assembly with timing-case cover fitted.
48. Fit timing-case cover. → 153123 Installing chain case lid
Guide rails
49. Place sealing ring over crankshaft using assembly sleeve.
Sealing ring with assembly sleeve

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

52. Pull assembly sleeve evenly off the sealing ring.
Assembly sleeve
Note
z If the sealing flange on the pulley is slightly rusted, polish the rust off
with a special polishing pad (e.g. Never Dull).
z If the sealing flange is badly corroded or contains deep grooves,

replace it.
Note
z A feather key is inserted into the crankshaft. When fitting the pulley, Crankshaft belt pulley
ensure that the feather key slots into the groove in the pulley.
z The key must not fall into the engine.
53. Fit crankshaft belt pulley.→ 137619 Removing and installing crankshaft belt pulley - section on "Installing"
54. Fit oil pan. → 175023 Oil pan installed (includes sealing)
55. Fit drive plate or flywheel.
56. Install chain tensioner with new sealing ring. → Tightening torque: 60 (44 ftlb.) Nm
Note
z To remove the play from the timing chain for the setting process, the crankshaft must be positioned approx.
45° in front of the TDC of cylinder 1 before turning!
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57. Set the timing. → 150516

Setting the timing.
58. Install the camshaft housing

cover on both cylinder banks
→ 159123 Installing the
camshaft housing cover.
59. Fit water pump. → 195019

coolant pump - section on
"Installing"
Installation location of chain tensioner Measurement on the oil pan
Subsequent work
Subsequent work
1. Fit left additional assembly bracket -2- and right engine carrier -8- . There are still two dowel sleeves (not
shown) on the additional assembly bracket.
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5- Engine carrier
8- Engine carrier
2. Fit power-steering pump. → 489819 Removing and installing hydraulic pump (Cayenne Turbo/Cayenne S) -
3. Fit generator. → 272219 Removing and installing generator - section on "Installing" [9PAAE1 9PAAE7]
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→ 272219 Removing and installing generator - section on "Installing" [9PAAF1 9PAAJ1]
4. Fit wire harness for engine. → 975219 Removing and installing wire harness for engine - section on
"Installing" [9PAAE1 9PAAE7]→ 975219 Removing and installing wire harness for engine - section on
"Installing" [9PAAF1 9PAAJ1]
5. Refit engine on transmission. → 343527 Removing and refitting the transmission [9PAAE7]→ 343527
the transmission [9PAAE1 9PAAF1 9PAAJ1]→ 373527 Removing and refitting the transmission [9PAAE7]
6. Install engine. → 100119 Removing and installing V8 4.5 l engine - section on "Installing"
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
10 01 AW The most important working regulations and warning

notes - as of MY 2003
- Folder 1
- Information
Folder 1
Group 1 - Engine
DANGER
Suspended load!
z Risk of serious crushing and injury
→ Do not work at or under a suspended load.

→ Never reach in between the engine and components during installation or removal.
→ Wear protective safety gear.
ATTENTION

Group 10 - Crankcase - suspension

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DANGER
Danger of injury from incorrect use of tools and from falling loads!
z Danger of crushing from heavy loads!
→ When working on the engine suspension, the engine must be appropriately secured against falling or
lowering.
→ 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.
→ Only use lifting equipment tested and approved by Porsche. Home-made and auxiliary constructions result
in improper use and are dangerous.
→ The transport eyebolt can only bear vertical traction with no side or transverse forces. Side loads (e.g. from
chains or cables) will damage the transport eyebolt, which must then be replaced. Extreme cases of
improper use can break the transport eyebolt.
→ Tools and lifting equipment must always be used properly. Improper use or dangerous home-made
constructions can break tools and result in falling loads.
→ Wear protective gloves.
DANGER
Danger of poisoning from silicone, grease and oil!
z Danger of poisoning and damage to skin
→ Do not consume food or drink while working (danger of mixing).

→ Silicones, greases and oils are toxic and must not be swallowed or handled without protection.
→ Observe the specifications on the containers. If swallowed, seek medical advice and show the information
on the containers.
→ Wear gloves.
Note
z When working on the crank mechanism, absolute cleanliness is essential.
z Any seals which have been removed must always be replaced.
z Only the auxiliary and assembly equipment recommended for the repair job may be used for the particular
assembly work.
z Only the auxiliary materials recommended by Porsche (such as lubricants or sealants) may be used.
z All screw fittings must be tightened according to the prescribed torque or torque angle.
Group 13 - Crank drive, pistons
DANGER
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on the containers.
→ Wear gloves.
DANGER
Danger of injury from rotating components and belt drive!
z Risk of severe hand injuries.
→ Never reach into running belt drives or rotating components.

→ Switch off engine.
WARNING
Do not remove the drive belt when the engine is warm!
z Risk of damage or deformation!
→ Drive belts should only be removed when they have cooled down.
DANGER
Danger of injury from running radiator fans (electric fans)!
→ The vehicle fans can continue running or start up when the ignition is switched off.
→ The power supply to the fans must be disconnected before starting work on the radiator or radiator fans.
(Remove fuse → Fuse carrier [9PAAE1 9PAAE7 9PAAF1]→ Fuse carrier [9PAAD1 9PAAD7 9PAAJ1]).
Note
z Work on the crank mechanism/pistons must be carried out very carefully and in clean conditions.
z A dirty engine should be cleaned before opening.
z No dirt may enter the engine when opened.
z During work interruptions, the open engine or components must be covered to protect them from dirt.
z Only processing materials (silicones, oils, greases, etc.) approved by Porsche may be used.
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Note
z Never remove the drive belt when it is hot.
Group 15 - Cylinder head, valve drive
DANGER

on the containers.
→ Wear gloves.
Note
z Work on the valve drive must be carried out very carefully and in clean conditions.
Group 17 - Lubrication
WARNING
Engine oil is toxic.
z Danger of poisoning!

→ If swallowed, observe the warning information on the containers, contact a doctor if necessary and show the
information on the containers.
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WARNING
Danger of scalding from hot oil!
→ Engine oil and components of the oil circuit can become very hot!
→ Allow engine and components to cool down.
→ Avoid contact with the skin and eyes.
→ Wear suitable protective clothing.
WARNING
Oil is combustible!
z Risk of fire due to oil and hot components (exhaust manifold, etc.)
→ Do not pour engine oil over very hot components (e.g. turbocharger).
→ Never place cloths soaked with oil on hot engine components.
→ In case of fire, use CO2 or dry powder fire extinguishers.
Note
z Only oils with the appropriate viscosity and approved by Porsche may be used.
z A mixture of different oils is not permitted.
z During an oil change, the old oil must be drained from the engine via the drain plugs provided. Extraction by
suction is not recommended.
z Engine oil and oil filters must be disposed of according to the respective, applicable national laws.
z Seals in the oil circuit must be replaced by new ones following disassembly.
z Observe the specified torques.
Group 19 - Cooling
ATTENTION
Danger of poisoning!
z Coolant additives and cleaning liquids are toxic.
→ Swallowing coolant additives and cleaning liquids must be urgently avoided.

→ Do not consume any food or drink while working (danger of accidental mixing).
→ If swallowed, observe the warning information on the containers and contact a doctor. If necessary, show
the doctor the warning information on the packaging.
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ATTENTION
Danger of scalding with hot coolant!
→ Never open the cooling system when it is hot. Emerging coolant may be very hot and can cause scalding.
→ The cooling system must be depressurised before being opened.
→ Allow engine to cool down.
DANGER
The vehicle fans can continue running or start up automatically.
z Injuries which can lead to the loss of body parts.
→ The power supply to the fans must be disconnected before starting work on the radiator, radiator fans, or the
belt drive. → Disconnect fuse carrier [9PAAE1 9PAAE7 9PAAF1]→ Disconnect fuse carrier [9PAAD1
9PAAD7 9PAAJ1] or battery → Work instructions after disconnecting the battery
ATTENTION
Risk of damaging the cooling system!
→ Do not relieve the system pressure of the cooling system and then run the engine.
→ Relieving the system pressure and subsequently starting the engine can cause severe damage to
components in the cooling system. If the cooling system must be opened when it is hot, allow the cooling
system to cool down before starting the engine again.
Note
z 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.
z Different coolant additives must not be mixed and doing so may damage the cooling system. Only use
original Porsche coolant additives.
z 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.
z Coolant additives, coolants and cleaning agents must be disposed of according to the respective, applicable
national laws.
z Seals in the cooling system must be replaced by new ones following disassembly.
Information
Group 20 - Fuel supply, control

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DANGER
Danger of poisoning from fuels!
→ Gasoline is toxic.
→ Inhaling vapours can cause irritation of the mucous membranes and eyes.
→ It can be carcinogenic. It represents a serious risk to health when inhaled, touched or swallowed over longer
periods.
→ Only work on the fuel system in well-ventilated rooms.
→ Wear protective gloves that are fuel-resistant.
→ Wear a breathing mask with active charcoal filter; do not breathe in any fuel vapours.
→ Ensure that there is adequate ventilation and extract all fuel vapours.
→ Before opening the fuel lines or fuel hoses, relieve the fuel pressure.
→ Collect escaping fuel, absorb it if necessary with a suitable binding material and dispose of properly.
→ Pay attention to cleanliness when working on the fuel system.
DANGER
Danger of fire from fuel!
→ Keep clear of ignition sources.

→ Do not smoke.
→ Disconnect battery.
→ Danger of fire due to naked flames and sparks, e.g. during welding or grinding work.
→ Danger of fire due to escaping fuel, e.g. on hot engine components or due to electrostatic charge. Allow
engine to cool down.
→ Secure the vehicle, e.g. with a warning sign.
→ Change any clothing soaked with fuel immediately.
Note
z The ignition must be switched off when working on the fuel system.
z Absorb any escaping fuel using a suitable binding material or a cloth.
z Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
z The fuel system must be depressurised before starting work on it.
z Only work on the fuel system in well-ventilated rooms.
Group 21 - Exhaust system, turbocharging

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ATTENTION
Danger of burns from very hot components (turbocharger, exhaust manifold)!
→ Components of the exhaust system can be extremely hot.

→ Allow the parts to cool down first and wear protective gloves.
Note
z After the connecting clamps in the exhaust system have been released, they must always be replaced.
z During assembly work on the exhaust system, ensure that the components are aligned and installed
correctly.
z Seals must be replaced by new ones following removal.
z Observe the correct tightening sequence and tightening torques.
Group 24 - Fuel system, electronic injection
DANGER
periods.
DANGER

→ Do not smoke.
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Note
Precautionary measures when handling oxygen sensors
ATTENTION
The oxygen sensor may be damaged if handled incorrectly.
z Change in engine emissions.
z Damage to the environment.
z Check Engine lamp may come on.
→ Do not remove the plastic cap on the thread until just prior to fitting the oxygen sensor. The thread grease
must never come into contact with the connector.
→ Protect sensors - before and after fitting - against mechanical shocks.
→ Sensors that were dropped on the floor must not be used owing to the risk of a broken ceramic insulator.
→ The cables must not be twisted or kinked when the sensors are screwed in. Avoid pulling on the cable and
connector.
→ Cleanliness in the housing of the plug connections is of utmost importance for the oxygen sensor to function
properly. Particles of dirt can impair the function of the oxygen sensor. The connector must therefore be
protected against any and all types of soiling.
→ Sensors with a soiled or damaged connector must no longer be used.
→ Protect the cables and plugs when carrying or moving the exhaust system with the sensors already fitted.
→ High-pressure cleaning equipment must not be used in the area of the sensors and plug connections.
→ Contact and corrosion agents, e.g. Stabilant, must not be applied to the plug contacts of the oxygen
sensors.
Group 26 - Exhaust system
ATTENTION
Danger of injury from heavy loads!
→ When working on the exhaust system, it must be appropriately secured against falling or lowering.
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→ Never use defective lifting equipment.

→ Only use lifting equipment tested and approved by Porsche.
ATTENTION
Engine exhaust gas!
→ Only operate the engine with an appropriate exhaust gas extraction system.
ATTENTION

Note
correctly.
Group 28 - Ignition system
ATTENTION
High-voltage ignition system!
z Danger of electric shocks!
z This can cause cardiac irregularities.
→ When working on the ignition system, the ignition key must be removed from the ignition lock.
→ The ignition system must be disconnected from the power supply before starting work on it.
→ Only connect/disconnect lines or plugs when the ignition is switched off.
→ Only connect measuring devices when the ignition is switched off.
Note
z The ignition system must be disconnected from the power supply before starting work on it.

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z Spark plug threads must not be greased.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
10 01 IN Securing engine on assembly support - as of MY 2003

- Preliminary work
- Securing engine on assembly support
Tools

Preliminary work
Preliminary work
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1. Lift the engine with a workshop crane. → 10 Lifting the engine with a workshop crane
Securing engine on assembly support
DANGER
Suspended load!

DANGER
lowering.
Note
z Some repair jobs involve suspending the engine on a suitable assembly support.
1. Secure engine support P 9676 on engine → Crankcase on engine support (shown with lower part of
crankcase) . To do this, use the four screws for mounting elements 9590 and tighten them slightly. Secure
engine on engine support. To do this, carefully guide the engine support axle into the take-up bore on the
engine support and secure it.

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as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15,
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
Crankcase on engine support (shown

with lower part of crankcase)
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
10 01 IN Determining the operating cycle of cylinder 1 - as of MY

2003
- Information
Information
Determining the operating cycle of cylinder 1 with the "cylinder pipe" dead centre finder.
ATTENTION
Risk of damage to timing drive mechanism!
z Never twist the crankshaft against the direction of rotation.
z Remove and install the chain tensioner only in overlapping TDC.
z Never twist the crankshaft when the chain tensioner is removed.
z Never twist the camshafts when the chain tensioner is removed.
z Never apply forces across the camshafts in the timing drive mechanism.
z Always counter the sprocket wheels when performing assembly work on them.
→ Forces from the valve drive can cause the timing chain to jump over or tilt.
Note
An alternative method for determining the overlapping TDC is the "cylinder pipe" (dead centre finder). This tool is
part of the pressure-loss tester WE 1066, Workshop Installation Manual 3.1.4.
For some tasks, it is necessary to be familiar with the position of the piston in the cylinder (ignition TDC,
overlapping TDC).
Ignition is off, ignition key is removed.
1. Remove spark plugs for the relevant cylinder 3.→ 287055 Replacing spark plugs
2. The dead centre finder or "cylinder pipe" consists of glass tubes (inspection glass) with pistons -1- , a hose
and a rubber taper -2- .
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Undoing spark plugs using spark plug V8 spark plugs

wrench - V6
Dead centre finder - "cylinder pipe"

3. The rubber taper is pressed onto the spark plug hole. The inspection
glass is either held by an assistant → Tool setup - dead centre finder
or secured vertically using a magnet so that it is clearly visible.
Tool setup - dead centre finder

4. If the engine is then turned in the direction of rotation on the crankshaft, the piston in the inspection glass is
pressed upward in the compression cycle → Top piston , and moves back down again immediately once the
TDC has been reached. The piston remains down in the inspection glass in the overlapping TDC → Bottom
piston .
Compression cycle for cylinder 1 (ignition TDC)
Note
z This method only works in ignition rod modules that have rubber seals facing the spark-plug recess.
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Bottom piston Top piston
Ignition rod module of cylinder 1 V8 spark plugs
2. Find ignition TDC of cylinder 1. To do this, insert the ignition rod module of the first cylinder into the
corresponding opening in the valve cover and press in firmly.
3. Twist the crankshaft in the direction of motion until the ignition rod
module comes out again with an audible plop.
Ignition rod module of cylinder 1 pops

out
Note
z If the crankshaft is then turned through 180°, the piston in cylinder 1 will be located in the bottom dead centre
(BDC). The emission cycle then follows.
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TDC marking of cylinder 1
4. Then twist the crankshaft until the fixing bore on the crankshaft belt pulley is aligned with the bore in the
timing case cover. The engine is now located in the ignition TDC of cylinder 1.
Intake cycle (overlapping TDC)
Note
1. Remove spark plugs for the relevant cylinder 3.→ 287055 Replacing
spark plugs
V8 spark plugs
2. Find overlapping TDC of cylinder 1. To do this, insert the ignition rod
module of the first cylinder into the corresponding opening in the valve
cover and press in firmly.
Ignition rod module of cylinder 1

3. Twist the crankshaft in the direction of rotation until the ignition rod module comes out again with an audible
plop .
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TDC marking of cylinder 1 Ignition rod module of cylinder 1 pops

out
Note
z If the crankshaft is then turned through 180°, the piston in cylinder 1
will be located in the bottom dead centre (BDC). The compression
cycle then follows.
5. Remove the marking mandrel if necessary and twist the crankshaft

through 360° in the direction of motion. The engine is now located in
the overlapping TDC of cylinder 1.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
10 01 IN Tightening torques for Cayenne S (M48/00) and Cayenne

Turbo (M48/50) - as of MY 2003
- Information
Information
Information
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V8 engine
Note
z This torque list is organised according to component groups in the same way as service numbering.
z The torque for the coolant pump is provided in Chapter 19.
z The tightening sequences are indicated in the figures in the corresponding chapters, and it is essential to
observe them.
z The most important torques are specified at the end of the respective chapters.
The torques in the table below generally apply to screws which are not specifically listed.
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Bolt quality 8.8 Bolt quality 10.9

Thread ftlb. Thread ftlb.
M4 3 M4 4
M5 6 M5 8
M6 10 M6 13
M8 23 M8 33
M10 45 M10 65
M10 x 1.25 50 M10 x 1.25 70
M12 80 M12 115
M12 x 1.25 90 M12 x 1.25 125
M12 x 1.5 85 M12 x 1.5 120
M14 130 M14 180
M16 200 M16 280
Group 10 - Crankcase, suspension
Location Thread Tightening torque [Nm] (ftlb.)

Thrust block screw fitting M12 x 1.5 x 132 40 (30) + 75° (observe sequence!)
Thrust block screw fitting M10 x 117 22 (16) + 60° (observe sequence!)
Oil spray valve on crankcase M6 x 16 10
Top section of crankcase with bottom section of M8 23
crankcase - cross bolt connection
Bracket for auxiliary units M10 x 45 65
Design cover M5 x 16 5
Engine carrier, cylinder row 1 - 4 M10 x 45 65
Bracket for torque support M6 x 40 13
Tightening sequences
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Sealing flange on timing case cover M6 10
Belt pulley (vibration balancer) on crankshaft M16 x 1.5 x 77 20, 50, 250, then 90° (always replace screw!)
Deflection roller, left M10 x 41 35
Deflection roller, right M10 x 85 35
Belt tensioner on bracket M8 x 33 35
Belt tensioner on timing case cover M8 x 100 35
Tensioner roller on belt tensioner M10 35
Connecting rod cap on connecting rod M9 x 56 8 (6), then 40 (30), then 90° (always replace
screws with new ones!)
Air-conditioning compressor on engine M8 x 95 23
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Servo pump on engine M8 x 35 23
Belt pulley on servo pump M8 x 16 23
Drive plate to crankshaft M10 x 22 60 (44) + 90° (always replace screws with new
ones!)
Group 15 - Cylinder head, pistons

Timing case cover M6 See Note
Timing case cover M8 x 50 23
Tensioning rail bearing M10/12 x 25 35
Chain tensioner M24 x 1.5 60
Guide rail bearing on camshaft housing M8 x 25 20
Guide rail M8 x 25 20
Deflector rail M8 x 35 32
Chain sprocket on exhaust camshaft M12 x 1.5 x 140 10 (7.5), then 50 (37), then 90°
Camshaft adjuster on inlet camshaft M12 x 1.5 x 140 10 (7.5), then 50 (37), then 135°
Camshaft housing cover (valve cover) M6 x 30 13 (9.5) (observe sequence!)
Camshaft bearing saddles M6 x 35 10 (7.5) (observe sequence!)
Thrust bearing cover on camshaft housing M6 x 35 10
Hall sender on camshaft housing M6 x 16 10
Camshaft housing on cylinder head M8 23
Hydraulic valve for camshaft adjuster M6 x 16 10
Adapter for torque support M10 x 24 20
Cylinder head M12 x 1.5 x 140 30 (22), then 50 (37), then loosen
30 (22), then 30 (22), then 90°
Ground point on camshaft housing M6 x 12 10
Cable duct on timing case cover M6 x 18 10
Cable duct on cylinder head 5 - 8 M6 x 12 10
Note
z The exterior fastening screws must have a quality of 10.9.
z If the quality is 8.8, the screws must be replaced.
z Tighten screws 1 to 4 (M6 / 8.8) to 7.5 ftlb.
z Tighten screws 5 to 6 (M8 / 8.8) to 17 ftlb.
z Tighten screws 7 to 32 (M6/10.9) to 13 Nm (9.5 ftlb.).

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Chain sprocket on oil pump M10 x 1 45
Oil pump on crankcase M8 x 50 23
Chain cover on oil pump M5 x 20 6
Tensioning rail bearing for oil pump M8 x 25 20
Short oil extraction pipe M6 x 25 13
Oil extraction pipe M6 x 25 13
Oil drain plug M18 x 1.5 50
Oil return line into oil pan M6 x 20 10
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Oil pan on crankcase M6 x 25 10

Oil level sender on oil pan M6 x 25 10
Guide tube for oil dipstick M6 x 16 10
Cover on oil filter bracket M6 x 20 10
Oil filter bracket on oil pan M8 x 70 23
Spacer sleeve for oil filter bracket M16 x 1.5 2 (1.5) to 5 (3.5)
Oil filter bracket on connection piece M8 x 50 23
Oil/water heat exchanger M6 x 20 10
Oil filter housing S80 x 3 25 (19) (sealing ring oiled)
Oil pressure switch on oil filter bracket M10 x 1 20
Group 19 - Cooling

Belt pulley on coolant pump M8 x 16 23
Water pump on crankcase M6 x 25 10 (7.5) (observe sequence!)
Thermostat housing cover M6 x 25 10 (7.5) (observe sequence!)
Coolant distribution pipe M6 x 25 10
Thermostat housing trough M6 x 16 10
Coolant pipe on crankcase M6 x 16 10
Coolant drain plug on distribution pipe M16 x 1.5 x 6 30
T-piece on generator M6 x 16 10
Supply connection fitting on generator M6 x 16 10
Coolant pipe on thermostat housing M6 x 12 10
Temperature sensor on coolant distribution pipe M14 x 1.5 30
Thermostat housing
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Water pump

Fuel tank restraining strap M8 x 25 23
Carbon canister and degassing tank M6 10
Filler neck fastening screws M6 10
Connection unit ring fastener 140
Filler neck fastening screws M6 x 20 10
Cover plate under rear seat M6 10

Knock sensor on crankcase M8 x 35 23
Intake distributor M7 x 52 10 (7.5), then 15 (11) (observe sequence!)
Throttle adjuster M6 x 45 8
Fuel distribution pipe on intake distributor M6 x 10 8
T-piece on intake distributor 2,2
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Suction module

Exhaust manifold on cylinder head M8 25, then 33 (observe sequence); replacing
fastening nuts
Oxygen sensors in exhaust manifold M18 x 1.5 45
Oxygen sensor holder on engine M6 x 12 10
Secondary air pump on holder M6 x 50 10
Secondary air pump holder M6 x 50 10
Exhaust system fastening screws M8 x 25 23
Exhaust clamps M10 60 (44) (replace)
Fastening screw for catalytic converter holder M8 23
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Exhaust manifold
Group 27 - Starter, power supply

Generator on crankcase M8 23
B+ wire on generator M8 plastic 18
Heat shield on generator M6 x 12 10
Starter M10 x 45 45 (33) to 53 (39)
B+ wire on starter M8 18
Terminal 50 on starter M6 9

New spark plug M14 x 1.25 30
Spark plug reinstallation M14 x 1.25 25
Ignition coils M6 x 16.5/M5 x 9 10
Knock sensor M8 x 35 23
9PAAE1, 9PAAE7
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
10 01 IN Lifting the engine with a workshop crane - as of MY 2003

- Removing design cover on cylinder bank 5-8
- Lifting the engine
Tools

Tools and materials
Special tools
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Suspending device

-A- Suspending device See Workshop Only this tool
3033 Equipment Manual, is tested and
Chapter 2.2.3 approved by
Porsche. It
guarantees
only vertical
traction of the
transport
eyebolt with
no side or
transverse
forces.
-B- Transport eyebolt See Workshop The transport
9700 Equipment Manual, eyebolt can
Chapter 2.2.2 only bear
vertical
traction with
no side or
transverse
forces. Side
loads (e.g.
from chains
or cables) will
damage the
transport
eyebolt, which
must then be
replaced. The
transport
eyebolt can
be broken in
extreme
cases.
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Removing design cover on cylinder bank 5-8
1. Remove design cover from cylinder bank 5-8. To do this, loosen the
four fastening screws -arrows- on the design cover.
Fastening screws
2. Lift the cover slightly with both hands at the side pointing towards the
intake system until it is released from its holder.
Unclipping cover
3. Lift the front of the design cover and remove it.
Removing the cover
Lifting the engine
Lifting the engine

The engine must be detached from the transmission. → 343527 Removing and mounting the
transmission [9PAAE7]→ 343527 Removing and mounting the transmission [9PAAE1 9PAAF1 9PAAJ1] or
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→ 373527 Removing and mounting the transmission [9PAAE1 9PAAF1 9PAAJ1]→ 373527 Removing and
mounting the transmission [9PAAE7]
DANGER
Suspended load!

DANGER
lowering.
Note
z Place a cloth between the secondary air pump bracket and design cover to avoid scratching the cover.
Note
z Never use defective lifting equipment (bent or damaged tools must not be used or repaired -3- . Always
replace these tools). Check tools for signs of damage before use.
z The transport eyebolt must only be pulled straight -1- . Never use side or transverse force on the transport
eyebolt -2- because this can damage the transport eyebolt.
1. Screw transport eyebolt 9700 hand-tight as far as you can into the opening on cylinder head 5 - 8 -arrow- .
2. Insert an M10 screw through the torque support bracket and secure it with a nut. Then attach the hooks of
the suspending device 3033 on both sides → Engaging torque support bracket → Engaging transport
eyebolt after screwing it in . Align the suspending device so that it only pulls the transport eyebolt. To do this,
adjust the spindles of the hooks in such a way that the suspending device 3033 is suspended as
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Bore for transport eyebolt
Damaged transport eyebolt
Engaging torque support bracket

horizontally as possible above the engine. Move the spindles on the suspending device into positions 4 and
9. Side forces, e.g. from cables or chains attached at an angle, will bend and break the transport
eyebolt.
Engaging transport eyebolt after

screwing it in
3. Engage spindles into positions 4 and 9 -A and B- of the
suspending device 3033 and tension spindles slightly. Lift the
engine carefully and balance it out. Raise the engine as shown.
→ Lifting the engine
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Position 4 and 9 -A and B- Lifting the engine
Suspending device
as of MY 2003
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ADVERTENCIA
10 01 IN Supporting the engine on the body - as of MY 2003

- Supporting the engine on the body
Tools

Safety device special tool 10-222
A
Tools and materials
Special tools required

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Overview of safety device

-A- Safety device 10-222 A Only this tool is tested and
approved by Porsche.
-B- Spring hook or chain For lengthening
-C- Transport eyebolt 9700 The transport eyebolt can only bear
vertical traction with no side or
transverse forces. Side loads (e.g.
from chains or cables) will damage
the transport eyebolt, which must
then be replaced. The transport
eyebolt can weaken and break if
this instruction is not observed.
Supporting the engine on the body
WARNING
Danger of injury from falling loads!
z Drive line components (engine, transmission, etc.) can fall down.
→ Before starting work, check the body for structural damage (accident, corrosion, etc.). The load capacity of
the wing mounting points must not be restricted.
→ Do not apply excessive force (e.g. a high screw torque) to supported units.
→ Units must not be supported on the body over an extended period of time.
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DANGER
lowering.
Note
z The transport eyebolt must only be pulled straight -1- . Never use
side or transverse force on the transport eyebolt -2- because this can
damage the transport eyebolt.
Note
z The engine must be supported on the body for some repair work on
the front axle and engine bearings.
Note
z When setting up the suspending device, make sure not to scratch or
damage adjacent components.

1. Remove design cover of cylinder bank 5-8. Unscrew the four fastening screws on the design cover.
2. To do this, lift the cover slightly with both hands at the side pointing towards the intake system until it is
released from its bracket.
4. Screw transport eyebolt 9700 hand-tight as far as you can into the opening on cylinder head 5 - 8 → Bore
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Supporting the design cover Design cover of cylinder bank 5-8
Bore for transport eyebolt Design cover of cylinder bank 5-8
for transport eyebolt .
5. Position the suspending device on the inner side of the wing, near the radiator tank, and align it. Then tighten
the two wing nuts.
6. Engage the hook of the suspending device in the transport eyebolt

and tighten the wing nut.
Hook in transport eyebolt
Note
z Place a cloth between secondary air pump bracket and design cover to avoid scratching the cover.
7. Insert an M10 screw through the torque support bracket and secure it with a nut. Then attach the hook of the
safety device 10-222 A. If the hook is too short, lengthen it with a suitable spring hook or chain → Fastening
to torque support bracket . Tighten wing nut. Pull the engine slightly and make sure that the force is
distributed evenly on both spindles → Complete view of engine support on body .
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Fastening to torque support bracket
Complete view of engine support on body
as of MY 2003
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10 01 WM (Special) tools required for repairing the M48/00 and

M48/50 engines - as of MY 2003
Tools

A
Spark plug wrench special tool 3122 B

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Oil filter spanner special tool 9204
Relay puller special tool 9235
Plug special tool 9264/7
Toothed segment special tool 9538/1

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Locating pin special tool 9595
Spacer special tool 9609/2
Engine support special tool 9676

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Camshaft guide special tool 9678
Arm bracket special tool 9679

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Assembly sleeve special tool 9701
Bonnet stay special tool 9704
Socket-wrench insert special tool 9714

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Chain pipe cutters special tool NR.166
Drift punch, 1 mm tip, special tool NR.167
Slide hammer kit special tool NR.168
Multiple-tooth socket wrench special tool NR.31

insert M12
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56-piece Torx screw tool set special tool NR.49-1
Circlip pliers for spring band special tool NR.72-1

clamps, Cayenne hose
connections
Flexible screwdriver a/f 7 special tool NR.73-1
Torque angle torque key special tool NR.88

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Mechanical angle disc for special tool NR.88-1

torque angle threaded joint
Tools and materials
(Special) tools required for repairing the M48/00 and M48/50 engines
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Tools overview 1

-1- Tester for cooling system See Workshop Equipment Required for leak test of cooling
Manual 3 system
-2- Socket-wrench insert 9714 See Workshop Equipment Very low height, for turning the engine
Manual 2.2.2
-3- Plug 9264/7 See Workshop Equipment For intake system leak test. Use with
Manual 2.2.2 compressed-air reducer
-4- Torque angle torque key NR.88 See Workshop Equipment For torque-angle-controlled tightening
Manual 2.4 of screws.
-5- Suspending device 3033 See Workshop Equipment Required to transport the engine
Manual 2.2.3
-6- Transport eyebolt 9700 See Workshop Equipment Required to transport the engine or to
Manual 2.2.2 support the body
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-7- Safety device 10-222 A See Workshop Equipment For supporting the body
Manual 2.2.3
-8- Spacer 9609/2 See Workshop Equipment Required to fit the radial shaft seal on
Manual 2.2.2 the flywheel
-9- Assembly sleeve 9701 See Workshop Equipment For positioning the sealing lip on the
Manual 2.2.2 camshaft switch-over valve
-10- Camshaft guide 9678 See Workshop Equipment For adjusting the timing
Manual 2.2.2
-11- Locating pin 9595 See Workshop Equipment For fixing the pulley. The piston is then
Manual 2.2.2 in the TDC
-12- Relay puller 9235 See Workshop Equipment For removing the camshaft switch-over
Manual 2.2.2 valve
-13- Arm bracket 9679 See Workshop Equipment Required to loosen the pulley
Manual 2.2.2 fastening.
-14- Bonnet stay 9704 See Workshop Equipment Facilitates the vertical raising of the
Manual 2.2.2 bonnet
-15- Chain pipe cutters NR.166 See Workshop Equipment For disconnecting the exhaust system
Manual 2.4
-16- Flexible screwdriver a/f 7 See Workshop Equipment For loosening and tightening hose
NR.73-1 Manual 2.4 clamps
-17- Antifreeze protection and battery See Workshop Equipment For checking antifreeze contents, acid
acid tester Manual 3 density and windscreen cleaner
-18- Circlip pliers for spring band See Workshop Equipment For opening and loosening spring-band
clamps, Cayenne hose Manual 2.4 clamps
connections NR.72-1
-19- 56-piece Torx screw tool set See Workshop Equipment Required for all assembly work on the
NR.49-1 Manual 2.4 vehicle
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Tools overview 2

-20- Mechanical angle disc for torque angle See Workshop Equipment For torque-angle-
threaded joint NR.88-1 Manual 2.4 controlled tightening
of large screws
(pulley, suspension
subframe)
-21- Spark plug wrench 3122 B See Workshop Equipment For installing and
Manual 2.2.3 removing spark
plugs.
-22- Filling device 9696 See Workshop Equipment For filling the cooling
Manual 2.2.2 system
-23- Porsche System Tester ll 9588 See Workshop Equipment For reading out the
Manual 2.2.2 fault memory or for
activating drive links
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-24- Oil filter spanner 9204 See Workshop Equipment For unscrewing and
Manual 2.2.2 tightening the oil filter
-25- Slide hammer kit NR.168 See Workshop Equipment For pulling out the
Manual 2.4 crankshaft sealing
ring on the flywheel
side
-26- Toothed segment 9538/1 See Workshop Equipment For fixing the
Manual 2.2.2 flywheel
-27- Multiple-tooth socket wrench insert M12 See Workshop Equipment For loosening the
NR.31 Manual 2.4 flywheel
-28- Drift punch, 1 mm tip, NR.167 See Workshop Equipment For perforating the
side
-29- Socket-wrench insert with recommended size See Workshop Equipment For removing and
→ 159121 Removing cover for camshaft housing Manual 2.4 installing the
camshaft housing
cover
-30- Plug 9710/3 See Workshop Equipment For checking the
Manual 2.4 exhaust system for
leaks
-31- Engine support 9676 See Workshop Equipment For attaching the
Manual 2.4 engine to the
assembly support.
-32- Engine unit elevating platform WE 1206 See Workshop Equipment
Manual 3.0.13
as of MY 2003
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10 04 33 Completing reconditioned engine - as of MY 2003
Completing reconditioned engine
Note
z In order to replace the old, removed engine with a new one, some re-fitting work must be done.
z Starting point for re-fitting work: old engine is secured to assembly support and the new one is in the
transport cradle.
z At higher mileages, components (cooling hoses, clips etc.) must be checked for damage and, if necessary,
replaced.
1. Remove numerous transport plugs for water and vacuum connection pieces of the new engine.
2. Check that all leads and hoses between the engines have been re-fitted and no component has been
forgotten.
3. Depending on the transmission version, the drive plate → 136319 Removing and installing drive plate for
torque converter [9PAAE1 9PAAF1 9PAAJ1]→ 136319 Removing and installing drive plate for torque
converter [9PAAE7] or flywheel → 136019 Removing and installing flywheel [9PAAE7]→ 136019 Removing
and installing flywheel [9PAAE1 9PAAF1 9PAAJ1] must be re-fitted.
as of MY 2003
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10 10 55 Replacing crankcase - as of MY 2003

- Preliminary work
- Information
- Replacing crankcase
- Subsequent work
Preliminary work
Preliminary work
5. Remove left additional assembly bracket -2- and right engine carrier -8- . There are still two dowel sleeves
(not shown) on the additional assembly bracket.
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5- Engine carrier
8- Engine carrier
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"Removing"
"Removing"
13. Remove oil spray jets on turbo engine and cap on naturally aspirated engine. → 101321 Removing oil spray
jets for piston cooling [9PAAF1 9PAAJ1]→ 101321 Removing oil spray jets for piston cooling [9PAAE1
9PAAE7]
Information
Component overview
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Upper crankcase section assembly
1- Crankcase, top
2- Closure cap
3- Seal
4- Closure cap
5- Screw → Tightening torque: 10 (7.5 ftlb.) Nm
6- Screw plug → Tightening torque: 10 (7.5 ftlb.) Nm
7- Sealing ring
8- Sealing ring (not marked in illustration)
9- Screw plug → Tightening torque: 75 (56 ftlb.) Nm
10 - Oil spray jets on turbo engine and cap on naturally aspirated engine
11 - Dowel sleeves
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Replacing crankcase
Replacing crankcase
ATTENTION
Risk of damage to cylinder liners on new crankcase if the old pistons are used.
z Piston separation could cause the dimensions of the old piston to be unacceptably large compared
with the new cylinder bore.
z Risk of piston and cylinder-liner scoring if old, worn pistons are used.
→ The piston rings on the pistons must always be replaced when replacing the crankcase.
ATTENTION

Note
The bearing shells of the main and connecting-rod bearings must be replaced on vehicles with high mileage.
1. Remove coolant guide. To do this, remove 10 screws -arrows- .

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Coolant pipe
Component overview for coolant guide

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Coolant guide
1 - Distributor pipe
2 - Temperature sensor
3 - Sealing ring
4 - Screw plug → Tightening torque: 30 (22 ftlb.) Nm
5 - Fastening screws on distributer pipe → Tightening torque: 10 (7.5 ftlb) Nm
6 - Gasket; replace
7 - Sealing ring; check and replace if necessary
8 - Coolant pipe
2. Remove coolant guide and remove seals. Clean sealing surfaces.
3. Re-fit crankcase. When doing so, watch out for dowel sleeves and studs.
4. Fit coolant guide with new seals.

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Subsequent work
Subsequent work
1. Assemble engine. → Assembling engine
as of MY 2003
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ADVERTENCIA
10 18 02 Testing pressure loss from the engine - as of MY 2003

- Preliminary work
- Information
- Testing pressure loss from the engine
- Subsequent work
Preliminary work
Preliminary work
1. Unscrew all spark plugs. → 287055 Replace spark plugs
Spark plugs
2. Position cylinder to be tested to ignition TDC and remove tool. There
are two ways of ascertaining the compression cycle in V8 engines
with sealed-off ignition rod modules. → Determining the operating
cycle of cylinder 1
Ignition rod module comes out at TDC

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Tools and materials
Tool kit for testing pressure loss

-A- Testing hose with spark plug see Workshop Equipment
thread WE1066 pressure loss Manual, Chapter 3.1.4
tester Bosch EFAW 210 A
-B- Test nozzle WE1066 pressure see Workshop Equipment Test nozzle for adjusting display scale.
loss tester Bosch EFAW 210 A Manual, Chapter 3.1.4 This must be done before every test.
-C- Pressure loss tester WE1066 see Workshop Equipment
pressure loss tester Bosch Manual, Chapter 3.1.4
EFAW 210 A
Information
Test evaluation
z The test does not show any meaningful result on a new engine (i.e. one that hasn't been run in).
z A difference in pressure loss between the individual cylinders of approx. 5% is not significant.
z 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.
z 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.
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Potentially faulty component Location of noise

Pistons, piston rings, cylinder Oil filler neck, positive crankcase
line ventilation
Cylinder head gasket, cylinder Coolant expansion tank
head
Exhaust valve Exhaust system
Inlet valve Intake system
Testing pressure loss from the engine
ATTENTION
Danger of damage or injury if pressure loss tester is operated incorrectly
→ Ensure that operational steps and tips from the tool instruction manual for the Bosch tester are observed at
all times.
WARNING
Danger of injury!
z The crankshaft can turn because of the pressure in the cylinder.
→ The piston must be located accurately in the upper reversing point.

→ Do not touch any belt drive components during the test.
→ Do not insert any tool on the belt pulley of the crankshaft.
Note
z The check for loss of pressure can be used to assess the mechanical condition of a combustion engine.
z 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.
z The worn components (e.g. piston rings) can be identified by the compressed air that is escaping.
1. Screw in the test hose by hand into the spark plug thread and tighten it by hand.
2. Connect the pressure loss tester to the compressed air system.
3. Adjust the scale. To do this, insert the test nozzle at the front into the device.
4. Turn the adjusting wheel until the scale pointer is at the "cal." marking or "23%". The pressure is then equal
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Adjusting the scale Test hose
Adjusting wheel
in the two test chambers of the tool.
5. Remove test hose and check that the pointer falls back. Connect the
test hose. The value that is displayed should not be greater than
30%. If the loss in pressure is greater, it can be assumed that the
engine needs an overhaul.
6. Interrupt the compressed air supply and unscrew the test hose.
7. Check the next cylinder by turning the crankshaft through another

90° and check the next cylinder in the firing order following the
instructions provided.
Firing order: 1 - 3 - 7 - 2 - 6 - 5 - 4 - 8
Check for loss of pressure
Subsequent work
Subsequent work
1. Remove the test hose once the test is complete and install the spark plugs. For tightening torques see
→ 287055 Replacing spark plugs
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Spark plugs
as of MY 2003
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10 19 02 Checking compression of cylinders - as of MY 2003

- Preliminary work
- Information
- Testing engine compression
- Subsequent work
Tools

Preliminary work
Preliminary work
1. Open the bonnet.
2. Open lid of central electrics box. To do this, loosen the four fastening screws.
WARNING
Risk of electric shocks from high-voltage ignition system and danger of damage to ignition rod modules!
z Connected ignition rod modules can be damaged.
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→ Always remove the ignition rod module fuse.

→ Always disconnect ignition rod module electrical connections.
ATTENTION
Risk of damage to components that affect the exhaust system!
z Unburnt injected fuel enters the exhaust system.
→ Prevent the fuel from injecting by removing the fuse.
Central electrics box

3. Remove the fuses -7- for the ignition rod modules -8- and injection
system.
Fuses for ignition rod modules and fuel injectors
4. Remove spark plugs.
Spark plugs
Tools and materials
Tools and materials

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Tools for testing pressure loss

-A- Spark plug wrench 3122 B See Workshop Equipment
Manual, Chapter 2.2.3
-B- Compression tester WE1065 See Workshop Equipment Tester range: between 3.5 and 17 bar
Moto-Meter compression tester Manual, Chapter 3.1.4 Number of cylinders: max. 8
-C- Flexible extension WE1065 See Workshop Equipment
Moto-Meter compression tester Manual, Chapter 3.1.4
-D- Extension with spark plug thread See Workshop Equipment
WE1065 Moto-Meter Manual, Chapter 3.1.4
compression tester
Information
Evaluating test results and prerequisites for testing
Note
z A test document is created when a compression test is performed.
z In order to prevent misuse, vehicle ID, date and current mileage must be entered.
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Test sheet
No. Designation Instructions

-A- Vehicle ID This is used to assign the test diagram to the vehicle that is
being tested. The engine number or the chassis number
can be entered here instead of the vehicle ID.
-B- Date Provides information about when the test was performed.
-C- Mileage Provides information about when the test was performed.
-I- Compression pressure in the cylinder that The pressure is measured in bars.
is tested 1 bar = 14.5 psi.
There are various diagram charts. The charts for petrol
engines are used.
-II- Difference in pressure between the The pressure difference between two cylinders must not be
individual cylinders greater than 1.5 bars.
z The throttle must remain open during the test.

z The vehicle voltage must remain more or less constant during the test (connect a charger).
z The vehicle voltage must not drop below 12 V.
z The fuses for the injection system and the ignition system must be removed during the test.
z The engine must be at operating temperature.
Testing engine compression
Note
The compression test can only provide an indication as to whether the tested cylinder is working or not working
properly. The cause of any loss can be further isolated by a pressure loss test.→ 101802 Testing pressure loss
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1. Press pressure tester onto the relevant cylinder.
Note
z Once the starter is activated, it switches on the engine for approx.
seven seconds.
z This process should not be interrupted.
z The vehicle voltage must not drop below 12 V during the test.
z The throttle must always remain in the same position throughout the
Pressure tester
test. A mechanical pressing-on tool is not permitted.
z The accelerator pedal must be fully depressed during the test.
2. Have the starter actuated by a second person. Testing of this cylinder is complete when the needle of the
test device ceases to rise. Keep the accelerator pedal fully depressed.
3. Deflate the pressure on the tester.
4. Move the scale on to another cylinder. To do this, pull the pin once
under the handle on the back → Moving the test device on by one
cylinder .
5. Then check the next cylinder according to number sequence (not

according to firing order).
Moving the test device on by one

cylinder
Subsequent work
Subsequent work
1. Fit spark plugs. For tightening torques see → 287055 Replacing

spark plugs – section on "Installing".
2. Fit the ignition rod module fuses and the injection system.
Spark plugs
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Fuses for ignition rod modules and injection valves
3. Fit lid of central electrics box.
as of MY 2003
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WARNUNG
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ATTENZIONE
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ADVERTENCIA
10 30 19 Removing and installing engine carrier - as of MY 2003

- Preliminary work
- Information
- Removing engine carrier
- Installing engine carrier
- Subsequent work
Preliminary work
Preliminary work
1. Support engine on the body.→ Supporting engine on the body.
2. Remove engine guard. → 108019 Removing and installing engine guard - chapter on "Removing"
3. Remove front axle until the engine carrier can be removed. → 400619 Removing and installing front-axle
carrier - chapter on "Removing" [9PAAJ1]→ 400619 Removing and installing front-axle carrier - chapter on
"Removing" [9PAAE1 9PAAE7 9PAAF1]
Information
Component overview
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Component overview
1 - Fastening nut, M12 X 1.5

2 - Bracket for auxiliary units
3 - Fastening screw, M10 x 45
4 - Align left-hand hydraulic mount with the aid of the engine carrier -5- then tighten the fastening nuts -1- .
5 - Engine carrier
6 - Fastening screw
7 - Align right-hand hydraulic mount with the aid of the engine carrier -5- then tighten the fastening nuts -1- .
8 - Engine carrier, right
Removing engine carrier

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WARNING
Danger of injury!
lowering.
→ The components are very heavy. There is a danger of crushing.
→ Please observe general warning notes.
Note
z This task can only be performed if the engine has been removed or suspended on the body.
Note
z Do not undo the engine mounts on the engine.
z If the engine mounts have been undone on the engine, they must be aligned using the engine carrier.
→ 103519 Removing and installing engine mount
Engine carrier
1. Undo the two fastening screws → Fastening screws for engine mounting to the left and right on the hydraulic
mounts.
2. Undo the two fastening screws from the engine carrier to the body and remove the engine carrier.
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Fastening screws for engine mounting

Installing engine carrier
1. Install engine carrier. To do this, first position the fastening screws

(M10 x 45) on the hydraulic mounts and tighten them. → 103519
Removing and installing engine mounting - "Installing" chapter
Subsequent work
Subsequent work
1. Screw in new fastening screws for securing the engine carrier to the body. → Initial tightening: 89 ftlb. →
Torque angle: 180 °
2. Install front axle. → 400619 Removing and installing front-axle carrier - chapter on "Installing" [9PAAJ1]
→ 400619 Removing and installing front-axle carrier - chapter on "Installing" [9PAAE1 9PAAE7 9PAAF1]
3. Install engine guard. → 108019 Removing and installing engine guard - chapter on "Installing"
as of MY 2003
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ATTENZIONE
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ADVERTENCIA
10 35 19 Removing and installing engine mounting - as of MY

2003
- Preliminary work
- Information
- Removing engine mounting
- Installing engine mounting
- Subsequent work
Preliminary work
Preliminary work
carrier - chapter on "Removing" [9PAAJ1]→ 400619 Removing and installing front-axle carrier - chapter on
"Removing" [9PAAE1 9PAAE7 9PAAF1]
Information
Component overview
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Component overview
1 - Fastening nut, M12 X 1.5

2 - Bracket for auxiliary units
4 - Align left-hand hydraulic mount with the aid of the engine carrier -5- then tighten the fastening nuts -1- .
5 - Engine carrier
6 - Fastening screw
7 - Align right-hand hydraulic mount with the aid of the engine carrier -5- then tighten the fastening nuts -1- .
8 - Engine carrier, right
Removing engine mounting

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WARNING
Danger of injury!
lowering.
Note
z This task can only be performed in the Cayenne S (M48/00) if the engine has been removed or suspended
on the body. This description covers suspension on the body.
z The engine must be removed on the Cayenne Turbo (M48/50) → 100119 Removing and installing V8 4.5 l
engine - section on "Removing". The turbochargers are removed next. → 213021 Removing turbocharger -
section on "Removing" [9PAAF1 9PAAJ1]→ 213021 21 Removing turbocharger - section on
"Removing" [9PAAE1 9PAAE7].
1. Undo the two fastening screws -Arrows- to the left and right on the
hydraulic mounts.
Hydraulic mount
2. Undo the two fastening screws from the engine carrier to the body
and remove the engine carrier. -Centre arrow-
3. Undo engine mounts. To do this, undo the fastening nuts on the

support arms and remove the engine mounts.
Engine carrier
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Installing engine mounting
Installing engine mounts
Note
z The engine mounts must be aligned using the engine carrier.
z The engine mounts differ (left/right) and must not be interchanged.
1. Position engine mounts on the support arm. When doing so, note the positioning pin on the mount. It must
engage in the recess on the support arm.
2. Position new fastening nuts and screw them on so that the positioning pin cannot pop out. Do not tighten the
fastening nuts.
3. Fit the engine carrier → Fastening screws for hydraulic mount .

Position the fastening screws (M10 x 45) for the hydraulic mounts
and tighten them. → Tightening torque: 44 ftlb.
4. Tighten engine mounts on the engine. Tighten the fastening nuts. →
Tightening torque : 56 ftlb.
Fastening screws for hydraulic mount
Subsequent work
Subsequent work
1. Screw in new fastening screws for securing the engine carrier to the body. → Initial tightening: 89 ftlb. →
Torque angle: 180 °
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
10 80 19 Removing and installing engine guard - as of MY 2003

- Information
- Removing engine guard
- Installing engine guard
Information
Overview
Engine cover, complete

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Engine cover screws
1- Engine guard, front

2- Engine guard
3- Fastening screw M6
4- Transverse strut
5- Fastening nut M6
-
Removing engine guard
1. Remove front engine guard. To do this, loosen the screws -1- at the
front and side. Then loosen the rear -2- and front screws -3- .
Front screws
2. Remove rear engine guard. To do this, loosen the fastening screws on the transmission cross member -1-
and the screws on the traverse strut -2- .
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Installing engine guard
Rear screws
1. Install the rear engine guard. To do this, screw in the front fastening
screws -2- and rear fastening screws -1- .
2. Tighten front fastening screws -3- and rear fastening screws -2- and
-1- → Tightening torque: 6.5 ftlb. .
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
10 83 19 Removing and installing design cover. - as of MY 2003

- Information
- Removing design cover
- Installing design cover
Information
Overview
Overview of design cover
Note
z A special paint is applied to the covers for reasons of appearance.
z When the engine is washed, a minimum clearance of 50 cm must be maintained between the cleaning
apparatus lance and the covers.
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z The covers are sensitive to scratching.
z Small scratches on the paintwork can be touched up with a special touch-up applicator.
Individual parts of design cover
1 - Design cover, cylinder row 5-8

2 - Countersunk screw, M5 x 16
3 - Sleeve
4 - Rubber sleeve
5 - M6 screw with M5 internal thread; for securing ignition coil
6 - Rubber ball socket
7 - Sheetmetal holder; fastening on valve cover; screw fastening points 4 and 5
9 - Throttle body cover
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Removing design cover
Removing throttle body cover
Throttle body cover

Removing design cover of cylinder row 1 - 4
Note
1. Remove engine compartment cover on the right and rear. → 700219 Removing and installing front cover
(engine compartment)
2. Detach the torque support. To do this, unscrew the fastening screw

on the torque support bracket and pull it out.

3. Detach the torque support from the body and swivel upwards.
4. Detach the secondary air pump from cylinder row 1-4. To do this, unscrew the 3 fastening screws, pull the
pump out of the support and lay it aside.
5. Unscrew the four fastening screws on the design cover (picture shows side 5 - 8).
6. Remove design cover from cylinder bank 1 - 4. Lift the cover slightly with both hands on the edge pointing
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Secondary air pump Swivelling the torque support
Lifting the design cover Fastening screws of design cover
towards the intake system until it snaps out of the fastening points.
7. Lift the cover at the front edge and slide the ignition coil cover of the
second cylinder out of the torque support bracket. Pull out cover to
the front.
Removing the design cover

Removing design cover of cylinder bank 5 - 8
Note
z Place a cloth between secondary air pump and design cover to avoid scratching the cover.
1. Unscrew the four fastening screws on the design cover.
2. Remove design cover of cylinder bank 5 - 8. To do this, lift the cover slightly with both hands at the edge
pointing towards the intake system until it is released from its holder.
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Pulling off the design cover Fastening screws on design cover

Installing design cover
Installing design cover of cylinder bank 1 - 4
Note
1. Slide the design cover of cylinder bank 1 - 4 under the secondary air
pump bracket as shown in the illustration and then slide the cover of
the second ignition coil through underneath the torque support
bracket.
Sliding on the design cover

2. Press down the two rubber mounts on the bracket. The rubber mounts must be felt to engage.
3. Tighten the four fastening screws on the ignition coils (illustration shows side 5-8). → Tightening torque:
3.5 ftlb.
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Fastening screws on the ignition coils Pressing the design cover on

4. Reinstall secondary air pump. Tighten the three fastening screws.
→ 266519 Removing and installing secondary air pump - chapter on
"Installing"
Secondary air pump

5. Reinstall torque support. Fit the fastening screw (M10 x 85) with a
new fastening nut on the bracket. → Tightening torque: 44 ftlb.
6. Screw in the fastening screw securing the torque support to the body
(M10 x 70). → Tightening torque: 44 ftlb.
7. Install engine compartment cover on the right and rear. → 700219
Removing and installing front cover (engine compartment)
Torque support on bracket

Note
1. Slide the design cover under the secondary air pump as illustrated.
2. Then press in the two rubber mountings on the bracket. The rubber mounts must be felt to engage.
3. Screw in the four fastening screws at the ignition coils → Tightening torque: 3.5 ftlb.
Installing throttle body cover

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Pressing the design cover on Design cover under secondary air

pump
Fastening screws securing design

cover over ignition coils
Throttle body cover

as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g gp g
ADVERTENCIA
13 10 19 Removing and installing pistons - as of MY 2003

- Information
- Preliminary work
- Removing pistons
- Installing pistons
- Subsequent work
Tools

Piston ring restraining strap for commercially NR.57

944 - S2 and Boxster and 911 available tool
Carrera (996)
Information
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Component overview of piston
Component overview
1 - Three piston rings (lowest is the oil scraper ring)

2 - Piston (arrow on piston crown points in direction of travel)
3 - Two piston-pin circlips
4 - Piston pin
5 - Connecting rod and connecting-rod bearing cap
6 - Two connecting rod bolts
7 - Two bearing shells
Identification of pistons
Markings on piston crown: Replacement pistons from Porsche Parts

Service are only obtainable in one dimensional group 'X' and in two weight
tolerances '+' and '-'. The weight tolerances are listed in the table.
z Marking X appears as a large coloured stamp in the centre of the

piston crown and as a small engraved feature -1- .
z Marking + or - appears as a large coloured stamp in the centre of the
Note
Pistons are installed as standard in three dimensional groups: I, X and II.
Piston marking
Pistons are installed as standard in two weight tolerances: + and -.
These data are all engraved on the piston crown. To uniquely identify a piston, it must be carefully cleaned (brass
brush, ultrasonic bath). If, in spite of very thorough cleaning, the data are unreadable, the piston must be weighed
together with piston rings, piston pin and the two circlips. Thorough cleaning (ultrasonic bath) is also absolutely
essential to the weighing operation as otherwise the measurement result will be false.
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1. A piston removed for repair is cleaned and identified. If it needs to be replaced, an X - piston with the
identified weight tolerance + or - is ordered as a replacement part and installed.
Weight tolerance Full weight in g (with piston rings)

- 546.6 - 540.6
+ 546.6 - 552.6
Preliminary work
Preliminary work for removing pistons
2. Remove cylinder head. → 157021 Removing cylinder head - section on "Removing"
3. Remove chain case cover. → 153121 21 Removing chain case cover - section on "Removing"
4. Remove oil pan → 175021 Oil pan removed - section on "Removing"
5. Remove lower section of crankcase. → Removing and installing crankshaft
Removing pistons
Removing pistons
1. Secure crankshaft with holding bridges 9677 at bearings 3 and 5 to

prevent it from falling out.
Note
z Connecting rod bolts and bearing shells must always be replaced.
z Turn the crankshaft so that the crank pin of the piston to be removed
stands vertically upwards.
2. Remove one piston after another, mark them and place them on a
clean tray. The arrow on the bottom of the piston points in the
Holding bridges at bearings 3 and 5
direction of travel.
3. Remove the piston of cylinder 1 by unscrewing the connecting-rod bolts.
4. Remove the connecting-rod bearing cap and place it on a clean surface.
5. Press the piston downwards out of the cylinder, for example with the handle of a hammer, and receive it with
the other hand.
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Matching numbers and installation

Arrow A
6. 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.
7. Mark piston with No. 1 (with a felt-tip, not with a prick punch or other sharp-edged tool).
8. Remove the remaining pistons using the same procedure.
Note
z Note the association between the connecting-rod big end and the
connecting-rod bearing cap as the cracked connecting rods only fit in
one position.
z 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.
z The connecting-rod bearing cap and the big end of the connecting-rod
bearing have the same connecting-rod numbers. Retaining lugs of connecting-rod
bearings
Note
connecting-rod bearing cap as the cracked connecting rods only fit in
one position.
z 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.
z The connecting-rod bearing cap and the big end of the connecting-rod
bearing have the same connecting-rod numbers. View of connecting rod numbers
Installing pistons
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Installing pistons
Note
z The identification of the connecting-rod bearings is located on the connecting-rod journal of the crankshaft →
Removing and installing crankshaft.
Note
z The pistons must already be pre-fitted (pistons, piston rings, connecting rods and fastening material) before
performing the next step. → 131037 Disassembling and assembling pistons - chapter on "assembling"
z Install with the number on the connecting rod -A- to the exhaust side.
z When installing the piston in the crankcase, the direction of travel arrow on the piston crown must point in the
z The code on the connecting-rod big end and connecting-rod bearing

cap must be on the same side -A- .
Surface with cylinder number marking

z The direction of travel arrow is on the same side as the connecting rod
code -A- as is evident on the piston shown. This can be installed as
standard on one cylinder bank side as shown, and on the other
cylinder bank side, the connecting rod code is on the opposite side.
However, when the pistons are fitted at a later time, it is absolutely
necessary that they be aligned in the direction of travel (see the
following point). Install with the number on the connecting rod -A- to
the exhaust side.
Allocation
z The direction of travel arrow must be pointing forwards when installed (in direction of travel).
1. Turn the engine in the engine support so that the crankshaft lies at the bottom.
2. Install piston. To do this, turn the crankshaft with a wrench (a/f 27) until the corresponding crank pin is
pointing vertically downwards.
3. Cylinder, piston and Piston ring restraining strap for 944 - S2 and Boxster and 911 Carrera (996) NR.57
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Turning crankshaft Installing pistons

leicht einölen.
4. Align piston-ring set (staggered by 120°) and compress piston rings

using piston ring restraining strap for 944 - S2 and Boxster and
911 Carrera (996) NR.57. Ensure all piston rings are correctly pre-
loaded by the special tool -see figure- .
Compressing piston rings

5. Position piston on the cylinder from above and push it into the
cylinder, using the handle of a hammer if necessary. When doing so,
make sure that the direction of travel arrow is pointing forwards
-see arrow (illustration shows cylinder 1)- .
Installing pistons
6. Push piston downwards until the connecting-rod bearing sits on the
crank pin. If necessary, use the handle of a hammer to push it
-see figure- .
7. Oil connecting-rod bearing shells and crank pins.
Note
z The piston connecting rods are cracked and only fit in one position (in
conjunction with the matching numbers).
Pressing in piston
z Install con-rod code towards exhaust side -A- .
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8. Then fit connecting-rod bearing cap with bearing shell (twist locks
facing each other) → Retaining lugs for connecting-rod bearings -B
and C- . The connecting rod numbers must face each other → View of
matching numbers -A- . Screw in con-rod bolts by hand.
Retaining lugs for connecting-rod

bearings -B and C-
9. Fit the opposite piston (cylinders 1 and 4).
10. Fit other pistons using the procedure described above.
11. Turn crankcase on the assembly support until the crankshaft is on top.
12. Tighten con-rod bolts that have been replaced. Turn the crankshaft
until the corresponding crank pin is pointing vertically upwards.
Tighten bolts with a multiple-tooth socket → Initial tightening 1: 6
ftlb. → Initial tightening 2: 15 ftlb. → Initial tightening 3: 30 ftlb. →
Torque angle (final tightening): 90 ° .
View of matching numbers -A-

13. Once all pistons have been correctly fitted and secured, turn the
crankshaft in a clockwise direction to check it, using a ring wrench (a/f
27). When doing so, watch out for stiffness and irregularities. If the
crankshaft cannot be turned or if it is very stiff, check whether the
installation direction (arrow) of the pistons, the pistons and the
cylinders (markings) and the connecting-rod cap and connecting-rod
big end all match.
14. Remove holding bridges 9677 .
Turning the crankshaft
Subsequent work
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Subsequent work for installing pistons
1. Install lower section of crankcase. → Removing and installing crankshaft
2. Install chain case cover. → 153123 23 Installing chain case cover - section on "Installing"
3. Install oil pan → 175023 Oil pan installed (including seal) - section on "Installing"
4. Install cylinder head. → 157023 Installing cylinder head - section on "Installing"
as of MY 2003
g gp g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g gp g
ADVERTENCIA
13 10 37 Disassembling and assembling pistons - as of MY 2003

- Preliminary work
- Information
- Disassembling pistons
- Assembling pistons
- Subsequent work
Tools

piston ring restraining strap commercially 57
available tool
Piston ring pliers commercially 58

available tool
Assembly aid special tool 9500/3

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Plunger special tool 9500/8
Assembly sleeve special tool 9500/9
Retaining device special tool 9597
piston ring pliers Gr. 1 commercially NR.58

available tool
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Preliminary work
Removing pistons, preliminary work

1. Remove piston → 131019 Removing and installing pistons - chapter on "removing".
Tools and materials
Piston disassembly
Tools

-A- Retaining device 9597 → "See Workshop As an assembly aid for fixing
Equipment Manual, the piston
Chapter 2.2.2"
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-B- Assembly aid 9500/3 → "See Workshop For pre-fitting the piston-pin
Equipment Manual, circlip in the assembly sleeve
Chapter 2.2.2"
-C- Assembly sleeve 9500/9 → "See Workshop For fitting the piston pin circlip
Equipment Manual, in the correct position
Chapter 2.2.2"
-D- Plunger 9500/8 → "See Workshop For fitting the piston pin and
Equipment Manual, piston pin circlip
Chapter 2.2.2"
-E- Piston ring pliers 58 → "See Workshop
Equipment Manual,
Chapter 2.4"
Information
Piston disassembly - component overview
Component overview
No. Designation Qty. Removal Fitting

1 Two compression rings 3 With piston ring pliers 58 With piston ring pliers 58
above, one oil scraper ring
below
2 Pistons 1 Push out from crankshaft Oil and install in crankcase with
together with connecting rod piston ring restraining strap
57
3 Piston-pin circlip 2 Lever out with a small Install in correct position with
screwdriver special tool (see below)
4 Piston pins 1 Drive out using plunger Drive in using plunger 9500/8
9500/8
5 Connecting rod big end and 1 Matching numbers face one
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connecting-rod bearing another

cover
6 Connecting-rod bolts M9 x 2 Replace Replace, apply light coat of oil,
56 tighten in accordance with
tightening specification
7 Connecting-rod bearing 2 Replace Install retaining lug to retaining
shells lug; retaining lugs must be
inserted in corresponding
grooves in connecting-rod big
end and connecting-rod cover

Service are only obtainable in one dimensional group 'X' and in two weight
tolerances '+' and '-'. The weight tolerances are listed in the table.

z Marking + or - appears as a large coloured stamp in the centre of
the piston crown and as a small engraved feature -2- .
Note
Pistons are installed as standard in three dimensional groups: I, X and II.
Piston marking
These data are all engraved on the piston crown. To uniquely identify a piston, it must be carefully cleaned (brass
brush, ultrasonic bath). If, in spite of very thorough cleaning, the data are unreadable, the piston must be weighed
together with piston rings, piston pin and the two circlips. Thorough cleaning (ultrasonic bath) is also absolutely
essential to the weighing operation as otherwise the measurement result will be false.

- 546.6 - 540.6
+ 546.6 - 552.6
Disassembling pistons
Note
z If reusing a piston, do not remove combustion residues on the piston crown are mechanically!
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Note
z 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. Fix piston on retaining device 9597 → Piston on retaining device .
Piston on retaining device

2. Remove both piston-pin circlips using a small screwdriver. To do this,
guide the screwdriver through the small cutout and carefully lever out
the piston-pin circlip → Levering out piston-pin circlips with a small
screwdriver .
Levering out piston-pin circlips with a

small screwdriver
3. Insert piston in retaining device 9597 (leave space below for the
piston pin) and drive out piston pin using plunger 9500/8 → Piston
pin with plunger .
4. Remove connecting rods from the pistons and place to one side.
ATTENTION
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.
Piston pin with plunger
5. Remove piston rings. Place the piston on a clean surface and look for the gaps in the piston rings.
Note
z Compression rings and oil scraper rings are installed and removed differently.
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Piston ring pliers on piston ring
6. Remove the piston rings starting from 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!
7. Relieve the piston ring pliers and remove the piston ring from the pliers.
8. Remove the three-piece oil scraper ring as follows: First, remove the upper and lower rings by hand by
carefully forcing them away from the piston. Then remove the oil scraper spring carefully in the same way.
Assembling pistons
Assembling pistons
1. First assemble the three-piece oil scraper ring. To do this, carefully stretch the oil scraper spring by hand at
its gap to a point where this can be positioned over the piston in ring groove 3. Carefully force apart a ring in
the oil scraper ring by hand and fit it into the third piston ring groove below the oil scraper spring. Fit the
second ring in the same way over the oil scraper spring.
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.
Note
z The two compression rings have different strengths and can only be
installed in the appropriate groove.
z 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 designation of the piston rings is pointing in the
direction of the piston crown -A- . Spread the piston ring until it just
fits over the piston. Piston ring designation
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.
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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. Pre-fit piston-pin circlip in assembly sleeve. To do this, insert the ring

in assembly sleeve 9500/9 so that the ring gap is at 6 o'clock or
alternatively 11 o'clock (piston crown on top), the assembly groove of
the assembly sleeve pointing towards the piston crown → Ring gap
indicating 11 o'clock .
Ring gap indicating 11 o'clock

7. Position the assembly sleeve on an even surface with the groove
facing downwards and use the assembly aid 9500/3 to drive down
the circlip into the installation position so that the circlip is under
tension and sitting in the correct position -arrow- .
Assembly aid in circlip

8. Check installation position of piston-pin circlip in the assembly sleeve
→ Ring gap here at 6 o'clock .
Ring gap here at 6 o'clock

9. Position the assembly sleeve on the piston so that the assembly groove of the assembly sleeve points to the
piston crown → Assembly sleeve on piston .
10. Insert plunger 9500/8 through the assembly sleeve and fit the piston-pin circlip by tapping it with a hammer
into the groove of the piston pin eye.
11. Fix piston on retaining device 9597 with fitted piston-pin circlip facing downwards → Piston on retaining
device .
12. Gap of circlip must point downwards away from the piston crown (analogous to 6 o'clock, alternatively 11
o'clock). Place piston pin and connecting rod in installation position. Align connecting rod with matching
number so that the matching numbers point to the exhaust side -A- . Illustration shows direction of travel in
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Piston on retaining device Assembly sleeve on piston
Allocation
this case and connecting rod code on one side.
13. Fit oiled piston pin through the piston and connecting-rod eye as far
as the circlip. Using a plastic hammer, tap gently on plunger 9500/8,
driving the piston pin into the pre-fitted piston-pin circlip -arrow- .
Plunger on piston pin

14. Fit the second piston-pin circlip using the same procedure. Align gap
of circlip so that it points downwards away from the piston crown
(analogous to 6 o'clock, alternatively 11 o'clock) -arrow- .
15. Check connecting rod and piston for smooth operation.
Align ring gap (here indicating 11

o'clock)
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Note
z The connecting rods are cracked and together with the matching
numbers cannot be mixed up!
z The identification of the connecting-rod bearings is located on the

connecting-rod journal of the crankshaft → Removing and installing
crankshaft.
16. Fit connecting-rod bearing shells in connecting-rod big end and Position of bearing shells
connecting-rod bearing cap. 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 on the same side
(when installed they point to the exhaust side). Tighten the
connecting rod bolts by hand and position the complete connecting
rod ready for assembly.
Surface with connecting rod number

marking (exhaust side)
Subsequent work

1. Install piston → 131019 Removing and installing pistons - "Installing" section.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g g g
ADVERTENCIA
13 48 19 Removing and installing crankshaft - as of MY 2003

- Preliminary work
- Removing crankshaft
- Installing crankshaft
- Subsequent work
Tools

Preliminary work
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Preliminary work
3. Remove oil pan. → 175019 21 Removing and installing oil pan - section on "Removing"
4. Remove oil pump. → 172019 Removing and installing oil pump - section on "Removing"
Removing crankshaft
Removing crankshaft
Overview, crankshaft and bearings

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1 - Crankshaft
2 - Straight pin
3 - Feather key
4 - Thrust washer, insert with grease no. 000.043.204.17
5 - Upper crankshaft bearing shell, lubricate with motor oil
6 - Lower crankshaft bearing shell, lubricate with motor oil
7 - Radial shaft sealing ring, crankshaft
H - Main bearing, location of colour dots
P - Connecting rod bearing, location of colour dots
Note
z The colour codes of the crankshaft bearings and bearing shells must match!
z To ensure that the bearings and bearing shells are of a matching class during installation, the bearing
numbers are to be written on the backs of the bearings during removal of the main bearing shells with a
waterproof felt-tipped pen, due to that fact that the ink markings wear off of the crankshaft journals as well as
the main bearing shells.
z New bearing shells are always to be installed when the engine is repaired.
Crankshaft
Main bearing shells Red yellow Blue
+ connecting-rod
bearing shells Red X
yellow X
Blue X
1. Remove chain drive wheel from crankshaft. Unscrew fastening screw

on belt pulley. Pull off chain sprocket with drive chain on oil pump; do
not lose feather key when doing so.
Belt pulley fastening screw
2. Unscrew the four hexagon socket head bolts on the clutch side (M8). → Clutch side
3. Unscrew the outer cross bolt connection (M8 x 70) in the opposite order to the sequence shown.
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Clutch side Chain sprocket and feather key
External cross bolt connection
4. The figures below indicate the tightening sequence. The fastening screws are undone in the opposite order
to the tightening sequence shown.. → Outer bearing seat
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Outer bearing seat
5. Undo inner bearing seat in the opposite order to the tightening sequence shown. → Inner bearing seat
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Inner bearing seat
6. Remove lower part of crankcase.
7. Remove any remaining sealant and the old sealing ring in the upper part of the crankcase.
8. Fit holding bridges 9677 on the crankshaft -arrows- .

9. Remove pistons. → 131019 Removing and installing pistons -
"Removing" chapter Rotate engine block in engine stand through
180° so that the crankshaft can be removed.
ATTENTION
Danger of crushing!
z Risk of crushing your hands when lifting the crankshaft.

→ Wear gloves. Holding bridges
10. Undo holding bridges 9677 and carefully remove crankshaft upwards.
Installing crankshaft
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Note
z If no clear markings can be seen after thorough cleaning of the crankshaft and the bearings, the crankshaft
and the corresponding bearing shells are to be replaced.
Correct position of the twist locks
Note
classes are indicated by the colour marking on the outside
-refer to Figure- . The colour marking must match the corresponding
colour dot on the crankshaft. The colours are red, yellow and blue
and must match between the bearings and the crankshaft.
z To ensure that the bearings and bearing shells are of a matching

class during installation, the bearing numbers are to be written on the
backs of the bearings during removal of the main bearing shells with
a waterproof felt-tipped pen, due to that fact that the ink markings Colour marking on the outside
wear off of the crankshaft journals as well as the main bearing shells.
z New connecting rod bearings main bearing shells are always to be installed when the motor is repaired.
1. Insert the bearing shells with the lubricating groove into the upper part of the crankcase. Make sure the twist
locks are positioned correctly -see figure- . Then lightly oil the bearing locations.
2. Insert the sickle-shaped washer (make sure of axial bearing play). To

do this, insert the two Insert 3 sickle-shaped washers on the left and
2 on the right (thrust washers) with some grease (000.043.204.17)
-see figure- , to prevent the sickle-shaped washers from falling off.
Each of the lubricating grooves of the sickle-shaped washers must
face outwards.
Sickle-shaped washers (thrust

washers)
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ATTENTION
Danger of crushing!

→ Wear gloves.
3. Insert crankshaft. The connection flange must point towards the back
of the engine. Then secure the crankshaft from falling down using
holding bridges 9677. Fix the holding bridges at bearing locations 3 Turning the crankshaft
and 5. Screw the fastening screw from the belt pulley at the front into
the crankshaft and tighten slightly so that the crankshaft can be
turned -see figure- .
5. Install pistons. → 131019 Removing and installing pistons -"Installing" chapter
6. Turn crankcase again through 180° on the assembly support.
Degrease parting surfaces between top and bottom section of crankcase. A totally grease-free product (e.g.
brake cleaner) must be used for this. Then insert a new O-ring at the front of the parting surface -3- .
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Crankcase bottom section

4- Application of sealant; Drei Bond Silikon 2210 liquid sealant must be applied and the screws screwed in
within five minutes and without interruption
10 - Dowel sleeve
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Centring pins
8. Screw the two thin centring pins 9321 into the outer fastening bores on the upper part of the crankcase
-see illustration (shown without crankshaft)- .
9. Insert bearing shells into lower part of crankcase and lightly oil them.
When doing so, ensure that the twist locks (retaining lugs) fit into the
appropriate recesses in the lower part of the crankcase.
Note
z The liquid sealant must be applied and the screws screwed in within
five minutes at most and without interruption.
z The required tool (torque wrench for 15 Nm (11 ftlb.) to 40 Nm (30

ftlb.); torque angle wrench; socket wrench E12, E14 and E14) must
be ready for use.
Twist locks (retaining lugs)
z The threads and head contact surface of the bearing seat screws (M10 x 1.5 and M12 x 1.5) must be oiled.
10. Apply the Drei Bond Silikon 2210 liquid sealant to the lower part of the crankcase as illustrated. The outer
surfaces marked -A- must be cleaned after fitting.
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Sealant application
destroyed.
Note
z Unscrew the centring pins again while securing the lower part of the crankcase.
12. The figures below indicate the tightening sequence. The screws are tightened in four steps. It is essential
that the tightening sequence is observed here. The screws must be tightened within five minutes.
→ Initial tightening: 30 ftlb.
→ Final tightening: 56 °
Inner bearing seat

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Tightening sequence, inner bearing seat
Outer bearing seat

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Tightening sequence, outer bearing seat
13. Then screw on the outer cross bolt connection (M8 x 70) in the sequence shown → Tightening torque: 17
ftlb. .
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Tightening sequence, outer cross bolt connection
14. Tighten the four hexagon socket bolts on the clutch side (M8 x 35) →
Tightening torque: 17 ftlb. .
Clutch side
15. Fit chain drive sprocket on the crankshaft. Unscrew fastening screw on belt pulley. Check that the feather
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Chain drive wheel
keys are fitted correctly and push on the chain sprocket with the oil pump drive chain → Chain drive wheel .
The double-tooth row must be facing forwards.
Subsequent work
Subsequent work
1. Install oil pump. → 172019 Removing and installing oil pump - section on "Installing"
2. Install oil pan. → 175019 23 Removing and installing oil pan - section on "Installing"
3. Install cylinder head. → 157023 Installing cylinder head - section on "installing"
4. Install chain case lid. → 153123 23 Installing chain case lid - section on "Installing"
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
13 59 19 Removing and installing crankshaft sealing ring on

flywheel side - as of MY 2003
- Preliminary work
- Removing crankshaft sealing ring on flywheel side
- Installing crankshaft sealing ring on flywheel side
- Subsequent work
Tools

Pressure piece special tool 9609/1
spacer special tool 9609/2

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Drift punch, 1 mm tip, commercially NR.167

available tool
Slide hammer kit commercially NR.168

available tool
Multiple-tooth socket wrench commercially NR.31

insert M12 available tool
Preliminary work
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Preliminary work
1. Remove drive plate or flywheel. → 136019 Removing and installing flywheel [9PAAE7]→ 136019 Removing
and installing flywheel [9PAAE1 9PAAF1 9PAAJ1] or → 136319 Removing and installing drive plate for
converter [9PAAE7]
Tools and materials
Required tools
Overview of special tool

-A- Slide hammer kit NR.168
-B- Pressure piece 9609/1 and
spacer 9609/2
-C- Extractor tip Contained in slide hammer kit
NR.168.
-D- Connecting piece Contained in slide hammer kit
NR.168.
-E- Multiple-tooth socket wrench
insert M12 NR.31
-F- Drift punch, 1 mm tip, NR.167
-G- Toothed segment 9538/1
Removing crankshaft sealing ring on flywheel side

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1. Using the tool drift punch (1-mm tip) NR.167, beat a small hole into
a non-rubberised spot (rectangular window in the ring) of the sealing
ring.
Drift punch
2. Screw in the extractor tip. Knock out the extractor tip using slide
hammer kit NR.168 in conjunction with the sealing ring.
Punching out the sealing ring

3. Clean the crankshaft flange The crankshaft flange must not be dirty
or rusty. If necessary, clean it with brake cleaner and grind off any
rust with a metal-polishing pad (e.g. Never Dull).
Cleaning the crankshaft flange
Installing crankshaft sealing ring on flywheel side
ATTENTION
Damage to the sealing ring!
→ The sealing ring is provided on a sleeve.

→ Never remove the sealing ring from the sleeve.
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→ Never deform or touch the sealing lips.

→ Never oil the sealing lips.
1. Connect the sealing ring and sleeve to the tool.
Pushing on the sealing ring

2. Position the centring device on the crankshaft flange. Pay attention to
the centring pin when doing this. Tighten the two fastening screws to
23 Nm (17 ftlb.).
Centring tool
3. Position the retracting bell and tighten the central screw (a/f 19) to 25
Nm (19 ftlb.).
4. Undo the retracting bell and screw it down.
5. Undo the two fastening screws on the centring device and remove
the tool.
Fitting bell
Subsequent work
Subsequent work
1. Install drive plate or flywheel. → 136019 Removing and installing flywheel [9PAAE7]→ 136019 Removing
converter [9PAAE7]
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as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g g p q g
ADVERTENCIA
13 63 19 Removing and installing drive plate for torque converter -

as of MY 2003
- Preliminary work
- Removing drive plate for torque converter
- Installing drive plate for torque converter
- Subsequent work
Tools

toothed segment special tool 95381
Internal puller commercially NR.108

available tool
Striker special tool VW

771/1
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Preliminary work
Preliminary work
1. Remove transmission. → 373519 Removing and installing transmission - chapter on "Removing" [9PAAJ1]
→ 373519 Removing and installing transmission - chapter on "Removing" [9PAAE1 9PAAF1]
Tools and materials
Special tools
Puller

-A- Internal puller NR.108, size See Workshop Equipment
approx. 14 - 20 Manual, Chapter 2.4
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-B- Striker VW 771/1 See Workshop Equipment

Removing drive plate for torque converter
1. Block drive plate. To do this, attach toothed segment 95381 to a

screw hole in the crankcase so that at least one tooth is in contact
with the starter teeth.
Toothed segment
2. Unscrew drive plate. To do this, loosen the ten diagonally opposite
fastening screws.
3. Remove drive plate.
4. If the drive plate is stuck, remove it using an internal puller and slide
hammer.
Drive plate
5. To do this, insert internal puller into the middle of the drive plate and
tighten.
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6. Then screw on the slide Internal puller

hammer and knock off the
drive plate.
Slide hammer
Installing drive plate for torque converter
Note
z Clean the crankshaft stub before installing the drive plate (remove rust).
z Use a special metal-polishing pad (e.g. Never Dull) for this.
1. Fit drive plate.

screw hole in the crankcase so that at least one tooth is in contact
with the starter teeth.
Toothed segment
3. Tighten the ten new fastening screws crosswise. → Tightening
torque: 44 ftlb. ; then → Torque angle: 90 °
4. Remove toothed segment 95381.
Fastening screws
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Subsequent work
Subsequent work
1. Install transmission. → 373519 Removing and installing transmission - chapter on "Installing" [9PAAJ1]
→ 373519 Removing and installing transmission - chapter on "Installing" [9PAAE1 9PAAF1]
9PAAE1, 9PAAF1, 9PAAJ1
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
13 73 19 Removing and installing belt tensioner - as of MY 2003

- Preliminary work
- Information
- Removing belt tensioner
- Installing belt tensioner
- Subsequent work
Preliminary work
Preliminary work
1. Loosen drive belt around the belt tensioner. → 137819 Removing and installing drive belt - chapter on
"Removing" [9PAAF1 9PAAJ1]→ 137819 Removing and installing drive belt - chapter on
"Removing" [9PAAE1 9PAAE7]
Information
Component overview
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Component overview of drive belt rollers
1 - Deflection roller, cylinder bank 1-4 → Tightening torque: 32 (24 ftlb.) Nm +/-3 (2 ftlb.) Nm
2 - Tensioning roller
3 - Holder for deflection roller
4 - Fastening screw for damper → Tightening torque: 32 (24 ftlb.) Nm +/-3 (2 ftlb.) Nm
5 - Support for tensioning roller → Tightening torque: 32 (24 ftlb.) Nm +/-3 (2 ftlb.) Nm
6 - Shock absorber/tensioning element; bellows must be facing upwards. Observe code on the component.
8 - Sheetmetal holder
Removing belt tensioner

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1. Loosen the bottom fastening screw on the shock absorber.
2. Loosen the top fastening screw.
3. Remove components and repair appropriate components.
4. In order to remove the tensioning roller

-figure shows deflector roller- , the cap must be levered off first. To
do this, insert a small screwdriver underneath the cap and lever it off.
Deflection roller
Installing belt tensioner
Note
z When fitting the shock absorber/tensioning element, ensure that the label can be read from outside.
z The bellows must be facing upwards.
1. Install holder with tensioning element. Tighten the top fastening

screw. → Tightening torque: 24 ftlb.
2. Tighten the bottom fastening screw. → Tightening torque: 24 ftlb.
Shock absorber/tensioning element
Subsequent work
Subsequent work
1. Fit drive belt. → 137819 Removing and installing drive belt - chapter on "Installing" [9PAAF1 9PAAJ1]
→ 137819 Removing and installing drive belt - chapter on "Installing" [9PAAE1 9PAAE7]
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as of MY 2003
g g g g p y g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g g g g p y g
ADVERTENCIA
13 74 19 Removing and installing sealing ring for crankshaft belt

pulley - as of MY 2003
- Information
- Preliminary work
- Removing sealing ring for crankshaft belt pulley
- Installing sealing ring for crankshaft belt pulley
- Subsequent work
Information
Component overview
-1- - Radial shaft seal (align using the plastic sleeve provided)
-2- - Upper fastening screw
-3- - Lower fastening screw
-4- - Chain tensioner
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Preliminary work
Preliminary work for removing sealing ring for crankshaft sealing ring
1. Remove pulley (vibration balancer) of the crankshaft → 137619 Removing and reinstalling crankshaft belt
pulley - chapter on "Removing".
Removing sealing ring for crankshaft belt pulley
Removing sealing ring for crankshaft pulley
1. Undo the 4 fastening screws and remove the cover and sealing ring.
2. Clean the sealing surface of the sheetmetal cover.
Removing cover with sealing ring
Installing sealing ring for crankshaft belt pulley
Installing sealing ring for crankshaft pulley
WARNING
Risk of damaging the sealing ring due to assembly fault!
z Never pull the sealing ring from the plastic sleeve!
z Do not touch the sealing lip!
z Do not oil the sealing ring on the running surface!
→ Sealing lip can be damaged!
Note
z 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.
z If there is bad corrosion or deep grooves, replace these components.

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1. Place seal with plastic sleeve across crankshaft.
Seal with plastic sleeve

2. Tighten the 2 upper fastening screws by hand → Tightening torque:
7.5 ftlb. , and then the lower fastening screws → Tightening torque:
7.5 ftlb. . Then tighten the screws in diagonally opposite sequence to
the specified torque.
Fastening screws to sealing ring

3. Pull off plastic sleeve evenly from sealing ring.
Plastic sleeve
Subsequent work
Subsequent work: installing sealing ring for crankshaft pulley

1. Install pulley (vibration balancer) of crankshaft → 137619 Removing and reinstalling crankshaft belt pulley -
chapter on "Installing".
as of MY 2003
g g p y g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g g p y g
ADVERTENCIA
13 76 19 Removing and installing crankshaft belt pulley - as of MY

2003
- Preliminary work
- Removing crankshaft belt pulley
- Installing crankshaft belt pulley
- Subsequent work
Tools

arm bracket special tool 96790
socket wrench insert special tool 9714
Mechanical angle disc for commercially NR.88-1

torque angle threaded joint available tool
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Preliminary work
Preliminary work for removing crankshaft pulley

1. Loosen lock carrier. → 503809 Loosening and fastening lock carrier (service position) - chapter on
"Loosening"
2. Loosen drive belt and remove from the pulley. For details see → 137819 Removing and reinstalling drive belt
- chapter on "Removing" [9PAAF1 9PAAJ1]→ 137819 Removing and reinstalling drive belt - chapter on
"Removing" [9PAAE1 9PAAE7].
Removing crankshaft belt pulley
Removing crankshaft pulley
1. Position arm bracket 96790 in the pulley and turn it until it locks.
ATTENTION
Material damage!
z If the tool slips or if the tool is faulty, the wings or the cooling
fan can be damaged as a result of excessive forces!
→ Only use an appropriately strong tool (e.g. 3/4 inch)

→ Ensuring that the tool is seated correctly
→ Never use the special wrench socket wrench insert 9714, for
loosening or tightening Arm bracket in the pulley
→ Working with a second worker
2. Position a large torque wrench and loosen the central screw. Do not use the screw again.
3. Remove the central screw and pull the pulley down and forward.
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Pulley Large torque wrench on the central

screw
Installing crankshaft belt pulley
Installing crankshaft pulley
Note
z A key is inserted into the crankshaft. When fitting the pulley, ensure
that the key lies in the groove in the pulley.
z The pulley and crankshaft stub must be cleaned.
1. Position the pulley on the crankshaft stub. Then press the pulley
slightly in the direction of the engine, while at the same time twisting
it until it slips definitively in the direction of the timing-case cover. Pulley on crankshaft stub
When doing so, pay attention to the key.
2. Mount the new central screw hand tight into the crankshaft.
Central screw in crankshaft
ATTENTION
Material damage!
z If the tool slips or if the tool is faulty, the wings or the cooling fan can be damaged as a result of
excessive forces!

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Arm bracket in the pulley

→ Never use the special wrench socket wrench insert 9714, for loosening or tightening
3. Position arm bracket 96790 in the pulley and turn it until it locks. Have a second worker operate the arm
bracket.
ATTENTION
Material damage!

loosening or tightening
→ Working with a second worker Central screw
4. Tighten central screw. → Initial tightening: 20 (15 ftlb.) Nm , then → Initial tightening: 50 (37 ftlb.) Nm ,
then → Initial tightening: 250 (185 ftlb.) Nm
5. Push on torque angle disc Mechanical angle disc for torque angle
threaded joint NR.88-1. Attach a magnetic foot to a metal part and
set the scale by turning the pointer to 0. As an alternative to the
torque angle disc, marks can be made on the vibration balancer
(crankshaft pulley) and the central screw using a waterproof pen. A
continuous line between the central screw and vibration balancer
represents the starting point, another line only on the vibration
balancer at an angular distance of 90° shows the torque angle target.
Torque angle disc
ATTENTION
Material damage!
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6. Tighten central screw to torque angle. → Torque angle - final

tightening: 90 °
Central screw
Subsequent work
Touching up installing the crankshaft pulley
1. Mount drive belt. For details see → 137819 Removing and

reinstalling drive belt - chapter on "Installing" [9PAAF1 9PAAJ1]
→ 137819 Removing and reinstalling drive belt - chapter on
"Installing" [9PAAE1 9PAAE7].
2. Fasten lock mount. → 503809 Detaching and fastening lock mount

(service position) - chapter on "fastening"
Drive belt
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
13 78 01 Checking drive belt - as of MY 2003

- Preliminary work
- Information
- Checking drive belt
- Subsequent work
Preliminary work
Preliminary work
1. Remove intake manifold (cowl). → 243519 Removing and installing cowl for throttle part (Y-shaped
pipe) [9PAAF1 9PAAJ1]→ 243519 Removing and installing cowl for throttle part (Y-shaped pipe) [9PAAE1
9PAAE7]
Information
Information
ATTENTION
Risk of damage to drive belt!
z If the drive belt is removed when it is hot, it may become deformed and damaged.
→ Never remove drive belt when it is hot.
ATTENTION
Consequential damage of broken pulley belt!
z Due to a broken drive belt during driving, surrounding components (panelling, electric cables etc.)
can be damaged by thrashing or flying belt parts.
z Parts of the drive belt can jam behind deflection rollers or vibration balancers and damage surfaces
and sealing rings there. In particular, the sealing ring of the crankshaft vibration balancer can
become leaky as a result of a broken belt.
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→ Following a belt breakage the surrounding components and the interior of the engine compartment must be
inspected for damage, and if necessary damaged parts (sealing ring of the crankshaft vibration balancer,
deflection rollers, panelling, lines, electric cables etc.) repaired or replaced.
→ The reason for the belt breakage must be established. Check deflection rollers or crankshaft vibration
balancers for prior damage.
WARNING
Danger of injury!
z The vehicle fans can continue running or start up automatically.
→ The power supply to the radiator fans or the battery must be disconnected before starting to work on the
radiator or fans (remove fuse → fuse carrier [9PAAJ1]→ fuse carrier [9PAAE1 9PAAE7 9PAAF1]).→ Work
instructions after disconnecting the battery
Installation position of drive belt
Damage symptoms
Note
z The following table indicates damage which necessitates replacement.
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Item Type of damage Explanation

-A- Slight crack in a rib Drive belt is OK
-B- Hairline crack that runs across the entire belt width, or Replace drive belt
the butt seam is damaged
-C- Crack running down to half of rib height Drive belt must be replaced if there is more
than one crack running down to half of rib
height
-D- Crack running to base of rib Replace drive belt
-E- Crack running to traction cord, or sides so worn that Replace drive belt
the traction cord becomes visible
-F- Rib detachment Replace drive belt
-G- Rib fracture Replace drive belt
Checking drive belt
Checking drive belt
Note
z 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. Using chalk, mark the drive belt in the area around the tensioning roller.
2. Turn engine at the vibration damper in the direction of movement using a socket wrench (a/f 27) until the
chalk mark is at the same place again. While turning at the crankshaft, check the belt at the deflection rollers
for signs of damage.
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Marking on the drive belt

Subsequent work
Subsequent work
1. Fit intake manifold (cowl). → 243519 Removing and installing cowl for throttle part (Y-shaped pipe) [9PAAF1
9PAAJ1]→ 243519 Removing and installing cowl for throttle part (Y-shaped pipe) [9PAAE1 9PAAE7]
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g g g
ADVERTENCIA
13 78 19 Removing and installing drive belt - as of MY 2003

- Preliminary work
- Information
- Removing drive belt - Cayenne S
- Installing drive belt - Cayenne S
- Subsequent work
Preliminary work
Preliminary work
1. Remove intake manifold (cowl). → 243519 Removing and installing cowl for throttle part (Y-shaped pipe)
Information
Information
ATTENTION
ATTENTION
z Due to a broken drive belt during driving, surrounding components (panelling, electric cables etc.)
can be damaged by thrashing or flying belt parts.
z Parts of the drive belt can jam behind deflection rollers or vibration balancers and damage surfaces
and sealing rings there. In particular, the sealing ring of the crankshaft vibration balancer can
become leaky as a result of a broken belt.
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→ Following a belt breakage the surrounding components and the interior of the engine compartment must be
inspected for damage, and if necessary damaged parts (sealing ring of the crankshaft vibration balancer,
deflection rollers, panelling, lines, electric cables etc.) repaired or replaced.
WARNING
Danger of injury!
radiator or fans (remove fuse → fuse carrier).→ Work instructions after disconnecting the battery
Removing drive belt - Cayenne S

1. Mark the rolling direction of the drive belt with chalk.
2. Relieve and remove drive belt. To do this, use an open-ended wrench (a/f 30) to turn the belt tensioner
clockwise and remove the drive belt from the tensioning roller. Relieve the belt tensioner slowly.
3. Remove the drive belt from all pulleys.
Installing drive belt - Cayenne S

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Installing drive belt - Cayenne

S
Note
z The figure → Drive belt
threading course shows the
complete belt threading
course. The pulleys are
numbered according to the
sequence of fitting.
Remove the drive belt from the Relieving drive belt

tensioning roller .
Drive belt threading course

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1. Make the belt into a loop and place over the crankshaft belt pulley
behind the dipstick.
Crankshaft belt pulley

2. Place the top part of the belt loop over the coolant pump pulley -1- .
Coolant pump pulley

3. Place the lower part of the belt loop around the crankshaft belt pulley
at the bottom -2- .

4. Guide the belt section from the coolant pump around the deflector
wheel -3- on cylinder bank 5 - 8.
Deflector wheel
5. Then guide the section of the belt around the air-conditioning compressor belt pulley -4- at the bottom.
6. Lay a loop around the power-steering pump -5- .

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Power-steering pump Air-conditioning compressor

7. Lay the loose end of the drive belt from the coolant pump downwards
and around the generator pulley -6- and deflector roller -7- of cylinder
bank 1 - 4.
Generator pulley
8. Gather the belt section between the deflection roller of cylinder bank
1 - 4 and the crankshaft pulley to form a loop and guide it upwards to
the tensioning roller -8- . Use a wrench (a/f 30) to turn the tensioning
roller -8- in a clockwise direction at the hexagon and put on the drive
belt. Slowly relieve the tensioning roller.
Tensioning roller
9. Check that the drive belt is positioned correctly on the pulleys.
Fitting the drive belt
Subsequent work
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Subsequent work
1. Fit intake manifold (cowl). → 243519 Removing and installing cowl for throttle part (Y-shaped pipe)
9PAAE1, 9PAAE7
as of MY 2003
C98, C99
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
15 03 21 Removing camshaft housing - as of MY 2003, until MY

2004
- Preliminary work
- Removing camshaft housing
Preliminary work
Preliminary work for removing camshaft housing
2. Remove intake-air distributor. → 244601 Checking intake-air distributor for leaks - section on "Removing"
3. Pull off the cable plug on the camshaft sensor.
4. Turbocharged engine (M48/50): Remove oil feed line from camshaft

housing. To do this, unscrew union nut.
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5. Turbocharged engine (M48/50): Remove sheetmetal bracket for turbocharger.
6. Unscrew ground connection.
7. Remove cover for camshaft housing . → 159121 Removing cover for

camshaft housing - section on "Removing"
8. Remove timing case cover. → 153121 Removing chain case lid
9. Remove camshafts . → 150521 Removing camshafts
10. Remove flat-base tappets and put down in accordance with

installation position. → Removing and installing flat-base tappets
Removing camshaft housing
Removing the camshaft housing
Explosion drawing, camshaft housing
1 - Camshaft housing
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2- Camshaft sensor fastening screw M6 x 16

3- Camshaft sensor
4- Plug
5- Cheese head bolt M8 x 20
7- Sealant application on camshaft housing. Make sure that no sealant can fall into the cylinder head. Carefully
remove old residual sealing compound.
8 - Camshaft housing securing screw M8 x 45
9 - Sealant application on spark plug recess. Make sure that no sealant can fall into the cylinder head. Carefully
10 - Oil duct sealing ring
Top view, camshaft housing
1. Unscrew the upper fastening screw -3- of oil line. Replace sealing ring -2- .
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2. Unscrew both hexagon socket head bolts M8 x 20 and M8 x 30 on the front end (on cylinder row 1-4, the
screws are located at the side on the exterior of the chain box).
Note
z When removing the camshaft housing, ensure that none of the sealing rings or residual sealant fall into the
cylinder head.
3. Unscrew 26 camshaft housing fastening screws M8 x 45 contrary to the indicated order and lever camshaft
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Illustration shows cylinder row 5-8
housing off the cylinder head. When removing the camshaft housing, ensure that none of the sealing rings or
residual sealant fall into the cylinder head.
→ see figure Illustration shows tightening sequence
4. Remove all residual sealing compound.

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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g g g
ADVERTENCIA
15 03 21 Removing camshaft housing - as of MY 2005

- Preliminary work
Preliminary work
4. Turbocharged engine (M48/50): Remove oil feed line from camshaft

housing. To do this, unscrew union nut.

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7. Remove cover for camshaft housing . → 159121 Removing cover for

camshaft housing - section on "Removing"
10. Remove flat-base tappets and put down in accordance with

installation position. → Removing and installing flat-base tappets
Exploded drawing, camshaft housing
1 - Camshaft housing
2 - Camshaft sensor fastening screw M6 x 16
3 - Camshaft sensor
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4- Plug
1. An oil strainer is fitted under the camshaft adjustment valve in the

camshaft housing. Check oil strainer and clean in solvent naphtha or
replace if necessary. Remove oil strainer with a small magnet -1- .
The oil strainer prevents dirt from getting into the camshaft
adjustment valve. → Oil strainer
Oil strainer, top view

Oil strainer partly inserted in camshaft housing
2. Unscrew upper fastening screw -3- of oil line. Replace sealing ring -2- .
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Oil strainer
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3. Unscrew both hexagon socket head bolts M8 x 20 and M8 x 30 on the front end (on cylinder row 1-4, the
screws are located at the side on the exterior of the chain box).
Note
z When removing the camshaft housing, ensure that none of the sealing rings or residual sealant fall into the
cylinder head.
4. Unscrew 26 camshaft-housing fastening screws (M8 x 45) contrary to the order shown → Tightening
sequence for camshaft housing and lever camshaft housing off the cylinder head. When removing the
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camshaft housing, ensure that none of the sealing rings or residual sealant falls into the cylinder head.
→ Tightening sequence for camshaft housing Illustration shows tightening sequence
as of MY 2005
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
15 03 23 Installing camshaft housing - as of MY 2003, until MY

2004
- Installing camshaft housing
- Subsequent work
Installing camshaft housing
ATTENTION

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1- Camshaft housing
3- Camshaft sensor
4- Plug
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Note
z Before installing, remove all residual sealing compound and clean sealing surfaces on cylinder head and
camshaft housing!
1. Clean sealing surfaces on camshaft housing and cylinder head using suitable means (e.g. acetone and
cloth).
Note
z The sealant application must not be too thick because otherwise excess sealant can enter the cylinder head!
z For applying the sealant, there are, amongst other things, two grooves on the front section of the camshaft
housing!
2. Replace oil duct sealing ring on cylinder head and apply a thin bead (approximate width 1.5 mm) of sealing
compound (000 043 300 39, status 12/05) onto the camshaft housing in accordance with -Illustration- .
When doing this, do not forget the sealing surfaces of the spark plug recesses.
Applying bead of sealing compound
A - Sealant application on inverted camshaft housing

B - Sealing ring for oil duct
C - Wipe off projecting residual sealing compound as far as timing case cover
3. Place camshaft housing on cylinder head. Position M8 fastening screws and tighten in tightening sequence
→ Tightening sequence for camshaft housing . → Tightening torque: 23 (17 ftlb.) Nm
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4. Tighten hexagon socket head bolts in control box -Arrows- as

required → Tightening torque: 23 (17 ftlb.) Nm (on cylinder row 1-4
the screws are located on the side, on the outside of the chain box).
Wipe off excess silicone as far as control box.
5. Secure oil line with new sealing ring -2- . To do this, screw down the
upper fastening screw -3- of oil line. → Tightening torque: 10 (7.5
ftlb.) Nm

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Fastening oil line
Subsequent work
Subsequent work
1. Turbocharged engine (M48/50): Screw down sheetmetal bracket for turbocharger. To do this, tighten the 2
fastening screws → Tightening torque: 23 (17 ftlb.) Nm and screw with new nut → Tightening torque: 30
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Sheetmetal bracket for turbocharger
(22 ftlb.) Nm . → Sheetmetal bracket for turbocharger
2. Push the cable plug onto the camshaft sensor.
Cable plug of camshaft sensor

3. Screw down ground connection. → Tightening torque: 10 (7.5 ftlb.)
Nm
Ground connection
4. Secure oil feed line by hand in the camshaft housing with the union
nut and then tighten. → Tightening torque: 35 (26 ftlb.) Nm
5. Install flat-base tappets. → Removing and installing flat-base tappets
6. Install camshafts . → 150523 Installing camshafts - section on

"Installing"
7. Install timing case cover . → 153123 23 Installing chain box lid -

8. Install cover for camshaft housing . → 159123 Installing cover for

camshaft housing - section on "Installing"
Oil feed line
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9. Install intake-air distributor. → 244619 Removing and installing intake-air distributor - section on "Installing"

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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
15 03 23 Installing camshaft housing - as of MY 2005

- Subsequent work
ATTENTION

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1- Camshaft housing
3- Camshaft sensor
4- Plug
8 - Camshaft housing fastening screw M8 x 45
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Note
camshaft housing!
cloth).
Note
z The sealant application must not be too thick because otherwise excess sealant can enter the cylinder head!
z For applying the sealant, there are, amongst other things, two grooves on the front section of the camshaft
housing!
2. Replace oil duct sealing ring on cylinder head and apply a thin bead (approximate width 1.5 mm) of liquid
sealing compound 000.043.300.39 Loctite 5970 (status 11/2005, for details of currently used sealant, see
Spare Parts Catalogue) onto the camshaft housing in accordance with -Illustration- . When doing this, do
not forget the sealing surfaces of the spark plug recesses.

3. Place camshaft housing on cylinder head. Position M8 fastening screws and tighten according to specified
tightening sequence → Tightening sequence for camshaft housing . → Tightening torque: 23 (17 ftlb.) Nm
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4. Tighten hexagon socket head bolts in control box -Arrows- as

required → Tightening torque: 23 (17 ftlb.) Nm (screws are located
on the side, on the outside of the chain box, on cylinder row 1 - 4).
Wipe off excess silicone as far as timing case.
Illustration shows cylinder row 5 - 8

camshaft housing. Check oil strainer and clean in solvent naphtha or
replace if necessary. Fit oil strainer into the bore on the camshaft
housing -1- . The oil strainer prevents dirt from getting into the
camshaft adjustment valve. → Oil strainer

6. Secure oil line with new sealing ring -2- . To do this, screw down the upper fastening screw -3- on oil line. →
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Oil strainer
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Fastening oil line
Subsequent work
Subsequent work
1. Turbocharged engine (M48/50): Screw down sheetmetal bracket for turbocharger. To do this, tighten the 2
fastening screws → Tightening torque: 23 (17 ftlb.) Nm and screw with new nut → Tightening torque: 30
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(22 ftlb.) Nm . → Sheetmetal bracket for turbocharger

3. Screw down ground connection. → Tightening torque: 10 (7.5 ftlb.)
Nm
Ground connection
4. Secure oil feed line by hand in the camshaft housing with the union
nut and then tighten. → Tightening torque: 35 (26 ftlb.) Nm
5. Install flat-base tappets. → Removing and installing flat-base tappets

"Installing"

8. Install cover for camshaft housing . → 159123 Installing cover for

camshaft housing - section on "Installing"
Oil feed line
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9. Install intake-air distributor. → 244619 Removing and installing intake-air distributor - section on "Installing"
as of MY 2005
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
15 05 02 Checking timing of camshafts - as of MY 2003

- Information
Information
Information
Note
z Checking the timing is not possible for the M48/00 and M48/50 engines. Only an adjustment can be
made→ 150516 Adjusting timing for camshafts.
as of MY 2003
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WARNUNG
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AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
15 05 16 Adjusting the timings for the camshafts - as of MY 2003

- Preliminary work
- Adjusting the timings for the camshafts
- Subsequent work
Tools

fixing pins special tool 9595/1

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Preliminary work
Preliminary work
Note
z To remove the play from the timing chain for the setting process, the crankshaft must be positioned at least
45° in front of the TDC of cylinder 1 before turning!
1. Remove camshaft housing cover on both cylinder rows → 159121 Removing camshaft housing cover -
Chapter "Removing".
ATTENTION
Damage to engine by turning crankshaft against the rotation
direction of the engine (engine assembled)!
→ Never rotate crankshaft against the operating direction if the timing

drive mechanism is mounted (timing chain jumps over).
→ Proceed carefully while working as otherwise the engine can be
damaged.
→ Always turn the engine on the crankshaft and never on the camshaft
as the timing chain may jump over.
Fixing pin in crankshaft gearwheel
→ After working on the camshaft wheels, the timing must be set.
→ Please observe the general warning notes and working regulations
→ 1001AW The most important working regulations and warning
notes
Note
z The setting is always checked simultaneously on both cylinder rows. Once a cylinder row has been set, the
crankshaft must not be turned to set the other cylinder row!
z The fastening screws on the sprocket wheels do not need to be replaced after they have been undone.
z The screws on the sprocket wheels are tightened by hand during assembly and are then loosened by one or
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two turns. This play is necessary so that the camshafts can still be turned.
z The setting is carried out with the standard chain tensioner that is installed.
2. Use socket wrench insert 9714 to turn crankshaft until cylinder 1 is in ignition TDC. Insert fixing pins
9595/1 into the relevant groove in the timing chain housing cover through the bore provided in the crankshaft
gearwheel -see figure- .
Note
z If the cams on cylinder 1 are not positioned as shown, check whether
the crankshaft needs to be turned through another turn (360°)!
3. Make sure that the cams of cylinders 1 and 5 are positioned as

shown (ignition TDC cylinder 1) → Cams of cylinder 1 → View shows
position of cams on cylinder 5 .
Cams of cylinder 1
View shows position of cams on

cylinder 5
Tools and materials
Special tools
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Tools

-A- Socket 9714 → "See Workshop Very low height, turn towards
Equipment Manual, engine
Chapter 2.2.2 "
-B- Camshaft guide 9678 → "See Workshop For adjusting the timing; guide
Equipment Manual, is positioned in both rear
Chapter 2.2.2 " grooves of the camshafts
-C- Locating pin 9595/1 → "See Workshop For fixing the pulley. The
Equipment Manual, piston of cylinder 1 is then at
Chapter 2.2.2 " TDC; position locating pin
correctly in groove provided in
timing case.
Adjusting the timings for the camshafts
Adjusting the timings for camshafts
The crankshaft is positioned in the TDC and is fixed using fixing pins 9595/1 once the above preliminary check
has been performed.
Note
1. Undo all four fastening screws of the camshaft wheels (two camshaft adjusters) on both cylinder rows. For
this purpose, hold the hexagon of the camshaft wheel on the respective camshaft with the ring wrench and
release pan-head screw M12 1 by 2 revolutions
--To illustrate the process more clearly, the figure does not show the timing case lid-- .
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Fastening screws of the camshaft

wheels
Note
z Cylinder rows 1 - 4 and 5 - 8 are adjusted at the same time without
the camshaft being turned!
2. Turn the four camshafts on the hexagon with an open-ended wrench

until the camshaft guide 9678 can be pushed into the grooves of
both camshafts of a cylinder row.
Hexagon on camshaft
Figure shows the camshafts fixed with

camshaft guide on a cylinder row.
Note
z Cylinder rows 1 - 4 and 5 - 8 are adjusted at the same time without
the camshaft being turned!
3. Then adjust camshafts of the other cylinder row. For this purpose,
turn the hexagon with the open-ended wrench and fix it with
camshaft guide 9678. . Check whether the camshaft guide
alternately fits into the grooves on both cylinder rows of the
camshafts.
Correct positioning of cams in cylinder

row 5 - 8
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Camshaft wheels with pan-head screw

M12
4. Tighten all camshaft wheels (two camshaft adjusters) again with pan-head screw M12. For this purpose, hold
hexagon of the respective camshaft with ring wrench and tighten M12 pan-head screw. For tightening
torques, see → 150719 Removing and installing camshaft wheel - Chapter "Reworking".
5. Remove camshaft guide 9678 and fixing pins 9595/1.
Subsequent work
Reworking
1. Install camshaft housing cover on both cylinder rows → 159123 Installing camshaft housing cover - Chapter
"Installing".
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
15 05 21 Removing camshafts - as of MY 2003, until MY 2004

- Preliminary work
- Removing camshafts
Preliminary work
Preliminary work for removing camshafts

1. Remove camshaft housing cover → 159121 Removing and installing cover for camshaft housing - chapter
on "Removing".
Carry out the next two work steps together.
2. Remove camshaft adjusters. For details, refer to → 158419 Removing and installing camshaft adjusters -
"Removing" chapter.
3. Remove camshaft timing gears. For details, see → 150719 Removing and installing camshaft timing gear -
chapter on "Removing".
Removing camshafts
Removing camshafts
Note
z While removing, note the installation position and allocation of the camshafts and bearing caps on a sheet of
paper in such a way that they cannot be mixed up.
z Protect camshafts, bearing caps and camshaft housing from dirt and layout the components on a clean
surface according to installation position.
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Position of camshafts
1. Unscrew fastening screws M6 x 16 of the inlet camshaft oil feed housing and pull it off to the front.
Note
Note
z When releasing the camshaft bearing caps, all the fastening screws must be released evenly half a turn at a
time in the reverse order to that illustrated so that the camshaft is not distorted!
2. Remove all the M6 x 35 fastening screws of the thrust bearing cap and bearing caps evenly half a turn at a
time in the reverse order to that illustrated -see figure- . Layout thrust bearing and bearing caps on a clean
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The view shows the tightening order for a camshaft
3. Remove camshafts and layout on a clean surface according to installation position.

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WARNUNG
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ATTENZIONE
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ADVERTENCIA
15 05 21 Removing camshafts - as of MY 2005

- Preliminary work
Preliminary work

1. Remove camshaft housing cover → 159121 Removing and installing cover for camshaft housing - chapter
on "Removing".
"Removing" chapter.
3. Remove camshaft timing gears. For details, see → 150719 Removing and installing camshaft timing gear -
Removing camshafts
Removing camshafts
Note
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1. Unscrew fastening screws (M6 x 16) of the inlet camshaft oil feed housing and pull it off to the front.
Note
Note
z When releasing the camshaft bearing caps, all the fastening screws must be released evenly half a turn at a
time in the reverse order to that illustrated so that the camshaft is not distorted!
Note
z As of model year 2005, the first camshaft bearing cap has two
standard bores for securing the hydraulic valve (two M6 x 60 screws)
-1- . An additional oil strainer is fitted under the hydraulic valve.
2. Remove all M6 x 35 fastening screws for the thrust bearing caps and
bearing caps evenly half a turn at a time in the reverse order to that
shown -see Figure- . Lay out thrust bearing and bearing caps on a
clean surface according to installation position.
Camshaft adjustment valve

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The view shows the tightening sequence for a camshaft
3. Remove camshafts and lay out on a clean surface according to installation position.
as of MY 2005
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
15 05 23 Installing camshafts - as of MY 2003, until MY 2004

- Installing camshafts
- Subsequent work
Tools

locating pin special tool 9595/1
socket special tool 9714
Installing camshafts
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Installation location of camshafts
Note
z Ensure the bearing caps are correctly positioned and allocated.
z Turn the crankshaft to about 30° before TDC cylinder 1 so that the
valves and pistons are not damaged when the camshaft bearing caps
are being tightened!
1. Remove locating pin 9595/1 from bore in crankshaft gearwheel

-see figure- . Using socket 9714, turn the crankshaft until it is
located 30° before TDC cylinder 1.
Fixing the crankshaft
2. Apply a layer of engine oil to the running surfaces of camshaft
bearings and bearing caps.
Note
z Place the camshafts in such a way that the cams are positioned as shown below!
Note
The camshafts of the turbocharged engine have a blue colour identification, the camshafts of the naturally
aspirated engine a white colour identification.
3. Place camshafts as shown in the -illustration- . When doing so, pay particular attention to the relative
position of the cams to each other.
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Installation position of cams
1 - Cam position cylinder 6

2 - Cam position cylinder 2 (A) and cylinder 3 (B)
D - Cam position cylinder bank 5 - 8 exhaust side
C - Cam position cylinder bank 5 - 8 inlet side
B - Cam position cylinder bank 1 - 4 inlet side
A - Cam position cylinder bank 1 - 4 exhaust side
4. Place oiled bearing caps on camshaft bearings. The matching number of the bearing caps must correspond
to the camshaft housing. For each cylinder, the bearing caps are numbered consecutively from the front
(timing chain side) -B- . The designation of the bearing cap and matching number can be read from the
exhaust side -A- .
Designation and matching numbers of bearing caps

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A- xxxx Camshaft housing bearing cap matching number

B- Bearing cap A/1 Bearing cap consecutive numbering exhaust cylinder 1
B- Bearing cap A/2-1 Bearing cap consecutive numbering exhaust between cylinders 1 and 2
B- Bearing cap A/3-2 Bearing cap consecutive numbering exhaust between cylinders 3 and 2 etc.
B- Bearing cap E/1 Bearing cap consecutive numbering inlet cylinder 1 etc
5. Fit bearing cap. The tightening sequence must be strictly observed → Tightening torque: 7.5 ftlb.
-tightening sequence- .
Camshaft bearing cap tightening sequence
6. Fit oil feed housing of inlet camshaft. To do this, slide the well-oiled oil feed housing over the plain
compression rings of the camshaft → Tightening torque: 7.5 ftlb. .
Subsequent work
Subsequent work for installing camshafts
Perform work steps 1 and 2 together.
1. Install camshaft adjusters. For details, refer to → 158419 Removing and installing camshaft adjusters -
"Installing" chapter.
2. Install camshaft timing gears. For details see → 150719 Removing and installing camshaft timing gear -
chapter on "installing".
3. Install camshaft housing cover → 159123 Removing and installing cover for camshaft housing - chapter on
"installing".

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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
15 05 23 Installing camshafts - as of MY 2005

- Subsequent work
Tools

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Installation position of camshafts
Note
z Turn the crankshaft to about 30° before TDC cylinder 1 so that the
valves and pistons are not damaged when the camshaft bearing caps
are being tightened!

-see Figure- . Using a socket 9714, turn the crankshaft until it is
located 30° before TDC of cylinder 1.
Note
Note
3. Place camshafts as shown in -Illustration- . When doing so, pay particular attention to the way the cams are
positioned in relation to each other.
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4. Put oiled bearing caps onto the camshaft bearings. The matching number of the bearing caps must
correspond to the camshaft housing. For each cylinder, the bearing caps are numbered consecutively from
the front (timing chain side) -B- . The designation of the bearing cap and matching number can be read from
the exhaust side -A- .

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A- xxxx Camshaft housing bearing cap matching number

B- Bearing cap A/1 Bearing cap consecutive numbering exhaust cylinder 1
B- Bearing cap A/2-1 Bearing cap consecutive numbering exhaust between cylinders 1 and 2
B- Bearing cap A/3-2 Bearing cap consecutive numbering exhaust between cylinders 3 and 2 etc.
B- Bearing cap E/1 Bearing cap consecutive numbering inlet cylinder 1 etc
Note
standard bores for securing the hydraulic valve (two M6 x 60 screws)
-1- . An additional oil strainer is fitted under the hydraulic valve.
5. Fit bearing cap. The tightening sequence must be strictly observed

→ Tightening torque: 10 (7.5 ftlb.) Nm -Tightening sequence- .
compression rings of the camshaft → Tightening torque: 10 (7.5 ftlb.) Nm .
Subsequent work
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3. Install camshaft housing cover → 159123 Removing and installing cover for camshaft housing - chapter on
"installing".
as of MY 2005
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
15 07 19 Removing and installing camshaft timing gear - as of MY

2003
- Preliminary work
- Removing camshaft timing gear
- Installing camshaft timing gear
- Subsequent work
Tools

Locating pin special tool 9595/1
Socket special tool 9714

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Preliminary work
Preliminary work for removing camshaft timing gear

1. Remove camshaft housing cover. → 159121 Removing and installing cover for camshaft housing - chapter
on "removing"
Tools and materials
Special tools
Tools

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Chapter 2.2.2 "

timing case.
Removing camshaft timing gear
Removing camshaft timing gear.
ATTENTION
Damage to engine by turning crankshaft against the rotation direction of the engine (engine assembled)!
→ Never rotate crankshaft against the operating direction if the timing drive mechanism is mounted (timing
chain jumps over).
→ Proceed carefully while working as otherwise the engine can be damaged.
→ Always turn the engine on the crankshaft and never on the camshaft as the timing chain may jump over.
→ Please observe the general warning notes and working regulations → 1001AW The most important working
regulations and warning notes
1. Using socket 9714, turn the crankshaft until cylinder 1 is located at ignition TDC.
Note
z If the cams on cylinder 1 are not positioned as shown, check whether
the crankshaft still needs to be turned through another turn (360°)!
2. Ensure the cams of cylinders 1 and 5 are in the position shown

(ignition TDC) -see figure- and → View shows position of cams on
cylinder 5 .

cylinder 1
3. Insert locating pin 9595/1 through the bore provided in the crankshaft gearwheel and into the relevant
groove in the timing chain housing cover -see figure- .
4. Remove chain tensioner -arrow- .
5. Loosen timing chain and pull upper plastic guide away from both pins. If necessary, turn camshaft timing
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View shows TDC position of View shows position of cams on

crankshaft cylinder 5
Installation location of chain tensioner
Upper plastic guide for timing chain

gear back and forth a little with the ring wrench so that the timing chain has more play between the wheels
→ Upper plastic guide for timing chain .
Note
z The fastening screws of the sprockets must be replaced after
removal.
z The diamond washers of the chain sprockets must be replaced after

removal.
z The screws of the sprocket wheels are tightened by hand during

assembly and are then loosened by one or two turns. This play is
necessary so that the camshafts can still be turned.
Loosening camshaft timing gear
6. Just loosen the fastening screw of the camshaft adjuster (1 or 2 turns). To do this, counter the a/f 32
hexagon of the camshaft adjuster and camshaft timing gear with a ring wrench. Only remove the cheese
head bolt of the camshaft timing gear
-to illustrate the operation more clearly, the figure does not include the timing case cover-- .
7. If necessary, use a rubber hammer to carefully loosen the camshaft timing gear from the back.
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ATTENTION
Engine damage due to small parts falling into the timing case (e.g. diamond washer)!
→ Do not let the diamond washer under the camshaft timing gear and camshaft adjuster fall into the timing
case.
Note
z There is a diamond washer between the camshaft and camshaft timing gear and between the camshaft and
camshaft adjuster. This is to be replaced after the corresponding wheel has been removed. If the fastening
screw of the wheel is only loosened to adjust the timing (1 or 2 revolutions), the diamond washer does not
need to be replaced.
8. Use both hands, to carefully remove the camshaft timing gear from the chain.
ATTENTION
Engine damage due to small parts falling into the timing case (e.g.
diamond washer)!
→ Do not let the diamond washer under the camshaft timing gear and
camshaft adjuster fall into the timing case.
9. Remove the diamond washer located under the camshaft adjuster. In

this case (removal of camshaft timing gear) replace the diamond
washer. Removing diamond washer
Installing camshaft timing gear
Installing camshaft timing gear.
Note
z If they have been removed, replace the diamond washer and M12 cheese head screw of the camshaft.
1. Replace the diamond washer and M12 cheese head screw located under the camshaft timing gear.
2. Lift the timing chain and carefully place the camshaft timing gear on the camshaft. To get sufficient play in
the timing chain, it may be necessary to turn the loosened camshaft adjuster back and forth. Place timing
chain on camshaft timing gear.
3. Position new M12 fastening screw on camshaft timing gear and screw in loosely (it must still be possible to
turn the camshaft timing gear).
4. Fit plastic guide for the timing chain.

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Installation location of chain tensioner Replacing the diamond washer

5. Install chain tensioner -arrow- . For tightening torque of chain tensioner, see → 153619 Removing and
installing chain tensioner - chapter on "installing".
Subsequent work
Subsequent work for installing camshaft timing gear

1. Adjust timing → 150516 Adjusting timing for camshafts - chapter on "adjusting". After adjusting the timing,
tighten the camshaft timing gears and camshaft adjusters → Initial tightening: 7.5 ftlb. → Initial
tightening: 37 ftlb. → Final tightening: 135 ° → Initial tightening: 7.5 ftlb. → Initial tightening: 37 ftlb.
→ Final tightening: 90 ° .
2. Install camshaft housing cover. → 159123 Removing and installing cover for camshaft housing - chapter on
"installing"
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
15 33 21 Removing chain case lid - as of MY 2003

- Preliminary work
- Information
- Removing chain case lid
Tools

engine support special tool 9676
Preliminary work
Preliminary work
2. Separate engine from transmission and suspend it on the assembly support using engine support 9676.
3. Drain off engine oil and dispose of it in accordance with the applicable national laws. For details and
tightening torques, see → 170117 Changing engine oil and oil filter - section on "Draining".
4. Remove cover for camshaft housing. → 159121 Removing cover for camshaft housing - section on
"Removing"
5. Loosen (do not remove) the three fastening screws on the water pump pulley.
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Fastening screws on water pump Draining engine oil

pulley
Fastening screws on engine mounts

6. Remove engine carrier. To do this, release the four fastening screws on the engine mounts.
7. Relieve and remove drive belt. → 137819 Removing and installing

drive belt - section on "Removing" [9PAAF1 9PAAJ1]→ 137819
Removing and installing drive belt - section on "Removing" [9PAAE1
9PAAE7]
Drive belt
Information
Component overview
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Installation location
Component overview
1- Radial shaft seal; align using the plastic sleeve provided

2- Top fastening screw (M6 x 50)
3- Bottom fastening screw (M6 x 12)
4- Chain tensioner
Removing chain case lid

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Note
z The description only explains how to remove the chain case lid. The removal of other components is
described in the corresponding chapters.
1. Remove the belt tensioner. To do this, loosen the fastening screws -4 and 5- on the carrier and on the
underside of the shock absorber.
Drive belt - overview
2. Remove the deflector wheel at cylinder row 1-4. To do this, lever off the lid and unscrew the fastening screw.
3. Remove water pump belt pulley.
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Note
z To ensure that the used
fastening screw of the
crankshaft belt pulley is not
used again, mark it with a felt-
tip pen.
4. Remove crankshaft belt

pulley. → 137619 Removing
and installing crankshaft belt
pulley - chapter on Crankshaft belt pulley Deflector wheel at cylinder row 1-4
"Removing"
5. Remove bracket for oil/water heat exchanger. → 176721 Removing

bracket for oil/water heat exchanger - chapter on "Removing"
Fastening screws for bracket for

oil/water heat exchanger
6. Remove cable duct at cylinder row 1-4.
Cable duct
7. Disconnect coolant line to the generator.
Coolant lines to generator

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8. Remove chain tensioner.

9. Remove oil dipstick. → 171719 Removing and installing guide for oil
dipstick - chapter on "Removing"
Installation position of chain tensioner

10. Remove crankshaft sealing ring on timing case cover. To do this,
loosen the four fastening screws.
ATTENTION
Risk of engine leaks!
z When dismantling the timing-case cover, the sealing bead
between the oil pan and crankcase can become damaged.
→ When dismantling the timing-case cover, the oil pan has to be

resealed every time.
Fastening screws for crankshaft
11. Remove timing-case cover. To do this, loosen all the fastening sealing ring
screws in reverse order (beginning with position 28).
Tightening sequence for fastening screws on timing-case cover
12. Remove oil pan. → 175021 Oil pan removed - chapter on "Removing".

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as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
15 33 23 Installing chain case lid - as of MY 2003

- Information
- Installing chain case lid
- Subsequent work
Information
Component overview
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Component overview
1- Radial shaft seal; align using the plastic sleeve provided

2- Top fastening screw (M6 x 50)
3- Bottom fastening screw (M6 x 12)
4- Chain tensioner
Installing chain case lid
ATTENTION

Note
z Acetone can be used to clean the sealing faces. Ventilate this for 5 minutes before applying more sealant.
1. Clean and degrease the sealing faces of the engine and housing lid.
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2. Attach the four seals -1, 2, 3 and 4- to the chain case lid.
Lid seals
3. Apply a bead of liquid sealant 000.043.300.39 Loctite 5970 (status 11/2005, for details of currently used
sealant, see Parts Catalogue) to the contact points of the camshaft housing/cylinder head, cylinder
head/crankcase and crankcase upper section/crankcase lower section. The bead of sealant should protrude
about 20 mm over the contact points. → Sealant application
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Sealant application
Note
z In the case of the M48/50 (turbo) engine, sealant must also be applied to the metal seal in the chain
tensioner area.
Sealant application
4. Screw down all fastening screws by hand. At this stage, the screw heads should not be all the way down.
Note
z The chain case lid must be aligned using a dial gauge or steel gauge.
z The chain case lid must not project over the lower section of the crankcase.
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z It must not go below ( -dimension A- )1/10 mm ( -dimension A < 1/10 mm- ).
Threaded joint and dimension
1 - M6 x 25 screw
2 - M6 x 50 screw
3 - M8 x 50 screw
5. Push the chain case lid upwards slightly and tighten the fastening screws -7, 8, 9 and 10- (about 1 - 2 Nm
(0.5 - 1.5 ftlb.) in such a way that the lid is slightly jammed. Then align the lid. → 153123 15 Installing chain
case lid - section on "Adjusting"
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Tightening sequence
Aligning the chain case lid with a dial gauge
ATTENTION
Danger of leaks!
z If the chain case lid is not aligned properly, this component or
the oil pan may start to leak during operation.
→ The chain case lid must not project over the crankcase.
→ It cannot go under 0.1 mm (dimension A = 0.1 mm).
1. Insert the dial gauge into the universal gauge holder and position it in
such a way that the dial gauge has a preload of about 1 mm. Adjusting the preload
2. Set dial gauge scale to 0. To do this, place the dial gauge holder on a
completely flat surface (e.g. crankcase flange) and turn the dial
gauge scale until the pointer is at 0.
Resetting dial gauge scale

3. Measure the offset. To do this, push with the holder starting from the lower section of the crankcase towards
the chain case lid (the foot of the dial gauge holder is not located on the same component as the dial gauge
probe) and measure the offset. The chain case lid must not be set back any more than 0.1 mm. It must not
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Measuring the setback distance
project out.
4. Align the chain case lid by tapping lightly with a rubber hammer.
Aligning the chain case lid

5. Once the chain case lid has been aligned, tighten two fastening
screws on the left and right of the chain case lid base to 10 Nm (7.5
ftlb.). Then, check the position of the chain case lid again using the
dial gauge.
6. Tighten the remaining fastening screws to the appropriate torque in

the sequence shown.
Note
See figure! → Tightening sequence
z The quality of the exterior fastening screws must be 10.9.

Checking the position
z Tighten screws 5 to 6 (M8/8.8) to 23 Nm (17 ftlb.).
z Then check all screws again (second time round).

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Tightening sequence
Tightening sequence
1 bis 4 - → Tightening torque: 7.5 ftlb.

5 bis 6 - → Tightening torque: 17 ftlb.
Subsequent work
Subsequent work
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1. Install oil pan. → 175023 Oil pan installed (includes sealing)
Oil pan tightening sequence
2. Install engine carrier. → 103519 Removing and installing engine

mount - section on "Installing"
Fastening screws

3. Fit front radial shaft seal. → 137419 Removing and installing crankshaft belt pulley - section on "Installing"
4. Fit crankshaft pulley. Fastening screw tightening torque: 250 Nm (185 ftlb.) + 90° torque angle. → 137619
Removing and installing crankshaft belt pulley - section on "Installing"
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Crankshaft belt pulley Radial shaft seal
Oil-water heat exchanger
5. Install bracket for oil-water heat exchanger. → 176723 Installing bracket for oil-water heat exchanger
6. Fit deflection roller of cylinder row 1 - 4. → Tightening torque: 32

(24 ftlb.) Nm Then clip on cap.
Deflection roller
7. Tighten coolant pump pulley. → 195019 Removing and installing
coolant pump pulley - section on "Installing"
Coolant pump pulley

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Belt tensioner
8. Install belt tensioner. Install holder with tensioning element. Tighten the top fastening screw → Tightening
torque: 33 (24 ftlb.) Nm . Tighten the bottom fastening screw → Tightening torque: 32 (24 ftlb.) Nm
→ 137319 Replacing belt tensioner.
9. Fit and tension the drive belt. → 137819 Removing and installing
drive belt [9PAAF1 9PAAJ1]→ 137819 Removing and installing
drive belt [9PAAE1 9PAAE7]
Drive belt
10. Install chain tensioner with new sealing ring. → 153619 Removing
and installing chain tensioner - section on "Installing"
11. Install oil dipstick. → 171719 Removing and installing guide for oil
dipstick - section on "Installing"
Chain tensioner
12. Check timing and adjust if necessary. → 150516 Setting the timing
13. Install cover for camshaft housing (valve cover). → 159123 Installing
cover for camshaft housing
14. Install engine. → 100119 Removing and installing V8 4.5 l engine -

Camshaft guide
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as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
15 35 21 Removing timing chain - as of MY 2003

- Preliminary work
- Information
- Removing timing chain
Preliminary work
Preliminary work
ATTENTION
chain jumps over).
2. Remove cover for camshaft housing. → 159121 Removing cover for camshaft housing
3. Remove chain case lid. → 153121 Removing chain case lid
Information
Component overview
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Overview of timing drive mechanism

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Component overview for timing chain
1- Camshaft timing gear

2- Cheese head bolt, M12 x 140
3- Guide rail
4- Guide rail fastening screw, M8 x 35
5- Timing chain; use same rolling direction when re-using.
Removing timing chain

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Note
If the timing chain has to be removed or replaced, check the guide and tensioning rails for wear and scoring and
replace them if necessary.
Note
z The rolling direction of the timing chain must always be the same.
z If the timing chain is to be reused, the rolling direction of the timing

chain must be marked before it is removed.
1. Loosen the fastening screws of the camshaft wheels and camshaft

adjusters (1 or 2 turns). To do this, hold the a/f 32 hexagon of the
camshaft adjuster and camshaft timing gear against the
corresponding camshaft with a ring wrench. Loosen the M12 cheese
head bolt by 1 or 2 turns with socket wrench insert T60. Camshaft timing gears and camshaft
adjusters
2. Pull guide rails between the camshafts away from the threaded pegs.
To do this, let timing chain dangle between the camshafts.
Note
z If the timing chain is to be reused, the rolling direction of the timing
chain must be marked before it is removed.
3. Mark rolling direction of timing chain. Remove timing chain from all
sprockets, pulling it forwards.
Figure shows guide rail with fitted

chain case lid and timing chain.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
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ADVERTENCIA
15 35 23 Fitting timing chain - as of MY 2003

- Information
- Fitting timing chain
- Subsequent work
Information
Component overview

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3- Guide rail
Fitting timing chain

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ATTENTION
chain jumps over).
Note
z If the timing chain is to be reused, the rolling direction of the timing chain must be marked before it is
removed.
Note
Camshaft timing gears and camshaft adjusters must be installed and it must be possible to turn them.
1. Place timing chain loosely on all sprockets. Ensure that the timing chain is in the correct position on the
guide rails.
2. Fit guide and tensioning rails. For details, see → Removing and installing guide and tensioning rails
3. Place guide rails between the camshafts on the threaded pegs. To

do this, let timing chain dangle between the camshafts.
Guide rails between camshafts

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Subsequent work
Subsequent work
1. Install chain case lid. → 153123 Installing chain case lid
2. Set timing of camshafts. → 150516 Setting the timing
3. Install cover for camshaft housing. → 159123 Installing cylinder head cover
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
15 36 19 Removing and installing chain tensioner - as of MY 2003

- Information
- Removing chain tensioner
- Installing chain tensioner
Information
Component overview
Removing chain tensioner

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ATTENTION
z Remove and install the chain tensioner only in overlapping TDC. (The chain tensioner is under the
least amount of pressure in this position).
Note
z All spark plugs (except for those on cylinder 3) must be removed to ensure that the relevant dead centre can
be found more easily.
z The torque support bracket can remain in place.
1. Remove spark plugs (except for cylinder 3) → 287055 Replacing

spark plugs
Spark plug wrench
Note
An alternative method for determining the overlapping TDC is the "cylinder
pipe" (dead centre finder). This tool is part of the pressure-loss tester WE
1066, Workshop Installation Manual 3.1.4.
2. Find overlapping TDC of cylinder 1. To do this, insert the ignition rod

module of the first cylinder into the corresponding opening in the
valve cover and press in firmly.

– Twist the crankshaft in the direction of motion until the ignition rod module comes out again with an audible
plop. Then twist the crankshaft until the fixing bore on the crankshaft belt pulley is aligned with the bore in
the timing case cover. The engine is now located in the ignition TDC of cylinder 1.
– Then twist the crankshaft through 360° in the direction of motion. The engine is now located in the
overlapping TDC of cylinder 1.
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TDC of cylinder 1 for vibration damper Ignition rod module of cylinder 1

fastening
Cable clip
3. Open cable clip -7- of the generator's electric cable and press the cable upwards.
4. Undo chain tensioner -arrow- and unscrew it by hand.
Installing chain tensioner
Note
z If the chain tensioner is removed, the aluminium sealing ring must be replaced.
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1. Screw chain tensioner with new sealing ring -arrow- down by hand and tighten. → Tightening torque: 44
ftlb.
2. Clip in the electric cable of the generator again.

3. To check, turn crankshaft two turns in a clockwise direction. Watch
out for any stiffness.
Cable clips
4. Install spark plugs and covers.→ 287055 Replacing spark plugs
Installing spark plugs
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
15 37 19 Removing and installing hydraulic valve for camshaft

adjustment - as of MY 2003, until MY 2004
- Preliminary work
- Removing hydraulic valve for camshaft adjustment
- Installing hydraulic valve for camshaft adjustment
- Subsequent work
Tools

relay puller special tool 9235
Preliminary work
Preliminary work
1. Remove cover for camshaft housing → 159121 Removing and installing cover for camshaft housing - section
on "Removing".
Removing hydraulic valve for camshaft adjustment

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Note
z The hydraulic valve for camshaft adjustment as of model year 2005 does not fit on the bearing cap and
camshaft housing of model years 2003 to 2004.
z If an engine of model years 2003 to 2004 is to be converted to suit a new hydraulic valve with oil strainer, the
camshaft housing and all camshaft bearing caps must be replaced.
1. Unscrew M6 x 16 fastening screw of the hydraulic valve -Arrow- .
Fastening screw for hydraulic valve

2. Carefully pull out the hydraulic valve in an upward direction. To do
this, use special tool relay puller 9235.
Relay puller on hydraulic valve
Installing hydraulic valve for camshaft adjustment
Note
1. Replace sealing ring on hydraulic valve -see Figure- . Do not insert sealing ring twisted when fitting.
2. Coat sealing ring lightly with engine oil and insert hydraulic valve into cylinder head.
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Fastening screw for hydraulic valve Hydraulic valve sealing ring
3. Screw in fastening screw -Arrow- and tighten. → Tightening torque: 10 (7.5 ftlb.) Nm
Subsequent work
Subsequent work
1. Install cover for camshaft housing → 159123 Removing and installing cover for camshaft housing - section
on "Installing".

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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA

adjustment - as of MY 2005
- Preliminary work
- Subsequent work
Preliminary work
Preliminary work
1. Remove cover for camshaft housing → 159121 Removing and installing cover for camshaft housing - section
on "Removing".
Note
1. Remove screws on hydraulic valve. -1-
2. Remove oil strainer with a small magnet. If the oil strainer cannot be removed through the housing, the
bearing cap must be removed.
3. The oil strainer is located in the camshaft housing under the first camshaft bearing cap.
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Oil strainer fitted Camshaft adjustment valve
Oil strainer partly inserted in camshaft

housing
Note
1. Insert the oil strainer into the camshaft housing under the first
camshaft bearing cap. You do not have to remove the camshaft
bearing cap to do this (Figure shows oil strainer without camshaft
bearing cap → Oil strainer partly inserted in camshaft housing ).

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housing

2. Place hydraulic valve in installation position. Make sure that the side with the fastening hole is always
pointing towards the intake-air distributor → Camshaft adjustment valve . Fit screws for hydraulic valve →
Tightening torque: 10 (7.5 ftlb.) Nm . -1-
Subsequent work
Subsequent work
1. Install cover for camshaft housing → 159123 Removing and installing cover for camshaft housing - section
on "Installing".
as of MY 2005
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
15 47 19 Removing and installing guide and tensioning rails - as

of MY 2003
- Preliminary work
- Information
- Replacing guide and tensioning rails
- Installing guide and tensioning rails
- Subsequent work
Preliminary work
Preliminary work
2. Remove cover for camshaft housing . → 159121 Removing cover for camshaft housing - section on
"Removing"
3. Remove chain case lid. → 153121 21 Removing chain case lid - section on "Removing"
4. Mark rolling direction of timing chain. Remove timing chain from all chain sprockets, pulling it forwards.
→ 153521 Removing timing chain - section on "Removing"
Information
Component overview
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Timing chain with guide and tensioning rails

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Component overview 1

3- Guide rails
4- Guide rail fastening screw
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1- Tensioning rail
2- Threaded pegs
3- Guide rails
4- Threaded pegs
5- Chain tensioner M24 x 1.5; replace sealing ring
6- Guide rail
Replacing guide and tensioning rails
Removing guide and tensioning rails

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Note
Note
removed.
Note
removed.
1. Remove top guide rails -6- if this has not yet been done. Pull guide rail -3- and tensioning rail -1- off threaded
pegs. Ensure that the spring of the tensioning rail for the oil pump drive is in the correct position in relation to
the guide rail -3- .
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Guide rail and tensioning rail
2. Remove guide rail -3- by loosening four fastening screws (M8 x 35).
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Guide rail
3. Remove plastic lid of oil pump drive -7- . To do this, unscrew two M5 x 20 screws -8- and remove plastic lid.
Remove guide rail -9- and tensioning rail -6- .
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Oil pump drive
Installing guide and tensioning rails

1. Insert guide rail -9- and tensioning rail -6- . Fit plastic lid of oil pump drive -7- . To do this, insert plastic lid
and screw in two screws -8- . → Tightening torque: 4.1 ftlb.
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Oil pump drive
2. Fit guide rail -3- . To do this, screw in four fastening screws (M8 x 35). → Tightening torque: 24 ftlb.
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Guide rail
3. Attach guide rail -3- and tensioning rail -1- to threaded pegs. Position the spring of the tensioning rail for oil
pump drive correctly on guide rail -3- . Fit top guide rails -6- when installing the timing chains.
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Subsequent work
Subsequent work
1. Install timing chain. → 153523 Installing timing chain - section on "Installing"
3. Set the timing. → 150516 Adjusting timing for camshafts - section on "Adjusting"
4. Install cover for camshaft housing . → 159123 Installing cover for camshaft housing - section on "Installing"
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as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
15 59 19 Removing and installing hydro-tappets - as of MY 2003

- Preliminary work
- Removing hydro-tappets
- Installing hydro-tappets
- Subsequent work
Preliminary work
Preliminary work
1. Remove camshafts . → 150521 Remove camshafts - Chapter "Removing"
Removing hydro-tappets
Note
z If the flat-base tappets are to be reused, they must be marked
according to installation position using a water-resistant felt-tip pen
and stored in such a way that they cannot be mixed up!
z If the flat-base tappets are to be reused, they must be installed in the

same location!
1. Pull the flat-base tappets out of the camshaft housing one after the
other and store them in such a way that they cannot be mixed up.
Pulling flat-base tappets out of the
camshaft housing
E - Intake side
A - Exhaust side
5 bis 8 - Cylinders
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Putting components down without

mixing them up (cylinder bank 5-6
shown here as an example)
Installing hydro-tappets
1. Grease flat-base tappets with engine oil and reinsert into the
camshaft housing.
Inserting flat-base tappets in camshaft

housing
Subsequent work
Subsequent work
1. Install camshafts . → 150523 Install camshafts - chapter on "Installing"
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
15 60 19 Removing and installing intake valve - as of MY 2003

- Preliminary work
- Information
- Removing intake valve
- Installing intake valve
- Subsequent work
- Information
Tools

valve key commercially NR.54-1
assembly/disassembly tool for available tool
the Cayenne
Preliminary work
Preliminary work
1. Remove cylinder head. → 157021 Removing cylinder head
2. Remove camshafts → 150521 Removing camshafts - section on "Removing".
3. Take flat-base tappets out of the cylinder head and lay them on a clean surface, arranged according to
cylinders and valves. → 155955 21 Removing and installing flat-base tappets - chapter on "Removing" . Do
not interchange components.
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Information
Component overview
In the Turbo, the exhaust valve is fitted with internal and external valve springs and adapted concave
washers (different to those shown in the figure below). The exhaust valve in the turbo engine has the same
dimensions as the exhaust valve in the naturally aspirated engine; because of the sodium filling it is lighter
however and when obtained as a spare part it features a coloured dot to distinguish it. For further details,
please see later chapter entitled "Valve dimensions".
Component overview of valves
1 - Valve collet (valve key)

2 - Top spring retainer
3 - Valve spring
4 - Spring plate, bottom
5 - Valve-stem seal
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6 - Valve guide
7 - Intake positioning ring
8 - Intake valve
9 - Exhaust positioning ring
10 - Exhaust valve
Removing intake valve
Note
z Secure the cylinder head on a level surface, which allows easy access to the valves from underneath.
z No valves should be hidden by the surface under the cylinder head.
z The cylinder head fastening must not tip over when tools are used.
Note
z The illustrations show part of the cylinder head installed.
1. The spark plugs must be removed and the valve lock screwed in
before the valves are removed → Screwing in tool . The valve lock
prevents the valves from being opened while being pressed down.
Alternatively, a rubber plate placed underneath helps if the cylinder
head surface is smooth -2- .
Screwing in tool
Locking valves
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Removing tool setup for valve springs
2. Fit and adjust lever tool from the valve key assembly/disassembly tool for the Cayenne NR.54-1 set on
the cylinder head. When doing so, ensure that the middle pipe is positioned centrally over the spark-plug
recesses. The operating lever can be secured centrally or excentrically. The fastening screws in the camshaft
bearing caps in the front and rear bearing position are used to secure the tool brackets → Removing tool
setup for valve springs (figure shows fitted cylinder head). Use the white plastic pressure piece with the
magnetic insert to remove the valve keys. The assembly must be performed as shown → Removing tool
setup for valve springs .
3. Press the white plastic pressure piece with the magnetic insert against
the top concave washer to remove the valve keys. The concave
washer -2- and the valve keys -1- are attracted to the magnetic insert
and release the valve (loosen valve keys with a screwdriver if they are
stuck). Remove loose components (valve springs, top concave
washer and valve keys). Repeat procedure as often as necessary for
the affected valves (reposition tool accordingly).
Valve keys in tool

4. Remove valve lock → Locking valves . Push valve out at the
combustion chamber side and remove it from the cylinder head.
Locking valves
Installing intake valve
Note
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z Intake valves come in different sizes to exhaust valves. It is impossible to mix them up. Intake valves are
identical in the naturally aspirated and turbo engines.
z Exhaust valves in the turbo engine weigh less than exhaust valves in the naturally aspirated engine. They are
marked with a green dot. Do not interchange them.
z The valves cannot be touched up afterwards.
z The valves can be grinded using commercially available valve grinding paste.
1. Apply a small amount 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 in the valve using the commercially available valve grinding tool
(with rubber suction cup) by means of rotary movements. To do this,
hold the valve grinder between the palms of both hands and press
against the valve seat with rotating movements → Grinding the valve
seat .
ATTENTION
Valve grinding paste residues can cause mechanical damage!
→ Remove all valve grinding paste fully after grinding.
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.
Grinding the valve seat

5. Fit valve lock. → Locking valves
6. Replace valve-stem seals. → 156319 Removing and installing valve-

stem seal
Locking valves
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. Pull
off the ring of the assembly tool -2- from the retaining springs -3- before inserting the valve keys. Position
valve keys with the thin side facing upwards -1- .
8. Insert valve keys into the assembly tool with the thin side facing upwards -1- . Ensure that the valve keys fit
symmetrically and are inserted as far as they will go in the assembly tool. The retaining springs are free -2- .
9. Secure the valve keys by pushing up the ring → Valve keys in assembly tool . Check that the valve keys are
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Valve keys in assembly tool Tool setup - valve keys
Valve keys in assembly tool

aligned correctly -1- .
10. Insert valve key assembly tool in tool setup and position in front of the
valve stem. → Valve key assembly
Valve key assembly

11. When assembling the valve keys, ensure that the assembly tool is
inserted at the valve stem end -2- and is then pushed down (the tool
remains secured when this is done -1- ). The valve keys click audibly
into the valve grooves when the valve key assembly tool is pressed
onto the valve. Check valve keys to ensure that they are installed
correctly.
Valve key assembly in valve key

grooves
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Subsequent work
Subsequent work
1. Fit flat-based tappets. Do not interchange components. → 155955 23 Removing and reinstalling flat-base
tappet - chapter on "Installing"
3. Fit cylinder head. → 157023 Installing cylinder head
Information
Valve dimensions
Dimension Intake valve Exhaust valve - naturally Exhaust valve - turbo

aspirated engine engine
Valve disc diameter 37.10 mm 32.50 mm 32.50 mm
Valve stem diameter 5.94 mm 5.94 mm 5.94 mm
Overall length (from valve 109.10 mm 109.05 mm 109.05 mm
disc to valve pressure area)
Angle at valve seat area 45° 45° 45°
Weight 56 g 47 g 43.7 g (lighter than in
naturally aspirated engine
because of filling); features
coloured dot to distinguish it
from the exhaust valve in the
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
15 62 19 Removing and installing exhaust valve - as of MY 2003

- Preliminary work
- Information
- Removing exhaust valve
- Installing exhaust valve
- Subsequent work
- Information
Tools

the Cayenne
Preliminary work
Preliminary work
cylinders and valves. → 155955 21 Removing and installing flat-base tappets - chapter on "Removing" . Do
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Information
Component overview
washers (different to those shown in the figure below). The exhaust valve in the turbo engine has the same
dimensions as the exhaust valve in the naturally aspirated engine; because of the sodium filling it is lighter
however and when obtained as a spare part it features a coloured dot to distinguish it. For further details,
please see later chapter entitled "Valve dimensions".

3 - Valve spring
5 - Valve-stem seal
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6 - Valve guide
8 - Intake valve
10 - Exhaust valve
Removing exhaust valve
Note
Note
before the valves are removed → Screwing in tool . The valve lock
prevents the valves from being opened while being pressed down.
Alternatively, a rubber plate placed underneath helps if the cylinder
head surface is smooth -2- .
Screwing in tool
Locking valves
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2. Fit and adjust lever tool from the valve key assembly/disassembly tool for the Cayenne NR.54-1 set on
the cylinder head. When doing so, ensure that the middle pipe is positioned centrally over the spark-plug
recesses. The operating lever can be secured centrally or excentrically. The fastening screws in the camshaft
bearing caps in the front and rear bearing position are used to secure the tool brackets → Removing tool
setup for valve springs (figure shows fitted cylinder head). Use the white plastic pressure piece with the
magnetic insert to remove the valve keys. The assembly must be performed as shown → Removing tool
setup for valve springs .
3. Press the white plastic pressure piece with the magnetic insert against
the top concave washer to remove the valve keys. The concave
washer -2- and the valve keys -1- are attracted to the magnetic insert
and release the valve (loosen valve keys with a screwdriver if they are
stuck). Remove loose components (valve springs, top concave
washer and valve keys). Repeat procedure as often as necessary for
the affected valves (reposition tool accordingly).
Valve keys in tool

Locking valves
Installing exhaust valve
Note
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z Exhaust valves in the turbo engine weigh less than exhaust valves in the naturally aspirated engine. They are
marked with a green dot. Do not interchange them.
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 in the valve using the commercially available valve grinding tool
(with rubber suction cup) by means of rotary movements. To do this,
hold the valve grinder between the palms of both hands and press
against the valve seat with rotating movements → Grinding the valve
seat .
ATTENTION
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.

6. Replace valve-stem seals. → 156319 Removing and installing valve-

stem seal
Locking valves
exhaust valve in the turbo engine) on the bottom concave washer. Place top concave washer in position. Pull
off the ring of the assembly tool -2- from the retaining springs -3- before inserting the valve keys. Position
8. Insert valve keys into the assembly tool with the thin side facing upwards -1- . Ensure that the valve keys fit
symmetrically and are inserted as far as they will go in the assembly tool. The retaining springs are free -2- .
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Valve keys in assembly tool Tool setup - valve keys

10. Insert valve key assembly tool in tool setup and position in front of the
valve stem. → Valve key assembly
Valve key assembly

correctly.

grooves
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Subsequent work
Subsequent work
Information
Valve dimensions

as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
15 63 19 Removing and installing valve-stem seal - as of MY 2003

- Preliminary work
- Information
- Removing valve-stem seal
- Installing valve-stem seal
- Subsequent work
- Information
Tools

puller special tool 3364
assembly driver special tool 9606/1

the Cayenne
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Preliminary work
Preliminary work
Note
The cylinder head can remain fitted while this work is carried out.
2. Remove camshafts on both cylinder banks. → 150521 Removing camshafts
cylinders and valves. → 155955 21 Removing and installing flat-base tappets - section on "Removing" . Do
Information
Component overview
washers (different to those shown in the figure below). The exhaust valve in the turbo engine has the
same dimensions as the exhaust valve in the naturally aspirated engine; because of the sodium filling it is
lighter however and when obtained as a spare part it features a coloured dot to distinguish it. For further
details, please see later chapter entitled "Valve dimensions".
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3 - Valve spring
5 - Valve-stem seal
6 - Valve guide
8 - Intake valve
10 - Exhaust valve
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Removing valve-stem seal
Note
When required, all valve-stem seals on both cylinder rows must be replaced.
Note
z Before switching to another cylinder, the cylinder must be positioned at the bottom dead centre and supplied
with compressed air (see above).
Note
z Position the pistons of the relevant cylinder at the bottom dead centre.
z Each piston is pressed downwards as pressure builds up in the cylinder.
1. Set piston for the corresponding cylinder to bottom dead centre. 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 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 the pressure in the cylinder so that the valve does not fall
into the cylinder while the work is being carried out. 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 adjust lever tool from the valve key assembly/disassembly
tool for the Cayenne NR.54-1 set on the cylinder head. When doing
so, ensure that the middle pipe is positioned centrally over the spark-
plug recesses. The operating lever can be secured centrally or
excentrically. The fastening screws in the camshaft bearing caps in
the front and rear bearing position are used to secure the tool
brackets → Removing valve keys (figure shows fitted cylinder head).
Use the white plastic pressure piece with the magnetic insert to
remove the valve keys. The assembly must be performed as shown
→ Removing valve keys .
Removing valve keys

4. Press the white plastic pressure piece with the magnetic insert
against the top concave washer to remove the valve keys. The
concave washer -2- and the valve keys -1- are attracted to the
magnetic insert and release the valve (loosen valve keys with a
screwdriver if they are stuck). Remove loose components (valve
springs, top concave washer and valve keys). Repeat procedure for
valves on pressurised cylinder (reposition tool accordingly).
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Valve keys in tool
Valve-stem seal before puller

5. 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
Valve-stem seal in puller

6. When engaging the puller 3364, push sliding sleeve down and close
tool. -arrow-
Closed puller
7. Remove valve-stem seal by activating the negative (slide) hammer.
-arrow- . Repeat procedure for valves on pressurised cylinder
(reposition tool accordingly).

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Installing valve-stem seal
Note
Note
z Before switching to another cylinder, the cylinder must be positioned at the bottom dead centre and supplied
with compressed air (see above).
Note
Note
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- .
Valve-stem seal with tool

2. Push protective cap onto valve stem end. → Protective cap
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3. Oil valve stem, protective cap 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.
Valve-stem seal pushed over

protective cap and valve
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-
Pushing on 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. Pull off the ring of the assembly tool -2- from the retaining
springs -3- before inserting the valve keys. Position valve keys with
the thin side facing upwards -1- .
Tool setup - valve keys

6. Insert valve keys into the assembly tool with the thin side facing
upwards -1- . Ensure that the valve keys fit symmetrically and are
inserted as far as they will go in the assembly tool. The retaining
springs are free -2- .

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8. Insert valve key assembly tool in tool setup and position in front of
the valve stem. → Valve key assembly
Valve key assembly

correctly.
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.

grooves
Subsequent work
Subsequent work
1. Fit flat-based tappets. → 155955 23 Removing and installing flat-base tappets - section on "Installing" . Do
Information
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Valve dimensions

as of MY 2003
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WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
15 70 21 Removing cylinder head - as of MY 2003

- Preliminary work
- Information
- Removing cylinder head
Preliminary work
Preliminary work
Note
z If more comprehensive work, e.g. replacement of the entire cylinder head, is intended, the exhaust manifolds
must also be removed. → 261019 Removing and installing exhaust manifold - Chapter "Removing" [9PAAE1
9PAAE7]→ 261019 Removing and installing exhaust manifold - Chapter "Removing" [9PAAF1 9PAAJ1]
"Removing"
3. Remove intake-air distributor. → 244619 Removing and reinstalling intake-air distributor - section on
"Removing"
4. Remove chain case lid. → 153121 21 Remove chain case lid – section on "Removing"
5. Remove camshaft housing. → 150321 Remove camshaft housing - section on "Removing"
Information
Component overview
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Component overview
1- Cap
2- Cylinder head
3- Straight pin
4- Pan-head screw M12 x 1.5 x 140
5- Cap
6- Spark plug
7- Cap
8- Cylinder-head gasket
9- Vent connection
Removing cylinder head

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1. Remove guide rail of timing chain -3- . To do this, unscrew fastening screws -4- .
Timing chain guide rail

2- M12 x 140 cheese-head bolt
3- Guide rails
5- Timing chain; use same running direction when reusing
2. Remove oil separator vent line from cylinder head. To do this, unscrew the fastening screws -3 and upper 4-
.
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Oil separator vent line from cylinder head.
3. Disconnect vent line for cylinder heads. To do this, press the ribbed surfaces of the buttons and pull off the
plugs.
Note
z In the case of the turbocharged engine (M48/50), only the upper fastening screws of the turbocharger need
to be undone.
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4. Uncover cable of oxygen

sensor front catalytic
converter.
Turbocharger fastening screws Cylinder head vent line

5. Unscrew starter catalyst from exhaust manifold. To do this, loosen
the 3 fastening nuts.
6. Unscrew fastening screws of cylinder head in the opposite order of

the tightening sequence -figure- .
Illustration shows tightening sequence
Fastening nuts for exhaust manifold
Tightening sequence for cylinder head fastening screws
7. Remove cylinder head and cylinder head gasket.
as of MY 2003
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ADVERTENCIA
15 70 23 Installing cylinder head - as of MY 2003

- Information
- Installing cylinder head
- Subsequent work
Information
Component overview
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Component overview
1- Cap
2- Cylinder head
3- Straight pin
4- Pan-head screw M12 x 1.5 x 140
5- Cap
6- Spark plug
7- Cap
8- Cylinder-head gasket
9- Vent connection
Installing cylinder head

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ATTENTION

Mechanical angle disc for torque angle screws
Note
z All sealing surfaces must be clean and free of grease!
z It is essential to work carefully!
z Tightening sequences and tightening torques must be observed!
z If more extensive work, such as complete replacement of the cylinder

head, is necessary, the exhaust manifolds must be modified as well.
→ 261019 Removing and installing exhaust manifolds [9PAAE1
9PAAE7]→ 261019 Removing and installing exhaust Cylinder bank 1 -4
manifolds [9PAAF1 9PAAJ1]
1. Place cylinder head gasket correctly, i.e. according to the specifications, onto the straight pins of the engine
crank housing. This must be done in such a way that the "Top" marking can be read -figure- .
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2. Fit cylinder head. Insert M12 x 1.5 x 140 cylinder head screws
(screws can be used again).
3. The tightening sequence 1-10 must be observed for every tightening

step.
Setting torque
→ Tightening torque: 22 ftlb.
Undo all cheese-head bolts.

Cylinder bank 5 - 8
Final tightening torque:
→ torque angle: 90 °
Note
z In the case of the turbocharged engine (M48/50), screw down the
upper fastening screws of the turbocharger.
Turbocharger fastening screws

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4. Fasten primary catalytic converter to the exhaust manifold. To do

this, fasten three fastening nuts → Fastening nuts for exhaust
manifold . → Tightening torque: 17 ftlb.
5. Secure cable of starter catalyst oxygen sensor in the cable guide.

6. Place vent line on the cylinder head flange. → Vent line on
connection piece of cylinder head To do this, press the ribbed
surfaces of the buttons and pull off the plugs.
7. Mount oil separator vent line onto cylinder head with new sealing ring
-2- . To do this, position and tighten the fastening screws
-3 and upper 4- . → Tightening torque: 7.5 ftlb.
Vent line on connection piece of

cylinder head
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Oil separator vent line
8. Fasten guide rail of timing chain -3- . To do this, tighten the fastening screws -4- . → Initial tightening: 11
ftlb. → Final tightening: 90 °
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2- M12 x 140 cheese-head bolt
3- Guide rails
5- Timing chain; use same running direction when reusing
Subsequent work
Subsequent work
1. Install camshaft housing. → 150323 Install camshaft housing – section on "Installing"
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2. Install chain case lid. → 153123 23 Install chain case lid – section on "Installing"
3. Install intake-air distributor. → 244619 Removing and reinstalling intake-air distributor - section on "Installing"
4. Install cover for camshaft housing . → 159123 Installing cover for camshaft housing - section on "Installing"
as of MY 2003
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ADVERTENCIA
15 73 56 Replacing attachment for exhaust manifold (stud) - as of

MY 2003
- Preliminary work
- Replacing attachment for exhaust manifold (stud)
- Subsequent work
Preliminary work
Preliminary work for replacing studs

1. Remove exhaust manifold. → 261019 Removing and installing exhaust manifold - chapter on
"removing" [9PAAE1 9PAAE7]→ 261019 Removing and installing exhaust manifold - chapter on
"removing" [9PAAF1 9PAAJ1]
2. Remove exhaust manifold seal.
Replacing attachment for exhaust manifold (stud)
Replacing attachment for exhaust manifold (studs)
Note
Only replace studs if they are damaged or their reliability can no longer be assured!
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Exhaust manifold
1. Screw two M8 nuts onto the stud and counter with two open-ended
wrenches.
Tightening nuts on stud
Countering both nuts in direction of

arrow
2. To unscrew stud, turn rear nut to left.
Note
z Before inserting the new stud, the internal thread in the cylinder head must be checked for damage!
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Unscrewing stud
3. Screw in new stud hand-tight, then screw two nuts onto the new stud
as before and counter.
Screwing in new studs hand-tight

arrow
4. Screw in new stud by turning front nut to right.
Screwing in new stud

5. The stud must be screwed in until dimension -A- is obtained. Check dimension with a caliper gauge.
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Dimension A Checking dimension with caliper

gauge
Engine type Dimension A
M48/00 (naturally aspirated engine) 24.5 - 25.5 mm
M48/50 (turbocharged engine) 23 - 24 mm
Subsequent work

1. Re-install exhaust manifold with new seal. → 261019 Removing and installing exhaust manifold - chapter on
"installing" [9PAAE1 9PAAE7]→ 261019 Removing and installing exhaust manifold - chapter on
"installing" [9PAAF1 9PAAJ1]
as of MY 2003
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WARNUNG
WARNING
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ATTENZIONE
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ADVERTENCIA
15 84 19 Removing and installing camshaft adjusters - as of MY

2003
- Preliminary work
- Removing camshaft adjusters
- Installing camshaft adjusters
- Subsequent work
Tools


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Preliminary work

1. Remove camshaft housing cover. → 159121 Removing and installing cover for camshaft housing - chapter
on "removing"
Tools and materials
Special tools
Tools

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Chapter 2.2.2 "

timing case.
Removing camshaft adjusters
Note
z The timing is always set simultaneously on both cylinder banks. Once a cylinder bank has been set, the
crankshaft must not be turned to set the other cylinder bank!
z The fastening screws of the chain sprockets must be replaced after removal.
z The diamond washers of the chain sprockets must be replaced after removal.
z The screws on the sprocket wheels are tightened by hand during assembly and are then loosened by one or
two turns. This play is necessary so that the camshafts can still be turned.
z The cylinder bank is set with the standard chain tensioner that is installed.
ATTENTION
chain jumps over).
Note
z If the cams on cylinder 1 are not positioned as shown, check whether the crankshaft needs to be turned
through another turn (360°)!
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cylinder 1
2. Make sure that the cams for the 1st cylinder and 5th cylinder are positioned as shown (cylinder 1 at ignition
TDC) -see figure- and → View shows position of cams on cylinder 5 .

cylinder 5
3. Insert fixing pin 9595/1 into the relevant groove in the timing chain
housing cover through the bore provided in the crankshaft wheel
-see figure- .
View shows TDC position of

crankshaft
5. Loosen the timing chain and pull the upper plastic guide off the two pins. If necessary, use a ring wrench to
turn the camshaft timing gear back and forth to provide more clearance for the timing chain between the
wheels → Upper plastic guide for timing chain .
Note
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Chain tensioner installation location

z The fastening screw and diamond washer of the camshaft adjuster
only need to be replaced if removed.
Camshaft adjuster and camshaft

timing gear
6. Only loosen the fastening screw of the camshaft timing gear (one or two turns). To do this, use a ring wrench
to counter at the a/f 32 hexagon on the camshaft adjuster and on the camshaft timing gear of the
corresponding camshaft. Unscrew only the M12 cheese head bolt of the camshaft adjuster using a T60
socket -figure shows procedure without timing-case cover for a better view- .
7. Loosen the camshaft adjuster from the back with a rubber hammer.
Loosening camshaft adjuster
ATTENTION
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Note
z There is a diamond washer between the camshaft and camshaft
timing gear or camshaft adjuster. This must be replaced after the
corresponding wheel has been removed. If the fastening screw of the
wheel is only loosened in order to adjust the timing (1 or 2
revolutions), the diamond washer and fastening screw do not need to
be replaced.
Take camshaft adjuster out of the
8. With both hands, carefully take the camshaft adjuster out of the chain
chain.
9. Remove the diamond washer which is located underneath the

camshaft adjuster.
Removing diamond washer
Installing camshaft adjusters
ATTENTION
chain jumps over).
Note
z If the diamond washer and pan-head screw M12 are removed, replace the camshaft.
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Replacing diamond washer
1. Replace the diamond washer and M12 cheese head bolt which are located underneath the camshaft
adjuster.
ATTENTION
Engine damage due to small parts falling into the timing case (e.g.
diamond washer)!
2. Lift timing chain and place camshaft adjuster carefully on the

camshaft. In order to have more play in the timing chain, if necessary
turn camshaft timing gear back and forth. Place timing chain on
Camshaft adjuster on camshaft
camshaft adjuster.
3. Fit plastic guide of the timing chain.
Turning camshaft timing gear

4. Position new M12 fastening screw and hexagon on the camshaft adjuster and screw in loosely (it must still
be possible to turn the camshaft timing gear)
-figure shows fastening screw and hexagon before installation- .
5. Install chain tensioner -arrow- . For chain tensioner tightening torque, see → 153619 Removing and
installing chain tensioner - chapter on "Installing".
Subsequent work
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Chain tensioner installation location Position fastening screws on the

camshaft adjuster
2. Install camshaft housing cover. → 159123 Removing and installing cover for camshaft housing - chapter on
"installing"
as of MY 2003
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WARNING
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ATTENZIONE
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ADVERTENCIA
15 90 55 Replacing lid seal for camshaft housing (valve lid seal) -

as of MY 2003
- Information
Information
Information
1. In order to change the camshaft housing cover seal, the camshaft housing cover must be removed and
installed.→ 159121 Removing camshaft housing cover → 159123 Installing camshaft housing cover
as of MY 2003
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WARNING
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ADVERTENCIA
15 91 21 Removing cover for camshaft housing - as of MY 2003

- Preliminary work
- Information
- Removing cover for camshaft housing on cylinder bank 1 - 4
Tools

Socket changeover ratchet, 1/4 commercially
inch available tool .gif
Torque wrench commercially 90

available tool
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Centring sleeve commercially 9701

available tool
Preliminary work
Preliminary work
1. Remove engine cover → 108319 Removing and installing engine cover - Chapter "Removing".
2. Remove secondary air pump with console → 266519 Removing and installing secondary air pump - Chapter
"Removing".
3. Remove ignition coils (ignition rod module). Refer to→ 282055 Replacing ignition coils
Tools and materials
Special tools
Note
z It is best to use a tool that has an head height of less than 50 mm -A-
(see special tools) to loosen and tighten the rear fastening screw of
the cylinder head cover close to the plenum panel.
Tool height
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Recommended special tools

-A- Centring sleeve 9701 → "See Workshop
Equipment Manual,
Chapter 2.2.2 or
2.2.1"
-B- Torque wrench 90 → "See Workshop
Equipment Manual,
Chapter 2.4"
-C- Socket changeover → "See Workshop
ratchet, 1/4 inch Equipment Manual,
Chapter 2.4"
-D- Socket insert wrench (a/f → "See Workshop
13), 1/4 inch Equipment Manual,
Chapter 2.4"
-E- T40 inner hexagon socket → "See Workshop
bit Equipment Manual,
Chapter 2.4"
Information
Component overview
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Camshaft housing lid overview
1 - Design cover
2 - Ball socket
3 - Cover holder
4 - BM8 x 45 screw
5 - Hexagon-head bolt M6 x 40
6 - Engine support bracket
7 - M6 x 30 oval-head screw
8 - Camshaft housing cover on cylinder 1 - 4
9 - Camshaft housing cover seal, inner and outer
10 - Seal for NVS camshaft housing
11 - Cap
12 - Ignition coil (ignition rod module)
13 - Screw with internal thread
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14 - Grommet
15 - Sleeve
Removing cover for camshaft housing on cylinder bank 1 - 4
Note
z The cover for the camshaft housing is removed and installed in the same way on cylinder bank 5 - 8 and
cylinder bank 1 - 4!
1. Press together the plug connection for the positive crankcase

ventilation on the camshaft housing lid -see arrows- and pull it off.
Plug connection of the positive

crankcase ventilation valve.
2. Pull off the cap and the cable plug for the hydraulic valve lying
beneath it by pressing on wire clip -a- .
Cap and cable plug of the hydraulic

valve
Note
z Plastic clips can be damaged once the wiring harness holder has been undone and must be checked to
ensure they can be used again!
3. Remove wiring harness holders by pulling carefully on the holders. Lay wiring harness aside.
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Wiring harness Wiring harness holder

4. Remove wiring harness on sheetmetal holders on the camshaft housing lid.
ATTENTION
Risk of damage to the position sensor on the camshaft's trigger wheel!
z The trigger wheel can be damaged when the cover of the camshaft housing is moved.
z Ignition faulty.
z Engine damage.
→ Move the camshaft housing lid carefully.

→ Carefully watch the trigger wheel when removing or fitting the cover of the camshaft housing.
Note
z If the camshaft housing lid is not removed carefully, it can cause the trigger wheel on the position sensor at
the rear on the camshaft to be bent out of shape!
Note
5. Unscrew screws -1 to 19- ( -16 and 19- were mounted on the torque
support bracket) and lift the camshaft housing lid carefully at the back
to avoid damaging the trigger wheel of the reference mark sender on
the camshaft (this is located in the vicinity of screws 1 and 7). Then
lift it off completely.
Tool height
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Camshaft housing lid
6. Turn the camshaft housing lid over and remove inner and outer seal
for camshaft housing. Clean sealing faces on the camshaft housing
lid and cylinder head.
Note
z Always replace seals.
Sealing faces on camshaft housing lid

and cylinder head
as of MY 2003
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WARNUNG
WARNING
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ADVERTENCIA
15 91 23 Installing cover for camshaft housing - as of MY 2003

- Information
- Installing cover for camshaft housing on cylinder bank 1 - 4
- Subsequent work
Tools

Socket changeover ratchet, 1/4 commercially
inch available tool .gif

available tool
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available tool
Tools and materials
Special tools
Note
Tool height

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Equipment Manual,
Chapter 2.2.2 or
2.2.1"
Equipment Manual,
Chapter 2.4"
Chapter 2.4"
Chapter 2.4"
-E- T40 inner hexagon socket → "See Workshop
bit Equipment Manual,
Chapter 2.4"
Information
Component overview
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1 - Design cover
2 - Ball socket
3 - Cover holder
4 - BM8 x 45 screw
11 - Cap
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14 - Grommet
15 - Sleeve
Installing cover for camshaft housing on cylinder bank 1 - 4
ATTENTION
z Ignition faulty.
z Engine damage.

Note
Note
z Always replace inner and outer seal for camshaft housing!
1. Thoroughly clean sealing faces on the camshaft housing lid and

cylinder head.
Camshaft housing lid and cylinder

head
2. Insert inner and outer seal in camshaft housing lid and apply a bead
of Drei Bond sealant to the lining between the cylinder head and
timing chain cover on both sides.

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Note
z If the camshaft housing cover is not fitted carefully, it can cause the
trigger wheel on the position sensor at the rear on the camshaft to be
bent out of shape!
3. Position the camshaft housing lid carefully; do not bend the trigger
wheel of the position sensor on the camshaft when doing so.
Sealant beads on both sides

4. Insert all ignition rod modules aligned in the corresponding camshaft
housing lid.
Inserting ignition rod modules

5. Using the assembly sleeve 9701, press the sealing lip of the
hydraulic valve over the hydraulic valve and align it.
Sealing lip with assembly sleeve
Note
z It is best to use a tool that has an addendum of less than 50 mm -A- (see special tool) to tighten the rear
fastening screw on the cylinder head cover close to the plenum panel.
6. Position all fastening screws and tighten them in accordance with the correct tightening sequence →
Tightening torque: 13 (9.5 ftlb.) Nm -see figures for both cylinder rows- . Screws
-18 and 19 cylinder rows 1 to 4- are inserted later with the torque support bracket.
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Tool height
Cylinder head cover - cylinder bank 1 to 4

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7. Fit wiring harness to sheetmetal holders on the camshaft housing lid.
Wiring harness
8. Fit wiring harness holder with new plastic clips. To do this, simply
press on the wiring harness holder.
Wiring harness holder

9. Connect the cable plug for the hydraulic valve and fit the cap.
10. Attach plug connection for the positive crankcase ventilation to the
flange on the camshaft housing lid.
11. Tighten the ignition coils. → Tightening torque: 10 (7.5 ftlb.) Nm
Cable plug
12. Connect ignition coil. To do this, push on the connector until it locks
with an audible click.
Ignition coil
13. Install bracket for torque support. Tighten the M8 x 45 Torx screws at the top screw points. → Tightening
torque: 17 ftlb. Tighten the M6 x 40 screws at the bottom screw fastening points (middle of valve cover). →
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Fastening screws on bracket for

torque support
Subsequent work
Subsequent work
1. Install ignition coils (ignition rod modules). Refer to→ 282055 Replacing ignition coils
2. Install secondary air pump with console. → 266519 Removing and installing secondary air pump - Chapter
"Installing".
3. Install engine cover . → 108319 Removing and installing engine cover - Chapter "Installing".
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
17 01 17 Engine oil and oil filter change - as of MY 2003

- Changing engine oil
- Checking engine oil level
Tools

oil filter spanner special tool 9204
Changing engine oil
Changing the engine oil (without oil filter)

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Overview
Note
z Engine oil should not be extracted as particles of dirt may remain in the oil pan.
1. Jack up the vehicle at the points provided → 03 Entire vehicle, general information.
WARNING
Hot oil!
z Danger of scalding!
→ Wear protective clothing specified!
2. Remove engine guard . → 108019 Removing and installing engine guard - chapter on "removing"
3. Loosen the 2 oil drain plugs and collect engine oil in a disposal
container. Dispose of waste oil in accordance with legal
requirements.
Loosening oil drain plugs

4. Clean oil drain plugs and screw in with a new aluminium sealing ring. → Tightening torque: 37 ftlb.
5. Fill in engine oil of the stipulated viscosity and quality. The oil change quantity is → filling capacity: 8.25
litre .
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Screwing in oil drain plug with

aluminium sealing ring
Changing the engine oil (with oil filter)
Note
z Engine oil should not be extracted as particles of dirt may remain in the oil pan.
1. Jack up the vehicle at the points provided → 03 Entire vehicle, general information.
WARNING
Hot oil!
z Danger of scalding!
→ Wear protective clothing specified!
3. Loosen the 2 oil drain plugs and collect engine oil in a disposal
container. Dispose of waste oil in accordance with legal
requirements.
4. Clean oil drain plug and screw in with new aluminium sealing ring. →

5. Loosen oil filter with special tool oil filter spanner 9204 and unscrew it.
6. Remove the oil filter housing vertically downwards. Drain the remaining oil into a disposal container.
7. Remove the filter element. Remove the filter downwards and dispose of in accordance with legal
requirements.
Note
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z Do not remove the O-ring with a sharp object.
z The oil filter housing contains a cutout via which the O-ring can be
removed.
Loosening oil filter

8. Clean the oil filter housing and replace the O-ring seal. Clean the oil
filter housing thoroughly inside and outside and replace the O-ring.
Carefully lever off the O-ring. The oil filter housing must not be
damaged during this procedure.
9. Install the filter element.
Note
z Lightly oil the O-ring when installing the oil filter housing.
10. Install the oil filter housing and tighten using special tool oil filter
spanner 9204. Lightly oil the O-ring when doing this. → Tightening Cleaning the oil-filter housing
torque: 19 ftlb.
11. Fill in engine oil. The oil change quantity is → filling capacity: 8.75 litre .
Checking engine oil level

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. Insert oil dipstick again fully, pull it out again,
and read off the oil level. Correct engine-oil level if necessary.
The oil level on the oil dipstick must never be below the MIN mark or above the MAX mark.
The difference quantity between the marks is → Filling capacity: 1.5 litre .
Note
z After changing the oil, the oil level must be checked using the dipstick.
z The engine must have reached its operating temperature.
z Max. mark
z Min. mark
z Range from min up to max. mark: no more oil must be added.
z Range below Min. mark: refill engine oil up to Max. mark.
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Oil dipstick min/max
as of MY 2003
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ADVERTENCIA
17 03 01 Checking oil pressure - as of MY 2003

- Checking oil pressure
Tools and materials
Special tools
Oil-pressure gauge

-A- Oil pressure tester "OP 85" → "see Workshop Is used to measure the engine
WE1276 Equipment Manual, oil pressure; use adapter insert4
Chapter 3.1.4" and screw in with suitable
sealing ring instead of the oil
pressure sender/switch
-B- Test hose (included in set) → "see Workshop
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Equipment Manual,
Chapter 3.1.4"
Checking oil pressure
WARNING

WARNING
WARNING
Oil is combustible!
Note
z The oil pressure may be too low for a number of reasons:
z Oil is diluted.
z Oil pump is faulty.
z Bearing clearance is too large (e.g. crankshaft bearing).
z Oil level is too low.

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z Oil pressure regulating valve is faulty.
z Incorrect oil has been used. Use only oil that has been approved by Porsche for the measurement.
Note
z The oil pressure switch is located on the oil-filter console to the right (in the direction of travel) under the
generator.
Overview
1. Remove front engine guard. → 108019 Removing and installing engine guard - chapter on "Removing"
2. Pull off connector on oil pressure sensor. To do this, press on the

button.
Connector on oil pressure sensor
Note
z When the oil pressure switch is unscrewed, approx. 0.3 litres of engine oil escapes.
3. Loosen the oil pressure switch and unscrew it. Collect the emerging oil and dispose of it in accordance with
the applicable national laws.
4. Screw in test adapter 4 with sealing ring in the oil-filter console and tighten by hand.
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Unscrewing oil pressure switch

5. Connect pressure gauge on the hose and tighten it hand-tight.
Note
z The oil temperature must range between 80°C and 100°C when
performing the measurement.
z Check the oil temperature using a special thermometer or the PST II

tester.
6. Start the engine and move off at the required test speed. Read off
the oil pressure on the pressure gauge when doing so. Connecting pressure gauge
Engine speed [rpm] Oil pressure [bar]

600 1,0
1500 2,2
6000 4,5
Note
z When the pressure gauge is unscrewed, approx. 0.3 l of engine oil escapes.
7. Remove pressure gauge with test hose. Collect the emerging engine oil and dispose of it in accordance with
the applicable national laws.
8. Install oil temperature switch with new sealing ring. → Tightening

torque: 15 ftlb.
Installing the oil pressure switch

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9. Push electric connector onto oil pressure switch. The connector must
engage audibly.
10. Install front engine guard. → 108019 Removing and installing engine
guard - chapter on "Installing"
11. Check oil level and correct if necessary.
Pushing on electric connector
as of MY 2003
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17 04 19 Removing and installing oil-pressure sender - as of MY

2003
- Removing oil-pressure sender
- Installing oil-pressure sender
Removing oil-pressure sender
WARNING

WARNING
WARNING
Oil is combustible!
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Note
z The oil pressure may be too low for a number of reasons:
z Oil is diluted.
z Oil pump is faulty.
z Bearing clearance is too large (e.g. crankshaft bearing)
z Oil level is too low.
z Oil pressure regulating valve is faulty.
z Incorrect oil has been used. Only use oil that has been approved by Porsche for the measurement.
Note
z The oil pressure switch is located on the oil-filter console to the right under the generator.
Overview
1. Remove front underside panel. → 108019 Removing and installing engine guard - chapter on "Removing"
2. Pull off connector on oil pressure sensor. To do this, press on the button.
Note
z When the oil pressure switch is unscrewed, approx. 0.3 litres of engine oil escapes.
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3. Loosen the oil pressure switch

and unscrew it. Collect the
emerging oil and dispose of it
in accordance with the
applicable national laws.
Unscrewing oil pressure switch Connector on oil pressure sensor
Installing oil-pressure sender
1. Install oil temperature switch with new sealing ring. → Tightening

torque: 15 ftlb. .
Installing the oil pressure switch

2. Push electric connector onto oil pressure switch. The connector must
engage audibly.
3. Install front underbody panel. → 108019 Removing and installing
engine guard - chapter on "Installing"
4. Check oil level and correct if necessary.
Electric connector on oil pressure

switch
as of MY 2003
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17 11 19 Removing and installing oil level sensor - as of MY 2003

- Removing oil level sensor
- Installing oil level sensor
Removing oil level sensor
Removing oil level sensor
WARNING

WARNING
WARNING
Oil is combustible!
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Overview
1. Remove underbody panel. → 108019 Removing and installing engine guard - chapter on "Removing"
Note
z If the oil is to be used again, it must be collected in a clean container.
2. Undo the 2 oil drain plugs and collect engine oil in a container.
Dispose of waste oil in accordance with legal requirements.

Screwing in oil drain plugs

4. Disconnect the electric connector on the oil level sensor.
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Loosening fastening screws for oil Electric connector on oil level sensor
level sensor
5. Loosen the 3 fastening screws and pull the oil level sensor out of the oil pan.
Installing oil level sensor
Installing oil level sensor
1. Install the new oil level sensor with a new seal. Tighten the 3
fastening screws. → Tightening torque: 7.5 ftlb.
Tightening fastening screws for oil

level sensor
2. Fill in engine oil of the stipulated viscosity and quality.
Filling engine oil

3. Start the vehicle briefly. Then check the oil level. It must be between the MIN and MAX markings on the
dipstick.
4. Install underbody panels. → 108019 Removing and installing engine guard - chapter on "Installing"
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as of MY 2003
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
Checking the oil level

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ADVERTENCIA
17 17 19 Removing and installing guide for oil dipstick - as of MY

2003
- Preliminary work
- Removing and installing guide for oil dipstick
- Subsequent work
Preliminary work
Preliminary work
1. Remove throttle body cover. Pull the cover up and off. → 108319
Removing and installing engine cover - chapter on "Removing"
2. Remove Y-shaped pipe. → 243519 Removing and installing air box
for throttle housing (Y-shaped pipe) - chapter on
"Removing" [9PAAF1 9PAAJ1]→ 243519 Removing and installing air
box for throttle housing (Y-shaped pipe) - chapter on
Cover over the throttle body
Removing and installing guide for oil dipstick
Removing and installing guide for oil dipstick

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Overview
1. Loosen the 2 fastening screws.

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Fastening screws for oil dipstick
2. Pull out oil dipstick.
3. Pull guide tube out of oil pan.
4. Replace O-ring.
5. Insert guide tube into oil pan.
6. Tighten the 2 fastening screws. First position the two screws. Then tighten the upper fastening screw. →
Tightening torque: 7.5 ftlb. and then the lower fastening screw → Tightening torque: 7.5 ftlb. .
Subsequent work
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Subsequent work
1. Reinstall the Y pipe. → 243519 Removing and installing air box for throttle housing (Y-shaped pipe) - chapter
on "Installing" [9PAAF1 9PAAJ1]→ 243519 Removing and installing air box for throttle housing (Y-shaped
pipe) - chapter on "Installing" [9PAAE1 9PAAE7]
2. Reinstall throttle body cover. To do this, press the 4 rubber elements

on the ball heads.
Throttle body cover
as of MY 2003
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17 20 19 Removing and installing oil pump - as of MY 2003

- Preliminary work
- Information
- Removing oil pump
- Installing oil pump
- Subsequent work
Preliminary work
Preliminary work
1. Remove oil pan. → 175021 Removing oil pan - chapter on "Removing"
Information
Component overview
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Overview
Note
z The oil pump must not be disassembled and reassembled!
z When carrying out work on the oil circuit, it must be ensured that no dirt gets into the engine!
Note
z The oil pump can be replaced while installed.
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Oil pump
1 - Rear intake pipe

3 - Front intake pipe
4 - Fastening screw M6 x 25
5 - Pin
6 - Tensioning rail
7 - Mounting chain case cover
9 - Guide rail
10 - When reusing drive chain, mark running direction.
11 - Drive wheel on the drive chain, pay attention to the feather key
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Removing oil pump
Removing oil pump
1. Unscrew chain tensioner of timing chain.
Unscrew the chain tensioner

2. Unscrew the 4 fastening screws M6 x 25 of the oil suction pipe on the
lower section of the crankcase.
Oil suction pipe fastening screws on

lower part of crankshaft housing
3. Unscrew oil return line from the oil pump.
Oil return line

4. Remove the oil pump timing chain cover. To do this, unscrew the 2 fastening screws M5 x 25.
5. Release the 3 fastening screws M8 x 50.
6. Tilt the oil pump forwards.
7. Push the tensioning rail for the oil pump drive aside with a finger. At the same time, raise the oil pump
slightly and tilt forwards.
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Oil pump fastening screws Chain cover fastening screws
Oil pump drive tensioning rail Oil pump
8. Take the oil pump drive chain off the oil pump sprocket and remove the oil pump.
9. Unscrew the oil suction snorkel from the oil pump.
Installing oil pump
Installing oil pump
Note
z In order to make it easier to install the oil suction pumps in the Cayenne Turbo (M48/50), it should be
ensured that the driving slits on the chain sprocket are as horizontal as possible.
1. Position the oil pump slanting forwards on the lower section of the
crankcase. At the same time, put the drive chain over the chain
sprocket.
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Oil pump
Oil pump fastening screws

2. Tighten the 3 fastening screws. → Tightening torque: 17 ftlb.
ATTENTION
Risk of damage!
z The tensioning rail can become wedged in!
→ Ensure that the drive chain is tense!
3. Check that the tensioning rail is in the correct position. To do this,

use a finger to push the tensioning rail away slightly from the chain.
When doing this, the tensioning rail must be under pressure and
holding the chain under tension. Oil pump drive tensioning rail
4. Mount the plastic cover of the chain sprocket. Tighten the two
Chain sprocket plastic cover fastening

screws
5. Secure the oil return line. Tighten fastening screw. → Tightening
torque: 7.5 ftlb.
Oil return line fastening screw

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6. Attach the four fastening screws for the oil suction tube to the lower
part of the crankshaft housing. → Tightening torque: 9.5 ftlb.
Oil suction pipe fastening screws on

lower part of crankshaft housing
7. Fit tensioner for the timing chain. For tightening torque, see
→ 153619 Removing and installing chain tensioner - "Installing"
chapter .
Subsequent work
Subsequent work
1. Check that the timing chain has not jumped over. To do this, turn the engine by two turns at the crankshaft.
Make sure you can turn the engine without any mechanical resistance. Otherwise, set the timing. → 150516
Setting the timing
2. Reinsert the cleaned oil pan. → 175023 Installing oil pan (includes sealing) - chapter on "Installing".
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
17 26 37 Disassembling and assembling oil pressure control valve

- as of MY 2003
- Disassembling oil pressure control valve
- Assembling oil pressure control valve
Disassembling oil pressure control valve
Overview
Note
z The description only applies when installed.
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Component overview
1 - Valve body; pay attention to the installation position

2 - Spring
3 - Sealing ring; replace
4 - M22 screw plug
1. Remove oil pan. → 175021 Removing oil pan - chapter on "Removing"
Note
z When unscrewing the oil pressure control valve, ensure that the
screw plug is under spring pressure.
z Do not let the valve body fall.
z Note the installation location of the valve body.
z More oil can leak out from the opening.
Screw plug of oil pressure control

2. Unscrew screw plug of oil pressure control valve (a/f 19) -arrow- .
valve
3. Remove the four components of the oil pressure control valve → Valve body . Always replace sealing ring.
Assembling oil pressure control valve
Note
z Ensure that the installation opening of the oil pump housing is clean!
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z Note the installation location

of the valve body.
z Always replace sealing ring.
1. Guide in the valve body with

the bores into the oil pump
housing first → Valve body .
Note
z Screw in the screw plug by Valve body Valve body
hand against the spring pressure.
2. Prevent the valve body from falling and screw in the spring, new sealing ring and screw plug.
3. Tighten screw plug (a/f 19) -arrow- . → Tightening torque: 33 ftlb.
4. Install oil pan. → 175023 Oil pan installed (includes sealing) - chapter
on "Installing"
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
17 30 19 Removing and installing oil filter - as of MY 2003

- Removing and installing oil filter
Tools

oil filter spanner special tool 9204
Removing and installing oil filter
WARNING

WARNING
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2. Loosen oil filter with special tool oil filter spanner 9204 and unscrew
it.
3. Remove the oil filter housing vertically downwards. Drain the

remaining oil into a disposal container.
4. Remove the filter element. Remove the filter downwards and dispose
of in accordance with legal requirements.
Oil filter
Note
z Do not remove the O-ring with a sharp object.
z The oil filter housing contains a cutout via which the O-ring can be
removed.
5. Clean the oil filter housing and replace the O-ring seal. Clean the oil
filter housing thoroughly inside and outside and replace the O-ring.
Carefully lever off the O-ring. The oil filter housing must not be
damaged during this procedure.
Oil-filter housing sealing ring
6. Install the filter element.
Note
z Lightly oil the O-ring when installing the oil filter housing.
7. Install the oil filter housing and tighten using special tool oil filter spanner 9204. → Tightening torque: 19
ftlb. Lightly oil the O-ring when doing this.
9. Fill engine oil, start engine and check oil level. → 170117 Engine oil and oil filter change - chapter on
"Checking"
as of MY 2003
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WARNUNG
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ADVERTENCIA
17 40 19 Removing and installing oil-water heat exchanger - as of

MY 2003
- Preliminary work
- Information
- Removing oil-water heat exchanger
- Installing oil-water heat exchanger
- Subsequent work
Preliminary work
Preliminary work
1. Drain cooling system.→ 193817 Draining and filling coolant (includes

bleeding)
2. Loosen lock carrier. → 503809 Loosening and fastening lock carrier
(service position) - chapter on "Loosening"
Draining cooling system
Information
Component overview
Note
z The illustrations apply to the Cayenne Turbo (M48/50).
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Overview of bracket to engine
1- Oil transfer flange

2- 5 O-rings
3- 2 fastening screws
4- Length-compensating element
6- 2 fastening screws, M8 x 70
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Overview of bracket
1 - Oil filter bracket

2 - 6 lens-head screws M6 x 20 (only loosen the screws if absolutely necessary)
3 - Lids
4 - Seal
5 - 2 seals
6 - O-ring
7 - Oil filter element
8 - Oil filter housing
9 - 4 oval-head screws, M6 x 20
10 - Oil-water heat exchanger
11 - Screw plug, M26 x 1.5
12 - Sealing ring, A26 x 31
13 - Oil pressure switch (hot oil can leak out while removing)
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Removing oil-water heat exchanger
Note
z If a fault in the oil-water heat exchanger has caused oil and coolant to mix, the oil circuit should be checked
to see if there is coolant in the engine or, if necessary, be cleaned.
z If oil has entered the coolant circuit, this is to be cleaned after repair . → 190129 Cooling system cleaned
(after oil/coolant mixing)
1. Release coolant hoses from oil/water heat exchanger. To do this,

release the two spring-band clamps and pull the lines upwards.
2. Release the 4 fastening screws on the heat exchanger and pull the
heat exchanger down and off. During this process, both engine oil
and coolant will leak out. Collect leaking liquids and dispose of in
accordance with legal requirements.
Sprind-band clamps for coolant lines
Installing oil-water heat exchanger
Öl/Wasser-Wärmetauscher einbauen
Note
z If a fault in the oil-water heat exchanger has caused oil and coolant to mix, the oil circuit should be checked
to see if there is coolant in the engine or, if necessary, be cleaned.
z If oil has entered the coolant circuit, this is to be cleaned after repair . → 190129 Cooling system cleaned
(after oil/coolant mixing)
1. Replace the 2 sealing rings of the oil circuit. When doing this, pay attention to the lugs on the sealing ring.
Subsequently, push the oil-water heat exchanger from underneath against the bracket and tighten the 4
2. Push the coolant hoses onto the connecting flanges and secure with the spring-band clamps.
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Subsequent work
Sprind-band clamps for coolant lines

Subsequent work
1. Fasten lock mount. → 503809 Detaching and fastening lock mount (service position) - chapter on "fastening"
2. Fit the sheetmetal brace under the radiator. To do this, tighten the
four fastening screws. → Tightening torque: 17 ftlb.
Fastening screws for sheetmatal brace

3. Tighten the front spoiler on the underside.
Fastening screws for front spoiler

5. Fill cooling system.→ 193817 Draining and filling coolant (includes

bleeding)
6. Check oil level and adjust.
Engine guard
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as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
17 50 21 Removing oil pan - as of MY 2003

- Preliminary work
- Information
- Removing oil pan
Tools

Workshop equipment special tool
description .gif
Gauge holder special tool 207

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special tool 62-1
spacer ring special tool 9597/1
Assembly driver special tool 9691
Dial gauge commercially NR.136

available tool
Preliminary work
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Preliminary work
1. Remove engine guard . → 108019 Removing and installing engine

guard - chapter on "removing"
Engine guard
2. Drain coolant circuit. → 193817 Draining and filling coolant (includes
bleeding) - chapter on "Draining"
Draining coolant
Note
z If the oil does not yet have to be replaced, collect it in a clean
container and use again.
3. Drain oil. To do this, loosen and unscrew the two oil drain plugs.
4. Clean oil drain plugs and screw in with a new sealing ring. →
Oil drain plugs
Note
z If the transmission is still connected, the 2 lower transmission screws must be removed first.
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5. Support the engine on the body. → 10 Supporting the engine on the

body
6. Remove the front-axle carrier. → 400619 Removing and installing

front axle carrier [9PAAJ1]→ 400619 Removing and installing front
axle carrier [9PAAE1 9PAAE7 9PAAF1]
7. Remove engine carrier. → 103019 Removing and installing engine

carrier - chapter on "Removing"
8. Loosen lock carrier (service position).→ 503819 Removing and

installing lock carrier
9. Remove oil dipstick. → 171719 Removing and installing guide for oil Transmission screws
dipstick - chapter on "Removing"
V8 engines
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Oil level sensor

10. Disconnect oil level sensor. To do this, pull off the connector and take the cable out of the fixing clip on the
oil pan.
11. Remove pulley from the crankshaft → 137619 Removing and

installing crankshaft pulley - chapter on "Removing". The central
screw must not be reused.
Pulley on crankshaft
12. Remove oil-filter console. To do this, unscrew the 4 fastening screws
(3x M 8 x 70 and 1x M 8 x 45). Pull oil-filter console off forwards.
Further details: → 176721 Removing bracket for oil-water heat
exchanger - chapter on "Removing"
Fastening screws for oil-filter console
Tools and materials
Special tools
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Tools

-A- Assembly driver 9691 → "See For installing the oil
Workshop transfer sleeve in the oil
Equipment pan
Manual, Chapter
2.2.2 or 2.2.1"
-B- Gauge holder 207 → "See
Workshop
Equipment
Manual, Chapter
2.2.2 or 2.2.1"
-C- Dial gauge NR.136 → "See
Workshop
Equipment
Manual, Chapter
2.4"
-D- Workshop equipment → "See
description Workshop
Equipment
Manual, Chapter
3.X"
-E- → "See Parts
Catalogue in Main
Group X"
62-1
Information
Component overview
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Oil pan - overview
1 - Oil pan; plastic feeder must not be removed.

2 - Sealant application; remove silicone residues; no more than 5 minutes should pass between the time
application begins and screwing. Do not smear the sealing bead when putting on the oil pan.
4 - Sealing ring 18 x 24; replace
5 - Drain plug; clean
6 - Oil level sensor (TOC); replace seal
8 - O-ring, 11.2 x 2.65, replace
9 - Oil dipstick
10 - Fastening screw with coned half dog M6 x 16
11 - O-ring, 23 x 3, replace, grease before assembly
12 - Socket; disassembly with spacer ring 9597/1 and internal puller; assembly with assembly driver 9691
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13 - O-ring, 25; replace, grease before assembly

14 - Moulded seal; replace
Removing oil pan
Removing the oil pan
Note
z The description only applies when installed.
z If the oil pan is removed when the transmission is disconnected, the oil pan must be aligned with the aid of a
dial gauge (see chapter Aligning oil pan with a dial gauge).
z To remove the oil pan, it is not necessary to remove the timing case cover. If the timing case cover is
removed while carrying out work later, the oil pan must be removed with it.
Oil pan in V8 - engine

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Oil transfer sleeve
Note
z In the case of the Cayenne
Turbo, the oil suction pump of
the turbocharger must also be
removed. To do this, release
screws -1 to 6- one after the
other.
1. Remove oil transfer sleeve.

To do this, insert internal
puller into the opening and Turbocharger oil suction pump
tighten. While doing this, fastening screws
counter the puller with an
open-ended wrench.
2. Subsequently, tighten the nut on the puller until the sleeve can be
pulled out.
3. Release foot of timing-case cover. Unscrew the 5 lower fastening

screws M 6 x 25 with an E10 wrench.
4. Release oil pan. To do this, unscrew the 24 fastening screws M 6 x

20 with an E10 key.
Note
z If the oil pan is stuck, loosen it by gently tapping with a plastic
hammer. Nut on puller
5. Remove oil pan. Remove the oil pan from the crankshaft. At the same time, swing downwards and forwards.
6. Clean sealing faces. Brush off rest of the sealant with a plastic brush and then degrease the sealing face.
Note
z The black plastic feeder must not be taken out of the oil pan.
z If this component has been damaged or removed, the entire oil pan must be removed.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
17 50 23 Installing oil pan (includes sealing) - as of MY 2003

- Installing oil pan
- Aligning the oil pan with a dial gauge
- Subsequent work
Tools

Workshop equipment special tool
description .gif
Gauge holder special tool 207

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special tool 62-1
Assembly driver special tool 9691
Dial gauge commercially NR.136

available tool
Tools and materials
Special tools
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Tools

-A- Assembly driver 9691 → "See For installing the oil
Workshop transfer sleeve in the oil
Equipment pan
Manual, Chapter
2.2.2 or 2.2.1"
-B- Gauge holder 207 → "See
Workshop
Equipment
Manual, Chapter
2.2.2 or 2.2.1"
-C- Dial gauge NR.136 → "See
Workshop
Equipment
Manual, Chapter
2.4"
-D- Workshop equipment → "See
description Workshop
Equipment
Manual, Chapter
3.X"
-E- → "See Parts
Catalogue in Main
Group X"
62-1
Installing oil pan
Installing oil pan

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ATTENTION

ATTENTION
Risk of damage and leaks!
z If the oil pan is not correctly aligned, it can become leaky during
operation.
→ Align the oil pan extremely accurately in compliance with this

description.
→ Ensure that there is no dirt between the 2 components.
1. Replace the 9 rubber profiles. Rubber profiles
2. Apply liquid sealant. Apply the sealing agent Loctite 5970 (000 043 300 39, status 12/05) using the hand-
held cartridge. The contour of the bead of sealant must comply with the figure shown below. The bead of
sealant should be approx. 1.5 mm high. The oil duct in the timing-case cover -A- must remain clear and must
not be obstructed with silicone.
Applying liquid sealant

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Note
z If the transmission is removed, the oil pan must be aligned with the aid of a dial gauge. → 175023 Oil pan
installed (includes sealing) - chapter on "Fitting"
3. Place the oil pan on the crankcase and push evenly against the transmission cover.
4. Screw in a fastening screw on each corner of the oil pan and tighten them by hand.
5. Then screw in all fastening screws by hand. While doing this, push the oil pan towards the transmission.
6. Tighten the 29 fastening screws beginning at the transmission flange and proceed forwards. → Tightening
Transmission flange fastening screws
7. Screw down the timing case cover. Tighten the 5 fastening screws M 6 x 25 with an E10 wrench. →
Note
z In the Cayenne Turbo (M48/50), the oil suction pump of the
turbocharger must also be fitted. Further details: → 218023
23 Installing oil suction pump for turbocharger - chapter on "Installing"
8. Install oil transfer flange. Replace and grease the O-rings of the
flange. Then place the connection piece on the assembly driver
9691 in such a way that the slightly thicker end points forwards.
Oil transfer flange

9. Insert the socket with the thicker end into the oil pan and push the assembly mandrel all the way by knocking
it slightly.
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Socket
Aligning the oil pan with a dial gauge
Fitting the oil pan with a dial gauge
ATTENTION
Risk of damage and leaks!
z If the oil pan is not correctly aligned, it can become leaky during operation.
→ Align the oil pan extremely accurately in compliance with this description.
→ Ensure that there is no dirt between the 2 components.
Place the oil pan on the crankcase and position a fastening screw on each corner.
Note
z The following work steps are only necessary if the transmission is
disconnected at the time the oil pan is being installed.
1. Insert the dial gauge into the universal dial gauge holder and position
it such that the dial gauge has a preload of about 1 mm.
Dial gauge
2. Set dial gauge scale to 0. To do this, place the dial gauge holder on a
completely flat surface (e.g. crankcase flange) and turn the dial
gauge scale until the pointer is on 0.
Dial gauge and dial gauge holder

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ATTENTION
Oil leakage!
z If the oil pan is not correctly aligned, it can become leaky.
→ The oil pan lid must not project over the crankcase.
→ The oil pan must not go under 0.1 mm.
→ Oil pan must be installed in a straight position.
3. Measure offset. In order to do this, push with the holder starting from
the crankcase flange towards the oil pan flange (the foot of the dial Measuring offset
gauge holder is located on the other component like the dial gauge
probe) and measure the offset. The oil pan must not be set back any
more than 0.1 mm. A projection is not permissible.
4. Align the oil pan by knocking lightly with a rubber hammer.
5. After the oil pan has been aligned, tighten the 4 fastening screws. →
Tightening torque: 7.5 ftlb. The check the position of the oil pan
again with the dial gauge.
6. Tightening the remaining fastening screws. → Tightening torque:
7.5 ftlb.
Checking the position of the oil pan

again
Fastening screws
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Subsequent work
Subsequent work
1. Tighten the 2 fastening screws of the transmission bell housing. →

Fastening screws for transmission bell

housing
2. Install bracket for oil-water heat exchanger. → 176723 Installing
bracket for oil-water heat exchanger
Length-compensating element
3. Install crankshaft pulley. → 137619 Removing and installing
crankshaft pulley - chapter on "Installing"
Crankshaft pulley
4. Install engine carrier.→ 103019 Removing and installing engine carrier - chapter on "Installing"
5. Install the suspension subframe (front-axle carrier). → 400619 Removing and installing front-axle carrier -
chapter on "Installing" [9PAAJ1]→ 400619 Removing and installing front-axle carrier - chapter on "Installing"
[9PAAE1 9PAAE7 9PAAF1]
6. Remove engine bridge. → Supporting the engine on the body
7. Install oil dipstick. → 171719 Removing and installing guide for oil dipstick - chapter on "Installing"
8. Tighten lock carrier.→ 503819 Removing and installing lock carrier

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9. Fill in engine oil.
10. Bleed and fill the cooling circuit. → 193817 Draining and filling
coolant (includes bleeding) - chapter on "Filling"
11. Carry out a check. After a test drive, check to ensure that the oil pan
is not leaking. Then check the oil level.
Engine carrier
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
17 67 21 Removing bracket for oil-water heat exchanger - as of MY

2003
- Preliminary work
- Information
- Removing bracket for oil-water heat exchanger
Preliminary work
Preliminary work
1. Drain cooling system.→ 193817 Draining and filling coolant (includes

bleeding)
2. Loosen lock carrier. → 503809 Loosening and fastening lock carrier
(service position) - chapter on "Loosening"

3. Undo the 2 oil drain plugs and collect engine oil in a disposal
container.
Oil drain plugs

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Information
Component overview
Note
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2- 5 O-rings
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Overview of bracket

3 - Lids
4 - Seal
5 - 2 seals
6 - O-ring
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Removing bracket for oil-water heat exchanger
Note
z The following step must only be performed for the M48/50 engine.
1. Undo both oil return lines from the turbochargers to the oil filter
bracket. Pull the connections slightly out of the bracket.
Oil return lines on oil filter bracket

2. Release coolant lines from oil-water heat exchanger. To do this,
release the two spring-band clamps and pull the lines upwards.
Coolant lines from oil-water heat

exchanger
3. Unscrew the 3 fastening screws on the bracket.
ATTENTION
Danger of injury!
z When pulling the bracket off, even greater amounts of engine oil
can leak out.
z If the bracket is stuck, it can loosen abruptly. If this happens,
your fingers could be injured.
→ Proceed carefully when pulling out the bracket.

→ Collect escaping fluids. Bracket fastening screws
4. Pull off the bracket from the engine in a forward direction. If the bracket is stuck very firmly, lever it off very
carefully using a suitable implement.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
17 67 23 Installing bracket for oil-water heat exchanger - as of MY

2003
- Information
- Installing bracket for oil-water heat exchanger
- Subsequent work
Information
Component overview
Note
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2- 5 O-rings
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Overview of bracket

3 - Lids
4 - Seal
5 - 2 seals
6 - O-ring
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Installing bracket for oil-water heat exchanger

1. Replace both O-rings in the flange. To do this, carefully lever out the O-rings with a non-abrasive implement
(plastic wedge) and replace them with new ones.
2. Replace the O-rings on the oil transfer flange. To do this, lever off the O-rings with a non-abrasive implement
(plastic wedge) and replace them with new ones.
ATTENTION
Danger from oil-water heat exchanger!
z If the compensating element is not screwed in, the bracket can
be braced and will break during operation as a result.
→ Before installing the bracket, screw the compensating element in

completely.
3. Screw in length-compensating element. To do this, insert an Allen

key through the screw hole into the bracket and turn the key anti- Allen key in bracket
clockwise until the compensating element touches the bracket.
4. Apply a thin coat of engine oil to the two transfer flanges and position the bracket on the engine. Then push
the bracket hard against the engine until the fastening screws can be put into place.
5. The sleeve -1- is screwed in. Position the two fastening screws
-arrows- and tighten until hand-tight.
Sleeve and fastening screws for the

bracket
6. Adjust compensating element. To do this, insert an Allen key
-picture- through the screw hole into the bracket and turn the key
clockwise until the compensating element touches the engine. →
Tightening torque: 1.5 ftlb. +2 ftlb.
Allen key in bracket

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Bracket fastening screws

7. Fit the upper fastening screw -arrow- . Insert the screw through the compensating element and tighten it. →
Tightening torque: 17 ftlb. Then tighten the 2 other fastening screws. → Tightening torque: 17 ftlb.
All three fastening screws

8. Fit coolant lines from oil-water heat exchanger. Push both coolant
lines onto the socket piece and fit the spring-band clamps using the
spring-band clamp pliers.
Pushing coolant lines onto connecting

piece
Note
z The following step must only be performed for the M48/50 (V8 Turbo)
engine.
9. Fit oil return lines for turbochargers. Insert the lines into the
connections and align them. Then screw in the union nuts by hand
Union nuts for oil return lines

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Subsequent work
Subsequent work
1. Fasten lock mount. → 503809 Detaching and fastening lock mount (service position) - chapter on "fastening"
2. Fit the support plate under the radiator. To do this, tighten the 4
fastening screws. → Tightening torque: 17 ftlb.
Support plate fastening screws

3. Tighten the front apron on the underside.
Front apron fastening screws

Engine guard
5. Fill and bleed the cooling system. → 193817 Draining and filling coolant (includes bleeding) - chapter on
"Filling"
6. Check oil level and adjust.

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as of MY 2003
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
Cooling system
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
19 01 01 Checking cooling system - as of MY 2003

- Checking cooling system
Tools

Tools and materials
Tools and materials

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Tools
A- Cooling system leak tester (pump) see Workshop Equipment Manual, Chapter 3 "WE1069"
B- Hose extension FZ 100
C- K22 cap adapter (for sports cars)
D- K60 cap adapter included (in scope of delivery Filling device 9696 )
Checking cooling system
Coolant: Checking the level and antifreeze content
ATTENTION

DANGER
→
The power supply to the fans must be disconnected before starting work on the radiator, radiator fans, or the
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ATTENTION
Note
national laws.
1. Open maintenance cover.
Maintenance cover
ATTENTION
2. Carefully open the cap on the coolant reservoir. Unscrew the cap in an anti-clockwise direction.
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Cap on coolant reservoir

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.
Note
z The following table specifies how much coolant must be replaced by
pure antifreeze in order to adjust the freezing point to -37 °C.
Checking the antifreeze content

Measured antifreeze protection in °C Antifreeze quantity to be added (in litres)
-5 9
- 10 8.5
- 15 7.5
- 20 7
- 25 5
- 30 3.5
- 35 1.5
Checking the antifreeze content of the coolant using a refractometer
Note
z The following diagram shows the scale used by Leitenberger.
z The scale can vary slightly, depending on the manufacturer.
z The ETHYLENE scale must be used for Porsche antifreeze.

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Refractometer
Item Designation of the display Explanation

-A- Scale for propylene-based coolant Do not use for engine type M48.
-B- Scale for ethylene-based coolant Coolant such as elf GLACELF
SUPRA. Use for engine type M48.
-C- Scale for battery acid The charge state of a battery can be
checked here. The values on the left
side indicate the specific gravity of the
electrolyte. The battery must be
recharged once the charge drops
below 1.20.
-D- Scale for alcohol-based windscreen cleaner The freezing point of the windscreen
cleaner can be read off here.
-E- Light/dark limit In conjunction with the points of
intersection of the relevant scales, it
specifies the value to be established.
-F- Waterline The light/dark limit must be located
here when sprinkled with distilled
water.
1. Using a pipette, take a sample from the coolant reservoir.

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Pipette
Depositing drops on the test surface
2. Deposit a few drops on the test surface.
3. Close the light-diffusing lens. A closed film must form.
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.
Note
z The following table specifies how much coolant must be replaced by
pure antifreeze in order to adjust the freezing point to -37 °C.
Closing the light-diffusing lens

-5 9
- 10 8.5
- 15 7.5
- 20 7
- 25 5
- 30 3.5
- 35 1.5
Checking the cooling system for leaks
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.
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Cooling system test device
Graduated disc in the opening of the

reservoir
2. Check the coolant level. A graduated disc with a "min" and "max" marking is located in the opening of the
reservoir. The "min" level must be covered with coolant.
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.
as of MY 2003
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WARNUNG
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ATTENZIONE
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ADVERTENCIA
19 01 29 Cooling system cleaned (after oil/coolant mixing) - as of

MY 2003
- Cleaning the cooling system
Tools

filling device special tool 9696
Cleaning the cooling system
ATTENTION

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DANGER
ATTENTION
Note
national laws.
1. Drain cooling system. → 193817 Draining and filling coolant

(includes bleeding)
Note
z The cleaning work steps must be repeated until no more oil rises to
the surface in the coolant reservoir.
z The radiator cleaning agent mixture must be approx. 23 litres in the

filling canister of the filling device filling device 9696.
z The cleaning agent is mixed with water at a ratio of 50:50 (Frostox R

Spezial). Draining cooling system
2. Fill the cooling circuit with the cleaning agent mixture. To do this, proceed with the cooling system
analogously to filling the coolant. → 193817 Draining and filling in coolant (includes bleeding) - chapter on
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"Filling in"
3. Start the vehicle.
4. After the vehicle has been bled and the coolant temperature is > 80 °C, let the stationary vehicle run at
medium engine speed for at least 15 minutes.
5. Switch off engine.
ATTENTION
→ Never open the cooling system when it is hot. Emerging coolant may
be very hot and can cause scalding.
6. Open coolant reservoir carefully and slowly in an anti-clockwise

direction with gloves and a cloth. Coolant reservoir

(includes bleeding)
8. Use hot water to rinse out any oil which has adhered inside the
coolant reservoir.
9. Close the cooling system and fill the coolant circuit with water only
and then bleed the cooling system according to regulations.
→ 193817 Draining and filling coolant (includes bleeding)
10. Start engine.
11. After the vehicle has been bled and the coolant temperature is > 80 °
C, let the stationary vehicle run at medium engine speed for at least Coolant drain plug
15 minutes.
ATTENTION
→ Never open the cooling system when it is hot. Emerging coolant may
be very hot and can cause scalding.
13. Open coolant reservoir carefully in an anti-clockwise direction with

gloves and a cloth and relieve any residual pressure. Coolant reservoir
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Coolant drain plug
14. Drain cooling system. → 193817 Draining and filling coolant (includes bleeding)
15. Close the cooling system and bleed with the approved antifreeze mixture according to regulations.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
19 08 19 Removing and installing electric fan - as of MY 2003

- Removing electric fan
- Installing electric fan
- Subsequent work
Removing electric fan
The small fan on the left is for the air conditioning - the big fan on the right is for engine cooling
Note
z The big fan is for the engine cooling, the small fan is for the air conditioning
z The sheetmetal clips on the fans are for balancing the fans and must not be pulled off.
1. Remove the radiator frame. → 192019 Removing and installing cooling fan housing (radiator frame) -
chapter on "Removing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 192019 21 Removing and installing
cooling fan housing (radiator frame) - chapter on "Removing" [9PAAJ1]
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Removing motor fan
1. Unclip the electric plug on the radiator frame.
Electric connector on radiator frame

2. Undo the 3 fastening screws on fan and pull fan down and out.
Fastening screws for securing fan to

engine
Removing fan for air conditioning

2. Undo the 3 fastening screws on fan and pull fan down and out. When doing so, guide the cables and control
unit.
Installing electric fan
Installing fan for air conditioning

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View shows the removal process Fastening screws for securing fan to
air conditioner
1. Push fan cable with control module from underneath through the
radiator frame.
View shows the installation

2. Tighten the three fastening screws. → Tightening torque: 3 ftlb.

air conditioner
3. Route cables correctly and clip electric plug into the frame at the top.

Installing engine fan
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1. Push fan from the bottom into the frame and tighten the 3 fastening
screws to 4 Nm (3 ftlb.).

engine
2. Route connecting cables correctly and clip electric connector into the
radiator frame at the top.
Subsequent work
Subsequent work
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Note
1. Install the radiator frame. → 192019 Removing and installing cooling fan housing (radiator frame) - chapter
on "Installing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 192019 23 Removing and installing cooling
fan housing (radiator frame) - chapter on "Installing" [9PAAJ1]
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
19 20 19 Removing and installing radiator fan housing (radiator

frame) - as of MY 2003
- Preliminary work
- Removing radiator fan housing (radiator frame)
- Installing radiator fan housing (radiator frame)
- Subsequent work
Preliminary work
Preliminary work
1. Removing the front engine compartment cover. → 700219 Removing and reinstalling front cover (engine
compartment) - chapter on "Removing"
2. Remove Y-shaped pipes. → 243519 Removing and installing air box for throttle housing (Y-shaped pipe) -
chapter on "Removing" [9PAAF1]→ 243519 Removing and installing air box for throttle housing (Y-shaped
pipe) - chapter on "Removing" [9PAAD1 9PAAD7]→ 243519 Removing and installing air box for throttle
housing (Y-shaped pipe) - chapter on "Removing" [9PAAE1 9PAAE7]
Removing radiator fan housing (radiator frame)
DANGER
9PAAD7] or battery → Work instructions after disconnecting the battery
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Note
The repair instructions differ slightly in the illustrations for the V6. The work steps are essentially identical.
Cooling fan housing (radiator frame)
1. Disconnect the electric plugs on the fans.
Electric connector for the fan

2. Unclip the cable harness fixed to the vehicle from the clips on the
radiator frame.
Wiring harness fixed to the vehicle

3. Loosen the two upper fastening screws of the radiator module on the lock carrier.
4. Press the radiator module towards the engine until the frame can be pulled up and out.
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5. Release the catch springs to

the left and right on the
radiator module and pull the
frame up and out.
View of the catch springs when the Upper fastening screws for radiator
radiator has been removed motor
If the radiator frame is stuck, it can be released carefully by means of a
crowbar.
Loosen stuck radiator frame with

mounting lever
Installing radiator fan housing (radiator frame)

1. Slide the radiator frame from the top to the bottom along the radiator into the engine compartment.
2. Check whether the installation is correct. To do this, check whether the catch springs on the left and right
have engaged properly and that the four fastening projections on the underside have engaged in the plastic
clamps.
3. Tighten the two upper fastening screws of the radiator module on the
lock carrier.
Upper fastening screws for radiator

motor
4. Join the two electric connectors on the top side.
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5. Press the wiring harness into the 4 fastening clips.
Pressing the wiring harness into

fastening clips
Subsequent work
Subsequent work
1. Install Y-shaped pipes. → 243519 Removing and installing air box for throttle housing (Y-shaped pipe) -
chapter on "Installing" [9PAAF1]→ 243519 Removing and installing air box for throttle housing (Y-shaped
pipe) - chapter on "Installing" [9PAAD1 9PAAD7]→ 243519 Removing and installing air box for throttle
housing (Y-shaped pipe) - chapter on "Installing" [9PAAE1 9PAAE7]
2. Install front engine cover. → 700219 Removing and reinstalling front cover (engine compartment) - chapter
on "Installing"
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
19 38 17 Draining and filling in coolant (includes bleeding) - as of

MY 2003
- Information
- Draining coolant
- Filling the cooling system (includes bleeding)
- Bleeding vehicles with auxiliary heater
Tools

Assembly tools for spring band commercially NR.72

clamps available tool

available tool
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Tools and materials
Special tools
Special tools 1
-- Flexible screwdriver a/f 7 (for loosening or tightening screw hose clamps) Flexible screwdriver a/f 7
A- NR.73-1
-- Antifreeze protection testing device (for checking the antifreeze content in the cooling system. The design
B- can deviate from that shown in the picture.)
-- Spring band clamp pliers (for opening and closing spring band clamps) Assembly tools for spring band
C- clamps NR.72
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Special tools 2 Filling device 9696
-1- - Canister (canister with lifting tube, capacity approx. 30 l, with volume scale)
-2- - Hose extension
-3- - Adapter K 22 (included in the scope of delivery of radiator vacuum filling device)
-4- - Venturi nozzle (included in the scope of delivery of radiator vacuum filling device)
-6- - Pressure gauge (included in the scope of delivery of radiator vacuum filling device)
Information
Components of the radiator vacuum filling device
Note
z Pay attention to the special features in the corresponding chapter for vehicles with auxiliary heater.
→ 193817 Draining and filling coolant (includes bleeding) - chapter on "Bleeding"
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Vacuum filling device components Filling device 9696
-1- - Adapter K 22 (installed in place of the cap on the coolant reservoir.)

-2- - Hose extension FZ 100 (installed between K22 and KVB 01.)
-3- - KVB 01 (vacuum pressure gauge with two shut-off valves)
- - Shut-off valve V1 (shutoff valve for the filler hose.)
V1-
V2-
-4- - Venturi nozzle (a vacuum is produced in this component by means of compressed air. A pressure between
6 and 10 bar must be present.)
-5- - Filler hose (the cooling system is refilled via this hose.)
-6- - Return lines (the compressed air and the extracted coolant are drawn off via this hose.)
Draining coolant
Draining coolant
ATTENTION

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ATTENTION
DANGER
ATTENTION
Note
national laws.
3. Open cap on the reservoir and remove.

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Cap on coolant reservoir Maintenance cover
Engine guard
5. Release the front apron on the underside.

6. Remove the support plate under the radiator. To do this, loosen the 4
fastening screws.

7. Drain cooling system. If present, remove the drain plug from the radiator, otherwise open the lowest coolant
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hose on the radiator, and drain the coolant into a container and dispose of it according to the applicable
national laws if no longer required.
8. Fit a new drain plug on the radiator and tighten it. If removed, fasten coolant hose.
9. Install the support plate under the radiator. Tighten the four fastening
screws. → Tightening torque: 17 ftlb.
Filling the cooling system (includes bleeding)
Filling cooling system (includes bleeding)

1. Screw the cap adapter for the coolant reservoir (K 60) 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° to flow direction).
4. Connect the Venturi nozzle to the vacuum pressure gauge.
Note
z The coolant amount provided must be approx. 2 litres more than the amount which has to be filled. →
Technical data for M48/00 engine (Cayenne S) [9PAAE1 9PAAE7]→ Technical data for M48/00 engine
(Cayenne S) [9PAAD1 9PAAD7 9PAAF1 9PAAJ1], → Technical data for M48/50 engine (Cayenne
Turbo) [9PAAF1 9PAAJ1]→ Technical data for M48/50 engine (Cayenne Turbo) [9PAAD1 9PAAD7 9PAAE1
9PAAE7], → Technical data for BFD engine (Cayenne ) [9PAAD1 9PAAD7]→ Technical data for BFD
engine (Cayenne ) [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]
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z Because differing quantities of coolant can drain away for different

types of repairs, the filling capacities 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
suctioned-in coolant quantity. Observe volume scale on the canister.
z 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 near the reservoir.
Connecting the Venturi nozzle to the

Note vacuum pressure gauge
z The bleeding process is completed more quickly if the canister is positioned at roughly the same height as
the coolant expansion tank.
6. Push the filler hose -5- of the vacuum pressure gauge onto the canister connection. Lay the return line -6-
from the Venturi nozzle to a second container (bucket).
Vacuum filling device components
Note
z A hissing sound after connecting the compressed air supply is usual.
7. Connect the compressed air supply.
Connecting the compressed air supply

8. Open both shut-off valves on the vacuum pressure gauge until the transparent filler hose -5- has completely
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Shut-off valves on the vacuum

pressure gauge
filled with coolant.
9. Close the left shut-off valve (V1) on the vacuum pressure gauge and
allow a vacuum to build up in the cooling system.
Closing the left shut-off valve (V1)
Note
z If no vacuum is generated (the pointer does not move to the green
area), there is a leak in the cooling system.
z Deformation of the rubber hoses of the cooling system is normal.
z When the pressure gauge pointer is in the green area of the display
scale, a sufficient vacuum has been built up.
z After both shutoff valves on the vacuum pressure gauge have been
closed and the compressed air supply has been disconnected, the When there is sufficient vacuum, close
vacuum must not drop. If the vacuum drops within approx. 30 the right shut-off valve (V2)
seconds, there is a leak in the coolant circuit.
10. When there is a sufficient vacuum in the cooling system (indicator is in the green area), close the right shut-
off valve (V2) and then disconnect the compressed air supply.
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
shut-off valve (V2).
13. Then remove the complete filling tool (including the cap K 60).
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Maximum marking for coolant Opening right shut-off valve

reservoir
14. If necessary, fill the coolant reservoir with coolant to the maximum marking.
Note
z If necessary, the system can be checked for leaks. → 190101
Checking cooling system - chapter on "Checking"

15. Screw on the cover of the reservoir in a clockwise direction.
16. Close the maintenance cover.
17. Re-install the complete engine guard. → 108019 Removing and

installing engine guard - chapter on "Installing"
18. 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 with coolant.
Reservoir cap
Bleeding vehicles with auxiliary heater

1. Fill and bleed the vehicle as described in the previous chapter using the vacuum filling device. → 193817
Draining and filling coolant (includes bleeding)
2. Warm engine to operating temperature (≥ 90 °C).

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Note
z Do not activate the 2/3 directional-control valve with the Porsche System Tester above 1500 rpm.
z Activate the 2/3 directional-control valve with the Porsche System Tester below 1500 rpm.
3. Operate engine for 5 minutes with changing engine speeds. When doing this, run the engine for 10 seconds
in idle and then for 10 seconds at 4,000 rpm. In the speed transition from higher engine speeds (1500 to
4000 rpm) to idle (approx. 600), the directional-control valve should be activated with the Porsche System
Tester below 1500 rpm. Note that the 2/3 directional-control valve is not activated with the Porsche System
Tester above 1500 rpm.
4. Let the vehicle cool down.
Maintenance cover
6. Carefully open the cap on the coolant reservoir. Unscrew the cap in
an anti-clockwise direction.

7. Check coolant level and, if necessary, fill the coolant reservoir with
coolant to the maximum marking.
Maximum marking for coolant

reservoir
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8. Screw on the cover of the reservoir.

Reservoir cap
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
19 40 19 Removing and installing coolant expansion tank - as of

MY 2003
- Preliminary work
- Removing coolant expansion tank
- Installing coolant expansion tank
- Subsequent work
Preliminary work
Preliminary work

(includes bleeding) - chapter on "Draining"
2. Remove the right-hand headlight. → 941519 Removing and installing

main headlight - chapter on "Removing"
3. Remove engine compartment cover on the right and rear. → 700219
Removing and reinstalling front cover (engine compartment) -
Removing coolant expansion tank
1. Remove electric connector from coolant reservoir.
2. Pull off the three coolant hoses shown.
3. Detach the torque support. To do this, unscrew the fastening screw on the torque support bracket and pull it
out.
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Coolant hoses Electric connector on coolant reservoir
Torque support on body Fastening screw for torque support

4. Detach the torque support from the body and swivel upwards. bracket
5. Undo torque support bracket fastening screw from the body. One
fastening screw is loosened through the headlight opening. The
second screw is accessible from the top.
View shows screw on spring dome
View shows how screw is connected

through headlight opening
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Taking out electric cable
6. Remove body bracket. When doing this, unclip the electric cable (2 x).
7. Loosen the secondary air pump from cylinder row 1-4. → 266519 Removing and installing secondary air
pump - chapter on "Removing"
8. Undo the coolant reservoir fastening screw.
Fastening screw
9. Pull coolant reservoir towards engine and take out of the holder.
Coolant reservoir
Installing coolant expansion tank
1. Insert coolant reservoir into the holder and push in the direction of the wing.
2. Tighten fastening screw. → Tightening torque: 7.5 ftlb.

3. Tighten the secondary air pump from cylinder row 1-4. → 266519 Removing and installing secondary air
pump - chapter on "Installing"
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Fastening screw, coolant reservoir Coolant reservoir

4. Reinstall body bracket for the torque support. Clip on electric cable
for coolant reservoir (2 x).
Clipping in electric cable

5. Tighten fastening screw (M10 x 20) through the headlight opening.
Tightening fastening screw through the

headlight opening
6. Tighten fastening screw (M10 x 37) from the engine compartment. →
Initial tightening: 37 ftlb. → Final tightening: 90 °
Tightening fastening screw from the

engine compartment
7. Reinstall torque support. Install the fastening screw (M10 x 85) with a new fastening nut on the bracket. →
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8. Tighten the fastening screw of the torque support onto the body (M10 x 70). → Tightening torque: 44 ftlb.
9. Mount and tighten the three coolant hoses.
Coolant hoses
10. Connect electric plug to reservoir.
Electric connector to reservoir
Subsequent work
Subsequent work
1. Install the engine compartment cover at the right and rear. → 700219 Removing and reinstalling front cover
(engine compartment) - chapter on "Installing"
2. Install right headlight. → 941519 Removing and installing main headlight - chapter on "Installing"
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"Filling"
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g g p p g
ADVERTENCIA
19 45 19 Removing and installing additional coolant pump - as of

MY 2003
- Preliminary work
- Removing additional coolant pump
- Installing additional coolant pump
- Subsequent work
Preliminary work
Preliminary work

(includes bleeding)

2. Remove front left wheel housing liner. → 505619 Removing and
reinstalling front wheel-housing liner - chapter on "Removing"
Front left wheel housing liner

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Removing additional coolant pump
Removing the additional coolant pump
1. Undo sheetmetal holder of coolant line by removing fastening screw

(M6 x 16) on the body. Unclip the coolant line from the holder.
Carefully pull the additional coolant pump forward under the wing.
Pull off electric connector -1- on the pump. Then open the coolant
hoses -2 and 3- and remove the pump by loosening the screw-type
hose clamp.
Additional coolant pump
Installing additional coolant pump
1. Insert the additional coolant pump in the screw-type hose clamp and
screw in the fastening screw hand-tight. Install the coolant hoses
-2 and 3- , position the spring-band clamps and then connect the
electric connector -1- . Clip coolant lines into holder and fasten
sheetmetal holder of coolant line by mounting the fastening screw on
the body. → Tightening torque: 7.5 ftlb.
Subsequent work
Subsequent work
Note
z If necessary, the system can be checked for leaks. → 190101 Checking cooling system
"Filling"
2. Install front left wheel housing liner. → 505619 Removing and installing front wheel housing liner - chapter on
"Installing".

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as of MY 2003
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99

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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
19 50 19 Removing and installing coolant pump - as of MY 2003

- Preliminary work
- Information
- Removing coolant pump
- Installing coolant pump
- Subsequent work
Preliminary work
Preliminary work

(includes bleeding)

2. Remove the radiator frame. → 193817 Draining and filling coolant
(includes bleeding)
Radiator frame
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Information
Component overview for coolant pump
Overview of coolant pump in engine

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1- Coolant pump
2- Seal for coolant pump (replace seal)
3- 2 dowel sleeves (do not remove)
4- 8 M6x25 fastening screws (tightening torque 10 Nm (7.5 ftlb.))
5- Support for cable duct (fit with the two upper fastening screws)
Removing coolant pump

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Electric connection on throttle adjuster

1. Separate the electric connection from the throttle adjuster. To do this, press on the plug at the top and
bottom and, at the same time, pull it off. Unclip the cable from the sheetmetal holder.
2. Remove the throttle adjuster.
Fastening screws on throttle adjuster
Note
z To ease removal, spray the pulley from the rear side with an anti-
corrosion agent.
3. Unscrew the three fastening screws on the coolant pump pulley.

Wrench size is T 40.
Fastening screws for coolant pump

pulley
4. Remove the drive belt from the coolant pump pulley. Mark the
direction of running of the drive belt with chalk.
Drive belt on coolant pump pulley

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5. Use an open-ended wrench (a/f 30) to turn the belt tensioner

clockwise and, at the same time, remove the drive belt from the
tensioning roller. Relieve the belt tensioner carefully. Remove the
drive belt from the coolant pump.
Belt tensioner
ATTENTION
Risk of damaging pulley!
→ The pulleys of the engine accessories are made of plastic. Do not

use damaged pulleys.
→ The pulley is sensitive to impacts.
→ Do not prise off the pulley with a screwdriver.
6. Remove the 3 loosened fastening screws on the pulley and remove

the pulley. Fastening screws for pulley
7. Remove the eight fastening screws on the coolant pump and remove
the pump. If the pump is stuck, loosen it by gently tapping with a
plastic hammer.
Loosening the coolant pump with a

plastic hammer
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Installing coolant pump
ATTENTION
→ The pulleys of the engine accessories are made of plastic. Do not use damaged pulleys.
1. Clean sealing surfaces. Mount new sheetmetal seal on the coolant

pump. Slide the new sheetmetal seal over the dowel pins.
New sheetmetal seal on the coolant

pump
2. Tighten the 8 fastening screws. → Tightening torque: 7.5 ftlb.
Mount the sheetmetal holder for the cable duct using the two upper
fastening screws.
3. Fit the pulley on the coolant pump. Screw in the three fastening
screws by hand.
4. Mount drive belt -as shown in the following- . To do this, turn the
belt tensioner clockwise and thread the drive belt around all the
pulleys. Then carefully relieve the tensioning roller . → 137819
Removing and installing drive belt - chapter on "Installing" [9PAAF1
9PAAJ1]→ 137819 Removing and installing drive belt - chapter on
"Installing" [9PAAE1 9PAAE7]
Mount the fastening screws for the
coolant pump
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Installation sequence for drive belt
5. Check whether the drive belt is correctly installed.
6. Tighten the three fastening screws of the coolant pump pulley. →


pulley
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Fastening screws on throttle adjuster

7. Tighten the throttle adjuster with new seal. → Tightening torque: 17 ftlb.

Subsequent work
Subsequent work
on "Installing" [9PAAE1 9PAAE7 9PAAF1]→ 192019 23 Removing and installing cooling fan housing
(radiator frame) - chapter on "Installing" [9PAAJ1]
2. Fill and bleed the cooling system according to instructions. → 193817 Draining and filling coolant (includes
bleeding) - chapter on "Filling"
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
19 58 19 Removing and installing coolant regulator (thermostat) -

as of MY 2003
- Preliminary work
- Information
- Removing thermostat
- Installing thermostat
- Subsequent work
Tools

assembly aid special tool 9627
Preliminary work
Preliminary work
1. Drain cooling system. → 193817 Draining and filling coolant (includes bleeding)
2. Remove intake-air distributor. → 244619 Removing and reinstalling intake-air distributor - chapter on
"Removing"
Information
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Component overview
Install location
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Component overview
1 - Thermostat housing (observe loosening and tightening sequence)

3 - O-rings, 22 x 3, replacing
4 - Coolant pipe for heater
6 - O-rings, 28 x 3, replacing
7 - Seal for thermostat housing; replacing
9 - Moulded seal; replacing
10 - Thermostat well
11 - O-ring, 50 x 3, replacing
12 - O-ring, 20 x 2.65, replacing
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Removing thermostat
1. Remove the two coolant lines on the thermostat housing cover. To

do this, remove the spring-band clamps and pull off the hoses.
Spring band clamps for coolant lines

on thermostat housing
2. Pull off the cable duct upwards over the coolant pump.
3. Release the upper fastening screw of the oil dipstick.
Cable duct over coolant pump

4. Loosen the fastening screw on the cable duct.
Fastening screw on the cable duct

5. Disconnect the coolant outlet on the generator. To do this, open the spring-band clamps and pull off the
hose. Collect the draining coolant.
6. Remove the coolant return line on the thermostat housing. To do this, loosen the fastening screw and pull off
the line.
7. Disconnect vent line for cylinder heads. To do this, press the ribbed surfaces of the buttons and pull off the
plugs.
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Fastening screw for coolant return line Spring band clamp for coolant return
to thermostat housing to generator
Fastening screws of heater pipes Button on the vent lines of cylinder

heads
8. Undo the 3 rear fastening screws of the heater pipes.
9. Undo the thermostat housing cover. The sequence shown must be observed when doing so.
Loosening sequence for thermostat housing
10. Lift the housing cover. Remove the thermostat using assembly aid 9627.
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Removing thermostat with assembly

aid
Installing thermostat
Note
z All seals between opened sealing surfaces must be replaced.
1. Insert thermostat in the cover and turn it until the two sheetmetal
edges are lying to the left and right of the holder.
Inserting thermostat into cover and

twisting
2. Replace inner and outer seal in thermostat housing cover.
3. Position thermostat housing cover and tighten the fastening screws

(M6 x 25) according to the sequence shown. → Tightening torque:
7.5 ftlb.
View shows assembly using the

special tool
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Tightening sequence for thermostat housing fastening screw
4. Tighten the three rear fastening screws (M6 x 16) on the heater
pipes. → Tightening torque: 7.5 ftlb.
Fastening screws of heater pipes

5. Connect vent lines for cylinder heads. The connectors must engage
audibly.
Vent lines for cylinder heads

6. Fit coolant line leading to the generator. Insert the line in the thermostat housing cover and tighten the
fastening screw. → Tightening torque: 7.5 ftlb.
7. Push coolant line onto generator and fit the spring-band clamp.
8. Push the holder onto the timing case cover below the cable duct and tighten the fastening screw. →
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Spring band clamp for coolant line to Coolant line to generator

generator
9. Tighten the upper fastening
screw of the oil dipstick. →
Fastening screw for oil dipstick Fastening screw, support to timing-

case cover
10. Push the cable duct onto the retaining bracket over the coolant
pump.
Push the cable duct onto the retaining

bracket over the coolant pump.
12. Fit coolant supply and return hose on thermostat housing cover.
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Subsequent work
Subsequent work
1. Install intake distributor. → 244619 Removing and reinstalling intake-air distributor - chapter on "Installing"
2. Fill coolant system and check for leaks. → 193817 Draining and filling coolant (includes bleeding) - chapter
on "Filling"
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
19 70 21 Removing radiator - as of MY 2003

- Preliminary work
- Information
- Removing radiator
Preliminary work
Preliminary work
1. Disconnect battery. → 90 Work instructions after disconnecting the battery
2. Drain cooling system. → 193817 Draining and topping up with coolant (includes bleeding) - chapter on
"Draining"
3. Remove lock mount. → 503819 Removing and installing lock mount - chapter on "Removing"
chapter on "Removing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 192019 21 Removing and installing
cooling fan housing (radiator frame) - chapter on "Removing" [9PAAJ1]
Information
Component overview
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Overview of radiator
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Component overview for radiator
1 - Radiator module (If at all possible, do not open the air-conditioning

system. Do not bend the lines.
2 - Lock carrier
3 - Front bumper
4 - 2 clamps
5 - Safety clip
Removing radiator
Do not open the air conditioner if at all possible when removing the - radiator module. Do not bend the lines
When installing the - radiator module do not bend the lines.

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Note
z The retaining clips should be mounted again immediately so that they
are not confused.
1. Remove coolant hoses on the radiator. To do this, pull out the

retaining clips on the two coolant flanges and pull off the hoses. Then
fit the retaining clips again so that they are not confused.
Coolant hoses on the radiator

2. Pull off the top right vent hose on the radiator.
Breather hose on the radiator

3. Unscrew both fastening screws -C- for securing condenser to the
coolant radiator (left direction of travel).
Fastening screws for securing

condenser to coolant radiator
4. Unscrew the fastening screw -D- (left direction of travel) for securing
power steering radiator lines to coolant radiator.
Fastening screw for lines to radiator

for power steering
5. Unclip the radiator for the power steering system. To do this, unclip the wiring to the front out of the holder
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Lines for power steering radiator
-A- and push it to the left out of the support -B- . Hang the radiator carefully downwards.
6. Lift both locks for the ATF cooler and air-conditioning condenser with
a screwdriver -1- and push down -arrow- .
Fuses for ATF cooler and on air-

conditioning condenser
Note
z Fix the remaining radiators in the installation position using tie wraps.
7. Lift up the radiator and take it out of the vehicle by moving it up and
to the right. When doing this, watch out for the connection lines of the
air-conditioning system on the left side.
Lifting the cooler
as of MY 2003
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C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39,
C45, C46, C98, C99
Secured ATF cooler and radiator for

power steering system
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
19 70 23 Installing radiator - as of MY 2003

- Information
- Installing radiator
- Subsequent work
Information
Component overview
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2 - Lock carrier
3 - Front bumper
4 - 2 clamps
5 - Safety clip
Installing radiator
Note
z The retaining clips should be mounted again immediately so that they are not confused.
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1. Insert the radiator from above on the right between the ATF cooler
and the air-conditioning condenser.
Inserting the radiator between ATF

cooler and air-conditioning condenser
2. Move the ATF cooler into the installation position and push on the
metal clips to fasten it.
Fastening ATF cooler with metal clips

3. Fasten servo oil cooler. To do this, push the servo oil cooler from left
to right into the support -A- and clip the lines into the support -B- .
Lines in the support on the servo

radiator
4. Tighten the fastening screw on the servo oil cooler line with a fastening screw. → Tightening torque: 7.5
ftlb.
5. Screw in both fastening screws -C- for securing condenser to the coolant radiator (left direction of travel). →
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Fastening screws for securing Fastening screw for servo oil coolant
condenser to coolant radiator line
6. Push on the cooler vent line onto the right radiator side and fit the
spring-band clamp.
Spring band clamp for cooler vent line

7. Push on the two coolant lines. The retaining clips on the flange must
engage audibly.
Pushing on coolant lines
Subsequent work
Subsequent work
on "Installing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 192019 23 Removing and installing cooling
fan housing (radiator frame) - chapter on "Installing" [9PAAJ1]
2. Install lock mount. → 503819 Removing and installing lock mount - chapter on "Installing"
"Filling in"
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4. Fit engine guard. → 108019 Removing and installing engine guard - chapter on "Installing"
5. Connect the battery . → 90 Work instructions after disconnecting the battery
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
19 78 19 Removing and installing coolant temperature sensor - as

of MY 2003
- Preliminary work
- Information
- Removing coolant temperature sensor
- Installing coolant temperature sensor
- Subsequent work
Preliminary work
Preliminary work
1. Drain coolant completely. → 193817 Draining and filling coolant

Draining coolant
Information
Component overview
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Installation position of coolant temperature sensor

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Component overview
2 - Coolant temperature sensor (when removing, collect emerging coolant, when installing, replace sealing ring)
3 - Sealing ring (replace when installing)
4 - 3 screw plugs, M16x1 (when removing, collect emerging coolant, when installing, replace sealing ring)
5 - 10 hexagon-head bolts M6x25
6 - 2 seals for distributor pipe (when installing, clean sealing faces and replace seal)
7 - 4 sealing rings (when installing, grease with Klüber Syntheso GLEP 1
8 - Lower cooling water tube
Removing coolant temperature sensor

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ATTENTION

ATTENTION
1. Pull off cable plug of the coolant temperature sensor -arrow- .
Cable plug of the coolant temperature

sensor
Note
z Even when the coolant has been completely drained, coolant
emerges from the open bore on the coolant temperature sensor!
2. Unscrew the coolant temperature sensor using a ring wrench (a/f 22)
-see picture- . Absorb emerging coolant.
Unscrewing the coolant temperature

sensor
Installing coolant temperature sensor

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Screwing in the coolant temperature

sensor
1. Clean sealing surfaces and screw in coolant temperature sensor with a new sealing ring into the distributor
pipe. → Tightening torque: 22 ftlb.
2. Fit cable plug again -arrow- .
Cable plug of the temperature sensor
Subsequent work
Subsequent work
1. Install intake-air distributor. → 244619 Removing and reinstalling intake-air distributor - chapter on
"Installing"
2. Fill up completely with coolant and bleed system. → 193817 Draining and filling coolant (includes bleeding) -
chapter on "Filling".
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
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→ Por ello le rogamos que tras el proceso de impresión compare siempre las copias impresas con la
imagen de la pantalla. En caso de error, corrija las copias impresas de forma que se correspondan
con el contenido de la imagen de la pantalla.
10 01 19 Removing and installing V8 4.5 l engine - as of MY

2003
- Preliminary work
- Removing V8 4.5 l engine
- Installing V8 4.5 l engine
- Subsequent work
Tools


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connections

available tool
Tools and materials
Required tools
The following tools are described in the Workshop Equipment Manual, Chapter 3.0.13 "WE 1206" (exceptions
are noted).
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Lifting platform

mounting in the engine cross
member; equipped with a locking
screw to prevent engine from tipping.
carrier
cross member
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Tools overview

backwards. The support is mounted
in the direction of travel towards the
rear.
-B- Wheel hub support Prevents the spring struts from
tipping to the side, thereby damaging
the axles.
carrier position 1.
engine carrier
position 3.
position 4.
member position 5
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Tools overview

Manual 2.2.3
Manual 2.2.2
NR.73-1 Manual 2.4
Manual, Chapter 3.0.6 and electrolytes
"WE 1036"
connections NR.72-1
Manual 2.2.2 system
Manual 2.2.2
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-H- Lifting platform Can be found in

Workshop Equipment
Manual, 3.0.13 "WE 1206"
Preliminary work
Preliminary work
z If the engine is to be replaced by a new one, make sure the air conditioner is evacuated and the existing
air-conditioning compressor removed during removal of the engine as the replacement engine is
delivered with the new compressor mounted. → 873419 Removing and installing air-conditioning
compressor - chapter on "Removing"
wheel in centre position with steering wheel holder)! If this is not done, the airbag contact unit will have to
be put in centre position after installation of the steering gear! → 945019 Removing and reinstalling
steering-column switch
z Remove engine compartment covers. → 700219 Removing and reinstalling front cover (engine
Removing V8 4.5 l engine
Removing engine
Special features that are required for the equipment or relate to the Cayenne Turbo (M48/50) are
described in the notes.
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V8 engine
1. Remove engine guard with transverse strut. → 108019 Removing and installing engine guard - chapter
on "Removing"

bleeding).
3. Remove both wiper arms → 922519 Removing and installing
wiper arm - chapter on "Removing".
Note
z The air quality sensor is located on the cover of the radiator tank.
This must be unclipped.
Coolant drain plug

4. Loosen the 4 bayonet screws -A- on the plenum panel cover. Then lift the cover in the middle, release
left and right and remove from the vehicle.
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Engine wire harness Plenum chamber cover

5. Disconnect the engine wire harness on the right-hand side of the vehicle. To do this, unplug the control
unit and disconnect the ground point.
6. Open the cover of the central electrical system on the left side of
the vehicle. To do this, loosen the four Torx screws.
7. Disconnect the connectors from the engine wire harness (white,

red, black and brown). Remove the wiring harness from the
retaining clips and lay it down on the engine.

electrical system
8. Disconnect B+ transfer point at the left of the engine
compartment.
B+ transfer point
Throttle body cover

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Fastening bolts on the throttle body Throttle adjuster electric connection
Note
z In the Cayenne Turbo (M48/50), the boost pressure sensor must
also be disconnected.
11. Release the fastening bolts on the throttle body. To do this, twist
both bolts through 45° in an anti-clockwise direction. The dot on
the bolt must appear as illustrated in the figure.
12. Remove the fastening bolts. To do this, take hold of the bolt by
the rubber ring with pliers and pull it out.

14. Disconnect the mass air flow connections. To do this, loosen the
hose clamps to the left and right on the bellows and pull the
bellows off the mass air flow (in the Cayenne Turbo, pull them off
the pressure pipes).
Note
z If the engine is to be subsequently transported by crane, the
right-hand design cover on cylinder row 5 - 8 should be removed
at this point. → 108319 Removing and installing engine cover -

z To do this, loosen the 4 fastening screws. Unclip the design cover from the intake system and slide out at
an angle towards the front.

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Air cleaner housing clamps Design cover of cylinder row 5 - 8
Note
z In vehicles with air suspension, the suction line of the compressor
must also be removed on the right air cleaner cover. To do this,
unclip the green cap, press circlip -1- inwards and pull off adapter
-2- .
Circlip and adapter

16. Remove the air cleaner covers on the right and left. → 242519
Removing and installing air cleaner housing - chapter on
"Removing" [9PAAF1 9PAAJ1]→ 242519 Removing and
installing air cleaner housing - chapter on "Removing" [9PAAE1
9PAAE7]
Air cleaner cover

Filter elements
18. Disconnect the 2 respective oxygen sensor connectors (brown, black) at the left and right of the water
splash panel and unclip the cable from the supports.
Note
z In the Cayenne Turbo (M48/50), the support for the vacuum pump must also be undone. To do this,
unscrew the two fastening screws and press the pump forward slightly.
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Fastening screws for vacuum pump Oxygen sensor connector

19. Disconnect the 2 coolant lines and vacuum line on the right side
of the engine compartment.
WARNING

→ Components that come into contact with servo oil must be
cleaned IMMEDIATELY with water! Coolant lines and vacuum line
→ Take suitable protective measures (e.g. gloves, safety goggles,
oil binding material)
20. Empty the servo oil reservoir with a syringe. Next, remove the
hose from the reservoir. Close the open connections with plugs.
Servo oil reservoir

engine and loosen the screw on the body. Then pivot up the
torque support.
DANGER
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z Damage to skin

22. Disconnect fuel line -1- and line -2- from the carbon canister on Fuel line and carbon canister line
the plenum panel splash panel.
23. Loosen the 3 fastening screws on the left and right spring struts.
The screws are loosened from inside the engine compartment.
Of the 3 screws per spring strut, one is in the plenum panel.
Replace screws.

24. Disconnect the coolant feed and return lines from the radiator.
To do this, pull out the securing clip and pull off the connection.
The clips should be mounted again immediately so that they are
not confused.
Note
z If at all possible, the air-conditioning system should not be

opened.
Securing clip on connection for coolant
z If the engine is to be replaced by a new one, make sure the air feed and return lines
conditioner is evacuated and the existing air-conditioning compressor removed during removal of the
engine as the replacement engine is delivered with the new compressor mounted. → 873419 Removing
and installing air-conditioning compressor - chapter on "Removing"
25. Slacken the drive belt (a/f 30) and remove from the tensioning
roller.

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Note
z In the Cayenne Turbo (M48/50), the control lines of the ambient
air valves on the T-piece should be pulled off.
Note
z In the case of vehicles with air suspension, the compressed air
line on the spring strut must also be disconnected. Loosen the
line carefully and allow the remaining pressure to escape. Loosen
the threaded joint completely only when the line is fully
depressurised.
Compressed air line on spring strut

disconnected in vehicles with air suspension or automatic
headlight levelling system.

sensor
26. Disconnect electric plug -1- on the spring struts in the wheel
housing. Then unclip the support -2 and 3- . Tie the cable on the
spring strut.

wheel housing
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Brake lines in the wheel housing

WARNING
ATF!

→ Components that come into contact with ATF must be cleaned
Ground point of right side member
ATF lines on cooler

30. Remove the heat protection shield on the steering gear
connection. To do this, loosen the 2 fastening screws.
Note
z In the case of vehicles with Servotronic, an electric plug must
also be removed from the steering gear.

connection
31. Loosen the clamping screw from the steering column on the steering gear and remove it. The screw
g g g g
must not be re-used. Force the steering column up and off the steering gear.
33. Disconnect the heat exchanger coolant lines in the left wheel
housing below. Approx. 2 litres of coolant will flow out when you
do this.
34. Remove the complete exhaust system from the connection point
on the catalytic converter to the tailpipes → 260119 Removing
and installing exhaust system - chapter on "Removing".
35. Remove rear cardan shaft → 393519 Removing and installing

rear cardan shaft [9PAAE1 9PAAE7 9PAAF1] → 393519
Removing and installing rear cardan shaft [9PAAJ1].
wheel housing
36. Disconnect electrical connections -1,2 and 3- on the transmission
and unclip the wiring harness.

transmission

g g g g

shield
37. Remove the heat shield on the left transmission side. To do so, loosen the 3 fastening screws and take
out the heat protection shield.
Note
38. Detach the selector lever cable on the transmission. To do this,

press the ball socket away from the transmission. Then pull out
top sheetmetal clip -A- and remove the cable in an upward
direction.
Note
z If the transmission is to be separated from the engine after
removal, the two lower fastening screws on the transmission
housing and front cardan shaft should be removed at this point,
since access to the lifting platform will be impaired.
Selector lever cable on the

transmission
WARNING

Note
z On the Cayenne Turbo (M48/50), the hose connections on the turbochargers must also be loosened. To
do this, pull out locking spring -1- on the turbocharger adapter. Then loosen hose clamp -2- of the
pressure pipe on the turbocharger.
z Disconnect the connection on the charge air cooler. To do this, remove locking clip -1- and pull off the
g g g g
Locking spring on turbocharger Lower line on servo oil cooler

adapter and hose clamp of
line. Line -2- of the ambient air valve must also be disconnected
on the right-hand side of the vehicle. To do this, remove the
spring band clamp and pull off the line.
Note
z It is easier to remove the air-conditioning compressor from its
installation position when the engine has already been lowered a
little.
z The air-conditioning compressor lines must not be kinked or

twisted. Locking clip and line of ambient air
valve
evacuated.
40. Loosen the 3 fastening screws and disconnect the electric plug
from the air-conditioning compressor. Set the air-conditioning
compressor aside.

compressor
Note
z For installation, it is a good idea to mark the installation position of the front axle carrier diagonally at 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).
g g g g
42. Mark the installation position of the front axle carrier diagonally at
at least two places on the body.
Note
z Because of the high loosening torque, the 6 fastening screws on
the front-axle carrier can now be loosened. Loosen the screws by
a maximum of one turn.

axle carrier
43. Place the elevating platform under the engine and raise it. When
you do this, ensure that the positioning guides of the elevating
platform are inserted into the body.
Elevating platform
44. Secure the spring struts. 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 elevating
platform.

g g g g

cross member
46. Secure the engine/transmission combination. Then secure the mounting mandrels on the engine
transverse bar with locking screws.
Note
mounted accidentally between engine and body. Thus a second
person should make sure that the cables and lines do not get caught.
48. Lower the lifting platform slowly. When this is done, a second
person should ensure that there is sufficient clearance around
the engine compartment and wheel housings.
transverse bar
Installing V8 4.5 l engine
Installing engine
g g g g

2. Secure the engine against tipping. To do this, attach the locks on

the engine cross member and raise the support under the oil pan
until it touches the oil pan.

mounting the transmission - section on "Mounting" [9PAAE1
9PAAF1 9PAAJ1]→ 373527 AG Removing and mounting the
transmission - section on "Mounting" [9PAAE7] or → 343527
Removing and mounting the transmission - section on
Lifting the engine with a workshop
"Mounting" [9PAAE7] → 343527 AG Removing and mounting the
crane
transmission - section on "Mounting" [9PAAE1 9PAAF1 9PAAJ1]
section on "Removing" [9PAAE1 9PAAE7]→ 267619 Removing and installing primary catalytic converter
- section on "Removing" [9PAAF1 9PAAJ1]
g g g g


7. Remove the support from under the oil pan and remove the
tipping protection from the engine cross member.

possible.
11. Raise the body to a comfortable working height with the platform
lift.
Note
Oxygen sensor cable for the rear
z When moving the unit into the body, ensure that the shift cable is oxygen sensors
on the transmission.

conditioner is evacuated before removing the engine and the new
air-conditioning compressor is connected during installation of the
engine as the replacement engine is delivered with the new
compressor mounted. → 873419 Removing and installing air-
conditioning compressor - chapter on "Installing"
Note
z Position the front-axle carrier back in the original, marked
installation position and be careful not to damage adjacent parts.
12. Raise the engine/transmission combination into the body with the
lifting platform. Ensure sufficient clearance. The insertion guides
on the lifting platform must fit into the holes in the body.
Guiding the engine/transmission

g g g g
13. Tighten the 6 new front- combination into the body with the
axle carrier engine carrier lifting platform
screws. For details, see
installing front axle carrier
- section on
"Installing" [9PAAJ1]
installing front axle carrier
- section on
"Installing" [9PAAE1
9PAAE7 9PAAF1] →
Initial tightening: 120 (89 Fastening screws for front-axle carrier
ftlb.) Nm → Final and engine carrier
tightening - torque
angle: 180 °
14. Install transmission cross member. For details see → 396519

Removing and installing transfer box - section on "Installing" -A- .

cross member

17. Connect electric connector -1, 2 and 3- on the transmission and
clip in the wiring harness.
Connector to transmission
18.
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Mount selector lever cable. For details see → 371519 Removing and installing selector lever cable -
section on "Installing" [9PAAE1 9PAAF1 9PAAJ1]→ 371519 23 Removing and installing selector lever
cable - section on "Installing" [9PAAE7].
Note
turbochargers must also be fastened. To do this, connect
pressure pipe -2- and tighten the hose clamp. Then fit the lead of
the charge air cooler. The connection piece must engage audibly.
Ensure that sheetmetal clip -1- is fitted correctly.


valve
19. Push the servo oil line onto the oil cooler and mount the spring
band clamp.
Note
z For vehicles with Servotronic, the electric connector on the
steering gear must also be connected.

g g g g

20. Fit the steering column onto the steering gear. For details see → 489019 Removing and installing
steering gear - section on "Installing".

22. Slide the heater coolant lines on the left side member and mount
the clips.

member
23. Push on the coolant connection piece on the lower left on the
radiator. The connection piece must engage audibly.
Coolant connection piece

g g g g
ATF lines
25. Mount the ground point of the generator on the right side
member. → Tightening torque: 20 (15 ftlb.) Nm

26. Tighten the catalytic converter fastening on the body. For details
see → 267319 Removing and installing (main) catalytic converter
- section on "Installing"

27. Install cardan shaft. → 393519 Removing and installing rear
cardan shaft - section on "Installing" [9PAAE1 9PAAE7 9PAAF1]
→ 393519 23 Removing and installing rear cardan shaft - section
on "Installing" [9PAAJ1]

g g g g

strut

transverse strut
Note
lines must also be screwed on.
Compressed air line


g g g g

struts
33. Fit the electric connections of the spring struts. To do this, connect cable -1- and then fasten supports
-2 and 3- .
35. Mount the three fastening screws on the left and right spring
struts from above (engine compartment side). -arrows- →
Tightening torques for front axle

spring struts

housing
g g g g

37. Connect the servo line to the reservoir and mount the spring
band clamp. Then fill the container with Pentosin.

reservoir
38. Connect the line from carbon canister -2- to the plenum panel
splash panel until it audibly engages and tighten fuel line -1- . →

39. On the left and right of the plenum panel splash panel, connect
the oxygen sensor plug connections in front of and behind the
catalytic converter and lay the cables so they are not subject to
chafing.
Plug connections for oxygen sensors
Note
z In the Cayenne Turbo, the support for the vacuum pump must also be screwed into position. →
g g g g

support
40. Connect the vacuum line to the right spring dome and mount the
spring band clamp. Then mount the 2 lines on the coolant
reservoir and secure with spring band clamps.

reservoir
41. Lay the engine wire harness into the plenum panel. Mount the
rubber sleeve into the middle opening. Then guide the control
unit connector to the right. Connect the control unit, connector,
and ground point. → Tightening torque: 10 (7.5 ftlb.) Nm

point
42. Plug in the 4 connectors (red, brown, white and black) in the left-
hand central electrical system box. Then mount the cover using 4
Torx screws.
clips.

44. Mount the plenum chamber cover. Do not forget the electric connector for the air-quality sensor. Mount
the 4 bayonet screws -A- .
45.
g g g g

cover
Position and tighten drive belt on all pulleys → 137819 Removing and installing drive belt - section on
"Installing" [9PAAF1 9PAAJ1]→ 137819 Removing and installing drive belt - section on
46. Connect the upper left coolant connection piece to the radiator.

47. Mount the torque support with new lock nuts. → Tightening
torque: 60 (44 ftlb.) Nm → Tightening torque: 60 (44 ftlb.) Nm

Note
Air-cleaner element
49. Mount both air cleaners with cover. Insert the air cleaners in the housings and slide on the covers from
the top downwards. Then close the two respective sheetmetal clips. The coolant overflow hose must also
g g g g

be clipped onto the air cleaner housing of cylinder bank 1-4. Connect the electric connectors of the hot
film mass air flow sensors.
Note
air valve on the T-piece must also be connected.

on T-piece
Note
z Clip on the leads when mounting the Y-shaped pipe on the
bottom.
Clipping in lines
Vacuum line
g g g g
Note
z In the Cayenne Turbo
(M48/50), the boost
pressure sensor -3- must
also be connected.
Boost-pressure sensor Hose clamps on the Y-shaped pipe

52. Slide the Y-shaped pipe onto the throttle adjuster. Then insert the
left and right fastening bolts. Turn both bolts 45° clockwise.

throttle adjuster
53. Connect the throttle adjuster. The connector must engage
audibly. Clip the connecting cable into the sheetmetal holder.


support
Subsequent work
Subsequent work
g g g g
1. Fill and bleed the cooling system. → 193817 Draining and filling in coolant (includes bleeding) - chapter
on "Filling in"
5. Mount engine compartment covers. → 700219 Removing and reinstalling front cover (engine
compartment) - chapter on "Installing"
8. Bleed offroad stabiliser if necessary. → 402607 Bleeding the Offroad Stabilisator System (ORS) - chapter
on "Adjusting and bleeding" [9PAAJ1]→ 402607 Bleeding the Offroad Stabilisator System (ORS) -
chapter on "Adjusting and bleeding" [9PAAE1 9PAAE7 9PAAF1]
instructions as a result of the change of air conditioning compressor. → 873419 Removing and
reinstalling air-conditioning compressor - chapter on "Installing" and → 870317 Evacuating and filling in
refrigerant - chapter on "filling"
12. Fit engine guard. → 108019 Removing and installing engine

guard - chapter on "installing"
13. Perform a test drive with the vehicle. Check the fluid level in the
reservoir after the coolant circuit has cooled again and, if
necessary, fill up to the max marking with coolant.
Engine guard
as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14, C15, C16, C18, C19, C20, C21, C22,
C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
g g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g g

10 01 21 Removing engine - as of MY 2003

- Preliminary work
- Removing engine
Tools


g g g

connections

available tool
Tools and materials
Required tools
are noted).
g g g
Lifting platform

carrier
cross member
g g g
Tools overview

rear.
the axles.
carrier position 1.
engine carrier
position 3.
position 4.
member position 5
g g g
Tools overview

Manual 2.2.3
Manual 2.2.2
NR.73-1 Manual 2.4
"WE 1036"
connections NR.72-1
Manual 2.2.2 system
Manual 2.2.2
g g g

Workshop Equipment
Manual, 3.0.13 "WE 1206"
Preliminary work
Preliminary work
wheel in centre position with steering wheel holder)! If this is not done, the airbag contact unit will have to
be put in centre position after installation of the steering gear! → 945019 Removing and reinstalling
steering-column switch
z Remove engine compartment covers. → 700219 Removing and reinstalling front cover (engine
Removing engine
Removing engine
g g g
V8 engine
1. Remove engine guard with transverse strut. → 108019 Removing and installing engine guard - chapter
on "Removing"

bleeding).
3. Remove both wiper arms → 922519 Removing and installing
wiper arm - chapter on "Removing".
Note
z The air quality sensor is located on the cover of the radiator tank.
This must be unclipped.
Coolant drain plug

4. Loosen the 4 bayonet screws -A- on the plenum panel cover. Then lift the cover in the middle, release
left and right and remove from the vehicle.
g g g
Engine wire harness Plenum chamber cover

5. Disconnect the engine wire harness on the right-hand side of the vehicle. To do this, unplug the control
unit and disconnect the ground point.
6. Open the cover of the central electrical system on the left side of
the vehicle. To do this, loosen the four Torx screws.
7. Disconnect the connectors from the engine wire harness (white,

red, black and brown). Remove the wiring harness from the
retaining clips and lay it down on the engine.

electrical system
8. Disconnect B+ transfer point at the left of the engine
compartment.
B+ transfer point
Throttle body cover

g g g
Fastening bolts on the throttle body Throttle adjuster electric connection
Note
z In the Cayenne Turbo (M48/50), the boost pressure sensor must
also be disconnected.
both bolts through 45° in an anti-clockwise direction. The dot on
the bolt must appear as illustrated in the figure.

14. Disconnect the mass air flow connections. To do this, loosen the
bellows off the mass air flow (in the Cayenne Turbo, pull them off
the pressure pipes).
Note
z If the engine is to be subsequently transported by crane, the
right-hand design cover on cylinder row 5 - 8 should be removed
at this point. → 108319 Removing and installing engine cover -

z To do this, loosen the 4 fastening screws. Unclip the design cover from the intake system and slide out at
an angle towards the front.

g g g
Air cleaner housing clamps Design cover of cylinder row 5 - 8
Note
z In vehicles with air suspension, the suction line of the compressor
must also be removed on the right air cleaner cover. To do this,
unclip the green cap, press circlip -1- inwards and pull off adapter
-2- .
Circlip and adapter

16. Remove the air cleaner covers on the right and left. → 242519
Removing and installing air cleaner housing - chapter on
"Removing" [9PAAF1 9PAAJ1]→ 242519 Removing and
installing air cleaner housing - chapter on "Removing" [9PAAE1
9PAAE7]
Air cleaner cover

Filter elements
18. Disconnect the 2 respective oxygen sensor connectors (brown, black) at the left and right of the water
splash panel and unclip the cable from the supports.
Note
z In the Cayenne Turbo (M48/50), the support for the vacuum pump must also be undone. To do this,
unscrew the two fastening screws and press the pump forward slightly.
g g g
Fastening screws for vacuum pump Oxygen sensor connector

19. Disconnect the 2 coolant lines and vacuum line on the right side
of the engine compartment.
WARNING

→ Components that come into contact with servo oil must be
cleaned IMMEDIATELY with water! Coolant lines and vacuum line
20. Empty the servo oil reservoir with a syringe. Next, remove the
hose from the reservoir. Close the open connections with plugs.
Servo oil reservoir

engine and loosen the screw on the body. Then pivot up the
torque support.
DANGER
g g g

z Damage to skin

22. Disconnect fuel line -1- and line -2- from the carbon canister on Fuel line and carbon canister line
the plenum panel splash panel.
23. Loosen the 3 fastening screws on the left and right spring struts.
The screws are loosened from inside the engine compartment.
Of the 3 screws per spring strut, one is in the plenum panel.
Replace screws.

24. Disconnect the coolant feed and return lines from the radiator.
To do this, pull out the securing clip and pull off the connection.
The clips should be mounted again immediately so that they are
not confused.
Note
z If at all possible, the air-conditioning system should not be

opened.
Securing clip on connection for coolant
z If the engine is to be replaced by a new one, make sure the air feed and return lines
conditioner is evacuated and the existing air-conditioning compressor removed during removal of the
engine as the replacement engine is delivered with the new compressor mounted. → 873419 Removing
and installing air-conditioning compressor - chapter on "Removing"
25. Slacken the drive belt (a/f 30) and remove from the tensioning
roller.

g g g
Note
air valves on the T-piece should be pulled off.
Note
line on the spring strut must also be disconnected. Loosen the
line carefully and allow the remaining pressure to escape. Loosen
the threaded joint completely only when the line is fully
depressurised.
Compressed air line on spring strut

disconnected in vehicles with air suspension or automatic
headlight levelling system.

sensor
26. Disconnect electric plug -1- on the spring struts in the wheel
housing. Then unclip the support -2 and 3- . Tie the cable on the
spring strut.

wheel housing
g g g
Brake lines in the wheel housing

WARNING
ATF!

→ Components that come into contact with ATF must be cleaned
Ground point of right side member
ATF lines on cooler

30. Remove the heat protection shield on the steering gear
connection. To do this, loosen the 2 fastening screws.
Note
z In the case of vehicles with Servotronic, an electric plug must
also be removed from the steering gear.

connection
31. Loosen the clamping screw from the steering column on the steering gear and remove it. The screw
g g g
must not be re-used. Force the steering column up and off the steering gear.
33. Disconnect the heat exchanger coolant lines in the left wheel
housing below. Approx. 2 litres of coolant will flow out when you
do this.
34. Remove the complete exhaust system from the connection point
on the catalytic converter to the tailpipes → 260119 Removing
and installing exhaust system - chapter on "Removing".
35. Remove rear cardan shaft → 393519 Removing and installing

rear cardan shaft [9PAAE1 9PAAE7 9PAAF1] → 393519
Removing and installing rear cardan shaft [9PAAJ1].
wheel housing
36. Disconnect electrical connections -1,2 and 3- on the transmission
and unclip the wiring harness.

transmission

g g g

shield
37. Remove the heat shield on the left transmission side. To do so, loosen the 3 fastening screws and take
out the heat protection shield.
Note
38. Detach the selector lever cable on the transmission. To do this,

press the ball socket away from the transmission. Then pull out
top sheetmetal clip -A- and remove the cable in an upward
direction.
Note
z If the transmission is to be separated from the engine after
removal, the two lower fastening screws on the transmission
housing and front cardan shaft should be removed at this point,
since access to the lifting platform will be impaired.
Selector lever cable on the

transmission
WARNING

Note
z On the Cayenne Turbo (M48/50), the hose connections on the turbochargers must also be loosened. To
do this, pull out locking spring -1- on the turbocharger adapter. Then loosen hose clamp -2- of the
pressure pipe on the turbocharger.
z Disconnect the connection on the charge air cooler. To do this, remove locking clip -1- and pull off the
g g g
Locking spring on turbocharger Lower line on servo oil cooler

adapter and hose clamp of
line. Line -2- of the ambient air valve must also be disconnected
on the right-hand side of the vehicle. To do this, remove the
spring band clamp and pull off the line.
Note
z It is easier to remove the air-conditioning compressor from its
installation position when the engine has already been lowered a
little.
z The air-conditioning compressor lines must not be kinked or

twisted. Locking clip and line of ambient air
valve
evacuated.
40. Loosen the 3 fastening screws and disconnect the electric plug
from the air-conditioning compressor. Set the air-conditioning
compressor aside.

compressor
Note
z For installation, it is a good idea to mark the installation position of the front axle carrier diagonally at 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).
g g g
42. Mark the installation position of the front axle carrier diagonally at
at least two places on the body.
Note
z Because of the high loosening torque, the 6 fastening screws on
the front-axle carrier can now be loosened. Loosen the screws by
a maximum of one turn.

axle carrier
43. Place the elevating platform under the engine and raise it. When
you do this, ensure that the positioning guides of the elevating
platform are inserted into the body.
Elevating platform
44. Secure the spring struts. 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 elevating
platform.

g g g

cross member
46. Secure the engine/transmission combination. Then secure the mounting mandrels on the engine
transverse bar with locking screws.
Note
mounted accidentally between engine and body. Thus a second
person should make sure that the cables and lines do not get caught.
48. Lower the lifting platform slowly. When this is done, a second
person should ensure that there is sufficient clearance around
the engine compartment and wheel housings.
transverse bar
as of MY 2003
g g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g g

10 01 23 Installing engine. - as of MY 2003

- Installing engine
- Subsequent work
Tools


g g g

connections

available tool
Tools and materials
Required tools
are noted).
g g g
Lifting platform

carrier
cross member
g g g
Tools overview

rear.
the axles.
carrier position 1.
engine carrier
position 3.
position 4.
member position 5
g g g
Tools overview

Manual 2.2.3
Manual 2.2.2
NR.73-1 Manual 2.4
"WE 1036"
connections NR.72-1
Manual 2.2.2 system
Manual 2.2.2
g g g

Workshop Equipment
Manual, 3.0.13 "WE 1206"
Installing engine
Installing engine
1. Suspend the engine at the jacking points provided on a workshop crane and set down on the front-axle
carrier.
2. Secure the engine against tipping. To do this, attach the locks on the engine cross member and raise the
g g g
Lifting the engine with a workshop

crane
support under the oil pan until it touches the oil pan.
3. Fit the transmission onto the engine. → 373527 Removing and mounting the transmission - section on
"Mounting" [9PAAE1 9PAAF1 9PAAJ1] → 373527 AG Removing and mounting the transmission - section
on "Mounting" [9PAAE7] or → 343527 Removing and mounting the transmission - section on
"Mounting" [9PAAE7] → 343527 AG Removing and mounting the transmission - section on
"Mounting" [9PAAE1 9PAAF1 9PAAJ1]
section on "Removing" [9PAAE1 9PAAE7]→ 267619 Removing and installing primary catalytic converter
- section on "Removing" [9PAAF1 9PAAJ1]


7. Remove the support from under the oil pan and remove the
tipping protection from the engine cross member.

possible.

11. Raise the body to a comfortable working height with the platform
lift.
Note
z When moving the unit into the body, ensure that the shift cable is Oxygen sensor cable for the rear
on the transmission. oxygen sensors
z If the engine is to be replaced by a new one, make sure the air conditioner is evacuated before removing
g g g
the engine and the new air-conditioning compressor is connected

during installation of the engine as the replacement engine is
delivered with the new compressor mounted. → 873419
Removing and installing air-conditioning compressor - chapter on
"Installing"
Note
z Position the front-axle carrier back in the original, marked
installation position and be careful not to damage adjacent parts.
12. Raise the engine/transmission combination into the body with the
lifting platform. Ensure sufficient clearance. The insertion guides
on the lifting platform must fit into the holes in the body.
Guiding the engine/transmission

combination into the body with the
lifting platform
13. Tighten the 6 new front-axle carrier engine carrier screws. For
details, see → 400619 Removing and installing front axle carrier -
section on "Installing" [9PAAJ1]→ 400619 Removing and
installing front axle carrier - section on "Installing" [9PAAE1
9PAAE7 9PAAF1] → Initial tightening: 120 (89 ftlb.) Nm →
Final tightening - torque angle: 180 °

and engine carrier
14. Install transmission cross member. For details see → 396519
Removing and installing transfer box - section on "Installing" -A- .

cross member
g g g
Connector to transmission Support of wheel hub
17. Connect electric connector -1, 2 and 3- on the transmission and clip in the wiring harness.
18. Mount selector lever cable. For details see → 371519 Removing
and installing selector lever cable - section on
"Installing" [9PAAE1 9PAAF1 9PAAJ1] → 371519 23 Removing
and installing selector lever cable - section on
"Installing" [9PAAE7].
Note
turbochargers must also be fastened. To do this, connect
pressure pipe -2- and tighten the hose clamp. Then fit the lead of
the charge air cooler. The connection piece must engage audibly.
Ensure that sheetmetal clip -1- is fitted correctly.


valve
19. Push the servo oil line onto the oil cooler and mount the spring band clamp.
g g g
Note
z For vehicles with Servotronic, the electric connector on the
steering gear must also be connected.

20. Fit the steering column onto the steering gear. For details see
→ 489019 Removing and installing steering gear - section on
"Installing".


22. Slide the heater coolant lines on the left side member and mount
the clips.

member
23. Push on the coolant connection piece on the lower left on the radiator. The connection piece must
engage audibly.
g g g
ATF lines Coolant connection piece
25. Mount the ground point of the generator on the right side
member. → Tightening torque: 20 (15 ftlb.) Nm

26. Tighten the catalytic converter fastening on the body. For details
see → 267319 Removing and installing (main) catalytic converter
- section on "Installing"

27. Install cardan shaft. → 393519 Removing and installing rear
cardan shaft - section on "Installing" [9PAAE1 9PAAE7 9PAAF1]
→ 393519 23 Removing and installing rear cardan shaft - section
on "Installing" [9PAAJ1]

g g g

strut

transverse strut
Note
lines must also be screwed on.
Compressed air line


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struts
33. Fit the electric connections of the spring struts. To do this, connect cable -1- and then fasten supports
-2 and 3- .
35. Mount the three fastening screws on the left and right spring
struts from above (engine compartment side). -arrows- →

spring struts

housing
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36. Mount B+ transfer point on left spring dome. → Tightening

torque: 23 (17 ftlb.) Nm

37. Connect the servo line to the reservoir and mount the spring
band clamp. Then fill the container with Pentosin.

reservoir
38. Connect the line from carbon canister -2- to the plenum panel
splash panel until it audibly engages and tighten fuel line -1- . →

39. On the left and right of the plenum panel splash panel, connect
the oxygen sensor plug connections in front of and behind the
catalytic converter and lay the cables so they are not subject to
chafing.
Plug connections for oxygen sensors
Note
z In the Cayenne Turbo, the support for the vacuum pump must also be screwed into position. →
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support
40. Connect the vacuum line to the right spring dome and mount the
spring band clamp. Then mount the 2 lines on the coolant
reservoir and secure with spring band clamps.

reservoir
41. Lay the engine wire harness into the plenum panel. Mount the
rubber sleeve into the middle opening. Then guide the control
unit connector to the right. Connect the control unit, connector,
and ground point. → Tightening torque: 10 (7.5 ftlb.) Nm

point
42. Plug in the 4 connectors (red, brown, white and black) in the left-
hand central electrical system box. Then mount the cover using 4
Torx screws.
clips.

44. Mount the plenum chamber cover. Do not forget the electric connector for the air-quality sensor. Mount
the 4 bayonet screws -A- .
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cover
"Installing" [9PAAF1 9PAAJ1]→ 137819 Removing and installing drive belt - section on
46. Connect the upper left coolant connection piece to the radiator.

47. Mount the torque support with new lock nuts. → Tightening
torque: 60 (44 ftlb.) Nm → Tightening torque: 60 (44 ftlb.) Nm

Note
Air-cleaner element
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49. Mount both air cleaners with cover. Insert the air cleaners in the housings and slide on the covers from
the top downwards. Then close the two respective sheetmetal clips. The coolant overflow hose must also
be clipped onto the air cleaner housing of cylinder bank 1-4. Connect the electric connectors of the hot
film mass air flow sensors.
Note
air valve on the T-piece must also be connected.

on T-piece
Note
z Clip on the leads when mounting the Y-shaped pipe on the
bottom.
Clipping in lines
Vacuum line
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Hose clamps on the Y-shaped pipe
Note
z In the Cayenne Turbo (M48/50), the boost pressure sensor -3-
must also be connected.
left and right fastening bolts. Turn both bolts 45° clockwise.

throttle adjuster

54. Press the 4 rubber elements in the cover onto the 4 ball head supports. The mounts must be felt to
engage.
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support
Subsequent work
Subsequent work
on "Filling in"
5. Mount engine compartment covers. → 700219 Removing and reinstalling front cover (engine
8. Bleed offroad stabiliser if necessary. → 402607 Bleeding the Offroad Stabilisator System (ORS) - chapter
on "Adjusting and bleeding" [9PAAJ1]→ 402607 Bleeding the Offroad Stabilisator System (ORS) -
chapter on "Adjusting and bleeding" [9PAAE1 9PAAE7 9PAAF1]
instructions as a result of the change of air conditioning compressor. → 873419 Removing and
reinstalling air-conditioning compressor - chapter on "Installing" and → 870317 Evacuating and filling in
refrigerant - chapter on "filling"
13. Perform a test drive with the vehicle. Check the fluid level in the reservoir after the coolant circuit has
cooled again and, if necessary, fill up to the max marking with coolant.

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as of MY 2003
Country C00, C02, C05, C07, C08, C09, C10, C11, C12, C13, C14,
C15, C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28,
C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
Engine guard
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
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10 01 29 Cleaning the engine (washing the engine) - as of MY

2003
- Notes on washing the engine
DANGER
Hot water under high pressure!
z Risk of damage for engine components.
z Incoming washer-fluid in electric components.
→ Only wash the engine when it is cold.

→ Only wash the engine when engine is switched off (electric shock through the ignition system).
→ Protect the oxygen sensor connectors from moisture.
→ Maintain a minimum clearance of 50 cm between the cleaning lance and engine component.
→ Protect the brake fluid reservoir from moisture.
Note
z The engine should be washed only if this is absolutely essential for repair work.
z Components sensitive to moisture must be adequately protected. Cover them, if necessary.
z Cleaning agents or water should never be applied directly to components that are sensitive to moisture,
such as electric connectors.
z When using high-pressure cleaning apparatus, maintain a minimum clearance of 50 cm between the
cleaning lance and the engine component.
z Never wash the engine when the engine is warm.
z For environmental reasons, the engine may only be washed in workshops in which oils are separated
from waste water.
1. Open the bonnet.

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2. Protect components sensitive to moisture, possibly by covering them with plastic sheeting. Oxygen
sensor connectors must not get wet.
3. Remove any maintenance labels (e.g. oil change schedule tag) and replace after the work is completed.
4. Pre-clean very dirty engines with pure water.
5. Spray engine components to be cleaned with an appropriate engine cleaning agent and allow it to work
in.
6. Clean the engine. Ensure that a minimum clearance of 50 cm is maintained between the cleaning lance
and engine component. The water temperature must not exceed 80 °C. Remove persistent dirt with a
non-abrasive sponge.
7. Moving components in the engine compartment, such as the hook for the bonnet, must be re-greased.
8. Carry out a test drive after washing the engine.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
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10 01 37 Disassembling and assembling engine - as of MY 2003

- Technical values
- Preliminary work
- Disassembling engine
- Preliminary work
- Assembling engine
- Subsequent work
Tools

piston ring restraining strap special tool 57
for 944 - S2 and Boxster
and 911 Carrera (996)

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Tools and materials
Required special tools
Note
z The special tools that are required are described in the chapter → (Special) tools required for repairing
the M48/00 and M48/50 engines or in the corresponding individual chapters.
Technical values
Technical values
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Note
z For information on all tightening torques, see → Tightening torques for Cayenne S (M48/00) and
Cayenne Turbo (M48/50) [9PAAF1 9PAAJ1]→ Tightening torques for Cayenne S (M48/00) and Cayenne
Turbo (M48/50) [9PAAE1 9PAAE7] or the corresponding individual chapters.
Preliminary work
Preliminary work for disassembling engine
2. Remove engine from transmission. → 343527 Removing and refitting the transmission [9PAAE7]
→ 343527 Removing and refitting the transmission [9PAAE1 9PAAF1 9PAAJ1] or → 373527 Removing
and refitting the transmission [9PAAE1 9PAAF1 9PAAJ1]→ 373527 Removing and refitting the
transmission [9PAAE7]
Note
z The engine must be disassembled in accordance with the
detailed descriptions in the Technical Manual!
z This chapter does not provide details or further information.

Further details can be found in the relevant individual
descriptions.
3. Secure engine support P 9676 on engine → Crankcase on

engine support (shown with lower part of crankcase) . To do this,
use the four screws for mounting elements 9590 and tighten
them slightly. Secure engine on engine support. To do this,
carefully guide the engine support axle into the take-up bore on
the engine support and secure it.
7. Remove left additional assembly bracket -2- and right engine carrier -8- . There are also two dowel
sleeves (not shown) on the additional assembly bracket.
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1 - Nut → Tightening torque: 75 (56 ftlb.) Nm

2 - Additional assembly bracket, left
3 - Screw x 10 → Tightening torque: 65 (48 ftlb.) Nm
4 - Hydraulic mount, left
5 - Engine carrier
7 - Hydraulic mount, right
8 - Engine carrier
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"Removing"
"Removing"
8. Remove oil spray jets on turbo engine and cap on naturally aspirated engine. → 101321 Removing oil
spray jets for piston cooling [9PAAF1 9PAAJ1]→ 101321 Removing oil spray jets for piston cooling
[9PAAE1 9PAAE7]
Preliminary work
Preliminary work for engine assembly

1. The crankcase must be prepared for installation (dowel sleeves, caps and pins screwed in).
Note

descriptions.
2. Attach top section of crankcase to engine support. To do this,

them slightly. Crankcase on engine support
Assembling engine
Assembling engine
ATTENTION
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→ 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.
Note

descriptions.
Note Caps and oil spray nozzles

z Four oil spray nozzle are installed in the M48/50 engine instead of the caps used in the M48/00 engine.
1. Fit caps on crankcase. When doing so, make sure that new O-rings are fitted. Tighten the → Tightening
Note
classes are indicated by the colour marking on the outside. The
colour marking must match the corresponding colour dot on the
crankshaft. Further details: → Removing and installing crankshaft
2. Insert the bearing shells with the lubricating groove into the upper
part of the crankcase → Inserting the bearing shells . Make sure
the twist locks are positioned correctly. Then lightly oil the
bearing locations.
Colour marking on bearing shell
3. Insert the sickle-shaped washer (make sure of axial bearing play). To do this, insert the two sickle-
shaped washers to the left and right on crankshaft bearing no. 3. Apply some grease (000.043.204.17)
between the crankshaft bearing and the sickle washers so that the sickle washers do not fall down. Each
of the lubricating grooves of the sickle-shaped washers must face outwards → Inserting the sickle-
shaped washers .
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WARNING
The crankshaft is heavy!
z There is a danger of
hands being crushed
when inserting the
crankshaft.
→ Hold the very outside of

the crankshaft.
→ Wear gloves. Crankshaft holding bridges Inserting the sickle-shaped washers
4. Insert crankshaft. The connection flange must point towards the back of the engine. Then secure the
crankshaft from falling down using holding bridges 9677. Attach the holding bridges at bearing
locations 3 and 5 → Crankshaft holding bridges . Then screw the fastening screw of the front pulley into
the crankshaft until they just make contact.
Note
z The pistons must already be pre-fitted (pistons, piston rings,
connecting rods and fastening material) before performing the
next step.
z The required bearing shells must be inserted in the connecting

rods.
z The connecting rod is symmetrical and can be fitted either on the

piston so that the number on the connecting rod is facing
outwards or inwards, or the tolerance class designation of the Turning the crankshaft
piston does not have to be on the same side as the connecting
rod code. The direction of travel arrow is on the same side as the connecting rod code -A- as is evident
on the piston shown. This can be installed as standard on one cylinder bank side on the same side as
shown here, and on the other cylinder bank side, the connecting rod code is on the opposite side. The
connecting rod code is installed to the exhaust side as standard.
z When installing the piston in the crankcase, the direction of travel

arrow must point in the direction of travel.
z For further information, see → 131019 Removing and installing

pistons
Connecting rod code and direction of

travel arrow
z The code on the connecting-rod big end and connecting-rod bearing cap must be on the same side and
at the exhaust side.
6. Install piston. To do this, turn the crankshaft with a wrench (a/f 27) until the corresponding lift pin is
pointing straight downwards.
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7. Lightly oil cylinder and piston.
Connecting rod code "A"

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

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

Sliding in the piston
Push piston in using the handle of a

hammer, if necessary.
10. Push the piston downwards until the connecting-rod bearing is sitting on the lift pin. Then fit connecting-
rod bearing cap with bearing shell. The connecting rod numbers must face each other. Screw in con-rod
bolts by hand. Make sure the twist locks and connecting rod code are positioned correctly during
assembly.
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View of connecting rod numbers Twist lock on bearing shells
11. Fit the opposite piston (e.g. 1 and 4).
12. Fit other pistons in accordance with the step above.
13. Turn crankcase on the assembly support until the crankshaft is on top.
Note
z Con-rod bolts must always be replaced.
14. Tighten con-rod bolts that have been replaced. See → 131019 Removing and installing pistons - section
on "Installing"
15. holding bridges 9677 must be removed from the crankshaft.
16. Screw the two thin centring pins 9321 into the outer fastening
bores on the upper part of the crankcase -Arrows- (crankshaft
not fitted in illustration).
Centring pin
17. Insert the bottom bearing shells into the bottom section of the crankcase (bed plate) and lightly oil
running surfaces. Pay attention to the twist locks when doing so.
Degrease parting surfaces between top and bottom section of crankcase. A totally grease-free product
(e.g. brake cleaner) must be used for this. Then insert a new O-ring at the front of the parting surface.
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Bottom section of crankcase (bed plate)

4- Application of sealant; Loctite 5970 liquid sealant (000.043.300.39) must be applied and the screws
screwed in within five minutes and without interruption
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10 - Dowel sleeve
Note
z Liquid sealant must be applied and screws tightened immediately and without interruption.
z The threads and head contact surface of the bearing seat screws (M10 x 1.5 and M12 x 1.5) must be
oiled.
19. Apply Loctite 5970 liquid sealant - 000.043.300.39 (status 11/2005, for details of current sealant, see
Parts Catalogue) to the lower part of the crankcase as shown. The surfaces marked -A- must be cleaned
after fitting.
Applying sealant to bottom section of crankcase
destroyed.
21. For details of the tightening sequence for the bottom section of the crankcase and tightening torques,
see → 134819 Removing and installing crankshaft - section on "Installing".
22. Then tighten the four fastening screws on the clutch side → Tightening torque: 23 (17 ftlb.) Nm
-Arrows- .
23. Fit chain drive sprocket on the crankshaft. Unscrew fastening screw on belt pulley. Check that the
feather keys are fitted correctly and push on the chain sprocket with the oil pump drive chain. The
double-tooth row must be facing forwards.
25. Fit guide rail -9- and tensioning rail -6- for the oil pump drive. Push the tensioning rail over the fastening
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Chain drive wheel Bottom section of crankcase (clutch

side)
Oil pump
pin and engage the guide rail in the bottom section of the crankcase as shown in the illustration.
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Oil pump components
26. Fit timing chain cover on oil pump. Tighten the → Tightening
27. Turn engine 180° on the assembly support.
Timing chain cover on oil pump

28. Install starter → 276019 Removing and installing starter - section on "Installing" [9PAAE1 9PAAE7
9PAAF1]→ 276019 23 Removing and installing starter - section on "Installing" [9PAAJ1].
29. Fit knock sensors. Align the knock sensors as shown in the illustration and tighten the → Tightening
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Figure shows knock sensor on bank 1 Installing starter

-4
torque: 23 (17 ftlb.) Nm .
30. Install thermostat housing. Fit a new O-ring at the water pump
inlet and then insert the thermostat housing. Tighten the two →
Tightening torque: 10 (7.5 ftlb.) Nm .
31. Mount cylinder heads. To do this, turn the engine on the

assembly support so that the required cylinder bank is pointing
vertically upwards.
Figure shows knock sensor on bank 5

-8
32. Fit new cylinder-head gasket. The gasket designation is shown
on the back and is legible from above when fitted correctly.
Cylinder bank 1 - 4
33. Fit cylinder head. The fastening screws must be tightened in the
sequence shown below. The tightening sequences and step-by-
step tightening torques must be observed! For details, see
→ 157023 Removing and installing cylinder head.
Cylinder bank 5 - 8
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Tightening sequence for cylinder head
34. Fit camshaft housing. Apply a bead of Loctite 5970 liquid sealant - 000.043.300.39 (status 11/2005, for
details of current sealant, see Parts Catalogue) -A- as shown. Then screw two thin centring pins 9321
into two opposing blind holes in the cylinder head. Insert the O-ring -B- into the oil duct. Wipe off any
sealant -C- that emerges as a result of screwing.
Sealant application
35. Position camshaft housing and then unscrew the two centring pins.
36. Tighten the camshaft housing screws in the sequence shown. Don't forget the two hexagon socket head
bolts at the front of the camshaft housing. For details, see → 150323 Removing and installing camshaft
housing.
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Note
z The bearing locations of the camshafts must be lightly oiled.
z Place the camshafts in such a way that the cams are positioned
as shown below!
Screws at the front
Positioning camshafts

D - Cam position cylinder bank 5 – 8 exhaust side
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C - Cam position cylinder bank 5 – 8 inlet side

B - Cam position cylinder bank 1 – 4 inlet side
A - Cam position cylinder bank 1 – 4 exhaust side
38. Fit oil return line to camshaft housing 5 - 8. Fit oil return line -1- with a new O-ring -2- . Tighten the four →
Tightening torque: 10 (7.5 ftlb.) Nm -3 and 4- (camshaft housing, cylinder head, crankcase and oil
pan).
Oil return line
39. Position oil feed housing of inlet camshaft and tighten → Tightening torque: 10 (7.5 ftlb.) Nm .
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Note
z If the camshaft timing gears and camshaft adjusters are removed
completely, the diamond washers and fastening screws must be
replaced!
40. Replace the diamond washer and fastening screw located

underneath the camshaft adjuster and camshaft timing gear.
41. Fitting deflection rail -4- . → 154756 23 Replacing guide and

tensioning rails – section on "Installing"
Diamond washer
Deflection rail
ATTENTION
Damage to the camshaft switch-over valve!
z Malfunction.
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→ Do not turn camshaft switch-over valve.
42. Install camshaft switch-over valves → Tightening torque: 10 (7.5

ftlb.) Nm . Figure → Fastening screw for camshaft switch-over
valve shows procedure with timing-case cover fitted.
43. Fit timing drive mechanism. Fit guide rail of cylinder bank 5 - 8.
Tighten the leaf spring of the oil pump tensioning rail at the same
time. → 154756 23 Replacing guide and tensioning rails – section
on "Installing"
44. Fit tensioning rail to cylinder bank 1 - 4. Fastening screw for camshaft switch-
over valve
45. Install timing chain. Position the chain on the crankshaft gear
wheel and then fit it over all four camshaft timing gears. To do
this, use both hands to carefully insert the camshaft adjuster and
camshaft timing gear into the timing chain. Screw in fastening
screws of the timing gears loosely to half a turn. Figure
→ Installing timing chain shows procedure with timing-case cover
fitted. Screw in fastening screws of the timing gears loosely to
half a turn.→ 153523 Installing timing chain
46. Fit U-rail. Insert the U-rail into the timing drive mechanism from
above. Tighten the four fastening screws.

47. Fit the short guide rails between the camshaft timing gears.
Figure → Guide rails shows assembly with timing-case cover
fitted.
48. Fit timing-case cover. → 153123 Installing chain case lid
Guide rails
49. Place sealing ring over crankshaft using assembly sleeve.
Sealing ring with assembly sleeve

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Crankshaft sealing ring

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

52. Pull assembly sleeve evenly off the sealing ring.
Assembly sleeve
Note
z If the sealing flange on the pulley is slightly rusted, polish the rust
off with a special polishing pad (e.g. Never Dull).
z If the sealing flange is badly corroded or contains deep grooves,

replace it.
Note
z A feather key is inserted into the crankshaft. When fitting the Crankshaft belt pulley
pulley, ensure that the feather key slots into the groove in the pulley.
53. Fit crankshaft belt pulley.→ 137619 Removing and installing crankshaft belt pulley - section on "Installing"
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54. Fit oil pan. → 175023 Oil pan installed (includes sealing)
55. Fit drive plate or flywheel.
Measurement on the oil pan

56. Install chain tensioner with new sealing ring. → Tightening
Note
z To remove the play from the timing chain for the setting process,
the crankshaft must be positioned approx. 45° in front of the TDC
of cylinder 1 before turning!
57. Set the timing. → 150516 Setting the timing.
58. Install the camshaft housing cover on both cylinder banks Installation location of chain tensioner
→ 159123 Installing the camshaft housing cover.
59. Fit water pump. → 195019 Removing and installing coolant pump - section on "Installing"
Subsequent work
Subsequent work
1. Fit left additional assembly bracket -2- and right engine carrier -8- . There are still two dowel sleeves (not
shown) on the additional assembly bracket.
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5 - Engine carrier
8 - Engine carrier
2. Fit power-steering pump. → 489819 Removing and installing hydraulic pump (Cayenne Turbo/Cayenne
S) - section on "Installing"
3. Fit generator. → 272219 Removing and installing generator - section on "Installing" [9PAAE1 9PAAE7]
→ 272219 Removing and installing generator - section on "Installing" [9PAAF1 9PAAJ1]
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4. Fit wire harness for engine. → 975219 Removing and installing wire harness for engine - section on
"Installing" [9PAAE1 9PAAE7]→ 975219 Removing and installing wire harness for engine - section on
5. Refit engine on transmission. → 343527 Removing and refitting the transmission [9PAAE7]→ 343527
the transmission [9PAAE1 9PAAF1 9PAAJ1]→ 373527 Removing and refitting the
transmission [9PAAE7]
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
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10 01 AW The most important working regulations and warning

notes - as of MY 2003
- Folder 1
- Information
Folder 1
Group 1 - Engine
DANGER
Suspended load!

ATTENTION

Group 10 - Crankcase - suspension
DANGER
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lowering.
→ Never use defective lifting equipment (bent or damaged tools must not be used or repaired. Always
→ Only use lifting equipment tested and approved by Porsche. Home-made and auxiliary constructions
result in improper use and are dangerous.
→ The transport eyebolt can only bear vertical traction with no side or transverse forces. Side loads (e.g.
from chains or cables) will damage the transport eyebolt, which must then be replaced. Extreme cases
of improper use can break the transport eyebolt.
DANGER

→ Observe the specifications on the containers. If swallowed, seek medical advice and show the
→ Wear gloves.
Note
z When working on the crank mechanism, absolute cleanliness is essential.
z Only the auxiliary and assembly equipment recommended for the repair job may be used for the
particular assembly work.
DANGER

→ Wear gloves.
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DANGER
Danger of injury from rotating components and belt drive!
→ Never reach into running belt drives or rotating components.

→ Switch off engine.
WARNING
Do not remove the drive belt when the engine is warm!
z Risk of damage or deformation!
→ Drive belts should only be removed when they have cooled down.
DANGER
Danger of injury from running radiator fans (electric fans)!
→ The vehicle fans can continue running or start up when the ignition is switched off.
→ The power supply to the fans must be disconnected before starting work on the radiator or radiator fans.
(Remove fuse → Fuse carrier [9PAAE1 9PAAE7 9PAAF1] → Fuse carrier [9PAAD1 9PAAD7 9PAAJ1]).
Note
z Work on the crank mechanism/pistons must be carried out very carefully and in clean conditions.
Note
z Never remove the drive belt when it is hot.

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Group 15 - Cylinder head, valve drive
DANGER

→ Wear gloves.
Note
z Work on the valve drive must be carried out very carefully and in clean conditions.
WARNING

→ If swallowed, observe the warning information on the containers, contact a doctor if necessary and show
the information on the containers.
WARNING
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WARNING
Oil is combustible!
Note
z Only oils with the appropriate viscosity and approved by Porsche may be used.
z A mixture of different oils is not permitted.
z During an oil change, the old oil must be drained from the engine via the drain plugs provided. Extraction
by suction is not recommended.
z Engine oil and oil filters must be disposed of according to the respective, applicable national laws.
z Seals in the oil circuit must be replaced by new ones following disassembly.
Group 19 - Cooling
ATTENTION

→ If swallowed, observe the warning information on the containers and contact a doctor. If necessary,
show the doctor the warning information on the packaging.
ATTENTION
→ Never open the cooling system when it is hot. Emerging coolant may be very hot and can cause
scalding.
DANGER
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→ The power supply to the fans must be disconnected before starting work on the radiator, radiator fans, or
the belt drive. → Disconnect fuse carrier [9PAAE1 9PAAE7 9PAAF1] → Disconnect fuse carrier [9PAAD1
ATTENTION
Note
z 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.
z Coolant additives, coolants and cleaning agents must be disposed of according to the respective,
Information
DANGER
→ It can be carcinogenic. It represents a serious risk to health when inhaled, touched or swallowed over
longer periods.
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DANGER

→ Do not smoke.
Note
Group 21 - Exhaust system, turbocharging
ATTENTION

Note
correctly.
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DANGER
longer periods.
DANGER

→ Do not smoke.
Note

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Precautionary measures when handling oxygen sensors
ATTENTION
The oxygen sensor may be damaged if handled incorrectly.
z Change in engine emissions.
z Damage to the environment.
z Check Engine lamp may come on.
→ Do not remove the plastic cap on the thread until just prior to fitting the oxygen sensor. The thread
grease must never come into contact with the connector.
→ Protect sensors - before and after fitting - against mechanical shocks.
→ Sensors that were dropped on the floor must not be used owing to the risk of a broken ceramic insulator.
→ The cables must not be twisted or kinked when the sensors are screwed in. Avoid pulling on the cable
and connector.
→ Cleanliness in the housing of the plug connections is of utmost importance for the oxygen sensor to
function properly. Particles of dirt can impair the function of the oxygen sensor. The connector must
therefore be protected against any and all types of soiling.
→ Sensors with a soiled or damaged connector must no longer be used.
→ Protect the cables and plugs when carrying or moving the exhaust system with the sensors already
fitted.
→ High-pressure cleaning equipment must not be used in the area of the sensors and plug connections.
→ Contact and corrosion agents, e.g. Stabilant, must not be applied to the plug contacts of the oxygen
sensors.
ATTENTION
Danger of injury from heavy loads!
→ When working on the exhaust system, it must be appropriately secured against falling or lowering.
ATTENTION
Engine exhaust gas!
→ Only operate the engine with an appropriate exhaust gas extraction system.
ATTENTION
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Note
correctly.
ATTENTION
High-voltage ignition system!
z Danger of electric shocks!
z This can cause cardiac irregularities.
→ When working on the ignition system, the ignition key must be removed from the ignition lock.
→ The ignition system must be disconnected from the power supply before starting work on it.
→ Only connect/disconnect lines or plugs when the ignition is switched off.
→ Only connect measuring devices when the ignition is switched off.
Note
z The ignition system must be disconnected from the power supply before starting work on it.
z Spark plug threads must not be greased.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
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10 01 IN Securing engine on assembly support - as of MY 2003

- Preliminary work
- Securing engine on assembly support
Tools

Preliminary work
Preliminary work
1. Lift the engine with a workshop crane. → 10 Lifting the engine with a workshop crane

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DANGER
Suspended load!

DANGER
lowering.
Note
z Some repair jobs involve suspending the engine on a suitable assembly support.
1. Secure engine support P 9676 on engine → Crankcase on

engine support (shown with lower part of crankcase) . To do this,
them slightly. Secure engine on engine support. To do this,
carefully guide the engine support axle into the take-up bore on
the engine support and secure it.


g g y pp g
as of MY 2003
g p g y y g
WARNUNG
WARNING
AVERTISSEMENT
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g p g y y g

10 01 IN Determining the operating cycle of cylinder 1 - as of

MY 2003
- Information
Information
Determining the operating cycle of cylinder 1 with the "cylinder pipe" dead centre finder.
ATTENTION
z Remove and install the chain tensioner only in overlapping TDC.
z Never twist the camshafts when the chain tensioner is removed.
z Never apply forces across the camshafts in the timing drive mechanism.
z Always counter the sprocket wheels when performing assembly work on them.
Note
An alternative method for determining the overlapping TDC is the "cylinder pipe" (dead centre finder). This
tool is part of the pressure-loss tester WE 1066, Workshop Installation Manual 3.1.4.
For some tasks, it is necessary to be familiar with the position of the piston in the cylinder (ignition TDC,
overlapping TDC).
2. The dead centre finder or "cylinder pipe" consists of glass tubes (inspection glass) with pistons -1- , a
hose and a rubber taper -2- .
3. The rubber taper is pressed onto the spark plug hole. The inspection glass is either held by an assistant
→ Tool setup - dead centre finder or secured vertically using a magnet so that it is clearly visible.
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Undoing spark plugs using spark plug V8 spark plugs

wrench - V6
Tool setup - dead centre finder Dead centre finder - "cylinder pipe"
Top piston
4. If the engine is then turned in the direction of rotation on the crankshaft, the piston in the inspection glass
is pressed upward in the compression cycle → Top piston , and moves back down again immediately
once the TDC has been reached. The piston remains down in the inspection glass in the overlapping
TDC → Bottom piston .
Compression cycle for cylinder 1 (ignition TDC)
Note
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Bottom piston
1. Remove spark plugs for the relevant cylinder 3.→ 287055
Replacing spark plugs
V8 spark plugs
2. Find ignition TDC of cylinder 1. To do this, insert the ignition rod
module of the first cylinder into the corresponding opening in the
valve cover and press in firmly.

3. Twist the crankshaft in the direction of motion until the ignition
rod module comes out again with an audible plop.

out
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Note
z If the crankshaft is then turned through 180°, the piston in
cylinder 1 will be located in the bottom dead centre (BDC). The
emission cycle then follows.
4. Then twist the crankshaft until the fixing bore on the crankshaft
belt pulley is aligned with the bore in the timing case cover. The
engine is now located in the ignition TDC of cylinder 1.

Intake cycle (overlapping TDC)
Note
1. Remove spark plugs for the relevant cylinder 3.→ 287055

V8 spark plugs
2. Find overlapping TDC of cylinder 1. To do this, insert the ignition
rod module of the first cylinder into the corresponding opening in
the valve cover and press in firmly.

3. Twist the crankshaft in the direction of rotation until the ignition
rod module comes out again with an audible plop .

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out

Note
z If the crankshaft is then turned through 180°, the piston in
cylinder 1 will be located in the bottom dead centre (BDC). The
compression cycle then follows.
5. Remove the marking mandrel if necessary and twist the

crankshaft through 360° in the direction of motion. The engine is
now located in the overlapping TDC of cylinder 1.
as of MY 2003
g g q y y g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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g g q y y g

10 01 IN Tightening torques for Cayenne S (M48/00) and

Cayenne Turbo (M48/50) - as of MY 2003
- Information
Information
Information
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V8 engine
Note
z This torque list is organised according to component groups in the same way as service numbering.
z The torque for the coolant pump is provided in Chapter 19.
z The tightening sequences are indicated in the figures in the corresponding chapters, and it is essential to
observe them.
z The most important torques are specified at the end of the respective chapters.
The torques in the table below generally apply to screws which are not specifically listed.
Bolt quality 8.8 Bolt quality 10.9

Thread ftlb. Thread ftlb.
M4 3 M4 4
M5 6 M5 8
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M6 10 M6 13
M8 23 M8 33
M10 45 M10 65
M10 x 1.25 50 M10 x 1.25 70
M12 80 M12 115
M12 x 1.25 90 M12 x 1.25 125
M12 x 1.5 85 M12 x 1.5 120
M14 130 M14 180
M16 200 M16 280
Group 10 - Crankcase, suspension

Thrust block screw fitting M12 x 1.5 x 132 40 (30) + 75° (observe sequence!)
Thrust block screw fitting M10 x 117 22 (16) + 60° (observe sequence!)
Oil spray valve on crankcase M6 x 16 10
Top section of crankcase with bottom section M8 23
of crankcase - cross bolt connection
Bracket for auxiliary units M10 x 45 65
Design cover M5 x 16 5
Engine carrier, cylinder row 1 - 4 M10 x 45 65
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g g q y y g
g g q y y g

Sealing flange on timing case cover M6 10
Belt pulley (vibration balancer) on crankshaft M16 x 1.5 x 77 20, 50, 250, then 90° (always replace
screw!)
Deflection roller, left M10 x 41 35
Deflection roller, right M10 x 85 35
Belt tensioner on bracket M8 x 33 35
Belt tensioner on timing case cover M8 x 100 35
Tensioner roller on belt tensioner M10 35
Connecting rod cap on connecting rod M9 x 56 8 (6), then 40 (30), then 90° (always replace
screws with new ones!)
Servo pump on engine M8 x 35 23
Belt pulley on servo pump M8 x 16 23
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Drive plate to crankshaft M10 x 22 60 (44) + 90° (always replace screws with
new ones!)
Group 15 - Cylinder head, pistons

Timing case cover M6 See Note
Timing case cover M8 x 50 23
Tensioning rail bearing M10/12 x 25 35
Chain tensioner M24 x 1.5 60
Guide rail bearing on camshaft housing M8 x 25 20
Guide rail M8 x 25 20
Deflector rail M8 x 35 32
Chain sprocket on exhaust camshaft M12 x 1.5 x 140 10 (7.5), then 50 (37), then 90°
Camshaft adjuster on inlet camshaft M12 x 1.5 x 140 10 (7.5), then 50 (37), then 135°
Camshaft housing cover (valve cover) M6 x 30 13 (9.5) (observe sequence!)
Camshaft bearing saddles M6 x 35 10 (7.5) (observe sequence!)
Thrust bearing cover on camshaft housing M6 x 35 10
Hall sender on camshaft housing M6 x 16 10
Camshaft housing on cylinder head M8 23
Hydraulic valve for camshaft adjuster M6 x 16 10
Adapter for torque support M10 x 24 20
Cylinder head M12 x 1.5 x 140 30 (22), then 50 (37), then loosen
30 (22), then 30 (22), then 90°
Ground point on camshaft housing M6 x 12 10
Cable duct on timing case cover M6 x 18 10
Cable duct on cylinder head 5 - 8 M6 x 12 10
Note
z The exterior fastening screws must have a quality of 10.9.
z Tighten screws 1 to 4 (M6 / 8.8) to 7.5 ftlb.
z Tighten screws 5 to 6 (M8 / 8.8) to 17 ftlb.

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g g q y y g

Chain sprocket on oil pump M10 x 1 45
Oil pump on crankcase M8 x 50 23
Chain cover on oil pump M5 x 20 6
Tensioning rail bearing for oil pump M8 x 25 20
Short oil extraction pipe M6 x 25 13
Oil extraction pipe M6 x 25 13
Oil drain plug M18 x 1.5 50
Oil return line into oil pan M6 x 20 10
Oil pan on crankcase M6 x 25 10
Oil level sender on oil pan M6 x 25 10
Guide tube for oil dipstick M6 x 16 10
Cover on oil filter bracket M6 x 20 10
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Oil filter bracket on oil pan M8 x 70 23

Spacer sleeve for oil filter bracket M16 x 1.5 2 (1.5) to 5 (3.5)
Oil filter bracket on connection piece M8 x 50 23
Oil/water heat exchanger M6 x 20 10
Oil filter housing S80 x 3 25 (19) (sealing ring oiled)
Oil pressure switch on oil filter bracket M10 x 1 20
Group 19 - Cooling

Belt pulley on coolant pump M8 x 16 23
Water pump on crankcase M6 x 25 10 (7.5) (observe sequence!)
Thermostat housing cover M6 x 25 10 (7.5) (observe sequence!)
Coolant distribution pipe M6 x 25 10
Thermostat housing trough M6 x 16 10
Coolant pipe on crankcase M6 x 16 10
Coolant drain plug on distribution pipe M16 x 1.5 x 6 30
T-piece on generator M6 x 16 10
Supply connection fitting on generator M6 x 16 10
Coolant pipe on thermostat housing M6 x 12 10
Temperature sensor on coolant distribution M14 x 1.5 30
pipe
Thermostat housing
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Water pump

Fuel tank restraining strap M8 x 25 23
Carbon canister and degassing tank M6 10
Filler neck fastening screws M6 10
Connection unit ring fastener 140
Filler neck fastening screws M6 x 20 10
Cover plate under rear seat M6 10

Knock sensor on crankcase M8 x 35 23
Intake distributor M7 x 52 10 (7.5), then 15 (11) (observe sequence!)
Throttle adjuster M6 x 45 8
Fuel distribution pipe on intake distributor M6 x 10 8
T-piece on intake distributor 2,2
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Suction module

Exhaust manifold on cylinder head M8 25, then 33 (observe sequence); replacing
fastening nuts
Oxygen sensors in exhaust manifold M18 x 1.5 45
Oxygen sensor holder on engine M6 x 12 10
Secondary air pump on holder M6 x 50 10
Secondary air pump holder M6 x 50 10
Exhaust system fastening screws M8 x 25 23
Exhaust clamps M10 60 (44) (replace)
Fastening screw for catalytic converter holder M8 23
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Exhaust manifold
Group 27 - Starter, power supply

Generator on crankcase M8 23
B+ wire on generator M8 plastic 18
Heat shield on generator M6 x 12 10
Starter M10 x 45 45 (33) to 53 (39)
B+ wire on starter M8 18
Terminal 50 on starter M6 9

New spark plug M14 x 1.25 30
Spark plug reinstallation M14 x 1.25 25
Ignition coils M6 x 16.5/M5 x 10
9
Knock sensor M8 x 35 23
9PAAE1, 9PAAE7
as of MY 2003
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g g p g

10 01 IN Lifting the engine with a workshop crane - as of MY

2003
- Removing design cover on cylinder bank 5-8
- Lifting the engine
Tools

Tools and materials
Special tools
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Suspending device

-A- Suspending device See Workshop Only this tool
3033 Equipment Manual, is tested and
Chapter 2.2.3 approved by
Porsche. It
guarantees
only vertical
traction of the
transport
eyebolt with
no side or
transverse
forces.
-B- Transport eyebolt See Workshop The transport
9700 Equipment Manual, eyebolt can
Chapter 2.2.2 only bear
vertical
traction with
no side or
transverse
forces. Side
loads (e.g.
from chains
or cables) will
damage the
transport
eyebolt,
which must
then be
replaced. The
transport
eyebolt can
be broken in
extreme
cases.
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1. Remove design cover from cylinder bank 5-8. To do this, loosen

the four fastening screws -arrows- on the design cover.
Fastening screws
2. Lift the cover slightly with both hands at the side pointing towards
the intake system until it is released from its holder.
Unclipping cover
Removing the cover
Lifting the engine
Lifting the engine

The engine must be detached from the transmission. → 343527 Removing and mounting the
transmission [9PAAE7]→ 343527 Removing and mounting the transmission [9PAAE1 9PAAF1 9PAAJ1] or
→ 373527 Removing and mounting the transmission [9PAAE1 9PAAF1 9PAAJ1]→ 373527 Removing and
mounting the transmission [9PAAE7]
DANGER
Suspended load!
g g p g

DANGER
lowering.
Note
z Place a cloth between the secondary air pump bracket and design cover to avoid scratching the cover.
Note
side or transverse force on the transport eyebolt -2- because this
can damage the transport eyebolt.

1. Screw transport eyebolt 9700 hand-tight as far as you can into the opening on cylinder head 5 - 8
g g p g
-arrow- .
2. Insert an M10 screw through the torque support bracket and

secure it with a nut. Then attach the hooks of the suspending
device 3033 on both sides → Engaging torque support bracket
→ Engaging transport eyebolt after screwing it in . Align the
suspending device so that it only pulls the transport eyebolt. To
do this, adjust the spindles of the hooks in such a way that the
suspending device 3033 is suspended as horizontally as
possible above the engine. Move the spindles on the suspending
device into positions 4 and 9. Side forces, e.g. from cables or
chains attached at an angle, will bend and break the
transport eyebolt.
Engaging torque support bracket
Engaging transport eyebolt after

screwing it in
3. Engage spindles into positions 4 and 9 -A and B- of the
suspending device 3033 and tension spindles slightly. Lift the
engine carefully and balance it out. Raise the engine as shown.
→ Lifting the engine
Lifting the engine

Position 4 and 9 -A and B-
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as of MY 2003
C15, C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28,
C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
Suspending device
pp g g y g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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pp g g y g

10 01 IN Supporting the engine on the body - as of MY 2003

- Supporting the engine on the body
Tools

A
Tools and materials
Special tools required

pp g g y g
Overview of safety device

-A- Safety device 10-222 A Only this tool is tested and
approved by Porsche.
-B- Spring hook or chain For lengthening
-C- Transport eyebolt 9700 The transport eyebolt can only
bear vertical traction with no side
or transverse forces. Side loads
(e.g. from chains or cables) will
damage the transport eyebolt,
which must then be replaced. The
transport eyebolt can weaken and
break if this instruction is not
observed.
WARNING
Danger of injury from falling loads!
z Drive line components (engine, transmission, etc.) can fall down.
→ Before starting work, check the body for structural damage (accident, corrosion, etc.). The load capacity
of the wing mounting points must not be restricted.
→ Do not apply excessive force (e.g. a high screw torque) to supported units.
→ Units must not be supported on the body over an extended period of time.
pp g g y g
DANGER
lowering.
Note
side or transverse force on the transport eyebolt -2- because this
can damage the transport eyebolt.
Note
z The engine must be supported on the body for some repair work
on the front axle and engine bearings.
Note
z When setting up the suspending device, make sure not to scratch
or damage adjacent components.

1. Remove design cover of cylinder bank 5-8. Unscrew the four
fastening screws on the design cover.
Design cover of cylinder bank 5-8

pp g g y g
Supporting the design cover
2. To do this, lift the cover slightly with both hands at the side pointing towards the intake system until it is
released from its bracket.

4. Screw transport eyebolt 9700 hand-tight as far as you can into
the opening on cylinder head 5 - 8 → Bore for transport eyebolt .
5. Position the suspending device on the inner side of the wing,

near the radiator tank, and align it. Then tighten the two wing
nuts.

6. Engage the hook of the suspending device in the transport
eyebolt and tighten the wing nut.
Hook in transport eyebolt
Note
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7. Insert an M10 screw through the torque support bracket and

secure it with a nut. Then attach the hook of the safety device
10-222 A. If the hook is too short, lengthen it with a suitable
spring hook or chain → Fastening to torque support bracket .
Tighten wing nut. Pull the engine slightly and make sure that the
force is distributed evenly on both spindles → Complete view of
engine support on body .
Fastening to torque support bracket
Complete view of engine support on body
as of MY 2003
p q p g g g
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WARNING
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p q p g g g

10 01 WM (Special) tools required for repairing the M48/00 and

M48/50 engines - as of MY 2003
Tools

A

p q p g g g
Oil filter spanner special tool 9204
Relay puller special tool 9235

p q p g g g
Locating pin special tool 9595
Spacer special tool 9609/2
Engine support special tool 9676

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Arm bracket special tool 9679
Assembly sleeve special tool 9701

p q p g g g
Bonnet stay special tool 9704
Socket-wrench insert special tool 9714
Chain pipe cutters special tool NR.166

p q p g g g
Drift punch, 1 mm tip, special tool NR.167
Slide hammer kit special tool NR.168
Multiple-tooth socket special tool NR.31

wrench insert M12
56-piece Torx screw tool set special tool NR.49-1

p q p g g g
Circlip pliers for spring band special tool NR.72-1

clamps, Cayenne hose
connections
Flexible screwdriver a/f 7 special tool NR.73-1
Torque angle torque key special tool NR.88
Mechanical angle disc for special tool NR.88-1

torque angle threaded joint
p q p g g g
Tools and materials
(Special) tools required for repairing the M48/00 and M48/50 engines
Tools overview 1
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-1- Tester for cooling system See Workshop Equipment Required for leak test of cooling
Manual 3 system
-2- Socket-wrench insert 9714 See Workshop Equipment Very low height, for turning the engine
Manual 2.2.2
-3- Plug 9264/7 See Workshop Equipment For intake system leak test. Use with
Manual 2.2.2 compressed-air reducer
-4- Torque angle torque key See Workshop Equipment For torque-angle-controlled tightening
NR.88 Manual 2.4 of screws.
-5- Suspending device 3033 See Workshop Equipment Required to transport the engine
Manual 2.2.3
-6- Transport eyebolt 9700 See Workshop Equipment Required to transport the engine or to
Manual 2.2.2 support the body
-7- Safety device 10-222 A See Workshop Equipment For supporting the body
Manual 2.2.3
-8- Spacer 9609/2 See Workshop Equipment Required to fit the radial shaft seal on
Manual 2.2.2 the flywheel
-9- Assembly sleeve 9701 See Workshop Equipment For positioning the sealing lip on the
Manual 2.2.2 camshaft switch-over valve
-10- Camshaft guide 9678 See Workshop Equipment For adjusting the timing
Manual 2.2.2
-11- Locating pin 9595 See Workshop Equipment For fixing the pulley. The piston is
Manual 2.2.2 then in the TDC
-12- Relay puller 9235 See Workshop Equipment For removing the camshaft switch-
Manual 2.2.2 over valve
-13- Arm bracket 9679 See Workshop Equipment Required to loosen the pulley
Manual 2.2.2 fastening.
-14- Bonnet stay 9704 See Workshop Equipment Facilitates the vertical raising of the
Manual 2.2.2 bonnet
-15- Chain pipe cutters NR.166 See Workshop Equipment For disconnecting the exhaust system
Manual 2.4
-16- Flexible screwdriver a/f 7 See Workshop Equipment For loosening and tightening hose
NR.73-1 Manual 2.4 clamps
-17- Antifreeze protection and battery See Workshop Equipment For checking antifreeze contents, acid
acid tester Manual 3 density and windscreen cleaner
-18- Circlip pliers for spring band See Workshop Equipment For opening and loosening spring-
clamps, Cayenne hose Manual 2.4 band clamps
connections NR.72-1
-19- 56-piece Torx screw tool set See Workshop Equipment Required for all assembly work on the
NR.49-1 Manual 2.4 vehicle
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Tools overview 2

-20- Mechanical angle disc for torque angle See Workshop Equipment For torque-angle-
threaded joint NR.88-1 Manual 2.4 controlled tightening
of large screws
(pulley, suspension
subframe)
-21- Spark plug wrench 3122 B See Workshop Equipment For installing and
Manual 2.2.3 removing spark
plugs.
-22- Filling device 9696 See Workshop Equipment For filling the
Manual 2.2.2 cooling system
-23- Porsche System Tester ll 9588 See Workshop Equipment For reading out the
Manual 2.2.2 fault memory or for
activating drive links
-24- Oil filter spanner 9204 See Workshop Equipment For unscrewing and
Manual 2.2.2 tightening the oil
filter
-25- Slide hammer kit NR.168 See Workshop Equipment For pulling out the
p q p g g g

side
-26- Toothed segment 9538/1 See Workshop Equipment For fixing the
Manual 2.2.2 flywheel
-27- Multiple-tooth socket wrench insert M12 See Workshop Equipment For loosening the
NR.31 Manual 2.4 flywheel
-28- Drift punch, 1 mm tip, NR.167 See Workshop Equipment For perforating the
side
-29- Socket-wrench insert with recommended size See Workshop Equipment For removing and
→ 159121 Removing cover for camshaft Manual 2.4 installing the
housing camshaft housing
cover
-30- Plug 9710/3 See Workshop Equipment For checking the
Manual 2.4 exhaust system for
leaks
-31- Engine support 9676 See Workshop Equipment For attaching the
Manual 2.4 engine to the
assembly support.
-32- Engine unit elevating platform WE 1206 See Workshop Equipment
Manual 3.0.13
as of MY 2003
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WARNING
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p g g g

10 04 33 Completing reconditioned engine - as of MY 2003
Completing reconditioned engine
Note
z In order to replace the old, removed engine with a new one, some re-fitting work must be done.
z Starting point for re-fitting work: old engine is secured to assembly support and the new one is in the
transport cradle.
z At higher mileages, components (cooling hoses, clips etc.) must be checked for damage and, if
necessary, replaced.
1. Remove numerous transport plugs for water and vacuum connection pieces of the new engine.
2. Check that all leads and hoses between the engines have been re-fitted and no component has been
forgotten.
3. Depending on the transmission version, the drive plate → 136319 Removing and installing drive plate for
converter [9PAAE7] or flywheel → 136019 Removing and installing flywheel [9PAAE7]→ 136019
Removing and installing flywheel [9PAAE1 9PAAF1 9PAAJ1] must be re-fitted.
as of MY 2003
p g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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p g g

10 10 55 Replacing crankcase - as of MY 2003

- Preliminary work
- Information
- Replacing crankcase
- Subsequent work
Preliminary work
Preliminary work
5. Remove left additional assembly bracket -2- and right engine carrier -8- . There are still two dowel
sleeves (not shown) on the additional assembly bracket.
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5 - Engine carrier
8 - Engine carrier
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"Removing"
"Removing"
13. Remove oil spray jets on turbo engine and cap on naturally aspirated engine. → 101321 Removing oil
spray jets for piston cooling [9PAAF1 9PAAJ1]→ 101321 Removing oil spray jets for piston
cooling [9PAAE1 9PAAE7]
Information
Component overview
p g g
Upper crankcase section assembly
1 - Crankcase, top
2 - Closure cap
3 - Seal
4 - Closure cap
5 - Screw → Tightening torque: 10 (7.5 ftlb.) Nm
6 - Screw plug → Tightening torque: 10 (7.5 ftlb.) Nm
7 - Sealing ring
8 - Sealing ring (not marked in illustration)
10 - Oil spray jets on turbo engine and cap on naturally aspirated engine
11 - Dowel sleeves
Replacing crankcase
p g g
Replacing crankcase
ATTENTION
Risk of damage to cylinder liners on new crankcase if the old pistons are used.
z Piston separation could cause the dimensions of the old piston to be unacceptably large
compared with the new cylinder bore.
z Risk of piston and cylinder-liner scoring if old, worn pistons are used.
→ The piston rings on the pistons must always be replaced when replacing the crankcase.
ATTENTION

Note
The bearing shells of the main and connecting-rod bearings must be replaced on vehicles with high mileage.
1. Remove coolant guide. To do this, remove 10 screws -arrows- .
Coolant pipe
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Component overview for coolant guide
Coolant guide
2 - Temperature sensor
3 - Sealing ring
5 - Fastening screws on distributer pipe → Tightening torque: 10 (7.5 ftlb) Nm
6 - Gasket; replace
7 - Sealing ring; check and replace if necessary
8 - Coolant pipe
2. Remove coolant guide and remove seals. Clean sealing surfaces.
3. Re-fit crankcase. When doing so, watch out for dowel sleeves and studs.
4. Fit coolant guide with new seals.

p g g
Subsequent work
Subsequent work
1. Assemble engine. → Assembling engine
as of MY 2003
gp g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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gp g g

10 18 02 Testing pressure loss from the engine - as of MY 2003

- Preliminary work
- Information
- Testing pressure loss from the engine
- Subsequent work
Preliminary work
Preliminary work
1. Unscrew all spark plugs. → 287055 Replace spark plugs
Spark plugs
2. Position cylinder to be tested to ignition TDC and remove tool.
There are two ways of ascertaining the compression cycle in V8
engines with sealed-off ignition rod modules. → Determining the
operating cycle of cylinder 1
Ignition rod module comes out at TDC
Tools and materials

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-A- Testing hose with spark plug see Workshop Equipment
thread WE1066 pressure loss Manual, Chapter 3.1.4
tester Bosch EFAW 210 A
-B- Test nozzle WE1066 pressure see Workshop Equipment Test nozzle for adjusting display
loss tester Bosch EFAW 210 Manual, Chapter 3.1.4 scale. This must be done before
A every test.
-C- Pressure loss tester WE1066 see Workshop Equipment
pressure loss tester Bosch Manual, Chapter 3.1.4
EFAW 210 A
Information
Test evaluation
z The test does not show any meaningful result on a new engine (i.e. one that hasn't been run in).
z A difference in pressure loss between the individual cylinders of approx. 5% is not significant.
z 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.
z 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 Oil filler neck, positive crankcase
line ventilation
Cylinder head gasket, cylinder Coolant expansion tank
head
Exhaust valve Exhaust system
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Inlet valve Intake system
ATTENTION
Danger of damage or injury if pressure loss tester is operated incorrectly
→ Ensure that operational steps and tips from the tool instruction manual for the Bosch tester are observed
at all times.
WARNING
Danger of injury!
z The crankshaft can turn because of the pressure in the cylinder.
→ The piston must be located accurately in the upper reversing point.

→ Do not touch any belt drive components during the test.
→ Do not insert any tool on the belt pulley of the crankshaft.
Note
z The check for loss of pressure can be used to assess the mechanical condition of a combustion engine.
z 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.
z The worn components (e.g. piston rings) can be identified by the compressed air that is escaping.
1. Screw in the test hose by hand into the spark plug thread and
tighten it by hand.
2. Connect the pressure loss tester to the compressed air system.
Test hose
3. Adjust the scale. To do this, insert the test nozzle at the front into the device.
4. 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.
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Adjusting the scale
Adjusting wheel
5. Remove test hose and check that the pointer falls back. Connect
the test hose. The value that is displayed should not be greater
than 30%. If the loss in pressure is greater, it can be assumed
that the engine needs an overhaul.
6. Interrupt the compressed air supply and unscrew the test hose.
7. Check the next cylinder by turning the crankshaft through another

90° and check the next cylinder in the firing order following the
instructions provided.
Firing order: 1 - 3 - 7 - 2 - 6 - 5 - 4 - 8
Check for loss of pressure
Subsequent work
Subsequent work
1. Remove the test hose once the test is complete and install the
spark plugs. For tightening torques see → 287055 Replacing
spark plugs
Spark plugs
as of MY 2003
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10 19 02 Checking compression of cylinders - as of MY 2003

- Preliminary work
- Information
- Testing engine compression
- Subsequent work
Tools

Preliminary work
Preliminary work
1. Open the bonnet.
2. Open lid of central electrics box. To do this, loosen the four

fastening screws.
WARNING
Risk of electric shocks from high-voltage ignition system and
danger of damage to ignition rod modules!
z Connected ignition rod modules can be damaged.
→ Always remove the ignition rod module fuse.

→ Always disconnect ignition rod module electrical connections.
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ATTENTION
Risk of damage to components that affect the exhaust system!
z Unburnt injected fuel enters the exhaust system.
→ Prevent the fuel from injecting by removing the fuse.
3. Remove the fuses -7- for the ignition rod modules -8- and injection system.
Fuses for ignition rod modules and fuel injectors
4. Remove spark plugs.
Spark plugs
Tools and materials
Tools and materials

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Tools for testing pressure loss

-A- Spark plug wrench 3122 B See Workshop Equipment
-B- Compression tester WE1065 See Workshop Equipment Tester range: between 3.5 and 17
Moto-Meter compression Manual, Chapter 3.1.4 bar
tester Number of cylinders: max. 8
-C- Flexible extension WE1065 See Workshop Equipment
Moto-Meter compression Manual, Chapter 3.1.4
tester
-D- Extension with spark plug thread See Workshop Equipment
WE1065 Moto-Meter Manual, Chapter 3.1.4
compression tester
Information
Evaluating test results and prerequisites for testing
Note
z A test document is created when a compression test is performed.
z In order to prevent misuse, vehicle ID, date and current mileage must be entered.
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Test sheet
No. Designation Instructions

-A- Vehicle ID This is used to assign the test diagram to the vehicle that
is being tested. The engine number or the chassis
number can be entered here instead of the vehicle ID.
-B- Date Provides information about when the test was
performed.
-C- Mileage Provides information about when the test was
performed.
-I- Compression pressure in the cylinder that The pressure is measured in bars.
is tested 1 bar = 14.5 psi.
There are various diagram charts. The charts for petrol
engines are used.
-II- Difference in pressure between the The pressure difference between two cylinders must not
individual cylinders be greater than 1.5 bars.
z The throttle must remain open during the test.

z The vehicle voltage must remain more or less constant during the test (connect a charger).
z The vehicle voltage must not drop below 12 V.
z The fuses for the injection system and the ignition system must be removed during the test.
z The engine must be at operating temperature.
Note
The compression test can only provide an indication as to whether the tested cylinder is working or not
working properly. The cause of any loss can be further isolated by a pressure loss test.→ 101802 Testing
pressure loss
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1. Press pressure tester onto the relevant cylinder.
Note
z Once the starter is activated, it switches on the engine for approx.
seven seconds.
z This process should not be interrupted.
z The vehicle voltage must not drop below 12 V during the test.
z The throttle must always remain in the same position throughout

Pressure tester
the test. A mechanical pressing-on tool is not permitted.
z The accelerator pedal must be fully depressed during the test.
2. Have the starter actuated by a second person. Testing of this cylinder is complete when the needle of
the test device ceases to rise. Keep the accelerator pedal fully depressed.
3. Deflate the pressure on the tester.
4. Move the scale on to another cylinder. To do this, pull the pin

once under the handle on the back → Moving the test device on
by one cylinder .
5. Then check the next cylinder according to number sequence (not

according to firing order).
Moving the test device on by one

cylinder
Subsequent work
Subsequent work
1. Fit spark plugs. For tightening torques see → 287055 Replacing

spark plugs – section on "Installing".
2. Fit the ignition rod module fuses and the injection system.
Spark plugs
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Fuses for ignition rod modules and injection valves
3. Fit lid of central electrics box.
as of MY 2003
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10 30 19 Removing and installing engine carrier - as of MY 2003

- Preliminary work
- Information
- Removing engine carrier
- Installing engine carrier
- Subsequent work
Preliminary work
Preliminary work
carrier - chapter on "Removing" [9PAAJ1]→ 400619 Removing and installing front-axle carrier - chapter
on "Removing" [9PAAE1 9PAAE7 9PAAF1]
Information
Component overview
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Component overview
1- Fastening nut, M12 X 1.5

2- Bracket for auxiliary units
4- Align left-hand hydraulic mount with the aid of the engine carrier -5- then tighten the fastening nuts -1- .
5- Engine carrier
6- Fastening screw
7- Align right-hand hydraulic mount with the aid of the engine carrier -5- then tighten the fastening nuts -1- .
8- Engine carrier, right

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WARNING
Danger of injury!
lowering.
Note
z This task can only be performed if the engine has been removed or suspended on the body.
Note
z Do not undo the engine mounts on the engine.
z If the engine mounts have been undone on the engine, they must be aligned using the engine carrier.
→ 103519 Removing and installing engine mount
Engine carrier
1. Undo the two fastening screws → Fastening screws for engine mounting to the left and right on the
hydraulic mounts.
2. Undo the two fastening screws from the engine carrier to the body and remove the engine carrier.

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1. Install engine carrier. To do this, first position the fastening

screws (M10 x 45) on the hydraulic mounts and tighten them.
→ 103519 Removing and installing engine mounting - "Installing"
chapter
Subsequent work
Subsequent work
1. Screw in new fastening screws for securing the engine carrier to the body. → Initial tightening: 89 ftlb.
→ Torque angle: 180 °
as of MY 2003
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10 35 19 Removing and installing engine mounting - as of MY

2003
- Preliminary work
- Information
- Removing engine mounting
- Installing engine mounting
- Subsequent work
Preliminary work
Preliminary work
carrier - chapter on "Removing" [9PAAJ1]→ 400619 Removing and installing front-axle carrier - chapter
on "Removing" [9PAAE1 9PAAE7 9PAAF1]
Information
Component overview
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Component overview
1- Fastening nut, M12 X 1.5

2- Bracket for auxiliary units
4- Align left-hand hydraulic mount with the aid of the engine carrier -5- then tighten the fastening nuts -1- .
5- Engine carrier
6- Fastening screw
7- Align right-hand hydraulic mount with the aid of the engine carrier -5- then tighten the fastening nuts -1- .
8- Engine carrier, right

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WARNING
Danger of injury!
lowering.
Note
z This task can only be performed in the Cayenne S (M48/00) if the engine has been removed or
suspended on the body. This description covers suspension on the body.
z The engine must be removed on the Cayenne Turbo (M48/50) → 100119 Removing and installing V8 4.5
l engine - section on "Removing". The turbochargers are removed next. → 213021 Removing
turbocharger - section on "Removing" [9PAAF1 9PAAJ1]→ 213021 21 Removing turbocharger - section
on "Removing" [9PAAE1 9PAAE7].
1. Undo the two fastening screws -Arrows- to the left and right on
the hydraulic mounts.
Hydraulic mount
2. Undo the two fastening screws from the engine carrier to the
body and remove the engine carrier. -Centre arrow-
3. Undo engine mounts. To do this, undo the fastening nuts on the

support arms and remove the engine mounts.
Engine carrier
Installing engine mounting

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Installing engine mounts
Note
z The engine mounts must be aligned using the engine carrier.
z The engine mounts differ (left/right) and must not be interchanged.
1. Position engine mounts on the support arm. When doing so, note the positioning pin on the mount. It
must engage in the recess on the support arm.
2. Position new fastening nuts and screw them on so that the positioning pin cannot pop out. Do not tighten
the fastening nuts.
3. Fit the engine carrier → Fastening screws for hydraulic mount .

Position the fastening screws (M10 x 45) for the hydraulic mounts
4. Tighten engine mounts on the engine. Tighten the fastening nuts.
→ Tightening torque : 56 ftlb.
Fastening screws for hydraulic mount
Subsequent work
Subsequent work
1. Screw in new fastening screws for securing the engine carrier to the body. → Initial tightening: 89 ftlb.
→ Torque angle: 180 °
as of MY 2003
g g g g g
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10 80 19 Removing and installing engine guard - as of MY 2003

- Information
- Removing engine guard
- Installing engine guard
Information
Overview
Engine cover, complete

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Engine cover screws
1- Engine guard, front

2- Engine guard
3- Fastening screw M6
4- Transverse strut
5- Fastening nut M6
-
1. Remove front engine guard. To do this, loosen the screws -1- at

the front and side. Then loosen the rear -2- and front screws -3- .
Front screws
2. Remove rear engine guard. To do this, loosen the fastening screws on the transmission cross member
-1- and the screws on the traverse strut -2- .

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Rear screws
1. Install the rear engine guard. To do this, screw in the front
fastening screws -2- and rear fastening screws -1- .
2. Tighten front fastening screws -3- and rear fastening screws -2-
and -1- → Tightening torque: 6.5 ftlb. .
as of MY 2003
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10 83 19 Removing and installing design cover. - as of MY 2003

- Information
Information
Overview
Overview of design cover
Note
z A special paint is applied to the covers for reasons of appearance.
z When the engine is washed, a minimum clearance of 50 cm must be maintained between the cleaning
apparatus lance and the covers.
z The covers are sensitive to scratching.
z Small scratches on the paintwork can be touched up with a special touch-up applicator.
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Individual parts of design cover

3 - Sleeve
4 - Rubber sleeve
5 - M6 screw with M5 internal thread; for securing ignition coil
6 - Rubber ball socket
9 - Throttle body cover

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Removing throttle body cover
Throttle body cover

Removing design cover of cylinder row 1 - 4
Note
1. Remove engine compartment cover on the right and rear. → 700219 Removing and installing front cover
(engine compartment)
2. Detach the torque support. To do this, unscrew the fastening

screw on the torque support bracket and pull it out.

Swivelling the torque support

4. Detach the secondary air pump from cylinder row 1-4. To do this, unscrew the 3 fastening screws, pull
the pump out of the support and lay it aside.
5. Unscrew the four fastening screws on the design cover (picture shows side 5 - 8).
6. Remove design cover from cylinder bank 1 - 4. Lift the cover slightly with both hands on the edge
pointing towards the intake system until it snaps out of the fastening points.
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Fastening screws of design cover Secondary air pump
Lifting the design cover

7. Lift the cover at the front edge and slide the ignition coil cover of
the second cylinder out of the torque support bracket. Pull out
cover to the front.

Note
1. Unscrew the four fastening screws on the design cover.
Fastening screws on design cover

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Pulling off the design cover

Note
1. Slide the design cover of cylinder bank 1 - 4 under the secondary

air pump bracket as shown in the illustration and then slide the
cover of the second ignition coil through underneath the torque
support bracket.
Sliding on the design cover

3.5 ftlb.
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Fastening screws on the ignition coils Pressing the design cover on

4. Reinstall secondary air pump. Tighten the three fastening
screws. → 266519 Removing and installing secondary air pump -
Secondary air pump

5. Reinstall torque support. Fit the fastening screw (M10 x 85) with
a new fastening nut on the bracket. → Tightening torque: 44
ftlb.
6. Screw in the fastening screw securing the torque support to the

body (M10 x 70). → Tightening torque: 44 ftlb.
7. Install engine compartment cover on the right and rear. → 700219
Torque support on bracket

Note
1. Slide the design cover under the secondary air pump as

illustrated.
Design cover under secondary air

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pump
Pressing the design cover on

3. Screw in the four fastening screws at the ignition coils →

Fastening screws securing design

cover over ignition coils
Installing throttle body cover
Throttle body cover
as of MY 2003
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13 10 19 Removing and installing pistons - as of MY 2003

- Information
- Preliminary work
- Removing pistons
- Installing pistons
- Subsequent work
Tools

Piston ring restraining strap commercially NR.57

for 944 - S2 and Boxster available tool
and 911 Carrera (996)
Information
Component overview of piston

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Component overview
1- Three piston rings (lowest is the oil scraper ring)

2- Piston (arrow on piston crown points in direction of travel)
3- Two piston-pin circlips
4- Piston pin
5- Connecting rod and connecting-rod bearing cap
6- Two connecting rod bolts
7- Two bearing shells

Service are only obtainable in one dimensional group 'X' and in two
weight tolerances '+' and '-'. The weight tolerances are listed in the
table.

z Marking + or - appears as a large coloured stamp in the centre
of the piston crown and as a small engraved feature -2- .
Note
Piston marking
Pistons are installed as standard in three dimensional groups: I, X and
II.
These data are all engraved on the piston crown. To uniquely identify a piston, it must be carefully cleaned
(brass brush, ultrasonic bath). If, in spite of very thorough cleaning, the data are unreadable, the piston must
be weighed together with piston rings, piston pin and the two circlips. Thorough cleaning (ultrasonic bath) is
also absolutely essential to the weighing operation as otherwise the measurement result will be false.
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- 546.6 - 540.6
+ 546.6 - 552.6
Preliminary work
Preliminary work for removing pistons
3. Remove chain case cover. → 153121 21 Removing chain case cover - section on "Removing"
4. Remove oil pan → 175021 Oil pan removed - section on "Removing"
5. Remove lower section of crankcase. → Removing and installing crankshaft
Removing pistons
Removing pistons
1. Secure crankshaft with holding bridges 9677 at bearings 3 and

5 to prevent it from falling out.
Note
z Connecting rod bolts and bearing shells must always be
replaced.
z Turn the crankshaft so that the crank pin of the piston to be

removed stands vertically upwards.
2. Remove one piston after another, mark them and place them on
Holding bridges at bearings 3 and 5
a clean tray. The arrow on the bottom of the piston points in the
3. Remove the piston of cylinder 1 by unscrewing the connecting-rod bolts.
4. Remove the connecting-rod bearing cap and place it on a clean surface.
5. Press the piston downwards out of the cylinder, for example with the handle of a hammer, and receive it
with the other hand.
6. 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.
7. Mark piston with No. 1 (with a felt-tip, not with a prick punch or other sharp-edged tool).
8. Remove the remaining pistons using the same procedure.

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Matching numbers and installation

Arrow A
Note
connecting-rod bearing cap as the cracked connecting rods only
fit in one position.
z 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.
z The connecting-rod bearing cap and the big end of the

connecting-rod bearing have the same connecting-rod numbers. Retaining lugs of connecting-rod
bearings
Note
connecting-rod bearing cap as the cracked connecting rods only
fit in one position.
z 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.
z The connecting-rod bearing cap and the big end of the

connecting-rod bearing have the same connecting-rod numbers. View of connecting rod numbers
Installing pistons
Installing pistons
Note
z The identification of the connecting-rod bearings is located on the connecting-rod journal of the
crankshaft → Removing and installing crankshaft.
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Note
z The pistons must already be pre-fitted (pistons, piston rings, connecting rods and fastening material)
before performing the next step. → 131037 Disassembling and assembling pistons - chapter on
"assembling"
z Install with the number on the connecting rod -A- to the exhaust side.
z When installing the piston in the crankcase, the direction of travel arrow on the piston crown must point in
the direction of travel.
z The code on the connecting-rod big end and connecting-rod

bearing cap must be on the same side -A- .

z The direction of travel arrow is on the same side as the
connecting rod code -A- as is evident on the piston shown. This
can be installed as standard on one cylinder bank side as shown,
and on the other cylinder bank side, the connecting rod code is
on the opposite side. However, when the pistons are fitted at a
later time, it is absolutely necessary that they be aligned in the
direction of travel (see the following point). Install with the number
on the connecting rod -A- to the exhaust side.
Allocation
z The direction of travel arrow must be pointing forwards when
installed (in direction of travel).
1. Turn the engine in the engine support so that the crankshaft lies
at the bottom.
Installing pistons
2. Install piston. To do this, turn the crankshaft with a wrench (a/f 27) until the corresponding crank pin is
pointing vertically downwards.
3. Cylinder, piston and Piston ring restraining strap for 944 - S2 and Boxster and 911 Carrera (996)
NR.57 leicht einölen.
4. Align piston-ring set (staggered by 120°) and compress piston rings using piston ring restraining strap
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Compressing piston rings Turning crankshaft
for 944 - S2 and Boxster and 911 Carrera (996) NR.57. Ensure all piston rings are correctly pre-loaded
by the special tool -see figure- .
5. Position piston on the cylinder from above and push it into the
cylinder, using the handle of a hammer if necessary. When doing
so, make sure that the direction of travel arrow is pointing
forwards -see arrow (illustration shows cylinder 1)- .
Installing pistons
6. Push piston downwards until the connecting-rod bearing sits on
the crank pin. If necessary, use the handle of a hammer to push
it -see figure- .
7. Oil connecting-rod bearing shells and crank pins.
Note
z The piston connecting rods are cracked and only fit in one
position (in conjunction with the matching numbers).
Pressing in piston
z Install con-rod code towards exhaust side -A- .

8. Then fit connecting-rod bearing cap with bearing shell (twist locks facing each other) → Retaining lugs for
connecting-rod bearings -B and C- . The connecting rod numbers must face each other → View of
matching numbers -A- . Screw in con-rod bolts by hand.
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Retaining lugs for connecting-rod

bearings -B and C-
9. Fit the opposite piston (cylinders 1 and 4).
10. Fit other pistons using the procedure described above.
11. Turn crankcase on the assembly support until the crankshaft is

on top.
12. Tighten con-rod bolts that have been replaced. Turn the
crankshaft until the corresponding crank pin is pointing vertically
upwards. Tighten bolts with a multiple-tooth socket → Initial
tightening 1: 6 ftlb. → Initial tightening 2: 15 ftlb. → Initial
tightening 3: 30 ftlb. → Torque angle (final tightening): 90 ° .
View of matching numbers -A-
13. Once all pistons have been correctly fitted and secured, turn the
crankshaft in a clockwise direction to check it, using a ring
wrench (a/f 27). When doing so, watch out for stiffness and
irregularities. If the crankshaft cannot be turned or if it is very stiff,
check whether the installation direction (arrow) of the pistons, the
pistons and the cylinders (markings) and the connecting-rod cap
and connecting-rod big end all match.
14. Remove holding bridges 9677 .
Subsequent work
1. Install lower section of crankcase. → Removing and installing crankshaft
2. Install chain case cover. → 153123 23 Installing chain case cover - section on "Installing"
3. Install oil pan → 175023 Oil pan installed (including seal) - section on "Installing"
4. Install cylinder head. → 157023 Installing cylinder head - section on "Installing"
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as of MY 2003
g gp g
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13 10 37 Disassembling and assembling pistons - as of MY 2003

- Preliminary work
- Information
- Disassembling pistons
- Assembling pistons
- Subsequent work
Tools

piston ring restraining strap commercially 57
available tool
Piston ring pliers commercially 58

available tool
Assembly aid special tool 9500/3

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Plunger special tool 9500/8
Assembly sleeve special tool 9500/9
Retaining device special tool 9597
piston ring pliers Gr. 1 commercially NR.58

available tool
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Preliminary work
Removing pistons, preliminary work

1. Remove piston → 131019 Removing and installing pistons - chapter on "removing".
Tools and materials
Piston disassembly
Tools

-A- Retaining device 9597 → "See Workshop As an assembly aid for fixing
Equipment Manual, the piston
Chapter 2.2.2"
-B- Assembly aid 9500/3 → "See Workshop For pre-fitting the piston-pin
Equipment Manual, circlip in the assembly
Chapter 2.2.2" sleeve
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-C- Assembly sleeve → "See Workshop For fitting the piston pin
9500/9 Equipment Manual, circlip in the correct position
Chapter 2.2.2"
-D- Plunger 9500/8 → "See Workshop For fitting the piston pin and
Equipment Manual, piston pin circlip
Chapter 2.2.2"
-E- Piston ring pliers 58 → "See Workshop
Equipment Manual,
Chapter 2.4"
Information
Piston disassembly - component overview
Component overview

1 Two compression rings 3 With piston ring pliers 58 With piston ring pliers 58
above, one oil scraper ring
below
2 Pistons 1 Push out from crankshaft Oil and install in crankcase
together with connecting rod with piston ring restraining
strap 57
3 Piston-pin circlip 2 Lever out with a small Install in correct position with
screwdriver special tool (see below)
4 Piston pins 1 Drive out using plunger Drive in using plunger 9500/8
9500/8
5 Connecting rod big end and 1 Matching numbers face one
connecting-rod bearing another
cover
6 Connecting-rod bolts M9 x 2 Replace Replace, apply light coat of oil,
56 tighten in accordance with
tightening specification
7 Connecting-rod bearing 2 Replace Install retaining lug to retaining
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shells lug; retaining lugs must be

inserted in corresponding
grooves in connecting-rod big
end and connecting-rod cover

Service are only obtainable in one dimensional group 'X' and in two
weight tolerances '+' and '-'. The weight tolerances are listed in the
table.

z Marking + or - appears as a large coloured stamp in the centre
of the piston crown and as a small engraved feature -2- .
Note
Piston marking
Pistons are installed as standard in three dimensional groups: I, X and
II.
These data are all engraved on the piston crown. To uniquely identify a piston, it must be carefully cleaned
(brass brush, ultrasonic bath). If, in spite of very thorough cleaning, the data are unreadable, the piston must
be weighed together with piston rings, piston pin and the two circlips. Thorough cleaning (ultrasonic bath) is
also absolutely essential to the weighing operation as otherwise the measurement result will be false.

- 546.6 - 540.6
+ 546.6 - 552.6
Note
z If reusing a piston, do not remove combustion residues on the piston crown are mechanically!
Note
z When disassembling the piston/connecting rod unit, note or mark the position, relationship to cylinder
and installation position using a waterproof felt tip pen.
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1. Fix piston on retaining device 9597 → Piston on retaining device .
2. Remove both piston-pin circlips using a small screwdriver. To do

this, guide the screwdriver through the small cutout and carefully
lever out the piston-pin circlip → Levering out piston-pin circlips
with a small screwdriver .
Levering out piston-pin circlips with a

small screwdriver
3. Insert piston in retaining device 9597 (leave space below for the
piston pin) and drive out piston pin using plunger 9500/8
→ Piston pin with plunger .
4. Remove connecting rods from the pistons and place to one side.
ATTENTION
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.
Piston pin with plunger
5. Remove piston rings. Place the piston on a clean surface and look for the gaps in the piston rings.
Note
z Compression rings and oil scraper rings are installed and
removed differently.
6. Remove the piston rings starting from 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!
Piston ring pliers on piston ring
7. Relieve the piston ring pliers and remove the piston ring from the
pliers.
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8. Remove the three-piece oil scraper ring as follows: First, remove the upper and lower rings by hand by
carefully forcing them away from the piston. Then remove the oil scraper spring carefully in the same
way.
Assembling pistons
Assembling pistons
1. First assemble the three-piece oil scraper ring. To do this, carefully stretch the oil scraper spring by hand
at its gap to a point where this can be positioned over the piston in ring groove 3. Carefully force apart a
ring in the oil scraper ring by hand and fit it into the third piston ring groove below the oil scraper spring.
Fit the second ring in the same way over the oil scraper spring.
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.
Note
z The two compression rings have different strengths and can only
be installed in the appropriate groove.
z 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 designation of the piston rings is pointing in the
direction of the piston crown -A- . Spread the piston ring until it
just fits over the piston. Piston ring designation
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. Pre-fit piston-pin circlip in assembly sleeve. To do this, insert the

ring in assembly sleeve 9500/9 so that the ring gap is at 6
o'clock or alternatively 11 o'clock (piston crown on top), the
assembly groove of the assembly sleeve pointing towards the
piston crown → Ring gap indicating 11 o'clock .
Ring gap indicating 11 o'clock

7. Position the assembly sleeve on an even surface with the groove facing downwards and use the
assembly aid 9500/3 to drive down the circlip into the installation position so that the circlip is under
tension and sitting in the correct position -arrow- .
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Ring gap here at 6 o'clock Assembly aid in circlip
8. Check installation position of piston-pin circlip in the assembly sleeve → Ring gap here at 6 o'clock .
9. Position the assembly sleeve on the piston so that the assembly

groove of the assembly sleeve points to the piston crown
→ Assembly sleeve on piston .
10. Insert plunger 9500/8 through the assembly sleeve and fit the
piston-pin circlip by tapping it with a hammer into the groove of
the piston pin eye.
Assembly sleeve on piston

11. Fix piston on retaining device 9597 with fitted piston-pin circlip
facing downwards → Piston on retaining device .

12. Gap of circlip must point downwards away from the piston crown
(analogous to 6 o'clock, alternatively 11 o'clock). Place piston pin
and connecting rod in installation position. Align connecting rod
with matching number so that the matching numbers point to the
exhaust side -A- . Illustration shows direction of travel in this case
and connecting rod code on one side.
Allocation
13. Fit oiled piston pin through the piston and connecting-rod eye as far as the circlip. Using a plastic
hammer, tap gently on plunger 9500/8, driving the piston pin into the pre-fitted piston-pin circlip -arrow- .
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Align ring gap (here indicating 11 Plunger on piston pin

o'clock)
14. Fit the second piston-pin circlip using the same procedure. Align gap of circlip so that it points
downwards away from the piston crown (analogous to 6 o'clock, alternatively 11 o'clock) -arrow- .
15. Check connecting rod and piston for smooth operation.
Note
z The connecting rods are cracked and together with the matching
numbers cannot be mixed up!
z Connecting rod bolts and bearing shells must always be

replaced.
z The identification of the connecting-rod bearings is located on the

connecting-rod journal of the crankshaft → Removing and
installing crankshaft.
Position of bearing shells
16. Fit connecting-rod bearing shells in connecting-rod big end and connecting-rod bearing cap. 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 on the same side (when installed they point to the exhaust
side). Tighten the connecting rod bolts by hand and position the complete connecting rod ready for
assembly.
Surface with connecting rod number

marking (exhaust side)
Subsequent work

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1. Install piston → 131019 Removing and installing pistons - "Installing" section.
as of MY 2003
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WARNING
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g g g

13 48 19 Removing and installing crankshaft - as of MY 2003

- Preliminary work
- Removing crankshaft
- Installing crankshaft
- Subsequent work
Tools

Preliminary work
Preliminary work

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3. Remove oil pan. → 175019 21 Removing and installing oil pan - section on "Removing"
4. Remove oil pump. → 172019 Removing and installing oil pump - section on "Removing"
Removing crankshaft
Removing crankshaft
Overview, crankshaft and bearings
1 - Crankshaft
2 - Straight pin
3 - Feather key
4 - Thrust washer, insert with grease no. 000.043.204.17
5 - Upper crankshaft bearing shell, lubricate with motor oil
6 - Lower crankshaft bearing shell, lubricate with motor oil
7 - Radial shaft sealing ring, crankshaft
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H - Main bearing, location of colour dots

P - Connecting rod bearing, location of colour dots
Note
z The colour codes of the crankshaft bearings and bearing shells must match!
z To ensure that the bearings and bearing shells are of a matching class during installation, the bearing
numbers are to be written on the backs of the bearings during removal of the main bearing shells with a
waterproof felt-tipped pen, due to that fact that the ink markings wear off of the crankshaft journals as
well as the main bearing shells.
z New bearing shells are always to be installed when the engine is repaired.
Crankshaft
Main bearing shells Red yellow Blue
+ connecting-rod
bearing shells Red X
yellow X
Blue X
1. Remove chain drive wheel from crankshaft. Unscrew fastening

screw on belt pulley. Pull off chain sprocket with drive chain on oil
pump; do not lose feather key when doing so.
Belt pulley fastening screw
Chain sprocket and feather key

2. Unscrew the four hexagon socket head bolts on the clutch side (M8). → Clutch side
3. Unscrew the outer cross bolt connection (M8 x 70) in the opposite order to the sequence shown.
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Clutch side
External cross bolt connection
4. The figures below indicate the tightening sequence. The fastening screws are undone in the opposite
order to the tightening sequence shown.. → Outer bearing seat
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Outer bearing seat
5. Undo inner bearing seat in the opposite order to the tightening sequence shown. → Inner bearing seat
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Inner bearing seat
6. Remove lower part of crankcase.
7. Remove any remaining sealant and the old sealing ring in the upper part of the crankcase.
8. Fit holding bridges 9677 on the crankshaft -arrows- .

9. Remove pistons. → 131019 Removing and installing pistons -
"Removing" chapter Rotate engine block in engine stand through
180° so that the crankshaft can be removed.
ATTENTION
Danger of crushing!
→ Hold the very outside of the crankshaft. Holding bridges

→ Wear gloves.
10. Undo holding bridges 9677 and carefully remove crankshaft upwards.
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Note
z If no clear markings can be seen after thorough cleaning of the crankshaft and the bearings, the
crankshaft and the corresponding bearing shells are to be replaced.
Correct position of the twist locks
Note
classes are indicated by the colour marking on the outside
-refer to Figure- . The colour marking must match the
corresponding colour dot on the crankshaft. The colours are red,
yellow and blue and must match between the bearings and the
crankshaft.
z To ensure that the bearings and bearing shells are of a matching

class during installation, the bearing numbers are to be written on
the backs of the bearings during removal of the main bearing Colour marking on the outside
shells with a waterproof felt-tipped pen, due to that fact that the
ink markings wear off of the crankshaft journals as well as the main bearing shells.
z New connecting rod bearings main bearing shells are always to be installed when the motor is repaired.
1. Insert the bearing shells with the lubricating groove into the upper part of the crankcase. Make sure the
twist locks are positioned correctly -see figure- . Then lightly oil the bearing locations.
2. Insert the sickle-shaped washer (make sure of axial bearing

play). To do this, insert the two Insert 3 sickle-shaped washers
on the left and 2 on the right (thrust washers) with some grease
(000.043.204.17) -see figure- , to prevent the sickle-shaped
washers from falling off. Each of the lubricating grooves of the
sickle-shaped washers must face outwards.
Sickle-shaped washers (thrust

washers)
ATTENTION
Danger of crushing!
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→ Wear gloves.
3. Insert crankshaft. The connection flange must point towards the

back of the engine. Then secure the crankshaft from falling down
using holding bridges 9677. Fix the holding bridges at bearing
locations 3 and 5. Screw the fastening screw from the belt pulley
at the front into the crankshaft and tighten slightly so that the
crankshaft can be turned -see figure- .

5. Install pistons. → 131019 Removing and installing pistons -
"Installing" chapter
6. Turn crankcase again through 180° on the assembly support.
Degrease parting surfaces between top and bottom section of crankcase. A totally grease-free product
(e.g. brake cleaner) must be used for this. Then insert a new O-ring at the front of the parting surface -3-
.
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Crankcase bottom section

4- Application of sealant; Drei Bond Silikon 2210 liquid sealant must be applied and the screws screwed in
within five minutes and without interruption
10 - Dowel sleeve
8. Screw the two thin centring pins 9321 into the outer fastening bores on the upper part of the crankcase
-see illustration (shown without crankshaft)- .
9. Insert bearing shells into lower part of crankcase and lightly oil them. When doing so, ensure that the
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Twist locks (retaining lugs)
Centring pins
twist locks (retaining lugs) fit into the appropriate recesses in the lower part of the crankcase.
Note
z The liquid sealant must be applied and the screws screwed in within five minutes at most and without
interruption.
z The required tool (torque wrench for 15 Nm (11 ftlb.) to 40 Nm (30 ftlb.); torque angle wrench; socket
wrench E12, E14 and E14) must be ready for use.
z The threads and head contact surface of the bearing seat screws (M10 x 1.5 and M12 x 1.5) must be
oiled.
10. Apply the Drei Bond Silikon 2210 liquid sealant to the lower part of the crankcase as illustrated. The
outer surfaces marked -A- must be cleaned after fitting.
Sealant application
destroyed.
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Note
z Unscrew the centring pins again while securing the lower part of the crankcase.
12. The figures below indicate the tightening sequence. The screws are tightened in four steps. It is essential
that the tightening sequence is observed here. The screws must be tightened within five minutes.
Inner bearing seat
Tightening sequence, inner bearing seat
Outer bearing seat

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Tightening sequence, outer bearing seat
13. Then screw on the outer cross bolt connection (M8 x 70) in the sequence shown → Tightening torque:
17 ftlb. .
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Tightening sequence, outer cross bolt connection
14. Tighten the four hexagon socket bolts on the clutch side (M8 x
35) → Tightening torque: 17 ftlb. .
Clutch side
15. Fit chain drive sprocket on the crankshaft. Unscrew fastening screw on belt pulley. Check that the
feather keys are fitted correctly and push on the chain sprocket with the oil pump drive chain → Chain
drive wheel . The double-tooth row must be facing forwards.
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Subsequent work
Chain drive wheel

Subsequent work
2. Install oil pan. → 175019 23 Removing and installing oil pan - section on "Installing"
3. Install cylinder head. → 157023 Installing cylinder head - section on "installing"
as of MY 2003
g g g g y g
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WARNING
AVERTISSEMENT
ATTENZIONE
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g g g g y g

13 59 19 Removing and installing crankshaft sealing ring on

flywheel side - as of MY 2003
- Preliminary work
- Removing crankshaft sealing ring on flywheel side
- Installing crankshaft sealing ring on flywheel side
- Subsequent work
Tools

Pressure piece special tool 9609/1
spacer special tool 9609/2

g g g g y g
Drift punch, 1 mm tip, commercially NR.167

available tool
Slide hammer kit commercially NR.168

available tool
Multiple-tooth socket commercially NR.31

wrench insert M12 available tool
Preliminary work
Preliminary work
1. Remove drive plate or flywheel. → 136019 Removing and installing flywheel [9PAAE7]→ 136019
Removing and installing flywheel [9PAAE1 9PAAF1 9PAAJ1] or → 136319 Removing and installing drive
g g g g y g
plate for torque converter [9PAAE1 9PAAF1 9PAAJ1]→ 136319 Removing and installing drive plate for
torque converter [9PAAE7]
Tools and materials
Required tools
Overview of special tool

-A- Slide hammer kit NR.168
-B- Pressure piece 9609/1 and
spacer 9609/2
-C- Extractor tip Contained in slide hammer kit
NR.168.
-D- Connecting piece Contained in slide hammer kit
NR.168.
-E- Multiple-tooth socket wrench
insert M12 NR.31
-F- Drift punch, 1 mm tip, NR.167
-G- Toothed segment 9538/1
1. Using the tool drift punch (1-mm tip) NR.167, beat a small hole into a non-rubberised spot (rectangular
window in the ring) of the sealing ring.
g g g g y g
Punching out the sealing ring Drift punch
2. Screw in the extractor tip. Knock out the extractor tip using slide hammer kit NR.168 in conjunction with
the sealing ring.
3. Clean the crankshaft flange The crankshaft flange must not be

dirty or rusty. If necessary, clean it with brake cleaner and grind
off any rust with a metal-polishing pad (e.g. Never Dull).
Cleaning the crankshaft flange
ATTENTION
Damage to the sealing ring!
→ The sealing ring is provided on a sleeve.

→ Never remove the sealing ring from the sleeve.
→ Never deform or touch the sealing lips.
→ Never oil the sealing lips.
1. Connect the sealing ring and sleeve to the tool.
2. Position the centring device on the crankshaft flange. Pay attention to the centring pin when doing this.
Tighten the two fastening screws to 23 Nm (17 ftlb.).
3. Position the retracting bell and tighten the central screw (a/f 19) to 25 Nm (19 ftlb.).
4. Undo the retracting bell and screw it down.
5. Undo the two fastening screws on the centring device and remove the tool.
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Centring tool Pushing on the sealing ring
Fitting bell
Subsequent work
Subsequent work
1. Install drive plate or flywheel. → 136019 Removing and installing flywheel [9PAAE7]→ 136019 Removing
converter [9PAAE7]
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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g g p q g

13 63 19 Removing and installing drive plate for torque

converter - as of MY 2003
- Preliminary work
- Removing drive plate for torque converter
- Installing drive plate for torque converter
- Subsequent work
Tools

toothed segment special tool 95381

available tool
Striker special tool VW

771/1
g g p q g
Preliminary work
Preliminary work
1. Remove transmission. → 373519 Removing and installing transmission - chapter on
"Removing" [9PAAJ1]→ 373519 Removing and installing transmission - chapter on "Removing" [9PAAE1
9PAAF1]
Tools and materials
Special tools
Puller

-A- Internal puller NR.108, size See Workshop Equipment
approx. 14 - 20 Manual, Chapter 2.4
-B- Striker VW 771/1 See Workshop Equipment
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screw hole in the crankcase so that at least one tooth is in
contact with the starter teeth.
Toothed segment
2. Unscrew drive plate. To do this, loosen the ten diagonally
opposite fastening screws.
3. Remove drive plate.
4. If the drive plate is stuck, remove it using an internal puller and

slide hammer.
Drive plate
5. To do this, insert internal puller into the middle of the drive plate
and tighten.
Internal puller
6. Then screw on the slide hammer and knock off the drive plate.

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Note
z Clean the crankshaft stub before installing the drive plate
(remove rust).
z Use a special metal-polishing pad (e.g. Never Dull) for this.
1. Fit drive plate.
Slide hammer
screw hole in the crankcase so that at least one tooth is in
contact with the starter teeth.
Toothed segment
3. Tighten the ten new fastening screws crosswise. → Tightening
torque: 44 ftlb. ; then → Torque angle: 90 °
4. Remove toothed segment 95381.
Fastening screws
Subsequent work
Subsequent work
1. Install transmission. → 373519 Removing and installing transmission - chapter on "Installing" [9PAAJ1]
→ 373519 Removing and installing transmission - chapter on "Installing" [9PAAE1 9PAAF1]
as of MY 2003
g g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g g

13 73 19 Removing and installing belt tensioner - as of MY 2003

- Preliminary work
- Information
- Removing belt tensioner
- Installing belt tensioner
- Subsequent work
Preliminary work
Preliminary work
1. Loosen drive belt around the belt tensioner. → 137819 Removing and installing drive belt - chapter on
"Removing" [9PAAF1 9PAAJ1]→ 137819 Removing and installing drive belt - chapter on
Information
Component overview
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Component overview of drive belt rollers
2 - Tensioning roller
3 - Holder for deflection roller
4 - Fastening screw for damper → Tightening torque: 32 (24 ftlb.) Nm +/-3 (2 ftlb.) Nm
5 - Support for tensioning roller → Tightening torque: 32 (24 ftlb.) Nm +/-3 (2 ftlb.) Nm
6 - Shock absorber/tensioning element; bellows must be facing upwards. Observe code on the component.
8 - Sheetmetal holder

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1. Loosen the bottom fastening screw on the shock absorber.
2. Loosen the top fastening screw.
3. Remove components and repair appropriate components.
4. In order to remove the tensioning roller

-figure shows deflector roller- , the cap must be levered off
first. To do this, insert a small screwdriver underneath the cap
and lever it off.
Deflection roller
Note
z When fitting the shock absorber/tensioning element, ensure that the label can be read from outside.
z The bellows must be facing upwards.
1. Install holder with tensioning element. Tighten the top fastening

2. Tighten the bottom fastening screw. → Tightening torque: 24

ftlb.
Shock absorber/tensioning element
Subsequent work
Subsequent work
1. Fit drive belt. → 137819 Removing and installing drive belt - chapter on "Installing" [9PAAF1 9PAAJ1]
→ 137819 Removing and installing drive belt - chapter on "Installing" [9PAAE1 9PAAE7]

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as of MY 2003
g g g g p y g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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g g g g p y g

13 74 19 Removing and installing sealing ring for crankshaft

belt pulley - as of MY 2003
- Information
- Preliminary work
- Removing sealing ring for crankshaft belt pulley
- Installing sealing ring for crankshaft belt pulley
- Subsequent work
Information
Component overview
-1- - Radial shaft seal (align using the plastic sleeve provided)
-2- - Upper fastening screw
-3- - Lower fastening screw
-4- - Chain tensioner
Preliminary work
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Preliminary work for removing sealing ring for crankshaft sealing ring
1. Remove pulley (vibration balancer) of the crankshaft → 137619 Removing and reinstalling crankshaft belt
pulley - chapter on "Removing".
Removing sealing ring for crankshaft belt pulley
Removing sealing ring for crankshaft pulley
1. Undo the 4 fastening screws and remove the cover and sealing
ring.
2. Clean the sealing surface of the sheetmetal cover.
Removing cover with sealing ring
Installing sealing ring for crankshaft belt pulley
Installing sealing ring for crankshaft pulley
WARNING
Risk of damaging the sealing ring due to assembly fault!
z Never pull the sealing ring from the plastic sleeve!
z Do not touch the sealing lip!
z Do not oil the sealing ring on the running surface!
→ Sealing lip can be damaged!
Note
z 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.
z If there is bad corrosion or deep grooves, replace these components.
1. Place seal with plastic sleeve across crankshaft.
2. Tighten the 2 upper fastening screws by hand → Tightening torque: 7.5 ftlb. , and then the lower
fastening screws → Tightening torque: 7.5 ftlb. . Then tighten the screws in diagonally opposite
sequence to the specified torque.
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Fastening screws to sealing ring Seal with plastic sleeve

3. Pull off plastic sleeve evenly from sealing ring.
Plastic sleeve
Subsequent work
Subsequent work: installing sealing ring for crankshaft pulley

1. Install pulley (vibration balancer) of crankshaft → 137619 Removing and reinstalling crankshaft belt pulley
- chapter on "Installing".
as of MY 2003
g g p y g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g p y g

13 76 19 Removing and installing crankshaft belt pulley - as of

MY 2003
- Preliminary work
- Removing crankshaft belt pulley
- Installing crankshaft belt pulley
- Subsequent work
Tools

Mechanical angle disc for commercially NR.88-1

torque angle threaded joint available tool
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Preliminary work
Preliminary work for removing crankshaft pulley

1. Loosen lock carrier. → 503809 Loosening and fastening lock carrier (service position) - chapter on
"Loosening"
2. Loosen drive belt and remove from the pulley. For details see → 137819 Removing and reinstalling drive
belt - chapter on "Removing" [9PAAF1 9PAAJ1]→ 137819 Removing and reinstalling drive belt - chapter
on "Removing" [9PAAE1 9PAAE7].
Removing crankshaft belt pulley
Removing crankshaft pulley
1. Position arm bracket 96790 in the pulley and turn it until it locks.
ATTENTION
Material damage!
z If the tool slips or if the tool is faulty, the wings or the
cooling fan can be damaged as a result of excessive forces!

→ Never use the special wrench socket wrench insert 9714, for Arm bracket in the pulley
2. Position a large torque wrench and loosen the central screw. Do not use the screw again.
3. Remove the central screw and pull the pulley down and forward.
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belt pulley
Pulley Large torque wrench on the central

screw
Installing crankshaft pulley
Note
z A key is inserted into the crankshaft. When fitting the pulley,
ensure that the key lies in the groove in the pulley.
z The pulley and crankshaft stub must be cleaned.
1. Position the pulley on the crankshaft stub. Then press the pulley
slightly in the direction of the engine, while at the same time
twisting it until it slips definitively in the direction of the timing- Pulley on crankshaft stub
case cover. When doing so, pay attention to the key.
2. Mount the new central screw hand tight into the crankshaft.
Central screw in crankshaft
ATTENTION
Material damage!

Arm bracket in the pulley
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3. Position arm bracket 96790 in the pulley and turn it until it locks. Have a second worker operate the arm
bracket.
ATTENTION
Material damage!

Central screw
4. Tighten central screw. → Initial tightening: 20 (15 ftlb.) Nm , then → Initial tightening: 50 (37 ftlb.)
Nm , then → Initial tightening: 250 (185 ftlb.) Nm
5. Push on torque angle disc Mechanical angle disc for torque

angle threaded joint NR.88-1. Attach a magnetic foot to a metal
part and set the scale by turning the pointer to 0. As an
alternative to the torque angle disc, marks can be made on the
vibration balancer (crankshaft pulley) and the central screw using
a waterproof pen. A continuous line between the central screw
and vibration balancer represents the starting point, another line
only on the vibration balancer at an angular distance of 90°
shows the torque angle target.
Torque angle disc
ATTENTION
Material damage!

Central screw
6. Tighten central screw to torque angle. → Torque angle - final tightening: 90 °
Subsequent work
Touching up installing the crankshaft pulley

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1. Mount drive belt. For details see → 137819 Removing and

reinstalling drive belt - chapter on "Installing" [9PAAF1 9PAAJ1]
→ 137819 Removing and reinstalling drive belt - chapter on
2. Fasten lock mount. → 503809 Detaching and fastening lock

mount (service position) - chapter on "fastening"
Drive belt
as of MY 2003
g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g

13 78 01 Checking drive belt - as of MY 2003

- Preliminary work
- Information
- Checking drive belt
- Subsequent work
Preliminary work
Preliminary work
1. Remove intake manifold (cowl). → 243519 Removing and installing cowl for throttle part (Y-shaped
pipe) [9PAAF1 9PAAJ1]→ 243519 Removing and installing cowl for throttle part (Y-shaped
pipe) [9PAAE1 9PAAE7]
Information
Information
ATTENTION
ATTENTION
z Due to a broken drive belt during driving, surrounding components (panelling, electric cables
etc.) can be damaged by thrashing or flying belt parts.
z Parts of the drive belt can jam behind deflection rollers or vibration balancers and damage
surfaces and sealing rings there. In particular, the sealing ring of the crankshaft vibration
balancer can become leaky as a result of a broken belt.
→ Following a belt breakage the surrounding components and the interior of the engine compartment must
be inspected for damage, and if necessary damaged parts (sealing ring of the crankshaft vibration
balancer, deflection rollers, panelling, lines, electric cables etc.) repaired or replaced.
The reason for the belt breakage must be established. Check deflection rollers or crankshaft vibration
g g
→ balancers for prior damage.
WARNING
Danger of injury!
radiator or fans (remove fuse → fuse carrier [9PAAJ1]→ fuse carrier [9PAAE1 9PAAE7 9PAAF1]).→
Work instructions after disconnecting the battery
Damage symptoms
Note
z The following table indicates damage which necessitates replacement.
g g
Item Type of damage Explanation

-A- Slight crack in a rib Drive belt is OK
-B- Hairline crack that runs across the entire belt width, Replace drive belt
or the butt seam is damaged
-C- Crack running down to half of rib height Drive belt must be replaced if there is more
than one crack running down to half of rib
height
-D- Crack running to base of rib Replace drive belt
-E- Crack running to traction cord, or sides so worn that Replace drive belt
the traction cord becomes visible
-F- Rib detachment Replace drive belt
-G- Rib fracture Replace drive belt
Checking drive belt
Checking drive belt
Note
z 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. Using chalk, mark the drive belt in the area around the tensioning roller.
2. Turn engine at the vibration damper in the direction of movement using a socket wrench (a/f 27) until the
chalk mark is at the same place again. While turning at the crankshaft, check the belt at the deflection
rollers for signs of damage.
Subsequent work
g g
Subsequent work
1. Fit intake manifold (cowl). → 243519 Removing and installing
cowl for throttle part (Y-shaped pipe) [9PAAF1 9PAAJ1]→ 243519
Removing and installing cowl for throttle part (Y-shaped
pipe) [9PAAE1 9PAAE7]
Marking on the drive belt
as of MY 2003
g g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g g

13 78 19 Removing and installing drive belt - as of MY 2003

- Preliminary work
- Information
- Removing drive belt - Cayenne S
- Installing drive belt - Cayenne S
- Subsequent work
Preliminary work
Preliminary work
1. Remove intake manifold (cowl). → 243519 Removing and installing cowl for throttle part (Y-shaped pipe)
Information
Information
ATTENTION
ATTENTION
z Due to a broken drive belt during driving, surrounding components (panelling, electric cables
etc.) can be damaged by thrashing or flying belt parts.
z Parts of the drive belt can jam behind deflection rollers or vibration balancers and damage
surfaces and sealing rings there. In particular, the sealing ring of the crankshaft vibration
balancer can become leaky as a result of a broken belt.
→ Following a belt breakage the surrounding components and the interior of the engine compartment must
be inspected for damage, and if necessary damaged parts (sealing ring of the crankshaft vibration
balancer, deflection rollers, panelling, lines, electric cables etc.) repaired or replaced.
g g g
WARNING
Danger of injury!
radiator or fans (remove fuse → fuse carrier).→ Work instructions after disconnecting the battery

1. Mark the rolling direction of the drive belt with chalk.
2. Relieve and remove drive belt. To do this, use an open-ended

wrench (a/f 30) to turn the belt tensioner clockwise and remove
the drive belt from the tensioning roller. Relieve the belt tensioner
slowly.
Relieving drive belt

3. Remove the drive belt from all pulleys.

g g g
Note
z The figure → Drive belt threading course shows the complete belt
threading course. The pulleys are numbered according to the
sequence of fitting.
Remove the drive belt from the

tensioning roller .
Drive belt threading course
1. Make the belt into a loop and place over the crankshaft belt pulley behind the dipstick.
2. Place the top part of the belt loop over the coolant pump pulley -1- .
g g g
Coolant pump pulley Crankshaft belt pulley

3. Place the lower part of the belt loop around the crankshaft belt
pulley at the bottom -2- .

4. Guide the belt section from the coolant pump around the
deflector wheel -3- on cylinder bank 5 - 8.
Deflector wheel
5. Then guide the section of the belt around the air-conditioning
compressor belt pulley -4- at the bottom.
6. Lay a loop around the power-steering pump -5- .
7. Lay the loose end of the drive belt from the coolant pump downwards and around the generator pulley
-6- and deflector roller -7- of cylinder bank 1 - 4.
8. Gather the belt section between the deflection roller of cylinder bank 1 - 4 and the crankshaft pulley to
form a loop and guide it upwards to the tensioning roller -8- . Use a wrench (a/f 30) to turn the tensioning
g g g
Generator pulley Power-steering pump
Tensioning roller
roller -8- in a clockwise direction at the hexagon and put on the drive belt. Slowly relieve the tensioning
roller.
9. Check that the drive belt is positioned correctly on the pulleys.
Fitting the drive belt
Subsequent work
Subsequent work
1. Fit intake manifold (cowl). → 243519 Removing and installing cowl for throttle part (Y-shaped pipe)
9PAAE1, 9PAAE7
as of MY 2003
C46, C98, C99
g g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g g

15 03 21 Removing camshaft housing - as of MY 2003, until MY

2004
- Preliminary work
Preliminary work
4. Turbocharged engine (M48/50): Remove oil feed line from

camshaft housing. To do this, unscrew union nut.
g g g
"Removing"
10. Remove flat-base tappets and put down in accordance with installation position. → Removing and
installing flat-base tappets
Removing the camshaft housing
1- Camshaft housing
3- Camshaft sensor
4- Plug
7- Sealant application on camshaft housing. Make sure that no sealant can fall into the cylinder head.
Carefully remove old residual sealing compound.
g g g

9 - Sealant application on spark plug recess. Make sure that no sealant can fall into the cylinder head.
1. Unscrew the upper fastening screw -3- of oil line. Replace sealing ring -2- .
g g g
2. Unscrew both hexagon socket head bolts M8 x 20 and M8 x 30

on the front end (on cylinder row 1-4, the screws are located at
the side on the exterior of the chain box).
Note
z When removing the camshaft housing, ensure that none of the
sealing rings or residual sealant fall into the cylinder head.
3. Unscrew 26 camshaft housing fastening screws M8 x 45 contrary

to the indicated order and lever camshaft housing off the cylinder
head. When removing the camshaft housing, ensure that none of
the sealing rings or residual sealant fall into the cylinder head. Illustration shows cylinder row 5-8
g g g
→ see figure Illustration shows tightening sequence

g g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g g

15 03 21 Removing camshaft housing - as of MY 2005

- Preliminary work
Preliminary work
4. Turbocharged engine (M48/50): Remove oil feed line from

camshaft housing. To do this, unscrew union nut.
"Removing"
g g g
10. Remove flat-base tappets and put down in accordance with installation position. → Removing and
installing flat-base tappets
1- Camshaft housing
3- Camshaft sensor
4- Plug
g g g

camshaft housing. Check oil strainer and clean in solvent
naphtha or replace if necessary. Remove oil strainer with a small
magnet -1- . The oil strainer prevents dirt from getting into the
camshaft adjustment valve. → Oil strainer

2. Unscrew upper fastening screw -3- of oil line. Replace sealing

ring -2- .
Oil strainer
g g g
3. Unscrew both hexagon socket head bolts M8 x 20 and M8 x 30

on the front end (on cylinder row 1-4, the screws are located at
the side on the exterior of the chain box).
Note
z When removing the camshaft housing, ensure that none of the
sealing rings or residual sealant fall into the cylinder head.
4. Unscrew 26 camshaft-housing fastening screws (M8 x 45)

contrary to the order shown → Tightening sequence for camshaft
housing and lever camshaft housing off the cylinder head. When
removing the camshaft housing, ensure that none of the sealing
rings or residual sealant falls into the cylinder head.
g g g
→ Tightening sequence for camshaft housing Illustration shows tightening sequence
as of MY 2005
g g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g g

15 03 23 Installing camshaft housing - as of MY 2003, until MY

2004
- Subsequent work
ATTENTION

g g g
1- Camshaft housing
3- Camshaft sensor
4- Plug
Note
camshaft housing!
cloth).
Note
z The sealant application must not be too thick because otherwise excess sealant can enter the cylinder
head!
z For applying the sealant, there are, amongst other things, two grooves on the front section of the
camshaft housing!
2. Replace oil duct sealing ring on cylinder head and apply a thin bead (approximate width 1.5 mm) of
sealing compound (000 043 300 39, status 12/05) onto the camshaft housing in accordance with
-Illustration- . When doing this, do not forget the sealing surfaces of the spark plug recesses.
g g g

3. Place camshaft housing on cylinder head. Position M8 fastening screws and tighten in tightening
sequence → Tightening sequence for camshaft housing . → Tightening torque: 23 (17 ftlb.) Nm
4. Tighten hexagon socket head bolts in control box -Arrows- as required → Tightening torque: 23 (17
ftlb.) Nm (on cylinder row 1-4 the screws are located on the side, on the outside of the chain box). Wipe
off excess silicone as far as control box.
5. Secure oil line with new sealing ring -2- . To do this, screw down the upper fastening screw -3- of oil line.
→ Tightening torque: 10 (7.5 ftlb.) Nm
g g g
Fastening oil line

g g g
Subsequent work
Subsequent work
1. Turbocharged engine (M48/50): Screw down sheetmetal bracket

for turbocharger. To do this, tighten the 2 fastening screws →
Tightening torque: 23 (17 ftlb.) Nm and screw with new nut →
Tightening torque: 30 (22 ftlb.) Nm . → Sheetmetal bracket for
turbocharger


3. Screw down ground connection. → Tightening torque: 10 (7.5
ftlb.) Nm
Ground connection
4. Secure oil feed line by hand in the camshaft housing with the
union nut and then tighten. → Tightening torque: 35 (26 ftlb.)
Nm
5. Install flat-base tappets. → Removing and installing flat-base

tappets

"Installing"

section on "Installing" Oil feed line
g g g
8. Install cover for camshaft housing . → 159123 Installing cover for camshaft housing - section on
"Installing"
9. Install intake-air distributor. → 244619 Removing and installing intake-air distributor - section on
"Installing"

g g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g g

15 03 23 Installing camshaft housing - as of MY 2005

- Subsequent work
ATTENTION


g g g
1- Camshaft housing
3- Camshaft sensor
4- Plug
8 - Camshaft housing fastening screw M8 x 45
Note
camshaft housing!
cloth).
Note
z The sealant application must not be too thick because otherwise excess sealant can enter the cylinder
head!
z For applying the sealant, there are, amongst other things, two grooves on the front section of the
camshaft housing!
2. Replace oil duct sealing ring on cylinder head and apply a thin bead (approximate width 1.5 mm) of liquid
sealing compound 000.043.300.39 Loctite 5970 (status 11/2005, for details of currently used sealant,
see Spare Parts Catalogue) onto the camshaft housing in accordance with -Illustration- . When doing
this, do not forget the sealing surfaces of the spark plug recesses.
g g g

3. Place camshaft housing on cylinder head. Position M8 fastening screws and tighten according to
specified tightening sequence → Tightening sequence for camshaft housing . → Tightening torque: 23
(17 ftlb.) Nm
4. Tighten hexagon socket head bolts in control box -Arrows- as required → Tightening torque: 23 (17
ftlb.) Nm (screws are located on the side, on the outside of the chain box, on cylinder row 1 - 4). Wipe
off excess silicone as far as timing case.
5. An oil strainer is fitted under the camshaft adjustment valve in the camshaft housing. Check oil strainer
and clean in solvent naphtha or replace if necessary. Fit oil strainer into the bore on the camshaft
g g g
Oil strainer, top view Illustration shows cylinder row 5 - 8
housing -1- . The oil strainer prevents dirt from getting into the camshaft adjustment valve. → Oil strainer

6. Secure oil line with new sealing ring -2- . To do this, screw down
the upper fastening screw -3- on oil line. → Tightening torque:
10 (7.5 ftlb.) Nm
Oil strainer
g g g
Fastening oil line
Subsequent work
Subsequent work
1. Turbocharged engine (M48/50): Screw down sheetmetal bracket for turbocharger. To do this, tighten the
2 fastening screws → Tightening torque: 23 (17 ftlb.) Nm and screw with new nut → Tightening
torque: 30 (22 ftlb.) Nm . → Sheetmetal bracket for turbocharger

g g g
Cable plug of camshaft sensor Sheetmetal bracket for turbocharger

3. Screw down ground connection. → Tightening torque: 10 (7.5
ftlb.) Nm
Ground connection
4. Secure oil feed line by hand in the camshaft housing with the
union nut and then tighten. → Tightening torque: 35 (26 ftlb.)
Nm
5. Install flat-base tappets. → Removing and installing flat-base

tappets

"Installing"

section on "Installing" Oil feed line
"Installing"
9. Install intake-air distributor. → 244619 Removing and installing intake-air distributor - section on
"Installing"
as of MY 2005
g g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g g

15 05 02 Checking timing of camshafts - as of MY 2003

- Information
Information
Information
Note
z Checking the timing is not possible for the M48/00 and M48/50 engines. Only an adjustment can be
made→ 150516 Adjusting timing for camshafts.
as of MY 2003
j g g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
j g g g

15 05 16 Adjusting the timings for the camshafts - as of MY

2003
- Preliminary work
- Adjusting the timings for the camshafts
- Subsequent work
Tools

fixing pins special tool 9595/1

j g g g
Preliminary work
Preliminary work
Note
z To remove the play from the timing chain for the setting process, the crankshaft must be positioned at
least 45° in front of the TDC of cylinder 1 before turning!
1. Remove camshaft housing cover on both cylinder rows → 159121 Removing camshaft housing cover -
Chapter "Removing".
ATTENTION
Damage to engine by turning crankshaft against the rotation
direction of the engine (engine assembled)!
→ Never rotate crankshaft against the operating direction if the

timing drive mechanism is mounted (timing chain jumps over).
→ Proceed carefully while working as otherwise the engine can be
damaged.
→ Always turn the engine on the crankshaft and never on the
camshaft as the timing chain may jump over.
Fixing pin in crankshaft gearwheel
→ Please observe the general warning notes and working
regulations → 1001AW The most important working regulations
and warning notes
Note
z The setting is always checked simultaneously on both cylinder rows. Once a cylinder row has been set,
the crankshaft must not be turned to set the other cylinder row!
z The screws on the sprocket wheels are tightened by hand during assembly and are then loosened by
one or two turns. This play is necessary so that the camshafts can still be turned.
z The setting is carried out with the standard chain tensioner that is installed.
j g g g
2. Use socket wrench insert 9714 to turn crankshaft until cylinder 1 is in ignition TDC. Insert fixing pins
9595/1 into the relevant groove in the timing chain housing cover through the bore provided in the
crankshaft gearwheel -see figure- .
Note
z If the cams on cylinder 1 are not positioned as shown, check
whether the crankshaft needs to be turned through another turn
(360°)!
3. Make sure that the cams of cylinders 1 and 5 are positioned as

shown (ignition TDC cylinder 1) → Cams of cylinder 1 → View
shows position of cams on cylinder 5 .
Cams of cylinder 1

cylinder 5
Tools and materials
Special tools
Tools
j g g g

Chapter 2.2.2 "
-B- Camshaft guide 9678 → "See Workshop For adjusting the timing;
Equipment Manual, guide is positioned in both
Chapter 2.2.2 " rear grooves of the
camshafts
correctly in groove provided
in timing case.
Adjusting the timings for the camshafts
Adjusting the timings for camshafts
The crankshaft is positioned in the TDC and is fixed using fixing pins 9595/1 once the above preliminary
check has been performed.
Note
z The fastening screws on the sprocket wheels do not need to be
replaced after they have been undone.
Fastening screws of the camshaft

wheels
1. Undo all four fastening screws of the camshaft wheels (two camshaft adjusters) on both cylinder rows.
For this purpose, hold the hexagon of the camshaft wheel on the respective camshaft with the ring
wrench and release pan-head screw M12 1 by 2 revolutions
--To illustrate the process more clearly, the figure does not show the timing case lid-- .
Note
z Cylinder rows 1 - 4 and 5 - 8 are adjusted at the same time
without the camshaft being turned!
2. Turn the four camshafts on the hexagon with an open-ended

wrench until the camshaft guide 9678 can be pushed into the
grooves of both camshafts of a cylinder row.
Hexagon on camshaft
j g g g
Note
z Cylinder rows 1 - 4 and 5 -
8 are adjusted at the same
time without the camshaft
being turned!
3. Then adjust camshafts of

the other cylinder row. For
this purpose, turn the
hexagon with the open-
ended wrench and fix it Correct positioning of cams in cylinder Figure shows the camshafts fixed with
with camshaft guide row 5 - 8 camshaft guide on a cylinder row.
9678. . Check whether the
camshaft guide alternately
fits into the grooves on
both cylinder rows of the
camshafts.
4. Tighten all camshaft wheels (two camshaft adjusters) again with

pan-head screw M12. For this purpose, hold hexagon of the
respective camshaft with ring wrench and tighten M12 pan-head
screw. For tightening torques, see → 150719 Removing and
installing camshaft wheel - Chapter "Reworking".
5. Remove camshaft guide 9678 and fixing pins 9595/1.
Camshaft wheels with pan-head screw

M12
Subsequent work
Reworking
1. Install camshaft housing cover on both cylinder rows → 159123 Installing camshaft housing cover -
Chapter "Installing".
as of MY 2003
g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g

15 05 21 Removing camshafts - as of MY 2003, until MY 2004

- Preliminary work
Preliminary work

1. Remove camshaft housing cover → 159121 Removing and installing cover for camshaft housing -
"Removing" chapter.
3. Remove camshaft timing gears. For details, see → 150719 Removing and installing camshaft timing gear
- chapter on "Removing".
Removing camshafts
Removing camshafts
Note
z While removing, note the installation position and allocation of the camshafts and bearing caps on a
sheet of paper in such a way that they cannot be mixed up.
g g
1. Unscrew fastening screws M6 x 16 of the inlet camshaft oil feed housing and pull it off to the front.
Note
Note
z When releasing the camshaft bearing caps, all the fastening screws must be released evenly half a turn
at a time in the reverse order to that illustrated so that the camshaft is not distorted!
2. Remove all the M6 x 35 fastening screws of the thrust bearing cap and bearing caps evenly half a turn at
a time in the reverse order to that illustrated -see figure- . Layout thrust bearing and bearing caps on a
clean surface according to installation position.
g g
The view shows the tightening order for a camshaft
3. Remove camshafts and layout on a clean surface according to installation position.

g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g

15 05 21 Removing camshafts - as of MY 2005

- Preliminary work
Preliminary work

1. Remove camshaft housing cover → 159121 Removing and installing cover for camshaft housing -
"Removing" chapter.
3. Remove camshaft timing gears. For details, see → 150719 Removing and installing camshaft timing gear
- chapter on "Removing".
Removing camshafts
Removing camshafts
Note
g g
1. Unscrew fastening screws (M6 x 16) of the inlet camshaft oil feed housing and pull it off to the front.
Note
Note
z When releasing the camshaft bearing caps, all the fastening screws must be released evenly half a turn
at a time in the reverse order to that illustrated so that the camshaft is not distorted!
Note
standard bores for securing the hydraulic valve (two M6 x 60
screws) -1- . An additional oil strainer is fitted under the hydraulic
valve.
2. Remove all M6 x 35 fastening screws for the thrust bearing caps

and bearing caps evenly half a turn at a time in the reverse order
to that shown -see Figure- . Lay out thrust bearing and bearing
caps on a clean surface according to installation position.
g g
The view shows the tightening sequence for a camshaft
3. Remove camshafts and lay out on a clean surface according to installation position.
as of MY 2005
g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g

15 05 23 Installing camshafts - as of MY 2003, until MY 2004

- Subsequent work
Tools

g g
Installation location of camshafts
Note
z Turn the crankshaft to about 30° before TDC cylinder 1 so that

the valves and pistons are not damaged when the camshaft
bearing caps are being tightened!

-see figure- . Using socket 9714, turn the crankshaft until it is
located 30° before TDC cylinder 1.
Note
Note
3. Place camshafts as shown in the -illustration- . When doing so, pay particular attention to the relative
position of the cams to each other.
g g

4. Place oiled bearing caps on camshaft bearings. The matching number of the bearing caps must
correspond to the camshaft housing. For each cylinder, the bearing caps are numbered consecutively
from the front (timing chain side) -B- . The designation of the bearing cap and matching number can be
read from the exhaust side -A- .
A - xxxx Camshaft housing bearing cap matching number

B - Bearing cap A/1 Bearing cap consecutive numbering exhaust cylinder 1
B - Bearing cap A/2-1 Bearing cap consecutive numbering exhaust between cylinders 1 and 2
g g
B - Bearing cap A/3-2 Bearing cap consecutive numbering exhaust between cylinders 3 and 2 etc.
B - Bearing cap E/1 Bearing cap consecutive numbering inlet cylinder 1 etc
5. Fit bearing cap. The tightening sequence must be strictly observed → Tightening torque: 7.5 ftlb.
-tightening sequence- .
compression rings of the camshaft → Tightening torque: 7.5 ftlb. .
Subsequent work
3. Install camshaft housing cover → 159123 Removing and installing cover for camshaft housing - chapter
on "installing".

g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g

15 05 23 Installing camshafts - as of MY 2005

- Subsequent work
Tools

g g
Installation position of camshafts
Note
z Turn the crankshaft to about 30° before TDC cylinder 1 so that

the valves and pistons are not damaged when the camshaft
bearing caps are being tightened!

-see Figure- . Using a socket 9714, turn the crankshaft until it is
located 30° before TDC of cylinder 1.
Note
Note
3. Place camshafts as shown in -Illustration- . When doing so, pay particular attention to the way the cams
are positioned in relation to each other.
g g

4. Put oiled bearing caps onto the camshaft bearings. The matching number of the bearing caps must
correspond to the camshaft housing. For each cylinder, the bearing caps are numbered consecutively
from the front (timing chain side) -B- . The designation of the bearing cap and matching number can be
read from the exhaust side -A- .
A - xxxx Camshaft housing bearing cap matching number

B - Bearing cap A/1 Bearing cap consecutive numbering exhaust cylinder 1
B - Bearing cap A/2-1 Bearing cap consecutive numbering exhaust between cylinders 1 and 2
g g
B - Bearing cap A/3-2 Bearing cap consecutive numbering exhaust between cylinders 3 and 2 etc.
B - Bearing cap E/1 Bearing cap consecutive numbering inlet cylinder 1 etc
Note
standard bores for securing the hydraulic valve (two M6 x 60
screws) -1- . An additional oil strainer is fitted under the hydraulic
valve.
5. Fit bearing cap. The tightening sequence must be strictly

observed → Tightening torque: 10 (7.5 ftlb.) Nm
-Tightening sequence- .
compression rings of the camshaft → Tightening torque: 10 (7.5 ftlb.) Nm .
Subsequent work
3. Install camshaft housing cover → 159123 Removing and installing cover for camshaft housing - chapter
on "installing".
g g
as of MY 2005
g g gg g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g gg g

15 07 19 Removing and installing camshaft timing gear - as of

MY 2003
- Preliminary work
- Removing camshaft timing gear
- Installing camshaft timing gear
- Subsequent work
Tools


g g gg g
Preliminary work

1. Remove camshaft housing cover. → 159121 Removing and installing cover for camshaft housing -
chapter on "removing"
Tools and materials
Special tools
Tools

Chapter 2.2.2 "
g g gg g
camshafts
in timing case.
Removing camshaft timing gear
Removing camshaft timing gear.
ATTENTION
Damage to engine by turning crankshaft against the rotation direction of the engine (engine
assembled)!
chain jumps over).
→ Please observe the general warning notes and working regulations → 1001AW The most important
working regulations and warning notes
Note
z If the cams on cylinder 1 are not positioned as shown, check
whether the crankshaft still needs to be turned through another
turn (360°)!
2. Ensure the cams of cylinders 1 and 5 are in the position shown

(ignition TDC) -see figure- and → View shows position of cams
on cylinder 5 .

cylinder 1
g g gg g

cylinder 5

crankshaft
3. Insert locating pin 9595/1 through the bore provided in the crankshaft gearwheel and into the relevant
groove in the timing chain housing cover -see figure- .

5. Loosen timing chain and pull upper plastic guide away from both
pins. If necessary, turn camshaft timing gear back and forth a
little with the ring wrench so that the timing chain has more play
between the wheels → Upper plastic guide for timing chain .
Note
z The fastening screws of the sprockets must be replaced after removal.
z The screws of the sprocket wheels are tightened by hand during assembly and are then loosened by one
or two turns. This play is necessary so that the camshafts can still be turned.
g g gg g
Loosening camshaft timing gear
6. Just loosen the fastening screw of the camshaft adjuster (1 or 2 turns). To do this, counter the a/f 32
hexagon of the camshaft adjuster and camshaft timing gear with a ring wrench. Only remove the cheese
head bolt of the camshaft timing gear
-to illustrate the operation more clearly, the figure does not include the timing case cover-- .
7. If necessary, use a rubber hammer to carefully loosen the camshaft timing gear from the back.
ATTENTION
→ Do not let the diamond washer under the camshaft timing gear and camshaft adjuster fall into the timing
case.
Note
z There is a diamond washer between the camshaft and camshaft timing gear and between the camshaft
and camshaft adjuster. This is to be replaced after the corresponding wheel has been removed. If the
fastening screw of the wheel is only loosened to adjust the timing (1 or 2 revolutions), the diamond
washer does not need to be replaced.
8. Use both hands, to carefully remove the camshaft timing gear from the chain.
ATTENTION
Engine damage due to small parts falling into the timing case
(e.g. diamond washer)!
→ Do not let the diamond washer under the camshaft timing gear
and camshaft adjuster fall into the timing case.
9. Remove the diamond washer located under the camshaft

adjuster. In this case (removal of camshaft timing gear) replace
the diamond washer. Removing diamond washer
Installing camshaft timing gear
Installing camshaft timing gear.

g g gg g
Note
z If they have been removed, replace the diamond washer and M12 cheese head screw of the camshaft.
1. Replace the diamond washer and M12 cheese head screw

located under the camshaft timing gear.
2. Lift the timing chain and carefully place the camshaft timing gear
on the camshaft. To get sufficient play in the timing chain, it may
be necessary to turn the loosened camshaft adjuster back and
forth. Place timing chain on camshaft timing gear.
3. Position new M12 fastening screw on camshaft timing gear and

screw in loosely (it must still be possible to turn the camshaft
timing gear).
4. Fit plastic guide for the timing chain.

Replacing the diamond washer
5. Install chain tensioner -arrow- . For tightening torque of chain
tensioner, see → 153619 Removing and installing chain tensioner
- chapter on "installing".
Subsequent work

2. Install camshaft housing cover. → 159123 Removing and installing cover for camshaft housing - chapter
on "installing"
as of MY 2003
g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g

15 33 21 Removing chain case lid - as of MY 2003

- Preliminary work
- Information
- Removing chain case lid
Tools

engine support special tool 9676
Preliminary work
Preliminary work
2. Separate engine from transmission and suspend it on the assembly support using engine support 9676.
3. Drain off engine oil and dispose of it in accordance with the

applicable national laws. For details and tightening torques, see
→ 170117 Changing engine oil and oil filter - section on
"Draining".
4. Remove cover for camshaft housing. → 159121 Removing cover
for camshaft housing - section on "Removing"
Draining engine oil

g g
Fastening screws on water pump

pulley
5. Loosen (do not remove) the three fastening screws on the water pump pulley.
6. Remove engine carrier. To do this, release the four fastening

screws on the engine mounts.

7. Relieve and remove drive belt. → 137819 Removing and
installing drive belt - section on "Removing" [9PAAF1 9PAAJ1]
→ 137819 Removing and installing drive belt - section on
Drive belt
Information
Component overview
g g
Component overview
1 - Radial shaft seal; align using the plastic sleeve provided

2 - Top fastening screw (M6 x 50)
3 - Bottom fastening screw (M6 x 12)
4 - Chain tensioner
Note
g g
z The description only explains how to remove the chain case lid. The removal of other components is
described in the corresponding chapters.
1. Remove the belt tensioner. To do this, loosen the fastening screws -4 and 5- on the carrier and on the
underside of the shock absorber.
Drive belt - overview
2. Remove the deflector wheel at cylinder row 1-4. To do this, lever

off the lid and unscrew the fastening screw.
3. Remove water pump belt pulley.
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Deflector wheel at cylinder row 1-4
Note
z To ensure that the used
fastening screw of the
crankshaft belt pulley is
not used again, mark it
with a felt-tip pen.
4. Remove crankshaft belt

pulley. → 137619
crankshaft belt pulley - Crankshaft belt pulley
5. Remove bracket for oil/water heat exchanger. → 176721

Removing bracket for oil/water heat exchanger - chapter on
"Removing"
Fastening screws for bracket for

oil/water heat exchanger
6. Remove cable duct at cylinder row 1-4.
Cable duct
7. Disconnect coolant line to the generator.
Coolant lines to generator

8. Remove chain tensioner.
9. Remove oil dipstick. → 171719 Removing and installing guide for oil dipstick - chapter on "Removing"
g g
Fastening screws for crankshaft Installation position of chain tensioner

sealing ring
10. Remove crankshaft sealing ring on timing case cover. To do this, loosen the four fastening screws.
ATTENTION
Risk of engine leaks!
z When dismantling the timing-case cover, the sealing bead between the oil pan and crankcase can
become damaged.
→ When dismantling the timing-case cover, the oil pan has to be resealed every time.
11. Remove timing-case cover. To do this, loosen all the fastening screws in reverse order (beginning with
position 28).
Tightening sequence for fastening screws on timing-case cover
12. Remove oil pan. → 175021 Oil pan removed - chapter on "Removing".
as of MY 2003
g g
g g
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g g

15 33 23 Installing chain case lid - as of MY 2003

- Information
- Installing chain case lid
- Subsequent work
Information
Component overview
g g
Component overview
1 - Radial shaft seal; align using the plastic sleeve provided

2 - Top fastening screw (M6 x 50)
3 - Bottom fastening screw (M6 x 12)
4 - Chain tensioner
ATTENTION

Note
z Acetone can be used to clean the sealing faces. Ventilate this for 5 minutes before applying more
sealant.
1. Clean and degrease the sealing faces of the engine and housing lid.
2. Attach the four seals -1, 2, 3 and 4- to the chain case lid.
g g
Lid seals
3. Apply a bead of liquid sealant 000.043.300.39 Loctite 5970 (status 11/2005, for details of currently used
sealant, see Parts Catalogue) to the contact points of the camshaft housing/cylinder head, cylinder
head/crankcase and crankcase upper section/crankcase lower section. The bead of sealant should
protrude about 20 mm over the contact points. → Sealant application
Sealant application
Note
z In the case of the M48/50 (turbo) engine, sealant must also be applied to the metal seal in the chain
g g
tensioner area.
Sealant application
4. Screw down all fastening screws by hand. At this stage, the screw heads should not be all the way down.
Note
z The chain case lid must be aligned using a dial gauge or steel gauge.
z The chain case lid must not project over the lower section of the crankcase.
z It must not go below ( -dimension A- )1/10 mm ( -dimension A < 1/10 mm- ).

g g
Threaded joint and dimension
1 - M6 x 25 screw
2 - M6 x 50 screw
3 - M8 x 50 screw
5. Push the chain case lid upwards slightly and tighten the fastening screws -7, 8, 9 and 10- (about 1 - 2
Nm (0.5 - 1.5 ftlb.) in such a way that the lid is slightly jammed. Then align the lid. → 153123 15 Installing
chain case lid - section on "Adjusting"
g g
Tightening sequence
Aligning the chain case lid with a dial gauge
ATTENTION
Danger of leaks!
z If the chain case lid is not aligned properly, this component
or the oil pan may start to leak during operation.
→ The chain case lid must not project over the crankcase.
→ It cannot go under 0.1 mm (dimension A = 0.1 mm).
1. Insert the dial gauge into the universal gauge holder and position Adjusting the preload
it in such a way that the dial gauge has a preload of about 1 mm.
2. Set dial gauge scale to 0. To do this, place the dial gauge holder
on a completely flat surface (e.g. crankcase flange) and turn the
dial gauge scale until the pointer is at 0.
Resetting dial gauge scale

3. Measure the offset. To do this, push with the holder starting from the lower section of the crankcase
towards the chain case lid (the foot of the dial gauge holder is not located on the same component as the
dial gauge probe) and measure the offset. The chain case lid must not be set back any more than 0.1
mm. It must not project out.
4. Align the chain case lid by tapping lightly with a rubber hammer.
g g
Aligning the chain case lid Measuring the setback distance

5. Once the chain case lid has been aligned, tighten two fastening
screws on the left and right of the chain case lid base to 10 Nm
(7.5 ftlb.). Then, check the position of the chain case lid again
using the dial gauge.
6. Tighten the remaining fastening screws to the appropriate torque

in the sequence shown.
Note
See figure! → Tightening sequence
z The quality of the exterior fastening screws must be 10.9. Checking the position
z Tighten screws 5 to 6 (M8/8.8) to 23 Nm (17 ftlb.).
z Then check all screws again (second time round).
Tightening sequence
g g
Tightening sequence

5 bis 6 - → Tightening torque: 17 ftlb.
Subsequent work
Subsequent work
1. Install oil pan. → 175023 Oil pan installed (includes sealing)
Oil pan tightening sequence
2. Install engine carrier. → 103519 Removing and installing engine mount - section on "Installing"
g g
Fastening screws

3. Fit front radial shaft seal. → 137419 Removing and installing
crankshaft belt pulley - section on "Installing"
Radial shaft seal

4. Fit crankshaft pulley. Fastening screw tightening torque: 250 Nm
(185 ftlb.) + 90° torque angle. → 137619 Removing and installing
crankshaft belt pulley - section on "Installing"

5. Install bracket for oil-water heat exchanger. → 176723 Installing bracket for oil-water heat exchanger
6. Fit deflection roller of cylinder row 1 - 4. → Tightening torque: 32 (24 ftlb.) Nm Then clip on cap.
7. Tighten coolant pump pulley. → 195019 Removing and installing coolant pump pulley - section on
"Installing"
g g
Deflection roller Oil-water heat exchanger
Coolant pump pulley

8. Install belt tensioner. Install holder with tensioning element.
Tighten the top fastening screw → Tightening torque: 33 (24
ftlb.) Nm . Tighten the bottom fastening screw → Tightening
torque: 32 (24 ftlb.) Nm → 137319 Replacing belt tensioner.
Belt tensioner
9. Fit and tension the drive belt. → 137819 Removing and installing
drive belt [9PAAF1 9PAAJ1]→ 137819 Removing and installing
drive belt [9PAAE1 9PAAE7]
Drive belt
10. Install chain tensioner with new sealing ring. → 153619 Removing and installing chain tensioner - section
on "Installing"
11. Install oil dipstick. → 171719 Removing and installing guide for oil dipstick - section on "Installing"
12. Check timing and adjust if necessary. → 150516 Setting the timing
g g
Camshaft guide Chain tensioner
13. Install cover for camshaft housing (valve cover). → 159123 Installing cover for camshaft housing
as of MY 2003
g g g
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g g g

15 35 21 Removing timing chain - as of MY 2003

- Preliminary work
- Information
- Removing timing chain
Preliminary work
Preliminary work
ATTENTION
assembled)!
chain jumps over).
2. Remove cover for camshaft housing. → 159121 Removing cover for camshaft housing
3. Remove chain case lid. → 153121 Removing chain case lid
Information
Component overview
g g g

g g g

3- Guide rail
Note
If the timing chain has to be removed or replaced, check the guide and tensioning rails for wear and scoring
and replace them if necessary.
g g g
Note
z If the timing chain is to be reused, the rolling direction of the

timing chain must be marked before it is removed.
1. Loosen the fastening screws of the camshaft wheels and

camshaft adjusters (1 or 2 turns). To do this, hold the a/f 32
hexagon of the camshaft adjuster and camshaft timing gear
against the corresponding camshaft with a ring wrench. Loosen
the M12 cheese head bolt by 1 or 2 turns with socket wrench Camshaft timing gears and camshaft
insert T60. adjusters
2. Pull guide rails between the camshafts away from the threaded
pegs. To do this, let timing chain dangle between the camshafts.
Note
z If the timing chain is to be reused, the rolling direction of the
timing chain must be marked before it is removed.
3. Mark rolling direction of timing chain. Remove timing chain from

all sprockets, pulling it forwards.
Figure shows guide rail with fitted

chain case lid and timing chain.
as of MY 2003
g g g
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g g g

15 35 23 Fitting timing chain - as of MY 2003

- Information
- Fitting timing chain
- Subsequent work
Information
Component overview

g g g

3- Guide rail
Fitting timing chain
ATTENTION
assembled)!
g g g
chain jumps over).
Note
removed.
Note
Camshaft timing gears and camshaft adjusters must be installed and it must be possible to turn them.
1. Place timing chain loosely on all sprockets. Ensure that the timing chain is in the correct position on the
guide rails.
2. Fit guide and tensioning rails. For details, see → Removing and installing guide and tensioning rails
3. Place guide rails between the camshafts on the threaded pegs.

To do this, let timing chain dangle between the camshafts.
Guide rails between camshafts
Subsequent work
Subsequent work
1. Install chain case lid. → 153123 Installing chain case lid

g g g
2. Set timing of camshafts. → 150516 Setting the timing
3. Install cover for camshaft housing. → 159123 Installing cylinder head cover
as of MY 2003
g g g
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g g g

15 36 19 Removing and installing chain tensioner - as of MY

2003
- Information
- Removing chain tensioner
- Installing chain tensioner
Information
Component overview
ATTENTION
g g g
z Remove and install the chain tensioner only in overlapping TDC. (The chain tensioner is under
the least amount of pressure in this position).
Note
z All spark plugs (except for those on cylinder 3) must be removed to ensure that the relevant dead centre
can be found more easily.
z The torque support bracket can remain in place.
1. Remove spark plugs (except for cylinder 3) → 287055 Replacing

spark plugs
Spark plug wrench
Note
An alternative method for determining the overlapping TDC is the
"cylinder pipe" (dead centre finder). This tool is part of the pressure-
loss tester WE 1066, Workshop Installation Manual 3.1.4.
2. Find overlapping TDC of cylinder 1. To do this, insert the ignition

rod module of the first cylinder into the corresponding opening in
the valve cover and press in firmly.

– Twist the crankshaft in the direction of motion until the ignition
rod module comes out again with an audible plop. Then twist the
crankshaft until the fixing bore on the crankshaft belt pulley is
aligned with the bore in the timing case cover. The engine is now
located in the ignition TDC of cylinder 1.

– Then twist the crankshaft through 360° in the direction of motion. The engine is now located in the
overlapping TDC of cylinder 1.
g g g
Cable clip TDC of cylinder 1 for vibration damper

fastening
3. Open cable clip -7- of the generator's electric cable and press the cable upwards.
4. Undo chain tensioner -arrow- and unscrew it by hand.
Note
z If the chain tensioner is removed, the aluminium sealing ring must be replaced.
1. Screw chain tensioner with new sealing ring -arrow- down by

hand and tighten. → Tightening torque: 44 ftlb.

2. Clip in the electric cable of the generator again.
3. To check, turn crankshaft two turns in a clockwise direction. Watch out for any stiffness.
g g g
Installing spark plugs Cable clips
4. Install spark plugs and covers.→ 287055 Replacing spark plugs
as of MY 2003
g g y j g
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g g y j g


adjustment - as of MY 2003, until MY 2004
- Preliminary work
- Subsequent work
Tools

relay puller special tool 9235
Preliminary work
Preliminary work
1. Remove cover for camshaft housing → 159121 Removing and installing cover for camshaft housing -
section on "Removing".
Note
g g y j g
z If an engine of model years 2003 to 2004 is to be converted to suit a new hydraulic valve with oil strainer,
the camshaft housing and all camshaft bearing caps must be replaced.
1. Unscrew M6 x 16 fastening screw of the hydraulic valve -Arrow-

.

2. Carefully pull out the hydraulic valve in an upward direction. To
do this, use special tool relay puller 9235.
Relay puller on hydraulic valve
Note
1. Replace sealing ring on hydraulic valve -see Figure- . Do not

insert sealing ring twisted when fitting.
2. Coat sealing ring lightly with engine oil and insert hydraulic valve
into cylinder head.
Hydraulic valve sealing ring

g g y j g
3. Screw in fastening screw -Arrow- and tighten. → Tightening torque: 10 (7.5 ftlb.) Nm
Subsequent work
Subsequent work
1. Install cover for camshaft housing → 159123 Removing and installing cover for camshaft housing -
section on "Installing".

g g y j g
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g g y j g


adjustment - as of MY 2005
- Preliminary work
- Subsequent work
Preliminary work
Preliminary work
1. Remove cover for camshaft housing → 159121 Removing and installing cover for camshaft housing -
Note
1. Remove screws on hydraulic valve. -1-

g g y j g
2. Remove oil strainer with a small magnet. If the oil strainer cannot
be removed through the housing, the bearing cap must be
removed.
Oil strainer fitted

3. The oil strainer is located in the camshaft housing under the first
camshaft bearing cap.

housing
Note
1. Insert the oil strainer into the camshaft housing under the first
camshaft bearing cap. You do not have to remove the camshaft
bearing cap to do this (Figure shows oil strainer without camshaft
bearing cap → Oil strainer partly inserted in camshaft housing ).

housing
2. Place hydraulic valve in installation position. Make sure that the side with the fastening hole is always
pointing towards the intake-air distributor → Camshaft adjustment valve . Fit screws for hydraulic valve →
g g y j g

Tightening torque: 10 (7.5 ftlb.) Nm . -1-
Subsequent work
Subsequent work
1. Install cover for camshaft housing → 159123 Removing and installing cover for camshaft housing -
section on "Installing".
as of MY 2005
g gg g g
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g gg g g

15 47 19 Removing and installing guide and tensioning rails - as

of MY 2003
- Preliminary work
- Information
- Replacing guide and tensioning rails
- Installing guide and tensioning rails
- Subsequent work
Preliminary work
Preliminary work
"Removing"
3. Remove chain case lid. → 153121 21 Removing chain case lid - section on "Removing"
4. Mark rolling direction of timing chain. Remove timing chain from all chain sprockets, pulling it forwards.
→ 153521 Removing timing chain - section on "Removing"
Information
Component overview
g gg g g
Timing chain with guide and tensioning rails

g gg g g

3- Guide rails
g gg g g
1 - Tensioning rail
2 - Threaded pegs
3 - Guide rails
4 - Threaded pegs
5 - Chain tensioner M24 x 1.5; replace sealing ring
6 - Guide rail
Replacing guide and tensioning rails
Removing guide and tensioning rails
Note
g gg g g
Note
removed.
Note
removed.
1. Remove top guide rails -6- if this has not yet been done. Pull guide rail -3- and tensioning rail -1- off
threaded pegs. Ensure that the spring of the tensioning rail for the oil pump drive is in the correct position
in relation to the guide rail -3- .
2. Remove guide rail -3- by loosening four fastening screws (M8 x 35).
g gg g g
Guide rail
3. Remove plastic lid of oil pump drive -7- . To do this, unscrew two M5 x 20 screws -8- and remove plastic
lid. Remove guide rail -9- and tensioning rail -6- .
g gg g g
Oil pump drive

1. Insert guide rail -9- and tensioning rail -6- . Fit plastic lid of oil pump drive -7- . To do this, insert plastic lid
and screw in two screws -8- . → Tightening torque: 4.1 ftlb.
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Oil pump drive
2. Fit guide rail -3- . To do this, screw in four fastening screws (M8 x 35). → Tightening torque: 24 ftlb.
g gg g g
Guide rail
3. Attach guide rail -3- and tensioning rail -1- to threaded pegs. Position the spring of the tensioning rail for
oil pump drive correctly on guide rail -3- . Fit top guide rails -6- when installing the timing chains.
g gg g g
Subsequent work
Subsequent work
1. Install timing chain. → 153523 Installing timing chain - section on "Installing"
3. Set the timing. → 150516 Adjusting timing for camshafts - section on "Adjusting"
"Installing"
g gg g g
as of MY 2003
g g y pp g
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g g y pp g

15 59 19 Removing and installing hydro-tappets - as of MY 2003

- Preliminary work
- Removing hydro-tappets
- Installing hydro-tappets
- Subsequent work
Preliminary work
Preliminary work
1. Remove camshafts . → 150521 Remove camshafts - Chapter "Removing"
Note
z If the flat-base tappets are to be reused, they must be marked
according to installation position using a water-resistant felt-tip
pen and stored in such a way that they cannot be mixed up!
z If the flat-base tappets are to be reused, they must be installed in

the same location!
1. Pull the flat-base tappets out of the camshaft housing one after
the other and store them in such a way that they cannot be mixed
up. Pulling flat-base tappets out of the
camshaft housing
E - Intake side
A - Exhaust side
5 bis 8 - Cylinders
g g y pp g
Putting components down without

mixing them up (cylinder bank 5-6
shown here as an example)
1. Grease flat-base tappets with engine oil and reinsert into the
camshaft housing.
Inserting flat-base tappets in camshaft

housing
Subsequent work
Subsequent work
1. Install camshafts . → 150523 Install camshafts - chapter on "Installing"
as of MY 2003
g g g
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g g g

15 60 19 Removing and installing intake valve - as of MY 2003

- Preliminary work
- Information
- Removing intake valve
- Installing intake valve
- Subsequent work
- Information
Tools

assembly/disassembly tool available tool
for the Cayenne
Preliminary work
Preliminary work
cylinders and valves. → 155955 21 Removing and installing flat-base tappets - chapter on "Removing" .
Do not interchange components.
Information
Component overview
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same dimensions as the exhaust valve in the naturally aspirated engine; because of the sodium filling
it is lighter however and when obtained as a spare part it features a coloured dot to distinguish it. For
further details, please see later chapter entitled "Valve dimensions".

3 - Valve spring
5 - Valve-stem seal
6 - Valve guide
8 - Intake valve
10 - Exhaust valve
g g g
Note
Note
before the valves are removed → Screwing in tool . The valve
lock prevents the valves from being opened while being pressed
down. Alternatively, a rubber plate placed underneath helps if the
cylinder head surface is smooth -2- .
Screwing in tool
Locking valves
2. Fit and adjust lever tool from the valve key
assembly/disassembly tool for the Cayenne NR.54-1 set on
the cylinder head. When doing so, ensure that the middle pipe is
positioned centrally over the spark-plug recesses. The operating
lever can be secured centrally or excentrically. The fastening
screws in the camshaft bearing caps in the front and rear bearing
position are used to secure the tool brackets → Removing tool
setup for valve springs (figure shows fitted cylinder head). Use
the white plastic pressure piece with the magnetic insert to
remove the valve keys. The assembly must be performed as
shown → Removing tool setup for valve springs .
g g g
Valve keys in tool

3. Press the white plastic pressure piece with the magnetic insert against the top concave washer to
remove the valve keys. The concave washer -2- and the valve keys -1- are attracted to the magnetic
insert and release the valve (loosen valve keys with a screwdriver if they are stuck). Remove loose
components (valve springs, top concave washer and valve keys). Repeat procedure as often as
necessary for the affected valves (reposition tool accordingly).

Locking valves
Note
z Exhaust valves in the turbo engine weigh less than exhaust valves in the naturally aspirated engine.
They are marked with a green dot. Do not interchange them.
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 in the valve using the commercially available valve grinding tool (with rubber suction cup) by
means of rotary movements. To do this, hold the valve grinder between the palms of both hands and
press against the valve seat with rotating movements → Grinding the valve seat .
g g g
ATTENTION
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.

6. Replace valve-stem seals. → 156319 Removing and installing

valve-stem seal
Locking valves
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. Pull off the ring of the assembly tool -2- from
the retaining springs -3- before inserting the valve keys. Position


9. Secure the valve keys by pushing up the ring → Valve keys in assembly tool . Check that the valve keys
are aligned correctly -1- .
g g g

10. Insert valve key assembly tool in tool setup and position in front
of the valve stem. → Valve key assembly
Valve key assembly

11. When assembling the valve keys, ensure that the assembly tool
is inserted at the valve stem end -2- and is then pushed down
(the tool remains secured when this is done -1- ). The valve keys
click audibly into the valve grooves when the valve key assembly
tool is pressed onto the valve. Check valve keys to ensure that
they are installed correctly.

grooves
Subsequent work
Subsequent work
Information
Valve dimensions
g g g

disc to valve pressure
area)
from the exhaust valve in
the naturally aspirated
engine
as of MY 2003
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print
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g g g

15 62 19 Removing and installing exhaust valve - as of MY 2003

- Preliminary work
- Information
- Removing exhaust valve
- Installing exhaust valve
- Subsequent work
- Information
Tools

for the Cayenne
Preliminary work
Preliminary work
cylinders and valves. → 155955 21 Removing and installing flat-base tappets - chapter on "Removing" .
Information
Component overview
g g g

3 - Valve spring
5 - Valve-stem seal
6 - Valve guide
8 - Intake valve
10 - Exhaust valve
g g g
Note
Note
before the valves are removed → Screwing in tool . The valve
lock prevents the valves from being opened while being pressed
down. Alternatively, a rubber plate placed underneath helps if the
cylinder head surface is smooth -2- .
Screwing in tool
Locking valves
position are used to secure the tool brackets → Removing tool
setup for valve springs (figure shows fitted cylinder head). Use
the white plastic pressure piece with the magnetic insert to
remove the valve keys. The assembly must be performed as
shown → Removing tool setup for valve springs .
g g g
Valve keys in tool

3. Press the white plastic pressure piece with the magnetic insert against the top concave washer to
remove the valve keys. The concave washer -2- and the valve keys -1- are attracted to the magnetic
insert and release the valve (loosen valve keys with a screwdriver if they are stuck). Remove loose
components (valve springs, top concave washer and valve keys). Repeat procedure as often as
necessary for the affected valves (reposition tool accordingly).

Locking valves
Note
z Exhaust valves in the turbo engine weigh less than exhaust valves in the naturally aspirated engine.
They are marked with a green dot. Do not interchange them.
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 in the valve using the commercially available valve grinding tool (with rubber suction cup) by
means of rotary movements. To do this, hold the valve grinder between the palms of both hands and
press against the valve seat with rotating movements → Grinding the valve seat .
g g g
ATTENTION
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.

6. Replace valve-stem seals. → 156319 Removing and installing

valve-stem seal
Locking valves
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. Pull off the ring of the assembly tool -2- from
the retaining springs -3- before inserting the valve keys. Position


9. Secure the valve keys by pushing up the ring → Valve keys in assembly tool . Check that the valve keys
are aligned correctly -1- .
g g g

Valve key assembly

11. When assembling the valve keys, ensure that the assembly tool
is inserted at the valve stem end -2- and is then pushed down
(the tool remains secured when this is done -1- ). The valve keys
click audibly into the valve grooves when the valve key assembly
tool is pressed onto the valve. Check valve keys to ensure that
they are installed correctly.

grooves
Subsequent work
Subsequent work
Information
Valve dimensions
g g g

area)
engine
as of MY 2003
g g g
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g g g

15 63 19 Removing and installing valve-stem seal - as of MY

2003
- Preliminary work
- Information
- Removing valve-stem seal
- Installing valve-stem seal
- Subsequent work
- Information
Tools

puller special tool 3364
assembly driver special tool 9606/1

for the Cayenne
g g g
Preliminary work
Preliminary work
Note
The cylinder head can remain fitted while this work is carried out.
2. Remove camshafts on both cylinder banks. → 150521 Removing camshafts
cylinders and valves. → 155955 21 Removing and installing flat-base tappets - section on "Removing" .
Information
Component overview
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3 - Valve spring
5 - Valve-stem seal
6 - Valve guide
8 - Intake valve
10 - Exhaust valve

g g g
Note
Note
z Before switching to another cylinder, the cylinder must be positioned at the bottom dead centre and
supplied with compressed air (see above).
Note
1. Set piston for the corresponding cylinder to bottom dead centre. 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 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 the pressure in the cylinder so that
the valve does not fall into the cylinder while the work is being carried out. 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.

position are used to secure the tool brackets → Removing valve
keys (figure shows fitted cylinder head). Use the white plastic
pressure piece with the magnetic insert to remove the valve keys.
The assembly must be performed as shown → Removing valve
keys .
Removing valve keys

4. Press the white plastic pressure piece with the magnetic insert
against the top concave washer to remove the valve keys. The
concave washer -2- and the valve keys -1- are attracted to the
magnetic insert and release the valve (loosen valve keys with a
screwdriver if they are stuck). Remove loose components (valve
springs, top concave washer and valve keys). Repeat procedure
for valves on pressurised cylinder (reposition tool accordingly).
Valve keys in tool

5. 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
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Valve-stem seal in puller Valve-stem seal before puller
Closed puller
6. When engaging the puller 3364, push sliding sleeve down and close tool. -arrow-
7. Remove valve-stem seal by activating the negative (slide)

hammer. -arrow- . Repeat procedure for valves on pressurised
cylinder (reposition tool accordingly).
Note
Note
z Before switching to another cylinder, the cylinder must be positioned at the bottom dead centre and
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supplied with compressed air (see above).
Note
Note
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- .
Valve-stem seal with tool

2. Push protective cap onto valve stem end. → Protective cap
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.
Valve-stem seal pushed over

protective cap and valve
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-
exhaust valve in the turbo engine) on the bottom concave washer. Place top concave washer in position.
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Tool setup - valve keys Pushing on valve-stem seal
Pull off the ring of the assembly tool -2- from the retaining springs -3- before inserting the valve keys.
Position valve keys with the thin side facing upwards -1- .

7. Secure the valve keys by pushing up the ring → Valve keys in
assembly tool . Check that the valve keys are aligned correctly
-1- .

Valve key assembly

9. When assembling the valve keys, ensure that the assembly tool is inserted at the valve stem end -2- and
is then pushed down (the tool remains secured when this is done -1- ). The valve keys click audibly into
the valve grooves when the valve key assembly tool is pressed onto the valve. Check valve keys to
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grooves
ensure that they are installed correctly.
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.
Subsequent work
Subsequent work
1. Fit flat-based tappets. → 155955 23 Removing and installing flat-base tappets - section on "Installing" .
Information
Valve dimensions

area)
engine
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as of MY 2003
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WARNING
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15 70 21 Removing cylinder head - as of MY 2003

- Preliminary work
- Information
- Removing cylinder head
Preliminary work
Preliminary work
Note
z If more comprehensive work, e.g. replacement of the entire cylinder head, is intended, the exhaust
manifolds must also be removed. → 261019 Removing and installing exhaust manifold - Chapter
"Removing" [9PAAE1 9PAAE7]→ 261019 Removing and installing exhaust manifold - Chapter
"Removing"
3. Remove intake-air distributor. → 244619 Removing and reinstalling intake-air distributor - section on
"Removing"
4. Remove chain case lid. → 153121 21 Remove chain case lid – section on "Removing"
5. Remove camshaft housing. → 150321 Remove camshaft housing - section on "Removing"
Information
Component overview
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Component overview
1 - Cap
2 - Cylinder head
3 - Straight pin
4 - Pan-head screw M12 x 1.5 x 140
5 - Cap
6 - Spark plug
7 - Cap
8 - Cylinder-head gasket
9 - Vent connection

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1. Remove guide rail of timing chain -3- . To do this, unscrew fastening screws -4- .
1 - Camshaft timing gear

2 - M12 x 140 cheese-head bolt
3 - Guide rails
4 - Guide rail fastening screw
5 - Timing chain; use same running direction when reusing
2. Remove oil separator vent line from cylinder head. To do this, unscrew the fastening screws
-3 and upper 4- .
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Oil separator vent line from cylinder head.
3. Disconnect vent line for cylinder heads. To do this, press the

ribbed surfaces of the buttons and pull off the plugs.
Cylinder head vent line

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Note
z In the case of the turbocharged engine (M48/50), only the upper
fastening screws of the turbocharger need to be undone.
4. Uncover cable of oxygen sensor front catalytic converter.

5. Unscrew starter catalyst from exhaust manifold. To do this,
loosen the 3 fastening nuts.
6. Unscrew fastening screws of cylinder head in the opposite order

of the tightening sequence -figure- .
Illustration shows tightening sequence
7. Remove cylinder head and cylinder head gasket.
as of MY 2003
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15 70 23 Installing cylinder head - as of MY 2003

- Information
- Installing cylinder head
- Subsequent work
Information
Component overview
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Component overview
1 - Cap
2 - Cylinder head
3 - Straight pin
4 - Pan-head screw M12 x 1.5 x 140
5 - Cap
6 - Spark plug
7 - Cap
8 - Cylinder-head gasket
9 - Vent connection

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ATTENTION

Mechanical angle disc for torque angle screws
Note
z All sealing surfaces must be clean and free of grease!
z It is essential to work carefully!
z Tightening sequences and tightening torques must be observed!
z If more extensive work, such as complete replacement of the

cylinder head, is necessary, the exhaust manifolds must be
modified as well. → 261019 Removing and installing exhaust
Cylinder bank 1 -4
manifolds [9PAAE1 9PAAE7]→ 261019 Removing and installing
exhaust manifolds [9PAAF1 9PAAJ1]
1. Place cylinder head gasket correctly, i.e. according to the specifications, onto the straight pins of the
engine crank housing. This must be done in such a way that the "Top" marking can be read -figure- .
2. Fit cylinder head. Insert M12 x 1.5 x 140 cylinder head screws (screws can be used again).
3. The tightening sequence 1-10 must be observed for every tightening step.
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Setting torque
Undo all cheese-head bolts.
Final tightening torque:
→ Tightening torque: 22 ftlb. Cylinder bank 5 - 8
→ torque angle: 90 °
Note
z In the case of the turbocharged engine (M48/50), screw down the
upper fastening screws of the turbocharger.

4. Fasten primary catalytic converter to the exhaust manifold. To do this, fasten three fastening nuts
→ Fastening nuts for exhaust manifold . → Tightening torque: 17 ftlb.
5. Secure cable of starter catalyst oxygen sensor in the cable guide.
6. Place vent line on the cylinder head flange. → Vent line on connection piece of cylinder head To do this,
press the ribbed surfaces of the buttons and pull off the plugs.
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Vent line on connection piece of Fastening nuts for exhaust manifold

cylinder head
7. Mount oil separator vent line onto cylinder head with new sealing ring -2- . To do this, position and
tighten the fastening screws -3 and upper 4- . → Tightening torque: 7.5 ftlb.
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Oil separator vent line
8. Fasten guide rail of timing chain -3- . To do this, tighten the fastening screws -4- . → Initial tightening:
11 ftlb. → Final tightening: 90 °
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1 - Camshaft timing gear

2 - M12 x 140 cheese-head bolt
3 - Guide rails
4 - Guide rail fastening screw
5 - Timing chain; use same running direction when reusing
Subsequent work
Subsequent work
1. Install camshaft housing. → 150323 Install camshaft housing – section on "Installing"
2. Install chain case lid. → 153123 23 Install chain case lid – section on "Installing"
3.
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Install intake-air distributor. → 244619 Removing and reinstalling intake-air distributor - section on
"Installing"
"Installing"
as of MY 2003
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15 73 56 Replacing attachment for exhaust manifold (stud) - as

of MY 2003
- Preliminary work
- Replacing attachment for exhaust manifold (stud)
- Subsequent work
Preliminary work

1. Remove exhaust manifold. → 261019 Removing and installing exhaust manifold - chapter on
"removing" [9PAAE1 9PAAE7]→ 261019 Removing and installing exhaust manifold - chapter on
"removing" [9PAAF1 9PAAJ1]
2. Remove exhaust manifold seal.
Replacing attachment for exhaust manifold (stud)
Replacing attachment for exhaust manifold (studs)
Note
Only replace studs if they are damaged or their reliability can no longer be assured!
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Exhaust manifold
1. Screw two M8 nuts onto the stud and counter with two open-
ended wrenches.
Tightening nuts on stud

arrow
2. To unscrew stud, turn rear nut to left.
Note
z Before inserting the new stud, the internal thread in the cylinder head must be checked for damage!
3. Screw in new stud hand-tight, then screw two nuts onto the new stud as before and counter.
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Screwing in new studs hand-tight Unscrewing stud

4. Screw in new stud by
turning front nut to right.
Screwing in new stud Countering both nuts in direction of

arrow
5. The stud must be screwed in until dimension -A- is obtained.
Check dimension with a caliper gauge.
Checking dimension with caliper

gauge
Dimension A
Engine type Dimension A
M48/00 (naturally aspirated engine) 24.5 - 25.5 mm
M48/50 (turbocharged engine) 23 - 24 mm
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Subsequent work

1. Re-install exhaust manifold with new seal. → 261019 Removing and installing exhaust manifold - chapter
on "installing" [9PAAE1 9PAAE7]→ 261019 Removing and installing exhaust manifold - chapter on
"installing" [9PAAF1 9PAAJ1]
as of MY 2003
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15 84 19 Removing and installing camshaft adjusters - as of MY

2003
- Preliminary work
- Removing camshaft adjusters
- Installing camshaft adjusters
- Subsequent work
Tools


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Preliminary work

1. Remove camshaft housing cover. → 159121 Removing and installing cover for camshaft housing -
Tools and materials
Special tools
Tools

Chapter 2.2.2 "
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camshafts
in timing case.
Note
z The timing is always set simultaneously on both cylinder banks. Once a cylinder bank has been set, the
crankshaft must not be turned to set the other cylinder bank!
z The fastening screws of the chain sprockets must be replaced after removal.
z The screws on the sprocket wheels are tightened by hand during assembly and are then loosened by
one or two turns. This play is necessary so that the camshafts can still be turned.
z The cylinder bank is set with the standard chain tensioner that is installed.
ATTENTION
assembled)!
chain jumps over).
Note
z If the cams on cylinder 1 are not positioned as shown, check whether the crankshaft needs to be turned
through another turn (360°)!
2. Make sure that the cams for the 1st cylinder and 5th cylinder are positioned as shown (cylinder 1 at
ignition TDC) -see figure- and → View shows position of cams on cylinder 5 .
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View shows position of cams on View shows position of cams on

cylinder 5 cylinder 1

crankshaft
3. Insert fixing pin 9595/1 into the relevant groove in the timing chain housing cover through the bore
provided in the crankshaft wheel -see figure- .

5. Loosen the timing chain and pull the upper plastic guide off the two pins. If necessary, use a ring wrench
to turn the camshaft timing gear back and forth to provide more clearance for the timing chain between
the wheels → Upper plastic guide for timing chain .
Note
z The fastening screw and diamond washer of the camshaft
adjuster only need to be replaced if removed.
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Camshaft adjuster and camshaft

timing gear
7. Loosen the camshaft adjuster from the back with a rubber

hammer.
Loosening camshaft adjuster
ATTENTION
Note
Take camshaft adjuster out of the
z There is a diamond washer between the camshaft and camshaft chain
timing gear or camshaft adjuster. This must be replaced after the
corresponding wheel has been removed. If the fastening screw of the wheel is only loosened in order to
adjust the timing (1 or 2 revolutions), the diamond washer and fastening screw do not need to be
replaced.
8. With both hands, carefully take the camshaft adjuster out of the chain.
9. Remove the diamond washer which is located underneath the camshaft adjuster.
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Removing diamond washer

ATTENTION
assembled)!
chain jumps over).
Note
z If the diamond washer and pan-head screw M12 are removed,
replace the camshaft.
1. Replace the diamond washer and M12 cheese head bolt which
are located underneath the camshaft adjuster.
Replacing diamond washer
ATTENTION
2. Lift timing chain and place camshaft adjuster carefully on the

camshaft. In order to have more play in the timing chain, if
necessary turn camshaft timing gear back and forth. Place timing Camshaft adjuster on camshaft
chain on camshaft adjuster.
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3. Fit plastic guide of the timing chain.
Turning camshaft timing gear
Position fastening screws on the

camshaft adjuster
4. Position new M12 fastening screw and hexagon on the camshaft adjuster and screw in loosely (it must
still be possible to turn the camshaft timing gear)
-figure shows fastening screw and hexagon before installation- .
5. Install chain tensioner -arrow- . For chain tensioner tightening

torque, see → 153619 Removing and installing chain tensioner -
Subsequent work

2. Install camshaft housing cover. → 159123 Removing and installing cover for camshaft housing - chapter
on "installing"
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as of MY 2003
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WARNUNG
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15 90 55 Replacing lid seal for camshaft housing (valve lid seal)

- as of MY 2003
- Information
Information
Information
1. In order to change the camshaft housing cover seal, the camshaft housing cover must be removed and
installed.→ 159121 Removing camshaft housing cover → 159123 Installing camshaft housing cover
as of MY 2003
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15 91 21 Removing cover for camshaft housing - as of MY 2003

- Preliminary work
- Information
- Removing cover for camshaft housing on cylinder bank 1 - 4
Tools

Socket changeover ratchet, commercially
1/4 inch available tool .gif

available tool

available tool
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Preliminary work
Preliminary work
1. Remove engine cover → 108319 Removing and installing engine cover - Chapter "Removing".
2. Remove secondary air pump with console → 266519 Removing and installing secondary air pump -
Chapter "Removing".
3. Remove ignition coils (ignition rod module). Refer to→ 282055 Replacing ignition coils
Tools and materials
Special tools
Note
z It is best to use a tool that has an head height of less than 50 mm
-A- (see special tools) to loosen and tighten the rear fastening
screw of the cylinder head cover close to the plenum panel.
Tool height
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Equipment Manual,
Chapter 2.2.2 or
2.2.1"
Equipment Manual,
Chapter 2.4"
Chapter 2.4"
Chapter 2.4"
-E- T40 inner hexagon → "See Workshop
socket bit Equipment Manual,
Chapter 2.4"
Information
Component overview
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1 - Design cover
2 - Ball socket
3 - Cover holder
4 - BM8 x 45 screw
11 - Cap
14 - Grommet
15 - Sleeve
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Note
1. Press together the plug connection for the positive crankcase

ventilation on the camshaft housing lid -see arrows- and pull it
off.
Plug connection of the positive

crankcase ventilation valve.
2. Pull off the cap and the cable plug for the hydraulic valve lying
beneath it by pressing on wire clip -a- .
Cap and cable plug of the hydraulic

valve
Note
z Plastic clips can be damaged once the wiring harness holder has
been undone and must be checked to ensure they can be used
again!
3. Remove wiring harness holders by pulling carefully on the

holders. Lay wiring harness aside.
Wiring harness holder

4. Remove wiring harness on sheetmetal holders on the camshaft housing lid.
ATTENTION
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z The trigger wheel can be damaged when the cover of the

camshaft housing is moved.
z Ignition faulty.
z Engine damage.

→ Carefully watch the trigger wheel when removing or fitting the
cover of the camshaft housing.
Note
Wiring harness
z If the camshaft housing lid is not removed carefully, it can cause
the trigger wheel on the position sensor at the rear on the camshaft to be bent out of shape!
Note
5. Unscrew screws -1 to 19- ( -16 and 19- were mounted on the

torque support bracket) and lift the camshaft housing lid carefully
at the back to avoid damaging the trigger wheel of the reference
mark sender on the camshaft (this is located in the vicinity of
screws 1 and 7). Then lift it off completely.
Tool height
6. Turn the camshaft housing lid over and remove inner and outer seal for camshaft housing. Clean sealing
faces on the camshaft housing lid and cylinder head.
Note
z Always replace seals.
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as of MY 2003
C15, C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28,
C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
Sealing faces on camshaft housing lid

and cylinder head
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15 91 23 Installing cover for camshaft housing - as of MY 2003

- Information
- Installing cover for camshaft housing on cylinder bank 1 - 4
- Subsequent work
Tools

Socket changeover ratchet, commercially
1/4 inch available tool .gif

available tool

available tool
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Tools and materials
Special tools
Note
Tool height

Equipment Manual,
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Chapter 2.2.2 or
2.2.1"
Equipment Manual,
Chapter 2.4"
Chapter 2.4"
Chapter 2.4"
-E- T40 inner hexagon → "See Workshop
socket bit Equipment Manual,
Chapter 2.4"
Information
Component overview
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1 - Design cover
2 - Ball socket
3 - Cover holder
4 - BM8 x 45 screw
11 - Cap
14 - Grommet
15 - Sleeve
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Installing cover for camshaft housing on cylinder bank 1 - 4
ATTENTION
z Ignition faulty.
z Engine damage.

Note
Note
z Always replace inner and outer seal for camshaft housing!
1. Thoroughly clean sealing faces on the camshaft housing lid and

cylinder head.
Camshaft housing lid and cylinder

head
2. Insert inner and outer seal in camshaft housing lid and apply a
bead of Drei Bond sealant to the lining between the cylinder head
and timing chain cover on both sides.
Note
z If the camshaft housing cover is not fitted carefully, it can cause the trigger wheel on the position sensor
at the rear on the camshaft to be bent out of shape!
3. Position the camshaft housing lid carefully; do not bend the trigger wheel of the position sensor on the
camshaft when doing so.
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Sealant beads on both sides

4. Insert all ignition rod modules aligned in the corresponding
camshaft housing lid.
Inserting ignition rod modules

5. Using the assembly sleeve 9701, press the sealing lip of the
hydraulic valve over the hydraulic valve and align it.
Sealing lip with assembly sleeve
Note
z It is best to use a tool that has an addendum of less than 50 mm
-A- (see special tool) to tighten the rear fastening screw on the
cylinder head cover close to the plenum panel.
6. Position all fastening screws and tighten them in accordance with

the correct tightening sequence → Tightening torque: 13 (9.5
ftlb.) Nm -see figures for both cylinder rows- . Screws
-18 and 19 cylinder rows 1 to 4- are inserted later with the
torque support bracket.
Tool height
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7. Fit wiring harness to sheetmetal holders on the camshaft housing

lid.
Wiring harness
8. Fit wiring harness holder with new plastic clips. To do this, simply press on the wiring harness holder.
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Cable plug Wiring harness holder
9. Connect the cable plug for the hydraulic valve and fit the cap.
10. Attach plug connection for the positive crankcase ventilation to the flange on the camshaft housing lid.
11. Tighten the ignition coils. → Tightening torque: 10 (7.5 ftlb.) Nm
12. Connect ignition coil. To do this, push on the connector until it

locks with an audible click.
Ignition coil
13. Install bracket for torque support. Tighten the M8 x 45 Torx
screws at the top screw points. → Tightening torque: 17 ftlb.
Tighten the M6 x 40 screws at the bottom screw fastening points
(middle of valve cover). → Tightening torque: 9.5 ftlb.
Fastening screws on bracket for

torque support
Subsequent work
Subsequent work
1. Install ignition coils (ignition rod modules). Refer to→ 282055 Replacing ignition coils
2. Install secondary air pump with console. → 266519 Removing and installing secondary air pump -
3.
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Install engine cover . → 108319 Removing and installing engine cover - Chapter "Installing".
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
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19 01 01 Checking cooling system - as of MY 2003

- Checking cooling system
Tools

Tools and materials
Tools and materials

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Tools
A - Cooling system leak tester (pump) see Workshop Equipment Manual, Chapter 3 "WE1069"
B - Hose extension FZ 100
C - K22 cap adapter (for sports cars)
D - K60 cap adapter included (in scope of delivery Filling device 9696 )
Checking cooling system
Coolant: Checking the level and antifreeze content
ATTENTION

DANGER
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ATTENTION
Note
Maintenance cover
ATTENTION
→ Never open the cooling system when it is hot. Emerging coolant

may be very hot and can cause scalding.
2. Carefully open the cap on the coolant reservoir. Unscrew the cap Cap on coolant reservoir
in an anti-clockwise direction.
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.
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Note
z The following table specifies how much coolant must be replaced
by pure antifreeze in order to adjust the freezing point to -37 °C.
Checking the antifreeze content

-5 9
- 10 8.5
- 15 7.5
- 20 7
- 25 5
- 30 3.5
- 35 1.5
Checking the antifreeze content of the coolant using a refractometer
Note
z The following diagram shows the scale used by Leitenberger.
z The scale can vary slightly, depending on the manufacturer.
z The ETHYLENE scale must be used for Porsche antifreeze.
Refractometer
Item Designation of the display Explanation

-A- Scale for propylene-based coolant Do not use for engine type M48.
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-B- Scale for ethylene-based coolant Coolant such as elf GLACELF

SUPRA. Use for engine type M48.
-C- Scale for battery acid The charge state of a battery can be
checked here. The values on the left
side indicate the specific gravity of
the electrolyte. The battery must be
recharged once the charge drops
below 1.20.
-D- Scale for alcohol-based windscreen The freezing point of the windscreen
cleaner cleaner can be read off here.
-E- Light/dark limit In conjunction with the points of
intersection of the relevant scales, it
specifies the value to be established.
-F- Waterline The light/dark limit must be located
here when sprinkled with distilled
water.
1. Using a pipette, take a sample from the coolant reservoir.
Pipette
2. Deposit a few drops on the test surface.
Depositing drops on the test surface

3. Close the light-diffusing lens. A closed film must form.
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.
Note
z The following table specifies how much coolant must be replaced
by pure antifreeze in order to adjust the freezing point to -37 °C.
Closing the light-diffusing lens
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-5 9
- 10 8.5
- 15 7.5
- 20 7
- 25 5
- 30 3.5
- 35 1.5
Checking the cooling system for leaks
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.

2. Check the coolant level. A graduated disc with a "min" and "max"
marking is located in the opening of the reservoir. The "min" level
must be covered with coolant.
Graduated disc in the opening of the

reservoir
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.
as of MY 2003
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WARNUNG
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19 01 29 Cooling system cleaned (after oil/coolant mixing) - as

of MY 2003
- Cleaning the cooling system
Tools

filling device special tool 9696
ATTENTION

DANGER
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ATTENTION
Note

(includes bleeding)
Note
z The cleaning work steps must be repeated until no more oil rises
to the surface in the coolant reservoir.
z The radiator cleaning agent mixture must be approx. 23 litres in

the filling canister of the filling device filling device 9696.
z The cleaning agent is mixed with water at a ratio of 50:50 Draining cooling system
(Frostox R Spezial).
2. Fill the cooling circuit with the cleaning agent mixture. To do this, proceed with the cooling system
analogously to filling the coolant. → 193817 Draining and filling in coolant (includes bleeding) - chapter on
"Filling in"
3. Start the vehicle.
4. After the vehicle has been bled and the coolant temperature is > 80 °C, let the stationary vehicle run at
medium engine speed for at least 15 minutes.

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ATTENTION

6. Open coolant reservoir carefully and slowly in an anti-clockwise Coolant reservoir

direction with gloves and a cloth.

(includes bleeding)
8. Use hot water to rinse out any oil which has adhered inside the
coolant reservoir.
9. Close the cooling system and fill the coolant circuit with water
only and then bleed the cooling system according to regulations.
10. Start engine.
11. After the vehicle has been bled and the coolant temperature is > Coolant drain plug
80 °C, let the stationary vehicle run at medium engine speed for
at least 15 minutes.
ATTENTION

13. Open coolant reservoir carefully in an anti-clockwise direction Coolant reservoir

with gloves and a cloth and relieve any residual pressure.

(includes bleeding)
15. Close the cooling system and bleed with the approved antifreeze
mixture according to regulations. → 193817 Draining and filling
coolant (includes bleeding)
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Coolant drain plug
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
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19 08 19 Removing and installing electric fan - as of MY 2003

- Removing electric fan
- Installing electric fan
- Subsequent work
Removing electric fan
Note
chapter on "Removing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 192019 21 Removing and
installing cooling fan housing (radiator frame) - chapter on "Removing" [9PAAJ1]
Removing motor fan

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Fastening screws for securing fan to Electric connector on radiator frame

engine
Removing fan for air conditioning

When doing so, guide the cables and control unit.

air conditioner
View shows the removal process

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Installing electric fan
Installing fan for air conditioning
1. Push fan cable with control module from underneath through the
radiator frame.
View shows the installation

2. Tighten the three fastening screws. → Tightening torque: 3 ftlb.

air conditioner
3. Route cables correctly and clip electric plug into the frame at the
top.

Installing engine fan
1. Push fan from the bottom into the frame and tighten the 3 fastening screws to 4 Nm (3 ftlb.).
2. Route connecting cables correctly and clip electric connector into the radiator frame at the top.
Subsequent work
Subsequent work
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Electric connector on radiator frame Fastening screws for securing fan to

engine
Note
1. Install the radiator frame. → 192019 Removing and installing cooling fan housing (radiator frame) -
chapter on "Installing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 192019 23 Removing and
installing cooling fan housing (radiator frame) - chapter on "Installing" [9PAAJ1]
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
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19 20 19 Removing and installing radiator fan housing (radiator

frame) - as of MY 2003
- Preliminary work
- Removing radiator fan housing (radiator frame)
- Installing radiator fan housing (radiator frame)
- Subsequent work
Preliminary work
Preliminary work
1. Removing the front engine compartment cover. → 700219 Removing and reinstalling front cover (engine
2. Remove Y-shaped pipes. → 243519 Removing and installing air box for throttle housing (Y-shaped pipe)
- chapter on "Removing" [9PAAF1]→ 243519 Removing and installing air box for throttle housing (Y-
shaped pipe) - chapter on "Removing" [9PAAD1 9PAAD7]→ 243519 Removing and installing air box for
throttle housing (Y-shaped pipe) - chapter on "Removing" [9PAAE1 9PAAE7]
DANGER
9PAAD7] or battery → Work instructions after disconnecting the battery
Note
The repair instructions differ slightly in the illustrations for the V6. The work steps are essentially identical.
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Cooling fan housing (radiator frame)
1. Disconnect the electric plugs on the fans.

2. Unclip the cable harness fixed to the vehicle from the clips on the
radiator frame.
Wiring harness fixed to the vehicle

3. Loosen the two upper fastening screws of the radiator module on
the lock carrier.
4. Press the radiator module towards the engine until the frame can
be pulled up and out.
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5. Release the catch springs Upper fastening screws for radiator

to the left and right on the motor
radiator module and pull
the frame up and out.
View of the catch springs when the

radiator has been removed
If the radiator frame is stuck, it can be released carefully by means of
a crowbar.
Loosen stuck radiator frame with

mounting lever

1. Slide the radiator frame from the top to the bottom along the radiator into the engine compartment.
2. Check whether the installation is correct. To do this, check whether the catch springs on the left and right
have engaged properly and that the four fastening projections on the underside have engaged in the
plastic clamps.
3. Tighten the two upper fastening screws of the radiator module on

the lock carrier.
Upper fastening screws for radiator

motor
4. Join the two electric connectors on the top side.
5. Press the wiring harness into the 4 fastening clips.

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Pressing the wiring harness into Electric connector for the fan
fastening clips
Subsequent work
Subsequent work
1. Install Y-shaped pipes. → 243519 Removing and installing air box for throttle housing (Y-shaped pipe) -
chapter on "Installing" [9PAAF1]→ 243519 Removing and installing air box for throttle housing (Y-shaped
pipe) - chapter on "Installing" [9PAAD1 9PAAD7]→ 243519 Removing and installing air box for throttle
housing (Y-shaped pipe) - chapter on "Installing" [9PAAE1 9PAAE7]
2. Install front engine cover. → 700219 Removing and reinstalling front cover (engine compartment) -
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g g g

19 38 17 Draining and filling in coolant (includes bleeding) - as

of MY 2003
- Information
- Draining coolant
- Filling the cooling system (includes bleeding)
- Bleeding vehicles with auxiliary heater
Tools

Assembly tools for spring commercially NR.72

band clamps available tool

available tool
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Tools and materials
Special tools
Special tools 1
- - Flexible screwdriver a/f 7 (for loosening or tightening screw hose clamps) Flexible screwdriver a/f 7
A- NR.73-1
- - Antifreeze protection testing device (for checking the antifreeze content in the cooling system. The
B- design can deviate from that shown in the picture.)
- - Spring band clamp pliers (for opening and closing spring band clamps) Assembly tools for spring
C- band clamps NR.72
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Special tools 2 Filling device 9696
-1- - Canister (canister with lifting tube, capacity approx. 30 l, with volume scale)
-2- - Hose extension
-4- - Venturi nozzle (included in the scope of delivery of radiator vacuum filling device)
-6- - Pressure gauge (included in the scope of delivery of radiator vacuum filling device)
Information
Components of the radiator vacuum filling device
Note
z Pay attention to the special features in the corresponding chapter for vehicles with auxiliary heater.
→ 193817 Draining and filling coolant (includes bleeding) - chapter on "Bleeding"
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Vacuum filling device components Filling device 9696
-1- - Adapter K 22 (installed in place of the cap on the coolant reservoir.)

-2- - Hose extension FZ 100 (installed between K22 and KVB 01.)
-3- - KVB 01 (vacuum pressure gauge with two shut-off valves)
V1-
V2-
-4- - Venturi nozzle (a vacuum is produced in this component by means of compressed air. A pressure
between 6 and 10 bar must be present.)
-5- - Filler hose (the cooling system is refilled via this hose.)
-6- - Return lines (the compressed air and the extracted coolant are drawn off via this hose.)
Draining coolant
Draining coolant
ATTENTION

ATTENTION
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scalding.
DANGER
ATTENTION
Note

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Maintenance cover
3. Open cap on the reservoir and remove.
4. Remove engine guard. → 108019 Removing and installing engine

guard - chapter on "Removing"
Engine guard
5. Release the front apron on the underside.

6. Remove the support plate under the radiator. To do this, loosen
the 4 fastening screws.

7. Drain cooling system. If present, remove the drain plug from the radiator, otherwise open the lowest
coolant hose on the radiator, and drain the coolant into a container and dispose of it according to the
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applicable national laws if no longer required.
8. Fit a new drain plug on the radiator and tighten it. If removed, fasten coolant hose.
9. Install the support plate under the radiator. Tighten the four
Filling the cooling system (includes bleeding)
Filling cooling system (includes bleeding)

1. Screw the cap adapter for the coolant reservoir (K 60) 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° to flow direction).
4. Connect the Venturi nozzle to the vacuum pressure gauge.
Note
z The coolant amount provided must be approx. 2 litres more than
the amount which has to be filled. → Technical data for M48/00
engine (Cayenne S) [9PAAE1 9PAAE7]→ Technical data for
M48/00 engine (Cayenne S) [9PAAD1 9PAAD7 9PAAF1
9PAAJ1], → Technical data for M48/50 engine (Cayenne
Turbo) [9PAAF1 9PAAJ1]→ Technical data for M48/50 engine
(Cayenne Turbo) [9PAAD1 9PAAD7 9PAAE1 9PAAE7], →
Connecting the Venturi nozzle to the
Technical data for BFD engine (Cayenne ) [9PAAD1 9PAAD7]
vacuum pressure gauge
→ Technical data for BFD engine (Cayenne ) [9PAAE1 9PAAE7
9PAAF1 9PAAJ1]
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z Because differing quantities of coolant can drain away for different types of repairs, the filling capacities
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 suctioned-in coolant quantity. Observe volume scale on the
canister.
z 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 near the reservoir.
Note
z The bleeding process is completed more quickly if the canister is positioned at roughly the same height
as the coolant expansion tank.
6. Push the filler hose -5- of the vacuum pressure gauge onto the canister connection. Lay the return line
-6- from the Venturi nozzle to a second container (bucket).
Vacuum filling device components
Note
z A hissing sound after connecting the compressed air supply is
usual.
7. Connect the compressed air supply.
Connecting the compressed air supply

8. Open both shut-off valves on the vacuum pressure gauge until the transparent filler hose -5- has
completely filled with coolant.
9. Close the left shut-off valve (V1) on the vacuum pressure gauge and allow a vacuum to build up in the
cooling system.
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Closing the left shut-off valve (V1) Shut-off valves on the vacuum
pressure gauge
Note
z If no vacuum is generated
(the pointer does not
move to the green area),
there is a leak in the
cooling system.
z Deformation of the rubber

hoses of the cooling
system is normal.
When there is sufficient vacuum, close
z When the pressure gauge the right shut-off valve (V2)
pointer is in the green
area of the display scale, a sufficient vacuum has been built up.
z 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 (indicator is in the green area), close the right
shut-off valve (V2) and then disconnect the compressed air supply.
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 shut-off valve (V2).
13. Then remove the complete filling tool (including the cap K 60).
Opening right shut-off valve

14. If necessary, fill the coolant reservoir with coolant to the maximum marking.
Note
z If necessary, the system can be checked for leaks. → 190101 Checking cooling system - chapter on
"Checking"
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Cooling system test device Maximum marking for coolant

reservoir
15. Screw on the cover of the reservoir in a clockwise direction.
17. Re-install the complete engine guard. → 108019 Removing and

installing engine guard - chapter on "Installing"
18. 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 with coolant.
Reservoir cap

1. Fill and bleed the vehicle as described in the previous chapter using the vacuum filling device. → 193817
Draining and filling coolant (includes bleeding)
2. Warm engine to operating temperature (≥ 90 °C).
Note
z Do not activate the 2/3 directional-control valve with the Porsche System Tester above 1500 rpm.
z Activate the 2/3 directional-control valve with the Porsche System Tester below 1500 rpm.
3. Operate engine for 5 minutes with changing engine speeds. When doing this, run the engine for 10
seconds in idle and then for 10 seconds at 4,000 rpm. In the speed transition from higher engine speeds
(1500 to 4000 rpm) to idle (approx. 600), the directional-control valve should be activated with the
Porsche System Tester below 1500 rpm. Note that the 2/3 directional-control valve is not activated with
the Porsche System Tester above 1500 rpm.
4. Let the vehicle cool down.
7. Check coolant level and, if necessary, fill the coolant reservoir with coolant to the maximum marking.
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Cap on coolant reservoir Maintenance cover
Maximum marking for coolant

reservoir
8. Screw on the cover of the reservoir.
Reservoir cap
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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g g p g

19 40 19 Removing and installing coolant expansion tank - as of

MY 2003
- Preliminary work
- Removing coolant expansion tank
- Installing coolant expansion tank
- Subsequent work
Preliminary work
Preliminary work

2. Remove the right-hand headlight. → 941519 Removing and

installing main headlight - chapter on "Removing"
3. Remove engine compartment cover on the right and rear.
→ 700219 Removing and reinstalling front cover (engine
Removing coolant expansion tank
1. Remove electric connector from coolant reservoir.
Electric connector on coolant reservoir

2. Pull off the three coolant hoses shown.
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Coolant hoses
3. Detach the torque support. To do this, unscrew the fastening
screw on the torque support bracket and pull it out.
Fastening screw for torque support

bracket
Torque support on body

5. Undo torque support bracket fastening screw from the body. One
fastening screw is loosened through the headlight opening. The
second screw is accessible from the top.
View shows screw on spring dome
6. Remove body bracket. When doing this, unclip the electric cable (2 x).
7. Loosen the secondary air pump from cylinder row 1-4. → 266519 Removing and installing secondary air
pump - chapter on "Removing"
8. Undo the coolant reservoir fastening screw.

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Taking out electric cable View shows how screw is connected

through headlight opening
Fastening screw
9. Pull coolant reservoir towards engine and take out of the holder.
Coolant reservoir
Installing coolant expansion tank
1. Insert coolant reservoir into the holder and push in the direction
of the wing.
Coolant reservoir
2. Tighten fastening screw. → Tightening torque: 7.5 ftlb.
3. Tighten the secondary air pump from cylinder row 1-4. → 266519 Removing and installing secondary air
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Fastening screw, coolant reservoir

pump - chapter on "Installing"
4. Reinstall body bracket for the torque support. Clip on electric

cable for coolant reservoir (2 x).
Clipping in electric cable

5. Tighten fastening screw (M10 x 20) through the headlight
opening. → Tightening torque: 44 ftlb.
Tightening fastening screw through the

headlight opening
6. Tighten fastening screw (M10 x 37) from the engine
compartment. → Initial tightening: 37 ftlb. → Final tightening:
90 °
Tightening fastening screw from the

engine compartment
7. Reinstall torque support. Install the fastening screw (M10 x 85) with a new fastening nut on the bracket.
8. Tighten the fastening screw of the torque support onto the body (M10 x 70). → Tightening torque: 44
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ftlb.
9. Mount and tighten the three coolant hoses.
Coolant hoses
10. Connect electric plug to reservoir.
Electric connector to reservoir
Subsequent work
Subsequent work
1. Install the engine compartment cover at the right and rear. → 700219 Removing and reinstalling front
cover (engine compartment) - chapter on "Installing"
2. Install right headlight. → 941519 Removing and installing main headlight - chapter on "Installing"
"Filling"

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as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g p p g

19 45 19 Removing and installing additional coolant pump - as

of MY 2003
- Preliminary work
- Removing additional coolant pump
- Installing additional coolant pump
- Subsequent work
Preliminary work
Preliminary work

(includes bleeding)

2. Remove front left wheel housing liner. → 505619 Removing and
reinstalling front wheel-housing liner - chapter on "Removing"
Removing additional coolant pump
Removing the additional coolant pump
1. Undo sheetmetal holder of coolant line by removing fastening screw (M6 x 16) on the body. Unclip the
coolant line from the holder. Carefully pull the additional coolant pump forward under the wing. Pull off
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electric connector -1- on the pump. Then open the coolant hoses -2 and 3- and remove the pump by
loosening the screw-type hose clamp.
Installing additional coolant pump
1. Insert the additional coolant pump in the screw-type hose clamp

and screw in the fastening screw hand-tight. Install the coolant
hoses -2 and 3- , position the spring-band clamps and then
connect the electric connector -1- . Clip coolant lines into holder
and fasten sheetmetal holder of coolant line by mounting the
fastening screw on the body. → Tightening torque: 7.5 ftlb.
Subsequent work
Subsequent work
Note
z If necessary, the system can be checked for leaks. → 190101 Checking cooling system
"Filling"
2. Install front left wheel housing liner. → 505619 Removing and

installing front wheel housing liner - chapter on "Installing".

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as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g p p g

19 50 19 Removing and installing coolant pump - as of MY 2003

- Preliminary work
- Information
- Removing coolant pump
- Installing coolant pump
- Subsequent work
Preliminary work
Preliminary work

(includes bleeding)

2. Remove the radiator frame. → 193817 Draining and filling coolant
(includes bleeding)
Radiator frame
Information

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Overview of coolant pump in engine

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1 - Coolant pump
2 - Seal for coolant pump (replace seal)
3 - 2 dowel sleeves (do not remove)
4 - 8 M6x25 fastening screws (tightening torque 10 Nm (7.5 ftlb.))
5 - Support for cable duct (fit with the two upper fastening screws)
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Fastening screws on throttle adjuster Electric connection on throttle adjuster
2. Remove the throttle adjuster.
Note
z To ease removal, spray the pulley from the rear side with an anti-
corrosion agent.
3. Unscrew the three fastening screws on the coolant pump pulley.

Wrench size is T 40.

pulley
4. Remove the drive belt from the coolant pump pulley. Mark the
direction of running of the drive belt with chalk.
Drive belt on coolant pump pulley

5. Use an open-ended wrench (a/f 30) to turn the belt tensioner
clockwise and, at the same time, remove the drive belt from the
tensioning roller. Relieve the belt tensioner carefully. Remove the
drive belt from the coolant pump.
Belt tensioner
ATTENTION
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→ The pulleys of the engine accessories are made of plastic. Do

not use damaged pulleys.
6. Remove the 3 loosened fastening screws on the pulley and

remove the pulley.
Fastening screws for pulley

7. Remove the eight fastening screws on the coolant pump and
remove the pump. If the pump is stuck, loosen it by gently
tapping with a plastic hammer.
Loosening the coolant pump with a

plastic hammer
ATTENTION
→ The pulleys of the engine accessories are made of plastic. Do not use damaged pulleys.
1. Clean sealing surfaces. Mount new sheetmetal seal on the coolant pump. Slide the new sheetmetal seal
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New sheetmetal seal on the coolant

pump
over the dowel pins.
2. Tighten the 8 fastening screws. → Tightening torque: 7.5 ftlb.

Mount the sheetmetal holder for the cable duct using the two
upper fastening screws.
3. Fit the pulley on the coolant pump. Screw in the three fastening
screws by hand.
4. Mount drive belt -as shown in the following- . To do this, turn
the belt tensioner clockwise and thread the drive belt around all
the pulleys. Then carefully relieve the tensioning roller .
→ 137819 Removing and installing drive belt - chapter on
"Installing" [9PAAF1 9PAAJ1]→ 137819 Removing and installing
drive belt - chapter on "Installing" [9PAAE1 9PAAE7] Mount the fastening screws for the
coolant pump
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Installation sequence for drive belt
6. Tighten the three fastening screws of the coolant pump pulley. →


pulley
7. Tighten the throttle adjuster with new seal. → Tightening torque: 17 ftlb.
8. Connect the throttle adjuster. The connector must engage audibly. Clip the connecting cable into the
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Connecting cable to throttle adjuster Fastening screws on throttle adjuster
sheetmetal holder.
Subsequent work
Subsequent work
chapter on "Installing" [9PAAE1 9PAAE7 9PAAF1]→ 192019 23 Removing and installing cooling fan
housing (radiator frame) - chapter on "Installing" [9PAAJ1]
2. Fill and bleed the cooling system according to instructions. → 193817 Draining and filling coolant
(includes bleeding) - chapter on "Filling"
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g g g

19 58 19 Removing and installing coolant regulator (thermostat)

- as of MY 2003
- Preliminary work
- Information
- Removing thermostat
- Installing thermostat
- Subsequent work
Tools

assembly aid special tool 9627
Preliminary work
Preliminary work

(includes bleeding)
2. Remove intake-air distributor. → 244619 Removing and
reinstalling intake-air distributor - chapter on "Removing"

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Information
Component overview
Install location
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Component overview
1- Thermostat housing (observe loosening and tightening sequence)

2- Fastening screw M6 x 25
3- O-rings, 22 x 3, replacing
4- Coolant pipe for heater
6- O-rings, 28 x 3, replacing
7- Seal for thermostat housing; replacing
9- Moulded seal; replacing
10 - Thermostat well
11 - O-ring, 50 x 3, replacing
12 - O-ring, 20 x 2.65, replacing
Removing thermostat
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1. Remove the two coolant lines on the thermostat housing cover.

To do this, remove the spring-band clamps and pull off the
hoses.
Spring band clamps for coolant lines

on thermostat housing
2. Pull off the cable duct upwards over the coolant pump.
3. Release the upper fastening screw of the oil dipstick.
Cable duct over coolant pump

4. Loosen the fastening screw on the cable duct.
Fastening screw on the cable duct

5. Disconnect the coolant outlet on the generator. To do this, open
the spring-band clamps and pull off the hose. Collect the draining
coolant.
Spring band clamp for coolant return

to generator
6. Remove the coolant return line on the thermostat housing. To do this, loosen the fastening screw and
pull off the line.
7. Disconnect vent line for cylinder heads. To do this, press the ribbed surfaces of the buttons and pull off
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Button on the vent lines of cylinder Fastening screw for coolant return line
heads to thermostat housing
the plugs.
8. Undo the 3 rear fastening screws of the heater pipes.
9. Undo the thermostat housing cover. The sequence shown must

be observed when doing so.
Loosening sequence for thermostat housing
10. Lift the housing cover. Remove the thermostat using assembly aid 9627.
Installing thermostat
Note
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z All seals between opened sealing surfaces must be replaced.
Removing thermostat with assembly

aid
1. Insert thermostat in the cover and turn it until the two sheetmetal
edges are lying to the left and right of the holder.
Inserting thermostat into cover and

twisting
2. Replace inner and outer seal in thermostat housing cover.
3. Position thermostat housing cover and tighten the fastening

screws (M6 x 25) according to the sequence shown. →
View shows assembly using the

special tool
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Tightening sequence for thermostat housing fastening screw
4. Tighten the three rear fastening screws (M6 x 16) on the heater
pipes. → Tightening torque: 7.5 ftlb.

5. Connect vent lines for cylinder heads. The connectors must
engage audibly.
Vent lines for cylinder heads

6. Fit coolant line leading to the generator. Insert the line in the
thermostat housing cover and tighten the fastening screw. →
Coolant line to generator

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7. Push coolant line onto generator and fit the spring-band clamp.
Spring band clamp for coolant line to

generator
8. Push the holder onto the timing case cover below the cable duct
and tighten the fastening screw. → Tightening torque: 7.5 ftlb.
Fastening screw, support to timing-

case cover
9. Tighten the upper fastening screw of the oil dipstick. →
Fastening screw for oil dipstick

10. Push the cable duct onto the retaining bracket over the coolant
pump.
Push the cable duct onto the retaining

bracket over the coolant pump.
12. Fit coolant supply and return hose on thermostat housing cover.
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Subsequent work
Subsequent work
1. Install intake distributor. → 244619 Removing and reinstalling intake-air distributor - chapter on
"Installing"
2. Fill coolant system and check for leaks. → 193817 Draining and filling coolant (includes bleeding) -
chapter on "Filling"
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g

19 70 21 Removing radiator - as of MY 2003

- Preliminary work
- Information
- Removing radiator
Preliminary work
Preliminary work
2. Drain cooling system. → 193817 Draining and topping up with coolant (includes bleeding) - chapter on
"Draining"
installing cooling fan housing (radiator frame) - chapter on "Removing" [9PAAJ1]
Information
Component overview
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g g

2 - Lock carrier
3 - Front bumper
4 - 2 clamps
5 - Safety clip
Removing radiator
Note
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1. Remove coolant hoses on the radiator. To do this, pull out the

retaining clips on the two coolant flanges and pull off the hoses.
Then fit the retaining clips again so that they are not confused.
Coolant hoses on the radiator

2. Pull off the top right vent hose on the radiator.
Breather hose on the radiator

3. Unscrew both fastening screws -C- for securing condenser to the
coolant radiator (left direction of travel).

condenser to coolant radiator
4. Unscrew the fastening screw -D- (left direction of travel) for
securing power steering radiator lines to coolant radiator.
Fastening screw for lines to radiator

for power steering
5. Unclip the radiator for the power steering system. To do this, unclip the wiring to the front out of the
holder -A- and push it to the left out of the support -B- . Hang the radiator carefully downwards.
6. Lift both locks for the ATF cooler and air-conditioning condenser with a screwdriver -1- and push down
-arrow- .
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Lines for power steering radiator
Fuses for ATF cooler and on air-

conditioning condenser
Note
z Fix the remaining radiators in the installation position using tie
wraps.
7. Lift up the radiator and take it out of the vehicle by moving it up

and to the right. When doing this, watch out for the connection
lines of the air-conditioning system on the left side.
Lifting the cooler
Secured ATF cooler and radiator for

power steering system
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
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19 70 23 Installing radiator - as of MY 2003

- Information
- Installing radiator
- Subsequent work
Information
Component overview
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2 - Lock carrier
3 - Front bumper
4 - 2 clamps
5 - Safety clip
Installing radiator
Note

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Inserting the radiator between ATF

cooler and air-conditioning condenser
1. Insert the radiator from above on the right between the ATF cooler and the air-conditioning condenser.
2. Move the ATF cooler into the installation position and push on
the metal clips to fasten it.
Fastening ATF cooler with metal clips

3. Fasten servo oil cooler. To do this, push the servo oil cooler from
left to right into the support -A- and clip the lines into the support
-B- .
Lines in the support on the servo

radiator
4. Tighten the fastening screw on the servo oil cooler line with a fastening screw. → Tightening torque: 7.5
ftlb.
5. Screw in both fastening screws -C- for securing condenser to the coolant radiator (left direction of travel).
6. Push on the cooler vent line onto the right radiator side and fit the spring-band clamp.
7. Push on the two coolant lines. The retaining clips on the flange must engage audibly.
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Fastening screws for securing Fastening screw for servo oil coolant
condenser to coolant radiator line
Pushing on coolant lines Spring band clamp for cooler vent line
Subsequent work
Subsequent work
chapter on "Installing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 192019 23 Removing and
installing cooling fan housing (radiator frame) - chapter on "Installing" [9PAAJ1]
on "Filling in"
4. Fit engine guard. → 108019 Removing and installing engine guard - chapter on "Installing"
as of MY 2003
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WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
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19 78 19 Removing and installing coolant temperature sensor -

as of MY 2003
- Preliminary work
- Information
- Removing coolant temperature sensor
- Installing coolant temperature sensor
- Subsequent work
Preliminary work
Preliminary work
1. Drain coolant completely. → 193817 Draining and filling coolant

2. Remove intake-air distributor. → 244619 Removing and
reinstalling intake-air distributor - chapter on "Removing"
Draining coolant
Information
Component overview
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Installation position of coolant temperature sensor

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Component overview
2 - Coolant temperature sensor (when removing, collect emerging coolant, when installing, replace sealing
ring)
3 - Sealing ring (replace when installing)
4 - 3 screw plugs, M16x1 (when removing, collect emerging coolant, when installing, replace sealing ring)
5 - 10 hexagon-head bolts M6x25
6 - 2 seals for distributor pipe (when installing, clean sealing faces and replace seal)
7 - 4 sealing rings (when installing, grease with Klüber Syntheso GLEP 1
8 - Lower cooling water tube
Removing coolant temperature sensor
ATTENTION
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ATTENTION
scalding.
1. Pull off cable plug of the coolant temperature sensor -arrow- .
Cable plug of the coolant temperature

sensor
Note
z Even when the coolant has been completely drained, coolant
emerges from the open bore on the coolant temperature sensor!
2. Unscrew the coolant temperature sensor using a ring wrench (a/f

22) -see picture- . Absorb emerging coolant.
Unscrewing the coolant temperature

sensor
Installing coolant temperature sensor
1. Clean sealing surfaces and screw in coolant temperature sensor with a new sealing ring into the
distributor pipe. → Tightening torque: 22 ftlb.
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Cable plug of the temperature sensor Screwing in the coolant temperature

sensor
2. Fit cable plug again -arrow- .
Subsequent work
Subsequent work
"Installing"
2. Fill up completely with coolant and bleed system. → 193817 Draining and filling coolant (includes
bleeding) - chapter on "Filling".
as of MY 2003
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ADVERTENCIA
20 02 01 Checking fuel pressure - as of MY 2003

- Information
- Checking fuel pressure
Tools

Connection line commercially 9559
available tool
Porsche System Tester ll commercially 9588

available tool
Measuring adapter commercially 9705

available tool
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Connecting lead commercially 9705/1

available tool
pressure gauge commercially p378

available tool
Pressure gauge commercially p378a

available tool
Tools and materials

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Special tools
Special tools
Item Designation of tool Explanation

-A- Porsche System Tester ll 9588 The fuel pumps are required for short-term
activation during the delivery rate test.
-B- Pressure gauge p378a For fuel pressure test.
-C- Connection line 9559 Hose line for pressure gauge. Do not
interchange with -G- . There is a sheetmetal
clip in the connecting piece for the fuel gallery
which opens the scavenging valve during the
test procedure.
-D- Commercially available measuring cup with scale Must hold at least 3 litres.
-E- Measuring adapter 9705 Controls the test pressure when measuring.
Must not be impinged with under/overpressure.
-F- Connecting lead 9705/1 Hose line for delivery rate test. Must not be
interchanged with -C- . There are no metal
clips in the connecting piece for the fuel
gallery.
-G- Commercially available stopwatch A wrist watch can also be used to be able to
time exactly 1 minute.
Information
Test conditions
z The battery voltage must not be < 12 volts.

z If an insufficient delivery rate is determined in the delivery rate test, the measurement on the second
scavenging valve of the fuel gallery will be repeated.
z Fuel system parts must not get dirty.
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Checking fuel pressure

2. Unscrew cap on the front right of the fuel gallery.
Design cover
3. Connect connection line 9559 to the pressure gauge p378 . Screw
the other end onto the fuel gallery.
Connection line
4. Switch on the ignition and start the engine. Read off fuel pressure on
pressure gauge. The value must be 4.0 ± 0.2 bar at idle speed.
Pressure gauge
DANGER
Danger of fire due to incorrect or faulty scavenging valves!
→ Replace scavenging valves after removing.

→ Only use the special, Porsche-approved valves in the fuel gallery.
→ Do not replace scavenging valves by tyre valves.
→ It is essential that the plastic cap is also replaced.
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Note
z The steady-state pressure must be greater than 2.0 bar after 1 hour.
5. Unscrew connection line and close the fuel gallery with a new plastic
cap.
Connection line
Design cover
as of MY 2003
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ADVERTENCIA
20 10 21 Removing fuel tank - as of MY 2003

- Preliminary work
- Removing fuel tank
Tools

Lifting platform commercially
available tool .gif
Keys special tool T10202

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Preliminary work
Preliminary work for removing fuel tank

1. Empty the fuel tank. → Draining and filling fuel
2. Remove the carbon canister. Details for loosening in installation location (wheel housing) see → 202521
Removing carbon canister. The degassing tank is removed with the fuel tank connected (joined).
3. Remove rear axle (spring struts and rear axle housing) push it aside on the lifting platform (scope of work
without further disassembly of rear axle) → 420519 Removing and installing rear axle housing - chapter on
"Removing"
Tools and materials
Required tools

-1- Lifting platform Can be found in Workshop For removing and installing the rear
Equipment Manual, 3.0.13 axle.
"WE 1206"
-2- Keys T10202 See Workshop Equipment For removing and installing the fuel
Manual 2.2.3 tank connection unit.
-3- Transmission jack with Workshop Installation For raising and lowering units and
transmission plate Manual 3.3.1 loads.

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DANGER
periods.
DANGER

→ Do not smoke.
Note

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Removing fuel tank
Removing fuel tank
Note
z The repair procedure may vary depending on engine type and country equipment. This relates in particular to
components in the right wheel housing.
z The description relates to ORVR vehicles.
z Sealing rings must generally be replaced.
Component overview of degassing tank and fuel tank in the network
The following exploded drawing shows how the fuel tank is attached to the vehicle floor.
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Fuel tank mount

Fuel tank 1 Do not damage fuel tank and Do not damage fuel tank and
connected lines. Lines cannot connected lines. Lines cannot
be replaced individually. be replaced individually.
-2- Restraining strap, front left 1 Before releasing the The direction of travel arrow
restraining straps, make sure must be pointing forwards.
that the tank cannot fall down.
-3- Fastening screw, M8 x 25 10
-4- Plastic covers, left 2
-5- Plastic cover, right 1
-6- Restraining strap, rear right 1 Before releasing the The direction of travel arrow
-7- Restraining strap, front right 1 Before releasing the The direction of travel arrow
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-8- Restraining strap, centre 1 The direction of travel arrow

must be pointing forwards.
-9- Restraining strap, rear left 1 Before releasing the The direction of travel arrow
1. Open filler flap.
2. Screw the tank cap down. Then remove the rubber sleeve around the
fuel filler neck, loosen the two fastening screws M6 x 25 and remove
the ground cable.
Tank filler neck

3. Remove the fuel supply -1- at the connection unit and disconnect the
2 connection points -2 and 3- .
Connection unit
4. Pull fuel filler neck and degassing tank out of the wheel housing and
secure with a piece of wire arrow -arrow- (picture shows degassing
tank with carbon canister).
Wire protection for degassing tank

5. Then, loosen the stone guard on the right side. Unscrew screws -2- .
6. Remove line holder under the stone shield by pressing on the centre plug -arrow- . Replace holder.
7. Remove the centre underbody cover at the left and right of the longitudinal side members. → 519319
Removing and installing centre cover - chapter on "removing"
8. Remove rear heat shield. To do so, undo the three speed nuts and the two screws.
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Holder Stone guard
Heat protection shield
DANGER
Danger of injury due to heavy filled tank!
→ For safety reasons, the tank should only be removed and installed
when empty!
9. Loosen the tank attachment band, which runs in the direction of travel
-arrows- . Then, position a transmission jack under the tank and
secure the tank from falling using a belt. When doing so, make sure
that the fuel lines are not damaged. Tank attachment band
ATTENTION
Risk of damaging to fuel lines!
z Lines can become kinked or can crack.
→ Never leave carbon canister hanging freely on the lines.

→ A second person should hold the carbon canister during removal.
10. Undo and remove the remaining restraining straps with the help of a
second worker. Slowly lower the tank with the transmission jack. Also
carefully guide the degassing tank in the right wheel housing. Tank on lever

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as of MY 2003
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ADVERTENCIA
20 10 23 Installing fuel tank - as of MY 2003

- Installing fuel tank
- Subsequent work
Tools

available tool .gif

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Tools and materials
Required tools

-1- Lifting platform Can be found in Workshop For removing and installing the rear
Equipment Manual, 3.0.13 axle.
"WE 1206"
DANGER
periods.
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DANGER

→ Do not smoke.
Note
Installing fuel tank
Note

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Fuel tank mount

-1- Fuel tank 1 Do not damage fuel tank and Do not damage fuel tank and
connected lines. Lines cannot connected lines. Lines cannot
be replaced individually. be replaced individually.
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Note
z The top left cover must be fitted before the tank is installed.
z When installing the tank and rear axle, make sure that cables and lines
are not damaged and are in the correct installation position.
z When introducing the tank into the body, a second person should
guide the degassing tank and safeguard it against damage using wire.
1. Raise the tank with a transmission jack. Make sure to secure the tank
with a tension strap to prevent it from falling.
2. With the help of a second worker, put the tank into the installation position. A second person should carefully
guide the degassing tank.
Note
z Note direction arrow stamped on the restraining straps and install
these in the direction of travel.
3. Attach lower covers and fit the four restraining straps, which run at
right angles to the direction of travel. Make sure that the stamped
arrow is pointing forwards in the direction of travel. Tighten fastening
screws to the specified tightening torque. → Tightening torque: 17
ftlb. Secure fuel filler neck and degassing tank again with a wire
-arrow- .
Figure shows secured degassing tank
(shown here with carbon canister
attached)
4. Lower the transmission jack and fit the centre restraining strap. The
arrow must be pointing forwards. Tighten fastening screws to the
specified torque. → Tightening torque: 17 ftlb.
Centre fuel tank restraining strap

5. Fit the exhaust system heat shield. If the shield is cracked or damaged, it must be replaced. Tighten the 3
sheetmetal nuts and the 2 screws.
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6. Mount the underbody panel of the side member on the left and right. → 519319 Removing and installing
middle cover
7. Replace holder and attach to side member. Clip in lines.
Holder
8. Then, fit the stone guard on the right side. Mount nuts -arrows- and
tighten to the specified torque. → Tightening torque: 7.5 ftlb.
Stone guard
9. Mount the fuel supply -1- to the connection unit and connect the 2
connection points -2 and 3- .
Connection unit
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Subsequent work
Subsequent work
1. Fit cover. Tighten the 4 fastening nuts. → Tightening torque: 7.5 ftlb.
Refit carpeted floor and fix with double-sided adhesive tape.
Fastening nuts for cap

2. Tighten the seat-belt buckle fastening plates. Use 3 new fastening
screws for this and tighten. For tightening torque see → 692519
Removing and installing rear belt lock
3. Fold rear seat down again.
4. Mount rear axle (spring struts and rear axle housing). → 420519
Removing and installing rear axle housing - chapter on "Installing"
5. Mount carbon canister. → 202523 Installing carbon canister

6. Fill fuel tank (refuel). → Filling with fuel
Fastening screws for retaining

brackets of seat-belt buckles
as of MY 2003
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WARNING
AVERTISSEMENT
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ADVERTENCIA
20 15 19 Removing and installing fuel level sensor - as of MY 2003

- Information
- Preliminary work
- Removing fuel level sensor
- Installing fuel level sensor
- Subsequent work
Tools

key special tool T10202
Information
Component information
Note
z The two senders have different shapes and may not be switched.
z The float installed in the left direction of travel is flat, while the float installed in the right direction of travel is
spherical.
z 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.
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Both fuel level sensors
Jammed fuel-level sensor
The effect of fuel and various tolerances means that the left fuel level sensor can become jammed under fuel lines
or the sensor's electric cable. The instrument cluster would then display an incorrect fuel level.
To prevent this, the two fuel lines coming from the left pump and the
electric cable should be tied together with a tie-wrap following repairs.
Tie-wrap fixed electric cable
Preliminary work
Opening the tank
z If the tank must be opened for emptying, disconnect all connections.
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Component overview: fuel tank
2. Fold rear seat forwards.
3. Fold up the retaining brackets of the (right and left) seat-belt buckles. To do so, loosen the four fastening
screws and fold up the bracket with the seat-belt buckle. Do not use the fastening screws again.
4. Undo the caps (figure shows both). To do so, cut out the carpeted floor along the perforated lines using a
carpet knife and fold it over. Then unscrew the four fastening nuts and remove the lid.
5. Empty the fuel tank if this has not already been done or if the fuel level in the fuel tank is very low. →
Draining and filling fuel
DANGER
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Fastening nuts for cap Fastening screws for retaining

Danger of poisoning from fuels! brackets of seat-belt buckles
→ Inhaling vapours can cause
irritation of the mucous
membranes and eyes.
→ It can be carcinogenic. It
represents a serious risk to
health when inhaled, touched
or swallowed over longer
periods.
→ Only work on the fuel system
in well-ventilated rooms. Fuel supply and disconnection points
→ Wear protective gloves that at right connection unit
are fuel-resistant.
→ Wear a breathing mask with
active charcoal filter; do not
breathe in any fuel vapours.
→ Ensure that there is adequate
ventilation and extract all fuel
vapours.
→ Before opening the fuel lines
or fuel hoses, relieve the fuel
pressure.
→ Collect escaping fuel, absorb it
if necessary with a suitable
binding material and dispose
of properly.
→ Pay attention to cleanliness
when working on the fuel
system.
DANGER

→ Do not smoke.
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Note
6. Carefully remove the fuel supply -1- at the relevant connection unit (right connection unit here) and loosen the
two disconnection points -2 and 3- . Also remove line (not shown here) in vehicles with auxiliary heating
(auxiliary heater). Do the same at the left connection unit. Disconnect all connections on the connection unit.
7. Open the relevant cap with the key T10202 and lift up the connection
unit (cap).
Cap
Preliminary work
1. Disconnect electric connectors -1 and 2- . Then pull off the fuel lines
-3 and 4- and remove the connection unit.
Connection unit
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Removing fuel level sensor

1. Reach carefully past the fuel pump and feel for the sender. This is located in front of the pump, pointing
diagonally outwards.
2. Press the retaining spring on the sender by hand while at the same
time pulling the sender up.
Installing fuel level sensor
1. Install a new tank gauge. Press the sender into its mounting. The
retaining spring must engage audibly.
View shows the left sender
View shows the right sender
Subsequent work
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Subsequent work
1. Fit new seal in the opening of the tank.
Seal for opening of tank

2. Connect connection unit. Connect the electric connectors for the tank
gauge and fuel pump. Then push on the fuel lines. The connectors
must engage audibly.
3. Fit connection unit into tank opening. When doing so, make sure that
the plastic lug is pointing forwards.
Connection unit
Closing the tank
1. Close the tank. To do so, fit the sheetmetal ring and tighten using the
key T10202. → Tightening torque: 104 ftlb.
Cap
2. Fit all connections (fuel lines, ventilation tubes and electric plugs).
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Fuel lines, ventilation tubes and

electric plugs

3. Fit the lid. Then tighten the four fastening nuts. → Tightening torque: 7.5 ftlb. Refit carpeted floor and fix
with double-sided adhesive tape.
4. Tighten the seat-belt buckle fastening plates. Use three new fastening
screws for this and tighten. For tightening torque, see → 692519
Removing and installing rear belt lock .
6. Fill fuel tank (refuel). → Draining and filling fuel

as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
20 25 21 Removing carbon canister - as of MY 2003

- Preliminary work
- Information
- Removing carbon canister
Preliminary work
Preliminary work
1. Take up the vehicle at the jacking points provided using a platform lift. → Lifting the vehicle [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Lifting the vehicle [9PAAJ1]
3. Screw the tank cap down. Then remove the rubber sleeve around the
tank filler neck, loosen the 2 M6 x 20 fastening screws and remove the
ground cable.
4. Remove right rear wheel. → 440519 Removing and installing wheel -
Tank filler neck

5. Remove right rear wheel housing liner. → 536919 Removing and installing rear wheel housing liner - chapter
on "Removing"

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Rear wheel housing liner mount
DANGER
Rear wheel housing liner
membranes and eyes.
or swallowed over longer
periods.
→ Only work on the fuel system Mud flap
in well-ventilated rooms.
→ Wear protective gloves that
are fuel-resistant.
vapours.
pressure.
→ Collect escaping fuel, absorb it
if necessary with a suitable
of properly.
system.
DANGER
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→ Do not smoke.
Note
Information
ATTENTION
Risk of damage!
z There is a risk of leaks if the overflow line on the fuel filler neck is above the valve.
→ Make sure that the line runs below the valve.

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Overview of fuel tank
Note
The following exploded drawing shows the attachment of the tank filler neck and carbon canister in the right wheel
housing.
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Carbon canister mount
3 - Fastening screw
5 - Fastening nut M6
6 - Carbon canister
7 - Degassing tank
Removing carbon canister

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ATTENTION
Risk of damage!

→ A second person should hold the carbon canister during removal.
1. Loosen the 5 fastening screws on the carbon canister and the two on
the degassing tank in the right wheel housing -arrows- .
Fastening screws
Carbon canister connections
Note
z In USA vehicles, the rubber hose -2- of the leak diagnosis pump is
extremely tight. If the hose is pulled, the connection piece can break
off at the leak diagnosis pump.
2. Carefully remove the 2 electric connectors -3- on the carbon canister

and on the leak diagnosis pump and the hose on the connection piece
-2- of the leak diagnosis pump (USA). There is always a risk of
damage. Then, disconnect plastic line -1- .

3. Cut through the tie-wraps of the ground cable on the carbon canister
and take the carbon canister out of the wheel housing. Replace tie-
wraps.
Cutting tie-wraps
4. Remove hose connection on the degassing tank.
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ATTENTION
Risk of damage!
z Lines can become kinked or
can crack.
→ Never leave carbon canister

hanging freely on the lines.
→ A second person should hold
the carbon canister during
removal.
Wire protection Hose connection on the degassing
tank
5. Pull fuel filler neck and degassing tank out of the wheel housing and
secure with a piece of wire -arrow- (figure shows degassing tank with
carbon canister).
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
20 25 23 Installing carbon canister - as of MY 2003

- Installing carbon canister
- Subsequent work
DANGER
periods.
DANGER

→ Do not smoke.
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Note
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Note
The following exploded drawing shows the attachment of the tank filler neck and carbon canister in the right wheel
housing.
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3 - Fastening screw
5 - Fastening nut M6
6 - Carbon canister
7 - Degassing tank
Installing carbon canister

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1. Replace the ground cable tie-wraps on the carbon canister and pre-assemble the ground cable. Lift the
carbon canister into the wheel housing.
2. Join all lines on the carbon canister and degassing tank at the plug connections.
3. Carefully mount the 2 electric connectors -3- on the carbon canister

and on the leak diagnosis pump and the hose on the connection piece
-2- of the leak diagnosis pump (USA). Then connect plastic line -1- .

4. Insert the hose on the degassing tank.
ATTENTION
Risk of damage!
z There is a risk of leaks if the overflow line on the fuel filler neck is
above the valve.
5. Swivel carbon canister down into installation position from behind. Degassing tank
Make sure that the fuel overflow line -1- is below the solenoid valve -2-
. If the line is not routed correctly, this will cause damage during
subsequent operation.
Picture shows the correct position of the line. View from above without rear side panel.
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Fuel overflow line and solenoid valve
1 - Overflow line
2 - Solenoid valve
6. Tighten the 5 fastening screws on the carbon canister and the 2 on

the degassing tank in the right wheel housing -arrows- . →
Fastening screws
Subsequent work
Subsequent work
1. Install the right rear wheel housing liner. → 536919 Removing and installing rear wheel housing liner - chapter
on "Installing"
2. Mount rear wheel. → 440519 Removing and installing wheel - chapter on "Installing"
3. Connect ground cable to fuel filler neck. Screw down the 2 fastening screws and mount rubber sleeve around
the tank filler neck. → Tightening torque: 7.5 ftlb.
4. Screw on tank cap.

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Mud flap
5. Activate air suspension.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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20 43 02 Fuel filter lines checked (in tank) - as of MY 2003

- Information
Information
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Overview - lines for fuel filter

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Connection overview, lines for fuel filter
1 - Fuel pump, left

2 - Connection to fuel filter
3 - Fuel supply line connection
5 - Fuel pump, right
7 - Connection to fuel pressure regulator
8 - Connection point for left fuel pump and pressure regulator
9 - Sucking jet pump of left pump
10 - Sucking jet pump of right pump
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as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
20 48 19 Removing and installing leakage diagnosis pump (LDP) -

as of MY 2003
- Preliminary work
- Information
- Removing leakage diagnosis pump (LDP)
- Installing leakage diagnosis pump (LDP)
- Subsequent work
DANGER
periods.
DANGER
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→ Do not smoke.
Note
Preliminary work
Preliminary work
1. Remove carbon canister and place it on a clean surface. → 202521 Removing carbon canister
Information
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Overview of active carbon filter
1 - Degassing tank
2 - Filler neck
3 - Pressure control valve
4 - Carbon canister
5 - Leakage diagnosis pump
→ Installation position of leakage diagnosis pump
Installation position of leakage

diagnosis pump
Removing leakage diagnosis pump (LDP)
1. Loosen three fastening screws on plastic support for pressure control valve. -Arrows-
To remove the top fastening screw, carefully press the pressure control valve hose aside using a screwdriver
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Pressure control valve Leakage diagnosis pump mount
and screw out the fastening screw. → Pressure control valve
2. Turn the pressure control valve to the side and remove the three
fastening screws on the leakage diagnosis pump. → Pressure control
valve and leakage diagnosis pump mount
Pressure control valve and leakage

diagnosis pump mount
3. Carefully lever the leakage diagnosis pump out of the bracket on the
active carbon filter using a screwdriver. → Levering out leakage
diagnosis pump
Levering out leakage diagnosis pump

4. Carefully lever the leakage diagnosis pump out of the rubber flange
on the housing using a screwdriver. → Rubber flange
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5. Pull off the air hose. → Pulling Rubber flange

off air hose
Pulling off air hose

6. If the rubber flange slips out of the housing and remains on the
connection piece of the leakage diagnosis pump while you are
removing the leakage diagnosis pump, check the rubber flange for
damage and insert it back flush into the carbon canister housing if it
is OK. → Rubber flange → Inserted rubber flange
Rubber flange
Inserted rubber flange
Installing leakage diagnosis pump (LDP)
1. If the rubber flange slips out of the housing and remains on the connection piece of the leakage diagnosis
pump while you are removing the leakage diagnosis pump, check the rubber flange for damage and insert it
back flush into the carbon canister housing if it is OK. → Rubber flange → Inserted rubber flange
2. Lightly lubricate the connection piece of the leakage diagnosis pump and rubber flange with KLUEBER
Syntheso Glep 1 (000 043 204 68 status 12/05) and carefully move leakage diagnosis pump into installation
position. Make sure that the rubber flange is not pushed into the housing.
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Rubber flange
Fitting leakage diagnosis pump

3. Ensure that the leakage diagnosis pump is seated correctly in the bracket for the active carbon filter. Fit the
three fastening screws for the leakage diagnosis pump → Tightening torque: 3 (2 ftlb.) Nm and turn
pressure control valve back into installation position. → Pressure control valve and leakage diagnosis pump
mount
4. Fit air hose. → Fitting air hose on leakage diagnosis pump
5. Fit three fastening screws on the plastic support for the pressure control valve → Tightening torque: 3 (2
ftlb.) Nm . -Arrows-
To fit the top fastening screw, carefully press the pressure control valve hose aside using a screwdriver and
screw in the fastening screw. → Pressure control valve
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Leakage diagnosis pump mount Fitting air hose on leakage diagnosis

Subsequent work pump
Pressure control valve

Subsequent work
1. Install carbon canister. → 202523 Installing carbon canister
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
20 60 19 Removing and installing fuel filter - as of MY 2003

- Preliminary work
- Information
- Removing fuel filter
- Installing fuel filter
- Subsequent work
Tools

Preliminary work
Preliminary work
Note
The fuel filter is located under the left connection unit, and the pressure regulator is under the right
connection unit. The procedure "Open tank" can be applied to both connection units (right pressure
regulator, left fuel filter)
Opening the tank

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Note
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DANGER
→ Inhaling vapours can cause irritation of the mucous membranes and
eyes.
→ It can be carcinogenic. It represents a serious risk to health when
inhaled, touched or swallowed over longer periods.
→ Wear protective gloves that are fuel-resistant. Fuel supply and disconnection points
→ Wear a breathing mask with active charcoal filter; do not breathe in at right connection unit
any fuel vapours.
→ Collect escaping fuel, absorb it if necessary with a suitable binding
material and dispose of properly.
DANGER

→ Do not smoke.
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Note
6. Carefully remove the fuel supply -1- at the relevant connection unit (right connection unit here) and loosen
the two disconnection points -2 and 3- . Also remove line (not shown here) in vehicles with auxiliary heating
unit (cap).
Cap
Information
Component overview
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Component overview of left connection unit (fuel filter)
1- Adapter for bleeding

2- Filter feed from left pump
3- Fuel supply to pressure regulator
4- Electric connection for fuel pump
5- Electric connection for fuel level sensor
6- Filter feed from right pump
Removing fuel filter
1. Disconnect electric connectors -1 and 2- . Then pull off the fuel lines
-3 and 4- and remove the filter unit.
Connection unit
Installing fuel filter

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Seal
2. Connect filter unit. Mount the electric connector -1 and 2- and the
hose connections -3 and 4- .
3. Place the connection unit into the tank. When doing so, make sure
that the plastic lug is pointing forwards.
Connection unit
Subsequent work
Closing the tank
Cap
3. Fit the lid. Then tighten the four fastening nuts. → Tightening torque: 7.5 ftlb. Refit carpeted floor and fix
with double-sided adhesive tape.
4. Tighten the seat-belt buckle fastening plates. Use three new fastening screws for this and tighten. For
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Fastening nuts for cap Fuel lines, ventilation tubes and

electric plugs

tightening torque, see → 692519 Removing and installing rear belt lock .
Subsequent work
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
20 66 01 Checking quantity of fuel delivered - as of MY 2003

- Information
- Checking quantity of fuel delivered
Tools

Pressure gauge special tool 378a

available tool

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measurement tool set commercially 9684

available tool

available tool

available tool
Tools and materials

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Special tools
Tool illustration for fuel pressure

-B- Pressure gauge 378a For fuel pressure test.
interchange with -F- . There is a sheetmetal
clip in the connecting piece for the fuel gallery
which opens the scavenging valve during the
test procedure.
Must not be impinged with under/overpressure.
interchanged with -C- . There is no metal clip
in the connecting piece for the fuel gallery.
Information
Test conditions

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Checking quantity of fuel delivered
Checking fuel delivery rate

Throttle body cover
WARNING
Danger of fire and injury!
z Danger of fire due to escaping fuel, e.g. on hot engine
components or due to electrostatic charge.
z Danger of fire due to naked flames and sparks, e.g. during
welding or grinding work.

→ Ensure that there is adequate ventilation and extract all fuel vapours. Test hose/measuring adapter
→ Before opening the fuel lines or fuel hoses, relieve the fuel pressure. connection
Note
z The fuel gallery is pressurised! Place a cloth near the front of the fuel gallery to prevent fuel dripping onto hot
engine parts.
3. Join the test hose to the measuring adapter and connect the other end to the scavenging valve on the fuel
gallery.
Note
z For the delivery rate check, a second person should clock the time.
4. Place the open hose end from the pressure regulator in the measuring beaker.
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5. Connect jumper lead 26 to two test leads 16 taken from

measurement tool set 9684 and use these to bridge the fuel pump.
The exact assignment of the contacts can be obtained from → Fuse
carrier [9PAAJ1]→ Fuse carrier [9PAAE1 9PAAE7 9PAAF1].
Note
z To avoid incorrect readings, make sure that the hose lines are
already full of fuel at the start of the test.
6. Keep fuel pump switched on until fuel emerges from the end of the
hose. Then empty the measuring beaker.
Test setup
7. Switch on fuel pump I (left pump) for one minute. Then monitor the fuel delivered and note the quantity. Now
repeat the process with pump II (right pump).
Fuel pump Delivery rate

Fuel pump I (left) > 1.6 l/min
Fuel pump II (right) > 1.3 l/min
If the test delivery rate produced in the test is too low, repeat it at the right scavenging valve of the fuel gallery.
8. On completion of the test, switch off the ignition and remove test tool.
DANGER
Danger of fire due to faulty scavenging valves!
→ Only use the special, Porsche-approved valves in the fuel gallery.

9. Press the four rubber elements in the cover onto the four ball socket
holders. The mounts must be felt to engage.
Cover
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
20 66 19 Removing and installing fuel pump - as of MY 2003

- Preliminary work
- Information
- Removing fuel pump
- Installing fuel pump
- Subsequent work
Tools

Preliminary work
Preliminary work
Information
General note
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Note
z The fuel pumps have different hose connections and must not be confused.
z The connections should be marked for identification when removing.
z In order that the connections do not fall in the fuel tank, they should be secured using tie-wraps.
The following overview is used as an orientation for connecting fuel pumps:
1 - Fuel pump, left

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5 - Fuel pump, right

7 - Connection to fuel pressure regulator
8 - Connection point for left fuel pump and pressure regulator
9 - Sucking jet pump of left pump
Removing fuel pump
Opening the tank
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DANGER
membranes and eyes.
or swallowed over longer Fuel supply and disconnection points
periods. at right connection unit
→ Only work on the fuel system
in well-ventilated rooms.
→ Wear protective gloves that
are fuel-resistant.
vapours.
pressure.
→ Collect escaping fuel, absorb
it if necessary with a suitable
of properly.
system.
DANGER

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→ Do not smoke.
Note
unit (cap).
Cap
Removing left fuel pump
1. Pull off electric connectors -1 and 2- on the left connection unit. Then pull off the fuel lines -3 and 4- and
remove the connection unit (filter unit).
2. Disconnect the sucking jet pump at the fuel pump. To do this, press on the left and right and pull off the
connection.
3. Raise the right connection unit slightly and disconnect the fuel pump line at the Y-piece (on the right side).
4. Turn the pump approx. 90° to the left until it disengages at the tank floor. Remove the pump from the tank.
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Sucking jet pump connection at the Electric connectors and fuel lines
fuel pump
Removing right fuel pump
Turning the pump

1. Disconnect the electric connectors for the fuel pump and fuel level
sensor. Then pull off the fuel lines on the pressure regulator and
remove the connection unit.
Electric connectors and fuel lines

2. Disconnect the sucking jet pump at the fuel pump. To do this, press
on the left and right and pull off the connection.
3. Disconnect the hose for the right fuel pump at the Y-piece.
Sucking jet pump connection at the

fuel pump
4. Turn the pump approx. 90° to the left until it disengages at the tank floor. Remove the pump from the tank.
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Turning the pump
Installing fuel pump
Installing left 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.
2. Connect the fuel line from the pump to the Y-piece (right side of the tank).
3. Attach the sucking jet pump connection. This must engage audibly.

fuel pump
4. Replace both seals on the connection units.
Seals on connection unit

5. Connect connection unit. Connect the electric connectors for the tank gauge and fuel pump. Then push on
the fuel lines. The connectors must engage audibly.
6. Place the connection unit into the tank. When doing so, make sure that the plastic lug is pointing forwards.
Installing right fuel pump

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1. Place the pump in the holder on the tank floor and turn it approx. 90°
to the right until it is seated securely.
2. Connect the fuel line from the right pump to the Y-piece.

3. Attach the sucking jet pump connection. This must engage audibly.

fuel pump
4. Replace connection unit seal.
5. Connect connection unit. Connect the electric connectors for the tank
gauge and fuel pump. Then push on the fuel lines. The connectors
must engage audibly.

Closing the tank
Cap
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electric plugs
3. Fit the lid. Then tighten the four fastening nuts. → Tightening
torque: 7.5 ftlb. Refit carpeted floor and fix with double-sided
adhesive tape.

4. Tighten the seat-belt buckle fastening plates. Use three new
fastening screws for this and tighten. For tightening torque, see
→ 692519 Removing and installing rear belt lock .

Subsequent work
Subsequent work
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
20 03 Draining and filling fuel - as of MY 2003

- Information
- Draining fuel (emptying fuel tank)
- Filling with fuel (filling fuel tank)
Tools

adapter special tool 9479
Tools and materials
Tools and materials

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Special tool
A - Fuel transfer unit (This tool has been tested and approved by PORSCHE.); see Workshop
Equipment Manual 3.2.2. "WE 1262"
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.); see Workshop Equipment Manual
3.2.2 "WE 1262"
C - Porsche adapter (This adapter fits 8-mm to 10-mm fuel lines (986; 996 and Cayenne.); see
Workshop Equipment Manual 3.2.2 "WE 1262"
D - Connecting piece between Porsche adapter and suction line (This is screwed into suction line
E and connected to the Porsche adapter.); see Workshop Equipment Manual 3.2.2 "WE 1262"
E - Suction line with venting device (Always attach venting device (rubber taper with transparent
hose) to the filler neck. This minimises the amount of escaping fuel vapours.); see Workshop
ohne - Adapter adapter 9479 (For controlling the fuel pumps); see Workshop Equipment Manual,
Bezeichnung Chapter 2.2.2
Information
Using equipment
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Overview of fuel transfer system
1 - Air connection (connection for unlubricated/oil-free compressed air)

2 - Fuel tank (capacity: 110 litres), (Tank can be changed. The scale at the side starts at approx. 10 litres. Other
markings are shown in 5-litre 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.
2. Connect the suction hose (or fuel nozzle) to the connection -1- and
then connect the venting device -2- .
Fuel transfer system

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.
Note
z Fuel can be removed directly through the fuel filler neck on older vehicles or vehicles from other
manufacturers by removing the connecting piece.
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Connecting piece Earth cable attached to vehicle

Draining fuel (emptying fuel tank)
Draining fuel (emptying the fuel tank)
DANGER
periods.
DANGER

→ Do not smoke.
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ATTENTION
Damage to the fuel tank!
→ Please observe the general warning notes and working regulations. → 10 The most important working
regulations and warning notes.
→ The tank can only be drained using the vehicle's own fuel pumps.
→ It is not possible to extract fuel via the fuel filler opening and doing so may cause damage.
Note
z All windows should be opened for better ventilation in the passenger compartment.
2. Fold up the retaining brackets of the right-hand belt anchor. To do so,

undo the three fastening screws and fold up the bracket with the belt
anchors. Do not use the fastening screws again.
Retaining brackets of the right-hand

belt anchor
3. Undo the right cap. To do so, cut out the carpeted floor along the
perforated lines using a carpet knife and fold it over. Then unscrew
the four fastening nuts and remove the lids. View shows both lids.
4. Reduce the fuel pressure in the fuel line. To do so, screw down the
protective cap on the fuel gallery and carefully press the valve.
Collect emerging fuel with a cloth.
Cap
5. Carefully pull off the fuel line -1- . Collect emerging fuel with a cloth.
6. Connect earth cable to the vehicle.
7. Attach Porsche adapter to the connection piece. Twist top and bottom part of adapter in opposite directions
until it is tight.
8. Screw the connecting piece into the suction hose and tighten it hand tight.
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Earth cable attached to vehicle Fuel line
Connecting piece Porsche adapter

9. Connect the connecting piece to the adapter.
Connecting piece connected to

adapter
10. Open lid of central electrics box. To do this, loosen the four fastening
screws.
ATTENTION
Risk of damage to fuel pumps!
z The Porsche adapter can slip from the tank connection.
→ Only switch fuel pumps on after the extraction pump has been
switched on.
→ Always set extraction pump to suction mode - never refill mode -
when the vehicle pump is running. Lid of central electrics box
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Note
z Use special tool adapter 9479 from the measurement tool box to activate the fuel pump.
z Alternatively, adapters 26 and 25 can be connected and the fuel relay can be bridged. A fault is stored in the
engine control module during this procedure.
11. Remove fuel pump relays -1- and -2- . The pump can be activated by bridging the relevant contacts. The
contact assignment is printed on the corresponding relay. No faults are stored in the engine control module
when special tool adapter 9479 is used. Both pumps should be activated. As soon as the tank is empty, fit
the fuel pump relays again and close the electrics box.
Fuel pump relay
12. Carry out any necessary repair work on the tank. Please observe the warning notes in the chapter entitled
→ 10 The most important working regulations and warning notes.
Connections
14. Fit the lid. Then tighten the four fastening nuts → Tightening torque: 10 (7.5 ftlb.) Nm . Refit carpeted floor
and fix with double-sided adhesive tape.
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Fastening screws for retaining Cap

tightening torque see → 692519 Removing and installing rear belt lock
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.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
24 24 55 Replacing air-cleaner element - as of MY 2003

- Preliminary work
- Replacing air-cleaner element - Cayenne S (type M48/00)
- Subsequent work
Preliminary work
Preliminary work
1. Remove throttle-housing cover. → 243519 Removing and installing throttle-housing cover (Y-shaped pipe)
2. Remove engine compartment covers on the left and right over the air cleaner housing. → 700219 Removing
and installing front cover (engine compartment)
Replacing air-cleaner element - Cayenne S (type M48/00)
Note
z In vehicles with air suspension, the compressor air tube on the air cleaner cover must be removed and
installed.
Note
z Under particularly difficult conditions (dusty environments) it may be necessary to change the filter element
outside the maintenance intervals.
z The description only applies to changing one filter element. The second element is changed in the same way.
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Air guide for V8 S
1. Remove the air tube on the right air cleaner cover. To do this, unclip
the green cap. Insert a screwdriver into the notch of the cap and
lever the cap off. → Air line
Air line
2. Push the circlip into the flange -1- and then pull it off together with the
flange -2- .
Connection
3. Clip the green cap on again after disassembly.
4. The coolant bleeder hose on the coolant expansion tank should be unclipped from the air cleaner housing
cover of the cylinder bank 1 - 4.
5. Open the two upper fastening clips on the air cleaner housing.
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Coolant bleeder hose Cover cap

6. Press the cover of the air
cleaner housing in the
direction of the engine, pulling
it upwards at the same time.
Cover for air filter housing Clamps

7. Remove the air-cleaner element from the air cleaner housing.
Air cleaner element

8. Insert filter element in the housing.
Filter element inserted correctly

9. Place the cover on the air cleaner housing and run in from top to bottom. Make sure that the three fastening
lugs run into the mounting points on the underside. The figure gives a clearer view of the dismantled air
cleaner housing.
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Fastening lugs on underside

10. Push cover up against the air cleaner housing and release the 2
fastening clips
Clamps
11. Push the air suspension line onto the right air cleaner cover.
Air suspension line

12. The coolant bleeder hose and the coolant overflow hose must be
clipped back onto the cylinder bank 1 - 4 on the air cleaner housing.
Coolant bleeder hose
Subsequent work
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Subsequent work
1. Install throttle-housing cover. → 243519 Removing and installing throttle-housing cover (Y-shaped pipe)
2. Install engine compartment covers on the left and right over the air cleaner housing. → 700219 Removing
9PAAE1, 9PAAE7
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
24 25 19 Removing and installing air cleaner housing - as of MY

2003
- Preliminary work
- Removing air cleaner housing - Cayenne S (type M48/00)
- Installing air cleaner housing - Cayenne S (type M48/00)
- Subsequent work
Preliminary work
Preliminary work
Note
z The description relates to one cylinder row. The air cleaner housing on the other cylinder row is removed and
installed in the same way.
1. Perform the steps required to replace the air-cleaner element. → 242455 Replacing air cleaner element
2. Remove the relevant wheel-housing liner. → 505619 Removing and installing front wheel housing liner.
Component overview
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Installation position for air guide for V8 S
Installation position for air guide for V8 Biturbo
Removing air cleaner housing - Cayenne S (type M48/00)
1. Pull the air guide of the air cleaner housing out of the wheel well. To do this take hold of the air guide in one
hand and pull it forwards at an angle.
2. Unscrew the fastening screw on the air cleaner housing.
3. Unclip the electric cable from the coolant expansion tank on the cylinder bank 1 - 4. The cable is clipped in at
2 points.
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Fastening screw Air guide

4. Lift the air cleaner housing, tip
it towards the engine and
remove it from the engine
compartment.
Air cleaner housing Electric cable
Installing air cleaner housing - Cayenne S (type M48/00)
1. Insert the air cleaner housing into the engine compartment at an angle
from above.
Air cleaner housing

2. Introduce the 2 retaining bolts on the underside into the take-up bores
in the body. Check the wheel well to make sure that the blue rubber
discs are present and ensure that the bolts are properly fitted.
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Fastening bolts and rubber washers
Fastening screw
3. Tighten the fastening screw on the air cleaner housing. → Tightening torque: 7.5 ftlb.
4. Unclip the electric cable from the coolant expansion tank on cylinder
bank 1 - 4. The cable is clipped in at two points.
Electric cable
5. Replace the air guide on the air cleaner housing from the wheel well.
Check that the elements are installed correctly.
Air guide
Subsequent work
Subsequent work
1. The steps required to replace the air-cleaner element are to be performed in the same way. → 242455
Replacing air cleaner element
2. Install the relevant wheel-housing liner. → 505619 Removing and installing front wheel housing liner.
9PAAE1, 9PAAE7
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as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
24 30 19 Removing and installing fuel pipe - as of MY 2003
Removing and installing fuel pipe

1. The steps involved in removing and installing the fuel pipe (fuel distributor pipe, pressure pipe) are identical
to those involved in removing and installing the fuel injectors. → 244019 Removing and installing injection
valve
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
24 35 19 Removing and installing cowl for throttle housing (Y-

shaped pipe) - as of MY 2003
- Removing cowl for throttle housing (Y-shaped pipe) - Cayenne S (type M48/00)
- Installing cowl for throttle housing (Y-shaped pipe) - Cayenne S (type M48/00)
Removing cowl for throttle housing (Y-shaped pipe) - Cayenne S (type M48/00)
Installation position for V8 S
1. Remove front engine compartment cover. → 700219 Removing and installing front cover (engine
compartment) - "Removing" section
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Cable plug for throttle housing Front design cover
Fastening bolts
4. Release the fastening bolts on the throttle body. To do this, twist bolts through 45° in an anti-clockwise
direction. The spot on the bolts must lie as shown in the picture. → Fastening bolts
Removing fastening bolts

7. Disconnect the air flow sensor connections. To do this, undo the
hose clamps to the left and right on the bellows and pull the bellows
off the air flow sensors.
Bellows
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Vacuum line
8. Remove the hose on the Y pipe. To do this, press the button and disconnect the vacuum line.
Installing cowl for throttle housing (Y-shaped pipe) - Cayenne S (type M48/00)
Vacuum line
2. Slide the bellows onto the air flow sensors and tighten the hose
clamps.
Bellows
3. Slide the Y-shaped pipe onto the throttle adjuster. Then insert the left and right fastening bolts. Turn the bolts
45° clockwise. → Fastening bolts
4. Connect the throttle adjuster. The plug must engage audibly. Clip the connecting cable into the sheetmetal
holder.
6. Install front engine compartment cover. → 700219 Removing and installing front cover (engine compartment)
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Cable plug for throttle housing Fastening bolts
Front design cover

- "Installing" section
9PAAE1, 9PAAE7
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
24 40 19 Removing and installing fuel injector - as of MY 2003

- Preliminary work
- Removing fuel injector
- Installing fuel injector
- Subsequent work
Preliminary work
Preliminary work: Installing fuel injectors

1. Remove engine compartment lining at the rear and on the right-hand side. → 700219 Removing and
installing front cover (engine compartment) - "Removing" section
2. Remove design covers from engine. → 108319 Removing and installing engine cover - "Removing" section
Component overview
Installation position for suction module and fuel injectors

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Fuel pipe and fuel injectors
1 - Intake-air distributor
2 - Positive crankcase ventilation (T flange)
3 - K50 x 12 lens-head screw → Tightening torque: 1.6 ftlb.
4 - Cap; replace
5 - Valve insert
7 - Fuel gallery; do not bend
8 - Fuel injector
9 - Safety clip
Removing fuel injector

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Removing injection valve
DANGER
eyes.
→ Wear protective gloves that are fuel-resistant. Fuel connections
→ Wear a breathing mask with active charcoal filter; do not breathe in
any fuel vapours.
DANGER

→ Do not smoke.
Note

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1. Disconnect fuel line -1- and line -2- from the carbon canister on the radiator tank splash panel.
2. Disconnect the electric connectors to the eight fuel injectors. To do

this, press the metal clip on the plug and pull off the plug.
Metal clip on plug

3. Unscrew the four fastening screws on the fuel distribution pipe.
4. Remove fuel distribution pipe with the fuel injectors.
Fastening screws for fuel distribution

pipe
5. Pull off the clamp on the fuel injector -A- and pull the fuel injector out
of the fuel distribution pipe -B - .
Fuel injector
Installing fuel injector
Note
z If the fuel injectors are to be reused, the sealing rings should be replaced.
1. Replace sealing rings on the injection valves. Take care not to damage the fuel injector when removing the
sealing rings.
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2. Insert injection valve into the fuel distribution pipe and align. The
electric connector must be positioned opposite the lug on the
distributor. Then fit sheetmetal clips -arrow- .
Valve alignment
3. Insert the fuel injector into the fuel distribution pipe -A- and insert the
clamp on the fuel injector -B - .
View shows fitting

4. Check that the sheetmetal clip is correctly fitted. The sheetmetal clip
must engage in the flanged edge on the fuel distribution pipe.
5. Insert fuel injectors into the openings in the intake module and press
the fuel gallery down.
Installation position for sheetmetal clip

6. Tighten the four fastening screws to the specified torque. →

pipe
7. Connect the 8 electric connectors to the injection valves. The connectors must engage audibly.
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8. Connect fuel line -1- and line

-2- from the carbon canister
on the radiator tank splash
panel.
9. Switch on ignition and check
the system for leaks.
Fuel connections Fuel injector clamp
Subsequent work
Work subsequent to installing injection valves

1. Install design covers for engine. → 108319 Removing and installing engine cover - "Installing" section
2. Install engine compartment cover at the rear and on the right-hand side. → 700219 Removing and installing
front cover (engine compartment) - "Installing" section
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
24 42 19 Removing and installing throttle body - as of MY 2003

- Preliminary work
- Removing throttle body
- Installing throttle body
- Subsequent work
Preliminary work
Preliminary work
1. Remove Y-shaped pipe (intake manifold in front of throttle housing). → 243519 Removing and installing air
box for throttle housing (Y-pipe) - section on "Removing" [9PAAF1 9PAAJ1]→ 243519 Removing and
installing air box for throttle housing (Y-pipe) - section on "Removing" [9PAAE1 9PAAE7]
Removing throttle body
Removing throttle housing

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Suction module
1 - Intake-air distributor and throttle housing

2 - Seals for intake-air distributor; replace
3 - Seal for throttle adjuster; replace
4 - Throttle adjuster; do not actuate by hand
5 - Support for throttle body cover; secure with the fastening screws for the throttle adjuster
7 - Fastening screws
1. Pull off cable plug on the throttle housing and pull cable out of the
clip -Arrows- .
Cable plug for throttle housing

2. Undo four screws on the throttle housing -Arrows- . Loosen sheetmetal reinforcement around the throttle
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Loosening throttle adjuster
housing. Remove throttle housing.
3. Check condition of sealing ring. Replace sealing ring if necessary

→ Sealing ring for throttle housing .
Sealing ring for throttle housing
Installing throttle body
Installing throttle housing


2. Move throttle housing into installation position and place sheetmetal reinforcement around the throttle
housing. Insert and screw in four screws -Arrows- . → Tightening torque: 8 (6 ftlb.) Nm
3. Attach cable plug to throttle housing and insert cable into clip -Arrows- .
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Cable plug for throttle housing Throttle adjuster mount

Subsequent work
Subsequent work
1. Install Y-shaped pipe (intake manifold in front of throttle housing). → 243519 Removing and installing air box
for throttle housing (Y-pipe) - section on "Installing" [9PAAF1 9PAAJ1]→ 243519 Removing and installing air
box for throttle housing (Y-pipe) - section on "Installing" [9PAAE1 9PAAE7]
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
24 45 19 Removing and installing air flow sensor - as of MY 2003

- Information
- Removing air flow sensor - Cayenne S (type M48/00)
- Installing air flow sensor - Cayenne S (type M48/00)
Information
Suction routes for V8 S

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Suction routes for V8 Turbo
Removing air flow sensor - Cayenne S (type M48/00)

1. Remove left and right engine compartment cover. → 700219 Removing and installing front cover (engine
2. Separate electric connections on the air flow sensor.
Cable plug for hot-film mass air flow

meter
hose clamps to the left and right on the bellows and pull the bellows
off the air flow sensors.
Bellows
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4. Pull out retaining clip on the air flow sensor. → Clamp for hot-film
mass air flow meter
5. Pull out air flow sensor.
Clamp for hot-film mass air flow meter
Installing air flow sensor - Cayenne S (type M48/00)
1. Insert air flow sensor in the pipe on the air cleaner housing cover.
When doing so, observe the flow direction. There is a small arrow on
the housing which must point towards the engine. Then connect the
retaining clip.

2. Connect the bellows and tighten the hose clamps.
Bellows
3. Connect electric connector to the air flow sensor.
4. Fit engine compartment cover. → 700219 Removing and installing

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meter
9PAAE1, 9PAAE7
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
24 46 01 Checking the intake-air distributor for leaks - as of MY

2003
- Leak test
Tools

Tools and materials
Required tools
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-A- Compressed-air reducer Commercially available, see Workshop
Equipment Manual. Set it to a maximum
operating pressure of 1.2 bar.
-B- Plug 9264/7
-C- Leak-locating spray Commercially available, see Workshop
Equipment Manual.
Leak test
Note
z The specified description can be used to check the intake system from the air cleaner outlet to the injection
valves for leaks.
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Suction routes for V8
Cylinders must not be located in the overlapping TDC. This happens only if the crankshaft was turned manually.
1. Remove engine compartment cover. → 700219 Removing and installing front cover (engine compartment) -
"Removing" section
2. Separate connections on the air cleaner covers. To do this, turn the

pins by 180° and pull them out. Then pull off the intake manifolds.
Fastening bolts
3. Connect the plugs 9264/7 to the two air cleaner connections and
push in the securing clip.
WARNING
Danger of damaging the intake system if pressure is too high!
z Intake system can burst.
z Danger of injury from flying components.
→ Do not subject intake system to excessive air pressure (max. 1.2 bar
of absolute pressure).
Plugs on intake manifold
WARNING
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Danger of injury from flying components.
→ Do not pull out the oil dipstick or open the engine during the test procedure.
4. Set compressed-air reducer to 0.2 bar (approx. 1.2 bar absolute pressure).
5. Push a compressed-air hose onto the connection from the plug 9264/7 and connect the other end to the
pressure reducer.
6. Spray the intake system systematically with a leak-locating spray.

Bubbles can be seen clearly at the locations where there are leaks
(e.g. -arrow- ).
Note
z Any leaks that exist between the air cleaner cover and the intake
distributor seal can be located using this method.
z Proceed systematically with the check.
7. Seal defective areas.

View shows a leaking Y pipe
8. Remove special tool.
9. Push the connections onto the cover of the air cleaner housing and
mount and lock the fastening pins.
10. Fit engine compartment cover. → 700219 Removing and installing

as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
24 46 19 Removing and installing intake-air distributor - as of MY

2003
- Preliminary work
- Information
- Removing intake-air distributor
- Installing intake-air distributor
- Subsequent work
Preliminary work
Preliminary work for removing intake distributor
1. Remove design cover → 108319 Removing and installing engine cover - "Removing" section.
Information
Component overview
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Installation location for intake-air distributor
I - Curved hose
II - Check valve
III - Hose
A - Vacuum line closed
B - Vacuum line closed
Vacuum line
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Suction module
1 - Intake-air distributor and throttle housing

2 - Seals for intake-air distributor; replace
3 - Seal for throttle adjuster; replace
4 - Throttle adjuster; do not actuate by hand
5 - Support for throttle body cover; secure with the fastening screws for the throttle adjuster
7 - Fastening screws
Removing intake-air distributor
Note

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1. Separate the electric connection from the throttle adjuster. To do this,

press on the plug at the top and bottom and, at the same time, pull it
off. Unclip the cable from the sheetmetal holder.
ATTENTION
Risk of damaging the fastening bolts!
z The fastening bolts will break if they are turned in the wrong
direction.
→ Only turn the fastening bolts in the correct direction of rotation for
opening and closing.
2. Release the fastening bolts on the throttle body. To do this, twist the
right and left pin through 45° in an anti-clockwise direction. Direction of rotation for fastening bolts
Fastening bolts
5. Disconnect the air flow sensor connections. To do this, undo the hose clamps to the left and right on the
bellows and pull the bellows off the air flow sensors.
6. Remove the vacuum line on the Y-shaped pipe. To do this, press the button and disconnect the vacuum line.
7. Disconnect the vacuum line on the rear of the intake system.
8. Disconnect positive crankcase ventilation line on the two valve covers. To do this press the plastic ring and
pull the connections. Then remove the positive crankcase ventilation line from the retaining clip.
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Vacuum line connection Bellows
Positive crankcase ventilation Vacuum line on rear side of suction

module
Positive crankcase ventilation line

connection
9. Then remove the line between the oil mist collector and the intake
distributor.
Line for oil mist separator

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DANGER

→ Do not smoke.
→ Danger of fire due to naked flames and sparks, e.g. during welding
or grinding work.
→ Danger of fire due to escaping fuel, e.g. on hot engine components
or due to electrostatic charge. Allow engine to cool down. Fuel lines
DANGER
periods.
Note
z Before the lines are opened, place a cloth or a suitable container underneath them!
z Collect escaping fuel.
10. Disconnect fuel line -1- and line -2- to the carbon canister on the radiator tank splash panel.
11. Disconnect the electric connectors to the eight fuel injectors. To do this, press the metal clip on the plug and
pull off the plug.
12. Unscrew the fastening screws on the intake distributor in the sequence shown below. → Loosening order for
suction module
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Cable plug for injection valves
Loosening order for suction module
13. Remove intake distributor from the engine in an upward direction.
Installing intake-air distributor
Note

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1. Replace intake distributor gaskets.

2. Place intake-air distributor on the engine and tighten the screws in
the sequence shown below. → Tightening sequence for suction
module → Initial tightening: 7.5 ftlb. → Final tightening: 11 ftlb.
Installation position for seals
Tightening sequence for suction module
3. Connect the 8 electric connectors to the injection valves. The

connectors must engage audibly.

4. Install positive crankcase ventilation line. The 2 connections must audibly engage. Then close the mounting
clip.
5. Install line between intake distributor and oil mist collector.

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Line for oil mist separator Positive crankcase ventilation
DANGER
eyes.
→ Wear protective gloves that are fuel-resistant. Fuel lines
→ Wear a breathing mask with active charcoal filter; do not breathe in
any fuel vapours.
DANGER

→ Do not smoke.
6. Connect fuel line -1- and line -2- from the carbon canister on the radiator tank splash panel.
7. Connect vacuum line to the rear of the intake distributor. The plug must engage audibly.
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Vacuum line on rear side of suction

module
Vacuum line connection

clamps.
Bellows
ATTENTION
direction.
and right fastening bolts. Turn the right and left bolts 45° clockwise. Direction of rotation for fastening bolts
11. Connect the throttle adjuster. The connector must engage audibly. Clip the connecting cable into the
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sheetmetal holder.
Subsequent work
Subsequent work for installing intake distributor

1. Install design cover → 108319 Removing and installing engine cover - "Installing" section.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
24 58 19 Removing and installing fuel pressure regulator - as of

MY 2003
- Preliminary work
- Information
- Removing fuel pressure regulator
- Installing fuel pressure regulator
- Subsequent work
Tools

Preliminary work
Preliminary work
Note

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Opening the tank
Note
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4. Undo the caps (figure shows both). To do so, cut out the carpeted
floor along the perforated lines using a carpet knife and fold it over.
Then unscrew the four fastening nuts and remove the lid.
5. Empty the fuel tank if this has not already been done or if the fuel
level in the fuel tank is very low. → Draining and filling fuel
DANGER
eyes.
→ Wear protective gloves that are fuel-resistant. Fuel supply and disconnection points
→ Wear a breathing mask with active charcoal filter; do not breathe in at right connection unit
any fuel vapours.
DANGER
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→ Do not smoke.
Note
unit (cap).
Cap
Information
Component overview
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Connecting flange with pressure regulator
1 - Fuel pressure line

2 - Electric connection for fuel pump
3 - Connection to fuel delivery unit right and left (unpressurised)
4 - Pressure regulator input from fuel filter
5 - Electric connection for fuel level indicator
6 - Fuel pressure regulator; 4 bar supply pressure
Removing fuel pressure regulator
1. Pull off electric connectors -1 and 2- . Then pull off the fuel lines
-3 and 4- and remove the connection unit (pressure regulator).
Connection unit (pressure regulator)
Installing fuel pressure regulator

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Note
z The pressure regulator is integrated into the connection unit.
z The connection unit together with integrated pressure regulator is replaced as a complete unit and not
disassembled.
Seal
2. Connect the connection unit. Fit electric connector -1 and 2- and
Connection unit
Subsequent work
Closing the tank
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2. Fit all connections (fuel lines, Cap

ventilation tubes and electric
plugs).

electric plugs
adhesive tape.


Subsequent work
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
24 69 19 Removing and installing oxygen sensors in front of

catalytic converter - as of MY 2003
- Preliminary work
- Removing oxygen sensors in front of catalytic converter - Cayenne S (M48/00)
- Installing oxygen sensors in front of catalytic converter - Cayenne S (M48/00)
- Subsequent work
Tools

Torque wrench, signal- commercially NR.90 Only in combination
transmitting with available tool with wrench inserts
changeover ratchet
Accessory for torque commercially NR.96-3 various overall

wrench: Open ring available tool lengths, e.g. Hazet
wrench angled 4681-1 to 3
Accessory for torque commercially NR.97 various overall

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assembly
Preliminary work
Preliminary work for removing oxygen sensors in front of catalytic converter - Cayenne S
(M48/00)
1. Remove front wheel → 440519 Removing and installing wheel.
2. Remove front wheel housing liner → 505619 Removing and installing front wheel housing liner - "Removing"
section.
3. Remove engine compartment cover above the oxygen sensor plugs → 700219 Removing and installing front
cover (engine compartment) - "Removing" section.
4. Disconnect oxygen sensor plug for the oxygen sensor in front of

catalytic converter at the right of the water splash panel and unclip
the cable from the holder.
5. Remove air cleaner housing → 242519 Removing and installing air
cleaner housing - "Removing" section.
ATTENTION
Danger of burns from hot exhaust system!
→ Only remove the exhaust system once it has cooled down.

→ Wear protective gloves. Cable plugs for oxygen sensors
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6. Release oxygen sensor wire from the cable guide and leave it at the oxygen sensor.
Tools and materials
Tools - oxygen sensor
Special tools - oxygen sensors
→ Special tools - oxygen - Accessory for torque wrench: Open ring wrench angled NR.96-3
sensors
→ Special tools - oxygen - Accessory for torque wrench: Open ring wrench angled NR.97
sensors
→ Special tools - oxygen - Accessory for torque wrench: Open ring wrench angled assembly
sensors NR.98
→ Special tools - oxygen - Torque wrench, signal-transmitting with changeover ratchet NR.90
sensors
Removing oxygen sensors in front of catalytic converter - Cayenne S (M48/00)
ATTENTION
The oxygen sensor cable can be damaged if twisted!
z Change in emissions.
z Check Engine light comes on.
→ Always release oxygen sensor cable so that the wire can turn when unscrewing or screwing in the sensor.
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→ Do not kink cable.
Component overview for primary catalytic converter
1 - Exhaust manifold, cylinders 1 -4

2 - Exhaust manifold, cylinders 5 - 8
3 - Seal for exhaust manifold; replace
4 - M8 hexagon nut; replace, coat thread of bolts with Microgleit
5 - Oxygen sensor ahead of catalytic converter
7 - Seal; replace
8 - M8 hexagon nut; replace
9 - Catalytic converter, front
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11 - Support
12 - Support
14 - Hexagon-head bolt, M8 x 15
15 - Stud M8 x 25
16 - Oxygen sensor behind catalytic converter
17 - Seal; replace
18 - Catalytic converter
20 - Screw
21 - Bracket
22 - Bracket
23 - Bracket
1. Remove the oxygen sensor in the exhaust manifold using a mirror. To do this, screw out the oxygen sensor
with an open-ended wrench SW 22.
Installing oxygen sensors in front of catalytic converter - Cayenne S (M48/00)
ATTENTION
→ Always expose oxygen sensor cable so that the wire can turn when
unscrewing or screwing in the sensor.
1. Preassemble the oxygen sensor in the exhaust manifold by hand Oxygen sensor for exhaust manifold
using a mirror. Tighten oxygen sensor using a special tool.
→ 246919 Removing and installing oxygen sensor ahead of catalytic
converter - "Tools and materials" section → Tightening torque: 33
ftlb. +/-3.5 ftlb.
Subsequent work
Touching up for installing oxygen sensors in front of catalytic converter - Cayenne S (M48/00)
1. Push oxygen sensor wire into the cable guide.
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Cable plugs for oxygen sensors Tool on exhaust manifold oxygen

sensor
2. Connect the oxygen sensor plug for the oxygen sensor in front of catalytic converter at the right of the water
splash panel and clip the wires into the guide. Fit cable plug.
3. Install air cleaner housing → 242519 Removing and installing air cleaner housing - chapter on "installing".
4. Fit engine compartment cover above the oxygen sensor plugs → 700219 Removing and installing front cover
(engine compartment) - "Installing" section.
5. Install front wheel housing liner → 505619 Removing and installing front wheel housing liner - "Installing"
section.
6. Fit front wheel → 440519 Removing and installing wheel.
9PAAE1, 9PAAE7
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g g g
ADVERTENCIA
24 70 19 Removing and installing DME control module - as of MY

2003
- Information
- Obtaining read-out and saving vehicle data from DME control module
- Removing DME control module
- Installing DME control module
- Programming new DME control module
- Programming DME control module
Information
z If the DME control module is replaced, it must be programmed using the Porsche System Tester. Thus, the
DME control module can be adapted to the vehicle, the national variant and the equipment. The DME control
module is located in the radiator tank near the right fender.
z If possible, before the DME control module is removed and replaced, a read-out of the vehicle data should be
obtained from the Porsche System Tester.
z Symbol for the Tab key = →|
z 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.
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Overview of the DME control module
Exhaust-gas standard
ME 7.1.1 min
Type Version Explanation
Low Emission Vehicle, USA
OBD 2 LEV
As of model year '03.
Rest of world
RoW EU2
European On-Board
EOBD EU4 Diagnosis.
Obtaining read-out and saving vehicle data from DME control module
1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on ignition. >>
Continue.
2. Select vehicle type using the cursor keys.
3. Using the →| key, move from the vehicle type to the control modules.
4. Select DME with the cursor keys and press the >> key.
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5. Select Control unit programming with the cursor keys and press the >> key.
6. Select Read out control unit (vehicle data) with the cursor keys and press the >> key.
7. The message Vehicle data read-out complete will appear on the screen of the Porsche System Tester.
8. After replacement of the DME control module, the vehicle data is installed in the menu Program control
module (see Section 6).
Removing DME control module
ATTENTION
Risk of short circuit!
→ Before removing the control unit, switch off the ignition.
Note
z Unscrew the two fastening screws for the cowl panel cover and lift up the cover in this area. → 664419
Removing and installing cowl panel cover
1. Push the two retaining clips aside -arrows- and remove control unit to
the front.
Retaining clips for control unit

2. Pull out latch on both connectors in -direction of arrow- and remove
the connectors.
Latch for connectors

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Installing DME control module
1. Insert both connectors into the control unit and push in latch in
-direction of arrow- .

2. Insert control unit and secure with the two retaining clips -arrow- .
Programming new DME control module
Note
z If a new DME control module is to be installed in a vehicle, the immobiliser code specified in IPAS must be
entered in the DME control module.
z You can get the codes from IPAS or from your importer by specifying the vehicle identification number.
z During DME programming, it is essential to guarantee the power supply for the Porsche System Tester. It is
essential to connect a battery charger with a current rating of at least 40 A to the vehicle battery.
z Symbol for the Tab key = →| .
z The procedure described here has been structured in general terms; different text or additions may appear in
the Porsche System Tester.
1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on ignition. Read out
DME control module. → 247019 Removing and installing DME control module - "Reading out" section
2. Switch off ignition and replace DME control module with a new unit. → 247019 Removing and installing DME
control module - "Removing" section
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3. Change to the Control module programming menu and press >> .
4. Program control module and press >> .
5. Observe System Tester conditions >> .
6. Select vehicle type and press >> .
7. Select transmission type and press >> .
8. Select emission standard and press >> . → 247019 Removing and installing DME control module -
"Information" section
9. Program control module and confirm with F8 .
10. The data and programming status is then loaded on to the DME control module. Do not interrupt the
programming sequence.
11. The System Tester indicates whether the control unit is programmable and the approximate programming
time.
Note
z During programming, the electric radiator fans may start.
12. Once the DME control module has been programmed successfully, switch to the Program immobiliser code
menu and press >> .
13. Enter the new immobiliser code (IPAS), confirm with the >> key, check the code again and confirm with the
F7 key.
14. When the programming period expires follow the instructions on the Porsche System Tester.
Note
z In some countries (currently USA, Canada) the Ready status must be obtained following a test drive and/or by
using the Porsche System Tester after a DME control module is programmed. If in doubt about this, contact
the relevant importer.
z See On-Board Diagnosis Manual (DME 7.1.1)
z With all DME systems, the engine must run for several minutes before the engine control unit can relearn the
idle speed and mixture adaptation values!
15. For the learning and adaptation routine of the throttle (E-gas), switch the ignition on for 30 seconds without
starting the engine. Do not actuate accelerator pedal. This completes the adaptation of the throttle adjusting
unit and the programming sequence is complete.
16. Read out the fault memory and delete the DME control module fault on every control unit connected to the
CAN.
17. Carry out a test drive and read out fault memory.
Note
z If faults are present, proceed in accordance with the DME 7.1.1 Manual. See On-Board Diagnosis Manual
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(DME 7.1.1)
Programming DME control module
Note
z If a DME control module from a different vehicle with ME 7.1.1 is being used, proceed as follows. As a check,
the immobiliser code of the vehicle in which the control unit is being installed (NEW) and of the vehicle from
which the control unit has been removed (OLD) are required.
z During DME programming, it is essential to guarantee the power supply for the Porsche System Tester. It is
essential to connect a battery charger with a current rating of at least 40 A to the vehicle battery.
z You can get the necessary codes from IPAS or from your importer by specifying the vehicle identification
number.
1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on ignition. Read out
DME control module. → 247019 Removing and installing DME control module - "Reading out" section
2. Switch off ignition and replace DME control module with a new unit. → 247019 Removing and installing DME
control module - "Removing" section
3. Change to the Control unit programming menu and press >> .
4. Program control module >> .
6. Select vehicle type >> .
11. The System Tester indicates whether the control unit is programmable and the approximate programming
time.
12. Once the DME control module has been programmed successfully, switch to the Program immobiliser code
menu and press >> .
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13. Enter the old immobiliser code (IPAS, vehicle - OLD), continue with the >> key, check the code again and
confirm with F7 .
14. Enter the new immobiliser code (IPAS, vehicle - NEW), continue with the >> key, check the code again and
confirm with F7 .
Note
z In some countries (currently USA, Canada) the Ready status must be obtained following a test drive and/or by
using the Porsche System Tester after a DME control module is programmed. If in doubt about this, contact
the relevant importer.
z With all DME systems, the engine must run for several minutes before the engine control unit can relearn the
idle speed and mixture adaptation values!
16. For the learning and adaptation routine of the throttle (E-gas), switch the ignition on for 30 seconds without
starting the engine. Do not actuate accelerator pedal. This completes the adaptation of the throttle adjusting
unit and the programming sequence is complete.
17. Read out the fault memory and delete the DME control module fault on every control unit connected to the
CAN.
Note
z If faults are present, proceed in accordance with the DME 7.1.1 Manual. See On-Board Diagnosis Manual
(DME 7.1.1)
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
24 73 19 Removing and installing oxygen sensors behind catalytic

converter - as of MY 2003
- Preliminary work
- Removing oxygen sensors behind catalytic converter - Cayenne S (M48/00)
- Installing oxygen sensors behind catalytic converter - Cayenne S (M48/00)
- Subsequent work
Tools

Torque wrench, signal- commercially NR.90 Only in combination
transmitting with available tool with wrench inserts
changeover ratchet


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assembly
Preliminary work
Preliminary work: Removing oxygen sensors behind catalytic converter
ATTENTION

1. Loosen and bend primary catalytic converter (primary catalytic

converter does not need to be removed completely). For details see
→ 267619 Removing and installing primary catalytic converter -
"Removing" section. Mount for primary catalytic converter in
Turbo
Tools and materials

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Mount for primary catalytic converter in

sensors
sensors
sensors NR.98
sensors
Removing oxygen sensors behind catalytic converter - Cayenne S (M48/00)

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1 - Exhaust manifold, cylinders 1 -4

3 - Seal for exhaust manifold; replace
4 - M8 hexagon nut; replace, coat thread of bolts with Microgleit
7 - Seal; replace
8 - M8 hexagon nut; replace
11 - Support
12 - Support
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15 - Stud M8 x 25
17 - Seal; replace
20 - Screw
21 - Bracket
22 - Bracket
23 - Bracket
ATTENTION
→ Always expose oxygen sensor cable so that the wire can turn when unscrewing or screwing in the sensor.
1. Carefully unscrew oxygen sensors on primary catalytic converter.
Installing oxygen sensors behind catalytic converter - Cayenne S (M48/00)

1. Position the oxygen sensor by hand and screw in as far as possible.
2. Tighten oxygen sensor using special tool → 247319 Removing and installing oxygen sensors behind
catalytic converter - "Tools and materials" section. → Tightening torque: 33 ftlb. +/-3.5 ftlb.
Subsequent work
Subsequent work: Installing oxygen sensor behind catalytic converter
1. Install primary catalytic converter→ 267619 Removing and installing primary catalytic converter - "Installing"
section.
9PAAE1, 9PAAE7
as of MY 2003
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Mount for primary catalytic converter in Mount for primary catalytic converter in
naturally aspirated engine Turbo
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
26 01 01 Checking exhaust system for leaks - as of MY 2003

- Preliminary work
- Leak test
- Subsequent work
Tools

plugs special tool 9710/3
Preliminary work
Preliminary work
1. Lift the vehicle. → 40 Lifting the vehicle
Leak test
ATTENTION
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→ Allow components to cool down.

Note
correctly.
z The general warning notes must be observed. → 10 The most important working regulations and warning
notes
1. Remove tailpipes. To do this, loosen the fastening screws and pull

the tailpipes out of the rear silencer by swivelling them gently to the
side.
2. Insert plugs 9710/3 on both sides of the rear silencer and twist these
by folding over the lever.
Fastening screw for tailpipe

3. Remove the protective cap of the test valve on one side and apply
excess pressure of approx. 0.3 bar using a tyre-inflating device.
Note
z The exhaust system must be completely sealed between the engine
and the catalytic converters.
4. Check exhaust system for leaks and repair if necessary.
5. Remove the plugs and insert the tailpipes into the rear silencer.
Tyre-inflating device on test valve
Subsequent work
Subsequent work
1. Align tailpipes with the bumper and secure them. → 263415 Aligning tailpipes [9PAAD1 9PAAD7 9PAAE1
9PAAE7]→ 263415 Aligning tailpipes [9PAAF1 9PAAJ1]
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2. Lower the vehicle. → 40 Lifting the vehicle
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
26 01 19 Removing and installing exhaust system - as of MY 2003

- Information
- Removing exhaust system
- Installing exhaust system
Tools

chain pipe cutters commercially NR.166
available tool
Information
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Component overview for V8 exhaust system

-I- Repair separation point 2 When carrying out repairs, Link up the separation point
separate at the central notch with 2 exhaust straps. Position
with chain pipe cutters the straps horizontally. (Nut
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NR.166. pointing downwards)

-A- Gap dimension Max. 5 mm
-B- Exhaust strap length 95 mm
-C- Inclination Maximum inclination: 10 °
-D- Offset of the rear silencer 2 10 mm
retainer
-E- Off-centre position of central 1 4 mm
mount
-F- Off-centre position of front 1 2 mm
mount
Removing exhaust system
Note
The exhaust system in the V6 is designed as a single strand. Repair instructions and notes apply to both exhaust
systems.
WARNING
→ Only remove the exhaust system when it has cooled down!

→ Wear protective gloves!
1. Release connecting straps between the catalytic converters and the

exhaust system. Then push the straps backwards onto the exhaust
system. The exhaust straps must not be reused.
Exhaust clamps
WARNING
Danger of injury from heavy exhaust system!
→ Before loosening the exhaust system, it should be secured to

prevent it from falling.
2. Release the front and middle retainers. To do this, loosen the 2

fastening screws.
Bracket for exhaust system
Note
z Before the rear silencer is released, the exhaust system must be supported with a transmission jack or held
by another person.
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3. Unscrew the fastening screws on the left and right of the rear
silencer.
Mount for rear silencer

4. Remove exhaust system.
Figure shows exhaust system on

transmission jack
Installing exhaust system
1. Position exhaust system under the vehicle supported by a

transmission jack or another person.

transmission jack
2. Tighten the fastening screws of the rear muffler. For tightening torques see → 263355 Replacing rear
silencer - "Replacing" section.
3. Tighten the front and middle supports -arrows- . → Tightening torque: 17 ftlb.
4. Install new exhaust clamps. The bolts must be pointing downwards. → Adjustment value: 10 ° →
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Bracket for exhaust system Mount for rear silencer

9PAAD1, 9PAAD7, 9PAAE1,
as of MY 2003
Country C00, C02, C05, C07, C08,
C09, C10, C11, C12, C13, C14,
C15, C16, C18, C19, C20, C21,
C22, C23, C24, C25, C26, C27,
C28, C32, C33, C34, C35, C36,
C37, C38, C39, C45, C46, C98,
C99
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
26 10 19 Removing and installing exhaust manifold - as of MY

2003
- Preliminary work
- Removing exhaust manifold — Cayenne S (type M48/00)
- Installing exhaust manifold — Cayenne S (type M48/00)
- Subsequent work
Preliminary work
Preliminary work for removing exhaust manifold
Removing exhaust manifold — Cayenne S (type M48/00)
Removing exhaust manifold - Cayenne S (type M48/00)
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Overview of exhaust manifold
1. Loosen starter catalyst from exhaust manifold. To do this, loosen the

three fastening screws -arrows- .
2. Unclip the oxygen sensor cable from all holders. Remove oxygen
sensor when replacing exhaust manifold.
3. Loosen the 12 fastening nuts in the sequence shown below. Remove
the exhaust manifold.
Fastening screws for securing primary

catalytic converter onto exhaust
manifold
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Fastening nuts
Installing exhaust manifold — Cayenne S (type M48/00)
Installing exhaust manifold - Cayenne S (type M48/00)
Note
z Visually inspect exhaust manifold for cracks and distortion.
z A cracked or distorted exhaust manifold may not be reinstalled.
z As a matter of principle, replace seals on manifold.
z If the studs in the cylinder head are damaged, they must be replaced. → 157356 Replace mount for exhaust
manifold (stud) - "Replacing" section
1. Clean sealing surfaces. The surfaces must be free from foreign objects.
2. Use a new seal. The seal must be positioned so that the part number is visible from the outside.
3. Push the manifold across the studs and fit it with 12 new fastening nuts. The fastening nuts are tightened in
two stages in accordance with the tightening sequence → Tightening sequence for fastening nuts →
Tightening torque: 19 ftlb. and → Tightening torque: 24 ftlb. .
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Tightening sequence for fastening nuts
4. Fit oxygen sensor when replacing exhaust manifold. For details see → 246919 Removing and installing
oxygen sensor ahead of catalytic converter - "Installing" section. Clip oxygen sensor cable into the holders.
5. Fit starting catalytic converters with new gaskets. For details see
"Installing" section.

manifold
Subsequent work
Subsequent work for installing exhaust manifold
9PAAE1, 9PAAE7
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
26 28 01 Checking exhaust system mount - as of MY 2003

Tools

available tool
Checking exhaust system mount
ATTENTION
→ Do not touch the exhaust system until it has cooled down!

Note
z Check the rubber-metal mounts between the body and the exhaust system for cracks and elongation and
check overall condition.
z During the life of the vehicle, the rubber-metal mounts must not soften to such an extent that the exhaust
system starts to hit against adjacent components or the body.
z Check the exhaust system for contact with adjacent parts by shaking it manually.
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z Examine the metal mount for corrosion and damage and check that it is positioned correctly.
z Damaged components must be replaced.
z The exhaust system must be moved to the correct installation position or damaged components must be
replaced if necessary.

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separate at the central notch with 2 exhaust straps. Position
with chain pipe cutters the straps horizontally. (Nut
NR.166. pointing downwards)
retainer
mount
mount
Main catalytic converter V6 and V8 are of the same design -10-

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Exhaust manifold and catalytic converters V6
1 - Cylinder head
2 - Exhaust manifold seal
3 - M8 fastening nut; replace
4 - Exhaust manifold
5 - Flange gasket; replace
6 - Primary catalytic converter, cylinders 1, 2 and 3
8 - Oxygen sensor in front of catalytic converter, cylinders 1, 2 and 3
10 - (Main) catalytic converter (of same design as V8)
11 - Fastening screws M8
12 - Oxygen sensor behind catalytic converter, cylinders 1, 2 and 3
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14 - Heat shield
15 - Fastening screw M8
16 - Fastening screws M8 for intake distributor
17 - Support for intake distributor
18 - Side fastening screws M8 for intake distributor
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
26 33 55 Replacing rear silencer - as of MY 2003

- Information
- Detaching rear silencer
- Replacing rear silencer
Tools

available tool
Information
Component overview
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Component overview for V8
Component overview for V6 (single-strand exhaust system)

I Repair separation point 2 When carrying out repairs, Link up the separation point
separate at the central with 2 exhaust straps. Position
notch with chain pipe the straps horizontally. (Nut
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cutters NR.166. pointing downwards)

A Gap dimension Max. 5 mm
B Exhaust strap length 95 mm
C Inclination Maximum inclination: 10 °
D Offset of rear silencer retainer 2 10 mm
E Off-centre position of central 1 4 mm
holder
F Off-centre position of front 1 2 mm
holder
Detaching rear silencer

1. Use a transmission jack to prevent the rear silencer from falling.
2. There is a small notch on the underside of the exhaust pipes that is

level with the rear axle transmission. The notch marks the
disconnection point.
View shows the disconnection point

3. Place the pipe cutter chain around the exhaust pipe near the notch
and engage in the other end of the pipe cutter. Then clamp the chain
firmly by twisting the handle.
Laying chain of pipe cutter around

exhaust pipe
4. Swivel the pipe cutter to and fro in large movements until the pipe is cut through. While doing this, keep
tightening the chain by twisting the handle.
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Note
The exhaust system in the V6 is designed as a single strand. Repair
instructions and notes apply to both exhaust systems.
5. Then cut through the second exhaust pipe.
Cutting through pipe with pipe cutter
Note
z Before the rear silencer is released, the exhaust system must be
supported with a transmission jack or held by another person.
6. Undo the four fastening screws to the left and right on the rear
silencer and remove the rear silencer from the vehicle.
Fastening screws for rear silencer
Replacing rear silencer

1. Remove the tailpipes on the old rear silencer and attach them to the new one. Fit new attaching rubbers.
Note
The exhaust system in the V6 is designed as a single strand. Repair instructions and notes apply to both exhaust
systems.
2. Push the two new connecting clamps onto the exhaust pipes on the rear silencer . Then install the rear
silencer using a transmission jack. Tighten the four fastening screws to the specified tightening torque. →
3. Push connecting clamps over the exhaust system and align them → 263355 Replacing rear muffler -
"Information" section. Tighten fastening screws. → Tightening torque: 44 ftlb.
as of MY 2003
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C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39,
C45, C46, C98, C99
Connecting clamps on exhaust system

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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
26 34 15 Adjusting tailpipes - as of MY 2003

- Adjusting tailpipes
Adjusting tailpipes
Adjusting tailpipes - Cayenne S (type M48/00) and V6
Overview of tailpipes
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Component overview
1- Rear muffler
2- 2 mounts (align during installation)
3- 2 tailpipe clamps
4- 2 tailpipes (align during installation)
1. Undo screw -arrow- on tailpipe clamp.

2. Align tailpipes. The circumferential gap -A- should be → Adjustment
value: 31 mm +/-1 mm .
Aligning tailpipes
3. Tighten bolt on tailpipe clamp. → Tightening torque: 44 ftlb. .
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9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
26 34 19 Removing and installing tailpipes - as of MY 2003

- Removing and installing tailpipes
Removing and installing tailpipes
Tailpipes (1/2 page)

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Component overview for Cayenne naturally-aspirated engine
1- Rear muffler
Component overview for Cayenne Turbo
1- Rear muffler
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2. Loosen tailpipes by turning and pulling off.
3. Clean extension positions and replace tailpipe clamp if necessary

depending on the condition.
4. Put tailpipes in installation position and align → 263415 Aligning
tailpipes [9PAAD1 9PAAD7 9PAAE1 9PAAE7]→ 263415 Aligning
tailpipes [9PAAF1 9PAAJ1].

5. Tighten the bolt on the tailpipe clamp. → Tightening torque: 60 (44
ftlb.) Nm .
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
26 65 19 Removing and installing secondary air pump - as of MY

2003
- Preliminary work
- Removing secondary air pump
- Installing secondary air pump
- Subsequent work
Preliminary work
Preliminary work for removing secondary air pump

1. Remove engine compartment cover on left, right and rear. → 700219 Removing and installing front cover
(engine compartment) - chapter on "removing"
Removing secondary air pump
z The description only relates to one secondary air pump.
z The second pump is removed in a similar way.
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Overview of secondary air pump

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Component overview
1 - Bracket for secondary air pump

3 - Secondary air pump valve
4 - Spring band clamp
5 - Connecting hose
6 - 2 fastening screws M6 x 20
7 - Seal (replace during installation)
9 - Secondary air pump
1. Remove hose from secondary air pump. Then separate the electric connector on the secondary air pump.
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Fastening screws for secondary air Hose and electric connector on

pump secondary air pump
2. Unscrew the 3 fastening screws on the secondary air pump.
3. Remove pump from support.
Removing bracket for secondary air pump
Note
On the right secondary air pump also unclip the cooling water hose and vacuum hose.
1. Undo the three fastening screws for the bracket and remove the bracket.
Installing bracket for secondary air pump
Note
1. Install bracket and tighten with the three fastening screws. → Tightening torque: 7.5 ftlb.
Installing secondary air pump

1. Push electric connector together and insert pump into the bracket. Then connect the hose to the secondary
air pump connection piece.
2. Tighten the three fastening screws. → Tightening torque: 7.5 ftlb.
Fastening screws for secondary air

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pump
Subsequent work
Subsequent work for installing secondary air pump

1. Install engine compartment cover on left, right and rear. → 700219 Removing and installing front cover
(engine compartment) - chapter on "installing"
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
26 73 19 Removing and installing (main) catalytic converter - as of

MY 2003
- Preliminary work
- Removing (main) catalytic converter
- Installing (main) catalytic converter
- Subsequent work
Preliminary work
Preliminary work
1. Remove the engine guard . → 108019 Removing and installing engine guard - chapter on "removing"
2. Lift the vehicle. → 03 Entire vehicle - General
Removing (main) catalytic converter
Removing (main) catalytic converter, cylinder bank 1 - 4
ATTENTION
Danger of burns from hot exhaust system
→ Do not remove the exhaust system until it has cooled down!

Note
z Cover the right wing and guide through a ratchet from above using several extensions in order to loosen the
top nut between the primary and main catalytic converters.
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Note
z If the working height of the vehicle has to be changed due to further work, the transmission support must be
re-fitted using the old bolts.
Cayenne Turbo (M48/50)
Component overview - Cayenne Turbo
1 - 2 exhaust manifolds
2 - 2 exhaust manifold gaskets (replace during installation)
3 - 24 hexagon nuts M8 (replace during installation; coat threads of studs with Microgleit)
4 - 6 Torx screws M8 x 75
5 - 2 turbocharger gaskets (replace during installation)
6 - 2 oxygen sensors ahead of catalytic converter
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7 - 2 gaskets (replace during installation)

8 - 16 hexagon nuts M8
9 - Front catalytic converter
11 - Support
12 - Support
13 - 4 hexagon-head bolts M10 x 25
15 - 2 oxygen sensors behind catalytic converter
19 - 6 screws
20 - Bracket
21 - 2 brackets
22 - Bracket
Cayenne S (M48/00)
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Component overview - Cayenne S

8 - 12 hexagon nuts M8 (replace during installation)
11 - Support
12 - Support
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15 - 6 studs M8 x 25
20 - 6 screws
21 - Bracket
22 - 2 brackets
23 - Bracket
1. Remove transverse strut. Undo screws (including the centre ones)

-arrows- .
Transverse strut
2. Release connecting clamps between catalytic converters and
exhaust system. Then push the clamps backwards onto the exhaust
system. The exhaust clamps must not be reused.
Clamps for connecting catalytic

converter to exhaust system
3. Release the catalytic converter mounts from the body and cross
member (two screws each).
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Fastening screws to body and cross

member
Cardan shaft between front-wheel

drive and transfer box
4. Remove cardan shaft between front-wheel drive and transfer box -see figure- . → 390219 Removing and
installing front cardan shaft - chapter on "removing" [9PAAE1 9PAAF1 9PAAJ1]→ 390219 Removing and
installing front cardan shaft - chapter on "removing" [9PAAE7]
5. Support transmission with transmission jack. Let main catalytic

converter hang down. Unscrew the three nuts connecting the primary
and main catalytic converters. Remove main catalytic converter.
Remove flange gasket.
6. Re-fit transmission support using old screws so that the transmission
jack can be removed from under the vehicle.
Nuts connecting primary and main

catalytic converters
ATTENTION


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11 - Support
12 - Support
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19 - 6 screws
20 - Bracket
21 - 2 brackets
22 - Bracket
Cayenne S (M48/00)
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11 - Support
12 - Support
15 - 6 studs M8 x 25
20 - 6 screws
21 - Bracket
22 - 2 brackets
23 - Bracket
1. Remove transverse strut. Undo the screws -arrows- (do not forget
the centre screw).
Transverse strut
2. Release connecting clamps between catalytic converters and exhaust system. Then push the clamps
backwards onto the exhaust system. The exhaust clamps must not be reused.
3. Release the catalytic converter mounts from the body and cross member (two screws each).
4. Unscrew the three nuts connecting the primary and main catalytic converters and guide out the main
catalytic converter. Remove flange gasket.
Installing (main) catalytic converter

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Fastening screws to body and cross Clamps for connecting catalytic

member converter to exhaust system

Installing (main) catalytic converter, cylinder bank 1 - 4
1. Transmission support removed and transmission supported with jack.
Note
z Gaskets and self-locking nuts and bolts must always be replaced!
2. Push new exhaust clamp onto exhaust pipe.
3. Ensure sealing faces of exhaust system are clean.
4. Replace flange gasket and push over the studs of the main catalytic
converter.

5. Put main catalytic converter in the installation position and fit new nuts and bolts.
6. Tighten nuts connecting primary and main catalytic converters to the specified tightening torque. →
Note
z To fit the cardan shaft, the transmission must be supported again and the transmission support removed.
Then fit the transmission support with new screws. → 390219 Removing and installing front cardan shaft -
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chapter on
"installing" [9PAAE1 9PAAF1
9PAAJ1]→ 390219 Removing
and installing front cardan
shaft - chapter on
"installing" [9PAAE7]
7. Re-install cardan shaft

between front-wheel drive and
transfer box. Make sure that
the main catalytic converter is
also positioned with the
cardan shaft over the
transmission Cardan shaft between front-wheel Nuts connecting primary and main
support.→ 390219 Removing drive and transfer box catalytic converters
shaft - chapter on
"installing" [9PAAE1 9PAAF1
9PAAJ1]→ 390219 Removing
shaft - chapter on
8. Tighten screws of the catalytic converters to the body and cross member with tightening torque. →
9. Fit exhaust clamps. For installation position and tightening torque,

see → 260119 Removing and installing exhaust system - chapter on
"installing".

10. Install transverse strut. Tighten the screws -arrows- (do not forget
the centre screw). → Tightening torque: 7.5 ftlb.
Transverse strut

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3. Replace flange gasket and push over the studs of the main catalytic
converter.

4. Put main catalytic converter in the installation position and fit new
nuts and bolts.
5. Tighten nuts connecting primary and main catalytic converters to the

specified tightening torque. → Tightening torque: 17 ftlb.
6. Tighten screws of the catalytic converters to the body and cross

member with tightening torque. → Tightening torque: 17 ftlb.

7. Fit exhaust clamps. For installation position and tightening torque,
see → 260119 Removing and installing exhaust system - chapter on
"installing".

8. Install transverse strut. Tighten the screws -arrows- (do not forget
the centre screw). → Tightening torque: 7.5 ftlb.
Transverse strut
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Subsequent work
Subsequent work
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
26 76 19 Removing and installing primary catalytic converter - as

of MY 2003
- Preliminary work
- Removing primary catalytic converter
- Installing primary catalytic converter
- Subsequent work
Preliminary work
Preliminary work
1. Remove engine compartment cover above the oxygen sensor connectors. → 700219 Removing and
installing front cover (engine compartment) - chapter on "removing"
2. Remove wheel . → 440519 Removing and installing wheel - chapter on "Removing"
3. Remove front wheel housing liner. → 505619 Removing and installing front wheel housing liner - chapter on
"removing"
4. Remove air cleaner housing. → 242519 Removing and installing air cleaner housing - chapter on "removing"
5. Remove main catalytic converter. → 267319 Removing and installing (main) catalytic converter - chapter on
"removing"
Removing primary catalytic converter
Removing primary catalytic converter, cylinder bank 1 - 4
ATTENTION

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Note
z Observe the most important working regulations and warning notes. → 10 The most important working
Component overview of primary catalytic converter
1- Exhaust manifold, cylinders 1 - 4

3- Exhaust manifold gasket; replace
4- Hexagon nut M8; replace nut and coat threads of studs with Microgleit
5- Oxygen sensor ahead of catalytic converter
7- Gasket; replace
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8- Hexagon nut M8; replace

9- Front catalytic converter
11 - Support
12 - Support
15 - Stud M8 x 25
17 - Gasket; replace
20 - Screw
21 - Bracket
22 - Bracket
23 - Bracket
1. At the water splash panel, disconnect the connector for the oxygen
sensor behind catalytic converter and unclip cable from support.
Oxygen sensor connector at water

splash panel
2. With the aid of a mirror, remove the fastening screw on the catalytic
converter bracket -arrow lower right- .
Fastening screw on catalytic converter

bracket
3. Remove the three fastening nuts between the exhaust manifold and primary catalytic converter.
4. Release oxygen sensor cable and remove primary catalytic converter in a downward direction. Remove
flange gasket.

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ATTENTION

Note
z Observe the most important working regulations and warning notes. Fastening nuts for securing exhaust
→ 10 The most important working regulations and warning notes manifold to primary catalytic converter

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3- Exhaust manifold gasket; replace
4- Hexagon nut M8; replace nut and coat threads of studs with Microgleit
7- Gasket; replace
8- Hexagon nut M8; replace
9- Front catalytic converter
11 - Support
12 - Support
15 - Stud M8 x 25
20 - Screw
21 - Bracket
22 - Bracket
23 - Bracket
1. At the water splash panel, disconnect the connector for the oxygen
sensor behind catalytic converter and unclip cable from support.
Disconnecting oxygen sensor

connector at the splash panel and
unclipping cable
2. With the aid of a mirror, remove the fastening screw on the catalytic converter bracket -arrow lower right- .
4. Release oxygen sensor cable and remove oxygen sensor.
5. Lower starter catalyst clear. Remove flange gasket.

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Installing primary
catalytic converter
Fastening nuts between exhaust Fastening screw on catalytic converter

manifold and primary catalytic bracket
converter
Installing primary catalytic converter, cylinder bank 1 - 4
Note
z Metal seals and self-locking nuts and bolts must always be replaced!
2. Replace flange gasket and push over the studs of the primary catalytic converter.
3. Place primary catalytic converter in installation position.
4. Through the wheel housing, position fastening screw on catalytic converter bracket.
5. Position the three fastening nuts between the exhaust manifold and
primary catalytic converter.
6. Tighten fastening screw to catalytic converter bracket and nuts to
specified tightening torque. → Tightening torque: 17 ftlb. →
ATTENTION
Danger of fire and material damage!
→ Lay the oxygen sensor cable so that it cannot touch the exhaust
manifold. Positioning fastening nuts for securing
exhaust manifold to primary catalytic
7. Lay cable of oxygen sensor and clip it in. converter
8. At the water splash panel, connect the connector for the oxygen sensor behind catalytic converter.
Note
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z Observe the most important working regulations and warning notes.

→ 10 The most important working regulations and warning notes
2. Replace flange gasket and push over the studs of the primary
catalytic converter.
3. Install oxygen sensor.
4. Place primary catalytic converter in installation position. Connecting oxygen sensor connector
at water splash panel
5. Position the three fastening nuts between the exhaust manifold and
primary catalytic converter.
Positioning fastening nuts for securing

converter
6. Through the wheel housing, position fastening screw on catalytic
converter bracket -lower right screw- .

ATTENTION
manifold. Positioning fastening screw on
catalytic converter bracket
8. Lay cable of oxygen sensor and clip it in.
9. At the water splash panel, connect the connector for the oxygen sensor behind catalytic converter.
Subsequent work
Subsequent work
1. Install main catalytic converter. → 267319 Removing and installing (main) catalytic converter - chapter on
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Connecting oxygen sensor connector

"installing"
2. Install air cleaner housing. → 242519 Removing and installing air cleaner housing - chapter on "installing"
3. Install front wheel housing liner. → 505619 Removing and installing front wheel housing liner - chapter on
"installing"
4. Mount wheel. → 440519 Removing and installing wheel - chapter on "installing"
5. Fit engine compartment cover above the oxygen sensor connectors. → 700219 Removing and installing
front cover (engine compartment) - chapter on "installing"
9PAAE1, 9PAAE7
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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27 06 19 Removing and installing battery - as of MY 2003

- Removing battery
- Installing battery
Removing battery
Removing battery
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Main illustration showing battery installation position in the vehicle
DANGER
Risk of explosion, injury, short circuit and damage to the generator and electronic control units.
z Do not disconnect battery with engine running.
z Disconnect and reconnect battery with extreme caution. Risk of short circuit and explosion.
z Do not tilt battery when removing it. Risk of acid burns as a result of emerging acid.
z Do not rub the battery with a dry cloth. Risk of explosion as a result of static charge.
Note
z The battery is located in the battery case under the left front seat.
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z 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 completely discharged. → External power connection, jump lead starting
Observe the warning notes and safety regulations for lead-acid batteries.→ Warning notes and safety regulations
for lead-acid batteries [9PAAD1 9PAAD7]→ Warning notes and safety regulations for lead-acid
batteries [9PAAE1 9PAAE7 9PAAF1]
Note
For vehicles with a Vehicle Tracking System (VTS), please read the
→ 906323 Vehicle Tracking System (VTS) TI!
fully forward.
2. Detach front seat trim towards the front -Arrow A- .
3. Fold the carpet sections forward and remove the two fastening
screws -1- .
4. Fold the seat back as far as possible -Arrow B- . With the seat in its
folded position, move the seat forward again using the fore-and-aft
adjustment -Arrow C- .
5. Open the four tension hooks on the battery case cover using a
screwdriver.
6. Remove the battery case cover and air duct.
7. Risk of short circuit! First connect the negative cable -2- , then the
positive -3- .
8. Unscrew the fastening screw on the sheetmetal bracket and remove the sheetmetal bracket.
9. Unscrew the screw on the battery mount and remove the battery mount.
10. Pull off the vent hose on the battery.
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Installing battery
Installing battery
1. Risk of contact with caustic fluid Position the battery in the battery
case below the stops, if at all possible without tilting it.
2. Position the battery mount and tighten with the fastening screw. →
3. Position the sheetmetal bracket and secure it with the fastening

4. Insert the vent hose on the battery.
Note
z Make sure that the two ends of the vent hose are routed and inserted correctly.
5. Risk of short circuit! First connect the positive cable -3- , then the
negative cable -2- . → Tightening torque: 3.5 ftlb.
6. Replace the battery box cover carefully. The cover must be mounted properly.
7. Attach the four tension hooks on the battery case cover and close using the screwdriver.
ATTENTION
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8. Move the seat in its folded position towards the rear -arrow A- and
then tip forward -arrow B- .
9. Screw in fastening screws -1- . → Tightening torque: 33 ftlb.

Carry out work instructions after disconnecting the battery.→ Work

instructions after disconnecting the battery.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
27 06 IN General information on the vehicle battery - as of MY 2003

- Information
Note
z To prevent contact corrosion, only approved bolts, nuts, washers, etc. should be used. These elements have a
special surface coating and must be stored separately.
The battery is one of the most important electrical components in the vehicle. Fault-free functioning of the battery
contributes greatly to customer satisfaction. To guarantee long and efficient operation, the battery must be checked
and maintained according to the description in this chapter.
Besides the start function, the battery also has the tasks of buffer and supplier of electrical power for the entire
vehicle electrical system.
Information
Treatment of the battery
Maintenance-free battery:
Note
z The tightening torque for the battery terminals is 5 Nm (3.5 ftlb.).
z If the battery is to be reconnected, proceed according to → 90 Work instructions after disconnecting the
battery.
Low-maintenance battery:
Note
z Battery terminals do not need to be greased.
z The battery terminal clamps must only be attached manually without using excessive force to prevent damage
to the battery housing.

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battery.
z To ensure that the battery does not leak, it is essential to ensure that the original plugs supplied with the
battery are screwed into the battery openings.
z In the event of loss or damage, only original plugs of the same design should be used.
z The plugs must be fitted with an O-ring seal.
Warning notes and safety regulations for lead-acid batteries

1. -1- Fire, sparks, naked flames and smoking are forbidden:
– Avoid sparking when using cables and electrical devices.
– Avoid short circuits.
– In batteries with central venting, there is an increased concentration of

detonating gas at the hose opening. The venting hose must not be
bent or blocked by dirt.
2. -2- Wear eye protection
3. -3- Keep children away from acids and batteries.
4. -4- Risk of causticisation!
– Battery acid is highly caustic, therefore wear protective gloves.

– Do not tip battery; acid can emerge from the vent opening.
Battery symbols
Note
z First aid: Rinse acid splashes in the eyes immediately with clean water for a few minutes. Consult a doctor
immediately. Neutralise acid splashes on the skin or clothing immediately with soap suds and rinse again with
plenty of water. If acid has been drunk unintentionally, consult a doctor immediately.
5. -5- Observe information on the battery in the Technical Manual and in the Driver's Manual.
6. -6- Risk of explosion:
– A highly explosive detonating gas mixture occurs when charging batteries.
7. -7- Waste disposal:
– Hand in old batteries at a collection point.
8. -8- Never dispose of old batteries in the domestic rubbish!
Notes on removing and installing the battery
Note
z The battery is located under the left front seat.
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z In order to avoid triggering the siren in vehicles with an additional alarm siren, the battery must be
disconnected while the ignition is on!
z All loads must be switched off beforehand! Remove ignition key!
z Never disconnect battery with engine running!
z Never start engine without a securely connected battery!
z The battery terminal clamps must only be attached by hand without using excessive force to prevent damage
to the battery housing.
z Check that the battery is seated correctly after installation. Otherwise, a loose battery presents risks such as: -
Reduced service life due to vibration damage. - Possible damage to the grid plates of the battery. - Damage to
the battery housing from mounting parts (possible acid leakage, with high subsequent costs). - Inadequate
crash safety.
Principle of operation of central venting
Note
z State of the art batteries are fitted with central venting -A- .
z The gas generated during charging emerges centrally through an

opening on the upper cover side. The backfire protection is integrated
at the same position, which prevents the ignition of the combustible
gas present in the battery.
Central venting
z In batteries with hose/pipe -A- for the central venting, ensure that the
hose is not pinched. Only then can the battery be freely vented.
Central venting
Visual inspection
Before measurements such as open-circuit voltage, acid density or the battery load test are carried out, a visual
inspection of the battery must be performed.
Through this check, it can be determined:
z Whether the housing of the battery is damaged. Acid can leak out due to damage of the housing.
z Whether the battery terminals (battery line connections) are damaged. Contact of the line connections cannot
be guaranteed if the battery terminals are damaged. This can cause a line fire and malfunctions in the
electrical system.
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Note
Central venting
Checking acid level
1. Switch ignition off and remove ignition key.
fully forward.
3. Detach front seat trim forwards -Arrow A- .
4. Fold the carpet cut-outs forwards and remove the two fastening
screws -Arrows 1- .
5. Fold the seat back completely -Arrow B- . With the seat in its folded
position, move the seat forward again using the fore-and-aft
adjustment -Arrow C- .
Folding back the front left seat

6. Open the four tension hooks on the battery box lid using a
screwdriver.
7. Remove battery box lid with vent duct.
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Low-maintenance battery Opening tension hook
WARNING
flame.
Note
z The correct acid level of the battery is an important factor for long and efficient operation of the battery.
z When the acid level is too low, a capacity loss (performance loss) of the battery occurs, which is caused by
the cell plates drying out. If the cell plates are not surrounded by electrolyte (battery acid), this will lead to
corrosion of the lead plates, the plate bridges and the cell connectors. The result of the corrosion is that
battery functioning cannot be guaranteed. The battery will become unserviceable.
z If the acid level is too high, damage can occur by the battery acid (sulphuric acid/water mixture) leaking out of
the battery.
2. Shine a torch into the battery. The acid level of the battery must be at the protruding lug.
– If the acid level is too low, refill with distilled water using the battery filling bottle.
4. Remount battery cover.
Note
z The charge state and acid level of the battery can be checked through the inspection glass -B- .
z If a battery is more than 5 years old and the indicator of the inspection glass is colourless, replace the battery.
z If the battery has been charged, air bubbles can form under the inspection glass. Before carrying out a visual
inspection, tap carefully on the inspection glass with something like the handle of a screwdriver.
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Green The battery charge is satisfactory.
Battery will start reliably.
Dark grey The battery has no charge or the charge is too low.
Recharge battery.
Transparent/clear Acid level has become critical.
Replace battery.
Checking acid density
WARNING
flame.
Note
z Only for low-maintenance batteries.
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Note
z Use commercially available battery acid tester.
z The acid density test provides information about the state of the battery in conjunction with the battery load
test.
z The temperature of the battery acid must be at least 10°C .
The density of the acid must be checked as follows in all battery cells (low-maintenance battery) :
1. Switch off ignition and remove ignition key.
2. Unscrew all battery plugs (plugs of the battery cells).
3. Dip the acid siphon or the pipette into the battery cell and take up the battery acid.
4. Read off the density of the acid in kg/dm³ on the scale of the battery acid tester and compare with the
following table.
Battery charge state in normal climatic zones Density in kg/dm³

discharged 1.12
half charged 1.20
well charged 1.28
Battery charge state in tropical climatic zones (hot countries) Density in kg/dm³
discharged 1.08
half charged 1.16
well charged 1.23
The acid density must be at least 1.24 kg/dm³ in normal climatic zones.
– If the acid density is too low, charge battery.
– After charging the battery, repeat the acid density test.
The measured values for the acid density of the individual battery cells must not differ by more than 0.03 kg/dm³
from each other.
Examples of non-permissible acid density deviations:

Battery cell: 1 2 3 4 5 6
Acid density per cell in kg/dm³
Example 1: 1.24 1.25 1.25 1.10 1.24 1.25
Example 2: 1.26 1.26 1.25 1.14 1.18 1.24
Example 1: The acid density in cell 4 is too low.
Example 2: The acid density in cells 4 and 5 is too low. The acid density deviations between the battery cells is
greater than 0.03 kg/dm³.
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– If the nominal values are not achieved, replace battery.
– If the nominal values are achieved, screw in the original plugs again.
ATTENTION
5. Move the seat in its folded position towards the rear -Arrow A- and
then tip forward -Arrow B- .
6. Screw in fastening screws -Arrow 1- . → Tightening torque: 33 ftlb.
7. Clip in front seat trim -Arrow C- .
Folding seat back and screwing down

Open-circuit voltage measurement
Note
z Use a hand-held multimeter to measure the battery voltage.
2. Disconnect ground strap on the battery.
Note
z After charging and waiting for at least 2 hours, during which time the battery should neither be loaded nor
charged:
3. Measure the battery voltage with a hand-held multimeter.
– The battery open-circuit voltage should not fall below 12.5V.
– If the hand-held multimeter shows 12.5V or more, the battery voltage is OK.
– If the hand-held multimeter shows a battery voltage below 12.5V: Charge battery.
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Battery load test
Note
z The acid density test provides information about the state of the battery in conjunction with the battery load
test.
z A battery test device is required for the load test.
z The battery need not be removed or disconnected.
z The battery must be charged before the load test is performed.
Carry out battery load test:
2. Observe the information in the operating instructions of the battery test device.
3. Connect the clamps of the test lines to the battery terminals as described in the operating instructions of the
test device.
– As the load current varies, the current must be set depending on the battery capacity (operating instructions of
test device).
4. Perform the battery load test in accordance with the operating instructions.
– The result of the battery load test is a voltage value that must be compared with the specified minimum
voltage (limit value).
Table:
Battery capacity: 70 Ah 95 Ah 110 Ah
Cold test current 340 A 450 A 520 A
Load current See tester instructions
Minimum voltage (limit value) See tester instructions
5. If the minimum voltage is not attained, replace battery.
Remarks on battery load test:
The battery voltage sinks during this test due to the severe load on the battery.
If the battery is in order, the voltage value only decreases to the minimum voltage.
If the battery is faulty, the battery voltage will sink very quickly below the specified minimum voltage.
After the test has taken place, the low voltage value remains over a long period of time; the voltage increases
again slowly.
Charging battery
WARNING
Danger of fire and explosion
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→ The battery plugs must always be screwed in correctly when charging and during voltage measurement and
load measurement.
→ Rooms in which batteries are being charged should not be entered with a naked flame or when smoking.
Gases form through the charging process in the batteries which are highly flammable.
Note
z A battery charging device is required.
z Observe charging device operating instructions.
z The battery must have a minimum temperature of 10°C.
z If possible, do not fast charge batteries as this can damage them.
z If exhaustively discharged batteries are charged quickly, they will not take up a charge current or they will be
identified too early as full due to the so-called "surface charge".
1. Switch off battery charging device.
3. First disconnect the ground strap of the battery, then the positive battery line.
4. Connect positive line of the battery charging device to the positive terminal of the battery.
5. Connect negative line of the battery charging device to the negative terminal of the battery.
6. Set the charge current on the battery charging device according to the battery capacity.
7. Switch on battery charging device.
Procedure for charging exhaustively discharged batteries:
Batteries which are not in operation for a long period of time discharge.
A battery is exhaustively discharged if the open-circuit voltage has sunk below 11.6 V.see open-circuit voltage
measurement
In exhaustively discharged batteries, the battery acid (sulphuric acid and water mixture) consists of virtually only
water, as the sulphuric acid proportion is considerably reduced.
Exhaustively discharged batteries sulphatise, i.e. the entire plate surfaces of the batteries harden.
If exhaustively discharged batteries are immediately recharged after an exhaustive discharge, the sulphatisation
recedes again.
If these batteries are not recharged, the plates continue to harden and charge take-up ability is limited. A reduction
in the battery performance is the result.
Exhaustively discharged batteries must be charged with a low charge current as follows:
– Set maximum charge current at 10% of battery capacity; i.e. with a 95 Ah battery the maximum charge current
is 9.5 A.
8. Charge battery.
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Battery trickle charge
Note
z When working or carrying out tests on the Cayenne, or when it is in the workshop, a battery charging device
with a rated current of at least 40 A must be connected.
z 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.
3. Remove cover for jump lead starting terminal.
Removing cover for jump lead starting

terminal
4. Open protective cover on the positive terminal -+- -A- .
5. First, connect the positive cable from the charging device to the
positive terminal for jump lead starting -+- . → Tightening torque: 3.5
ftlb.
6. Connect the negative cable from the charging device to the ground
point for jump lead starting - - - . → Tightening torque: 3.5 ftlb.
7. Set the charge current on the battery charging device according to the
battery capacity.
Opening protective cover

Connecting the battery for trickle charging
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A suitable battery charging device must be connected to the vehicle electrical system when performing the
following tasks. All unnecessary 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
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
27 07 19 Removing and installing auxiliary battery - as of MY 2003

- Removing auxiliary battery
- Installing auxiliary battery
Removing auxiliary battery
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Overview of auxiliary battery
DANGER
→ Do not disconnect battery with engine running.

→ Disconnect and reconnect battery with extreme caution. Risk of short circuit and explosion.
→ Do not tilt battery when removing it. Risk of acid burns as a result of emerging acid.
→ Do not rub the battery with a dry cloth. Risk of explosion as a result of static charge.
1. Switch off all loads and remove ignition key.
2. Observe the warning notes and safety regulations for hydrocyanic acid batteries → 2706 Battery
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3.1. Remove knob -A- and position it on bolt -B- .

3.2. Unscrew the bolt -B- and remove it together with the collapsible
spare wheel.
Removing collapsible spare wheel

4.1. Remove tyre sealant -1- if present.
4.2. Unscrew the two fastening nuts -2- .
4.3. Undo fastening screw -3- and washer.
Mount for subwoofer

5. Disconnect plug connection and remove subwoofer:
5.1. Remove plug connection from retaining bracket on the subwoofer

and disconnect the plug connection.
Disconnecting plug connection on

subwoofer and removing subwoofer
6. Removing cover for housing:
6.1. Unscrew the four fastening nuts -arrows A- .
6.2. Unclip the four fastening clips -arrows B- using a screwdriver.
7. Disconnecting and removing the battery:

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Disconnecting and removing battery Removing cover for housing
7.1. Risk of short circuit! First disconnect the negative cable -arrow 1- , then the positive cable -arrow 2- .
7.2. Pull off vent hose -arrow 4- on the battery.
7.3. Unscrew the battery mount nut and remove the retaining bracket for the battery mount -arrow 5- .
7.4. Risk of causticisation! Remove battery from the battery case by the folding handles, if at all possible
without tilting it.
Installing auxiliary battery
1. Inserting and connecting battery:
1.1. Risk of causticisation! Position the battery in the battery case below
the stops, if at all possible without tilting it.
1.2. Position retaining bracket and tighten with fastening nut -arrow 5- .
Note
z Make sure that the two ends of the vent hose are routed and inserted
correctly.
1.3. Insert vent hose -arrow 4- on battery.
1.4. Risk of short circuit! First connect the positive cable -arrow 1- ,
then the negative cable -arrow 2- . → Tightening torque: 3.5 ftlb.
Position and tighten retaining strip,

insert breather hose, connect poles
2. Positioning battery case cover and screwing it on:
2.1. Put on the battery case cover, position it and clip in the four fastening clips -arrows A- onto the cover.
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Positioning cover for housing and

screwing it on
2.2. Push the retraining straps across the four fastening bolts on the body floor and screw on the four fastening
nuts -arrows B- . → Tightening torque: 4.5 ftlb.
3. Install subwoofer:
3.2. Push the electrical plug connection together until the plug is felt to
engage.
Installing subwoofer
Note
4.1. Insert fastening screw -3- with washer and tighten. → Tightening
torque: 3.5 ftlb.
4.2. Position both fastening nuts -2- and tighten them. → Tightening
torque: 1.5 ftlb. Mount for subwoofer
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4.3. If present, place tyre sealant -1- in well.
4.2. Screw in fastening screw -B- .

4.3. Position twist grip -A- and tighten fastening screw -B- .
Installing collapsible spare wheel
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
27 22 19 Removing and installing three-phase generator - as of

MY 2003
- Preliminary work
- Removing the three-phase generator
- Installing the three-phase generator
- Perform additional assembly work when replacing the three-phase generator
- Subsequent work
Tools

repair kit for wiring harnesses special tool NR.155-
1
repair kit for Cayenne wiring special tool NR.155-

harnesses 2
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Preliminary work
Preliminary work
1. Before the three-phase generator can be removed, the battery must be disconnected and the terminal
covered. → 90 Work instructions after disconnecting the battery
2. Remove right wheel housing liner. → 505619 Removing and installing front wheel housing liner - chapter on
"removing"
3. Remove right air cleaner housing. → 242519 Removing and installing air cleaner housing - chapter on
"removing"
5. Drain coolant . → 193817 Draining and filling in coolant (includes bleeding) - chapter on "draining"
6. Remove drive belt. → 137819 Removing and installing drive belt - chapter on "removing"
Removing the three-phase generator
Note
z When the engine is being cleaned with high-pressure cleaning equipment, make sure that the high pressure
blast is not directed directly onto the three-phase generator (risk of bearing damage).
Overview of three-phase generator
Note
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z If the impact bracket is used, the routing of the wires may differ from
this description!
1. Unscrew the three fastening screws -8- for the impact bracket and
remove the impact bracket.
Unscrewing the fastening screws for

the impact bracket
2. Unscrew fastening screw -3- of ground lead and lay ground lead to
one side.
3. Lever out fastening clips -4- for the electrical lead using a
screwdriver.
Unscrewing fastening screw of ground

lead.
4. Seal the coolant hoses -A and B- with a hose clamp to prevent them
from leaking.
Sealing coolant hoses with hose clip

5. Unscrew fastening screws -A and B- of coolant hoses.
Unscrewing fastening screws of

coolant hoses.
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Note
z If the protective cap cannot be removed, use a knife to carefully cut if
off the three-phase generator. Make sure that the plug connection
and the electrical lead are not damaged and that there is no more
than minimal damage to the protective cap.
6. Pull off protective cap for electrical plug connection from receptacle
on three-phase generator.
Pulling off protective cap for electrical

plug connection of three-phase
generator
7. Release -a- and pull off plug.
8. Unscrew fastening nut for B+ lead and remove the B+ lead.
Pulling plug off three-phase generator

9. Unscrew the three fastening screws -1 and 2- and support the three-
phase generator with your hand.
10. Remove the three-phase generator through the opening - wheel
housing liner with air-cleaner box removed.
Unscrewing fastening screws of three-

phase generator
Installing the three-phase generator
Note
Additional assembly operations must be performed if a new three-phase generator has to be fitted. → 272219
Removing and installing new three-phase generator - chapter on "completing"
1. Insert the three-phase generator through the opening - wheel housing liner with air-cleaner box removed -
-Arrow A- and position it on the engine -Arrow B- .
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Tightening the fastening screws of the Position three-phase generator on the

three phase generator engine
2. Position the three fastening screws -1 and 2- and tighten them. → Tightening torque: 17 ftlb.
3. Additional assembly operations must be performed if a new three-phase generator has to be fitted.
4. Insert the plug -6- until the locking tab -A- is felt to engage.
5. Clip the line into the two retaining clips -7- .
6. Tighten electrical B+ lead with fastening nut -5- . → Tightening

torque: 11 ftlb.
Tightening fastening nut for B + lead
Note
z Check condition of protective cap; if it is damaged it must be repaired
using body sealant.
7. Position protective cap and press it on, ensuring it fits securely and is
sealed against moisture.
Positioning protective cap for electrical

generator
8. Replace sealing rings. Push in coolant connections on the three-phase generator and screw into place using
fastening screws -A and B- . → Tightening torque: 7.5 ftlb.
9. Connect coolant lines and position holding clamps.
10. Secure ground lead to three-phase generator with fastening screw -3- . → Tightening torque: 15 ftlb.
11. Attach clip -4- of the electrical lead to the three-phase generator.
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Tightening fastening screw of ground Tightening coolant connections to

lead to three phase generator three phase generator
12. Position the impact bracket and screw into place with the fastening screws -8- . → Tightening torque: 7.5
ftlb.
Perform additional assembly work when replacing the three-phase generator
Additional assembly work when replacing three-phase generator
Note
The parts pack of a new three-phase generator contains all the parts required (insulator, PIN and socket).
1. Lay the lead of the new three-phase generator as for the old lead and
clip into the three retaining clips -Arrows A- .
2. Trim the lead (with 2-pole plug) included in the engine wiring harness
to the three-phase generator -arrow- such that, together with the
new lead already laid from the three-phase generator, it can be
joined without tension and without too much slack.
3. In the wiring harness, insulate and immobilise the wire to PIN 2 of the
plug that was cut off.
Laying and trimming lead of three-

phase generator
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Crimping plug to wiring harness
4. In the wiring harness, remove the insulation of the wire to PIN 1 of the plug that was cut off and push new
insulator -1- onto the wire.
5. Crimp new PIN -2- using repair kit for wiring harnesses NR.155-1 and repair kit for Cayenne wiring
harnesses NR.155-2 .
6. Insert wire with new PIN into the new socket -3- and lock.
7. Push the plug connection -1- together until it is felt to engage.
8. Tie the plug connection with a tie-wrap -2- to the nearby wiring
harness.
9. Clip line holder -3- to the shaft tube.
Pushing plug connection together and

clipping the line holder
Subsequent work
Subsequent work
1. Install drive belt. → 137819 Removing and installing drive belt - chapter on "installing"
2. Fill in coolant. → 193817 Draining and filling in coolant (includes bleeding) - chapter on "filling in"
3. Install right air-cleaner box. → 242519 Removing and installing air cleaner housing - chapter on "installing"
4. Install right wheel housing liner. → 505619 Removing and installing front wheel housing liner - chapter on
"installing"
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5. Connect the battery and carry out the work instructions. → 90 Work instructions after disconnecting the
battery
9PAAE1, 9PAAE7
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
27 22 19 Removing and installing the generator - as of MY 2006

- Preliminary work
- Removing the generator
- Installing the generator
- Subsequent work
Preliminary work
Preliminary work
1. Before the generator can be removed, the battery must be disconnected and the terminal covered. → 90
2. Remove right front wheel.→ 440519 Removing and installing wheel - section on "Removing"
3. Remove right wheel housing liner. → 505619 Removing and installing front wheel housing liner - section on
"Removing"
4. Remove right air cleaner housing. → 242519 Removing and installing air cleaner housing - section on
"Removing"
5. Remove engine guard. → 108019 Removing and installing engine guard - section on "Removing"
6. Drain coolant. → 193817 Draining and filling in coolant (includes bleeding) - section on "Draining"
7. Remove drive belt. → 137819 Removing and installing drive belt - section on "Removing"
Removing the generator
Note
This description applies to engine numbers as of M48/00 816 09867.
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Note
Overview of generator

the impact bracket
2. Unscrew fastening screw -3- on ground lead and lay ground lead to one side.
3. Lever out fastening clips -4- for the electric line using a screwdriver.
4. Seal the coolant hoses -A and B- with a hose clamp to prevent them from leaking.
5. Unscrew fastening screw -4- on the return connection piece.
6. Unscrew fastening screw -2- on the supply connection piece -1- .

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Sealing coolant hoses with hose clip Unscrewing fastening screw on ground
lead.
Unscrewing fastening screw on the

return connection piece
Unscrewing fastening screw on heat Unscrewing fastening screw on the

protection shield for generator lines supply connection piece
7. Unscrew fastening screw -2- on the heat protection shield for generator lines.
8. Unscrew fastening nut -5- on the B+ line. Unclip the B+ line at the
two retaining clips -6- and remove it.
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9. Unclip wire harness for the Screwing off B+ line on generator

generator at the three
retaining clips -Arrows A- .
Unclipping wire harness for generator

10. Cut both tie-wraps -3- on the wire harness for the generator -2- .
11. Release plug connection for generator -1- ( -Arrow A- ) and
disconnect it -Arrows B- .
Disconnecting plug connection for

generator
12. Unscrew the three fastening screws -1 and 2- and support the
generator with your hand.
13. Remove the generator through the opening – wheel housing liner
with air-cleaner box removed.
Unscrewing fastening screws on

generator
Installing the generator
1. Insert the generator through the opening - wheel housing liner with air-cleaner box removed - -Arrow A- and
position it on the engine -Arrow B- .
2. Position the three fastening screws -1 and 2- and tighten them. → Tightening torque: 23 (17 ftlb.) Nm

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Tightening fastening screws on the Positioning the generator on the

generator engine

clipping in the line holder
4. Secure wire harness -2- to the wire harness running parallel using two tie-wraps -3- .
5. Secure the heat protection shield with the generator lines to the
generator using the fastening screw -2- . → Tightening torque: 10
(7.5 ftlb.) Nm
Securing heat protection shield with

generator lines to the generator
6. Clip wire harness for the generator in at the three retaining clips
-Arrows A- .
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7. Secure B+ line with the Clipping in wire harness for generator

fastening nut -5- . →
Tightening torque: 15 (11
ftlb.) Nm
Securing B+ line to generator

8. Screw on supply connection piece -1- .
8.1. Grease the new seal on the supply connection piece -1- with
Vaseline.
8.2. Press supply connection piece -1- as far as it will go into the supply
coolant bore on the generator and secure with the new fastening
screw -2- . → Tightening torque: 10 (7.5 ftlb.) Nm
Screwing on supply connection piece

9. Grease new sealing ring with Vaseline. Attach return connection
piece to the generator and secure with fastening screws -4- . →
10. Remove hose clamps on the coolant hoses.
Securing return connection piece

11. Secure ground lead to the generator with the fastening screw -3- . →
12. Attach clip -4- on the electric line to the generator.
Tightening fastening screw securing

ground lead to generator
13. Position the impact bracket and secure with the fastening screws -8- . → Tightening torque: 10 (7.5 ftlb.)
Nm
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Tightening fastening screws for the

impact bracket
Subsequent work
Subsequent work
1. Install drive belt. → 137819 Removing and installing drive belt - section on "Installing"
2. Fill in coolant. → 193817 Draining and filling in coolant (includes bleeding) - section on "Filling in"
3. Install right air cleaner housing. → 242519 Removing and installing air cleaner housing - section on
"Installing"
4. Install right wheel housing liner. → 505619 Removing and installing front wheel housing liner - section on
"Installing"
5. Fit right front wheel. → 440519 Removing and installing wheel - section on "Installing"
battery
7. Fit engine guard. → 108019 Removing and installing engine guard - section on "Installing"
9PAAE1, 9PAAE7
as of MY 2006
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
27 22 55 Replacing the generator - as of MY 2006

- Preliminary work
- Subsequent work
Tools

Repair kit for wire harnesses special tool NR.155-
1
Repair kit for Cayenne wire commercially NR.155-

harnesses available tool 2
Preliminary work
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Preliminary work
3. Remove right wheel housing liner. → 505619 Removing and installing front wheel housing liner - section on
"Removing"
"Removing"
Note
This description applies to engine numbers up to M48/00 816 09866.
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the impact bracket
2. Unscrew fastening screw -3- on ground lead and lay ground lead to
one side.
Unscrewing fastening screw on ground

lead.
5. Unscrew fastening screws -A and B- on coolant connections.
6. Cut off the electric line directly behind the protection cap -Arrow- on the generator.
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Unscrewing fastening screws on Sealing coolant hoses with hose clamp

coolant hoses.
Cutting off electric line behind the

protection cap on the generator
Screwing off B+ line on generator

8. Unscrew fastening screw -2- on the heat protection shield for
generator lines.
Unscrewing fastening screw on heat

protection shield for generator lines
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Unscrewing fastening screws on the

generator
9. Unscrew the three fastening screws -1 and 2- and support the generator with your hand.
10. Remove the generator through the opening – wheel housing liner with air-cleaner box removed.
Note
The following parts are required for installing the Hitachi generator.
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Range of spare parts for the Hitachi generator
1- Generator
2- Return connection piece
3- Supply connection piece
4- 3x screw, M6 x 16
5- 1x hose clamp
6- Heat protection shield
8- 1x line
9- 1x connector
10 - 1x shrink-fit hose
11 - 1x cable connection
Parts -1 to 7- are available as spare parts.
Parts -8 to 11- are included in the Repair kit for Cayenne wire harnesses NR.155-2.
1. Fit return connection piece -4- on the new generator -1- .
1.1. Pull off both caps for the coolant bores -2- on the new generator -1- ( -Arrows A- ).
1.2. Grease the seal -3- on the new return connection piece -4- with Vaseline.
1.3. Press return connection piece -4- as far as it will go into the return coolant bore on the new generator -1- (
-Arrow B- ) and secure with the new fastening screw -5- . → Tightening torque: 10 (7.5 ftlb.) Nm
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Fitting return connection piece on the

new generator
2. Insert the generator through the opening - wheel-housing liner with
air-cleaner box removed - -Arrow A- and position it on the engine
-Arrow B- .
Positioning the generator on the

engine
3. Position the three fastening screws -1 and 2- and tighten them. →
Tightening fastening screws on the

generator
4. Secure the heat protection shield with the generator lines to the generator using the fastening screw -2- . →
5. Secure B+ line with the fastening nut -5- . → Tightening torque: 15 (11 ftlb.) Nm
6. Remove old supply connection piece -1- .

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Securing B+ line to generator Securing heat protection shield with

Removing old supply connection piece
6.1. Press hose clamp -2- together and pull supply connection piece -1- out of the coolant hose.
7. Install new supply connection piece -1- .
7.1. Grease the seal -2- on the new supply connection piece -1- with
Vaseline.
7.2. Press supply connection piece -1- as far as it will go into the supply
coolant bore on the new generator -Arrow A- and secure with the
new fastening screw -3- . → Tightening torque: 10 (7.5 ftlb.) Nm
7.3. Fit the coolant hose -4- with a new hose clamp -5- and push it onto
the supply connection piece -1- ( -Arrow B- ).
Installing new supply connection piece

8. Lay the line for the new generator in the same way as the old line and clip it into the three retaining clips
-Arrows A- .
9. Join the new line -1- to the new connector -2- .
9.1. Push new line -1- with the PIN fully into the connector housing -2- ( -Arrow A- ).
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Laying generator line
Joining connector to new line
9.2. Lock connector -2- ( -Arrow B- ) until it engages audibly.

Check that connector -2- is locked correctly.
Note
Select a place for the joint where there is enough space to join all the lines present.
Do not cut the lines too short in case they have to be laid in a different position if there is insufficient space in the
area of the joint.
Note
The electric lines are located in the splash water area and are thus exposed to the highest demands.
The greatest care must be taken in the individual work steps for stripping insulation from, crimping, and
shrinking/insulating the electric lines.
The procedure for stripping insulation from, crimping, and shrinking/insulating the electric lines must be complied
with and observed. The procedures are described in detail in the Repair kit for Cayenne wire harnesses
NR.155-2.
Crimping samples are to be prepared before beginning work.
Note
Allocation of lines - see wiring diagram.
10. Crimp the line from the new generator -1- with the line from the engine wire harness -4- .
10.1. Trim the line from the engine wire harness -4- so that it can be joined to the new line that was already laid
from the generator -1- without tension and without too much slack.
10.2. In the engine wire harness -4- , insulate and immobilise the wire to PIN 2 of the connector that was cut off.
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Joining line from new generator to line

from engine wire harness
10.3. In the engine wire harness -4- , strip 10 mm of the line to PIN 1 of the connector that was cut off and push
new shrink-fit hose -3- onto the line.
10.4. Crimp both lines -1 and 4- using a new crimping sleeve -2- and the hand crimping pliers from the Repair
kit for wire harnesses NR.155-1.
10.5. Slide new shrink-fit hose -3- over the crimp connection and carefully shrink it to make it watertight using the
hot-air blower with special nozzle (recommended accessories for the repair kit for wire harnesses).
11. Wrap commercially available PVC tape all around the area of the connection point.
13. Secure wire harness -2- to the wire harness running parallel using
two tie-wraps -3- .


16. Secure ground lead to the generator with the fastening screw -3- . → Tightening torque: 20 (15 ftlb.) Nm
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18. Position the impact bracket

and secure with the fastening
screws -8- . → Tightening
Tightening fastening screws for the Tightening fastening screw securing

impact bracket ground lead to generator
Subsequent work
Subsequent work
"Installing"
"Installing"
battery
9PAAE1, 9PAAE7
as of MY 2006
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27 60 19 Removing and installing starter - as of MY 2003

- Preliminary work
- Removing the starter
- Installing the starter
- Subsequent work
Preliminary work
Preliminary work
"Removing"
2. Disconnect battery. → 270619 Removing and reinstalling battery - chapter on "Removing"; → 90 Work
Removing the starter
WARNING
Risk of damage to starter
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Overview of starter
1. Unscrew fastening nuts -1- and -2- on the starter, remove the lines
and lay them to one side.
Fastening nuts on starter

2. Unscrew the two fastening screws -3- .
Fastening screws
3. Pull starter forward in the direction of travel -arrow A- , turn slightly -arrow B- and remove in an upward
direction -arrow C- .
Installing the starter

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1. Place the starter from above

on the engine -arrow C- , turn
slightly -arrow B- and position
in the mounting -arrow A- on
the engine.
Positioning the starter Removing starter

2. Insert fastening screws -3- on starter, screw into the engine housing
and tighten. → Tightening torque: 33 ftlb.
Screwing in fastening screws in engine

housing
3. Position electric lines on the starter and tighten with fastening nuts
-1- and -2- . → Tightening torque: 11 ftlb. , → Tightening torque:
6 ftlb.
Positioning and tightening electric lines

to starter
Subsequent work
Subsequent work
2. Connect the battery . → 270619 Removing and reinstalling battery - chapter on "Installing"; → 90 Work

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as of MY 2003
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27 06 External power connection, jump lead starting - as of MY

2003
- Information
Information
Note
z 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
Risk of damage and injury as a result of a short circuit.
→ Use only standard jump leads with a sufficiently wide cross section and fully insulated terminal clamps.
Observe the cable manufacturer's specifications.
→ Route the jump leads so that they cannot become entangled in moving parts in the engine compartment.
→ No contact is allowed between the vehicles, otherwise electricity could flow as soon as the positive terminal
is connected.
The flat battery must be properly connected to the vehicle electrical system.
2. Open protective cover on the positive terminal -+- for jump lead starting -arrow A- .
3. Connect the positive cable to the positive terminal for jump-lead starting -+- , then to the positive terminal of
the battery supplying the power.
4. First, connect the negative cable to the negative terminal of the battery supplying the power, then to the
ground point for jump-lead starting - - - .
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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

-arrow B- .
Protective cover on positive terminal Removing the cover.

for jump-lead starting
9. Position the cover.
Positioning the cover
as of MY 2003
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28 04 19 Removing and installing ignition switch - as of MY 2003

- Preliminary work
- Removing ignition switch
- Installing ignition switch
- Subsequent work
- Information
Tools

wrench special tool T10152
Preliminary work
Preliminary work
Removing ignition switch
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Overview of ignition starter switch
1. Carefully lift rubber sleeve on the ignition starter switch -arrow A- using a screwdriver, for example, and
remove it.
2. Carefully unclip moulding for dashboard -arrow B- with a plastic spatula. Observe the two upper lugs when
doing do.
3. Turn union nut using a narrow plastic spatula, for example, or using the special wrench T10152 tool and
unscrew the ring from the ignition starter switch.
4. Press ignition switch inwards and remove towards the bottom.
5. Press connector -arrow- and pull off from ignition starter switch.
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Union nut
Installing ignition switch
Rubber sleeve on ignition starter

switch
Removing ignition starter switch

1. Connect the connector to the ignition starter switch until it engages
firmly.
Pushing connector onto ignition starter

switch
2. Position ignition starter switch in the dashboard. Position union nut,
re-adjust switch and tighten union nut using wrench T10152. →
Positioning the union nut

3. Check clips on the moulding for the dashboard for damage and replace if necessary.
4. Position moulding and press onto the dashboard until the clips engage.
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Clips on moulding for dashboard
Subsequent work
Subsequent work
1. Install cover under instrument panel on left. → 702219 Removing and reinstalling cover under dashboard -
Information
Emergency operation of the ignition key lock
Note
z In the event of insufficient or non-existent battery positive voltage, the ignition key can be removed using the
emergency operation.
1. Push a ball-point pen, for example, into the opening next to the key,
turn the ignition key to position 0 and pull out.
Ignition key
2. Key in position 0, press release -arrow- and pull key out.
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Keyless Entry and Drive
as of MY 2003
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28 20 55 Replacing ignition coils - as of MY 2003

- Preliminary work
- Replacing ignition coils
- Subsequent work
Preliminary work
Preliminary work
1. Switch ignition off and remove ignition key
2. Remove engine compartment cover on the right and rear. → 700219 Removing and reinstalling front cover
(engine compartment) - chapter on "Removing"
Replacing ignition coils
Replacing ignition coils of cylinder row 1-4
1. Loosen the torque support. To do this unscrew the fastening screw

on the torque support bracket.
Fastening screw on the torque support

bracket
2. Loosen the torque support on the body and swivel upwards.
3. Loosen the secondary air pump from cylinder row 1-4. To do this, unscrew the 3 fastening screws, pull the
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Fastening screws for secondary air Torque support to body

pump
pump out of the support and lay it aside.
Note
z Place a cloth between design cover and support for secondary air
pump to avoid scratching cover.
4. Loosen the 4 fastening screws on the ignition coil cover (picture

shows side 5-8).
Fastening screws on ignition coil cover

5. Remove design cover from cylinder bank 1-4. Lift the cover slightly
with both hands on the side pointing towards the intake system until it
snaps out of the fastening points.

the front.
Pulling out cover to the front

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Fastening screws for torque support

bracket
7. Remove torque support bracket. To do so, undo the 4 fastening screws and set bracket aside.
8. Disconnect the ignition coil. To do this, press the button on the

connector and pull off the connector.
Pulling off plug

9. Loosen ignition coil. To do this, unscrew the fastening screw on the
valve cover.
Fastening screws on valve cover

10. Pull the ignition coil out and replace it.
Ignition coil
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11. Reconnect the new ignition coil. Tighten the fastening screws. →
Fastening screws for ignition coil

12. Connect ignition coil. To do this slide on the connector until it locks
Sliding on the connector

13. Install bracket for torque support. The M8 x 45 Torx screws are
tightened on the upper screw points. → Tightening torque: 17 ftlb.
The M6 x 40 screws are tightened on the lower screw fastening
points (centre of the valve cover) → Initial tightening: 3.5 ftlb. →
Final tightening: 7.5 ftlb.
Fastening screws for torque support

bracket
Note
z A rag should be placed between the secondary air pump support and
the design cover to prevent the cover from being scratched.
14. Slide the design cover of cylinder row 1-4 under the secondary air
pump support as shown in the illustration and then slide the cover of
the second ignition coil through underneath the torque support
bracket.
Install cover
15. Press down the two rubber mountings on the support. The rubber mountings must be felt to engage.
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Fastening screws on the ignition coils Rubber mounting on support
3.5 ftlb.
17. Reinstall secondary air pump. Tighten the 3 fastening screws. →


pump
18. Reinstall torque support. Install the fastening screw (M10 x 85) with a
new fastening nut on the bracket. → Tightening torque: 44 ftlb.
19. Tighten torque support fastening screw on the body (M10 x 70) . →

bracket
Note
z A rag should be placed between the secondary air pump and the design cover to prevent the cover from
being scratched.
1. Unscrew the 4 fastening screws on the ignition coil cover.

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2. Remove design cover of

cylinder bank 5-8. To do this,
lift the cover slightly with both
hands at the side pointing
towards the intake system
until it is released from its
bracket.
Design cover of cylinder bank 5-8 Fastening screws on ignition coil cover

4. Disconnect the ignition coil. To do this, press the button on the
connector and pull off the connector.
Pulling off plug

5. Loosen ignition coil. To do this, unscrew the fastening screw on the
valve cover.

7. Reconnect a new ignition coil. Tighten the fastening screws. → Tightening torque: 7.5 ftlb.
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Fastening screws for ignition coil Pulling the ignition coil out and
replacing it
8. Connect ignition coil. To do this slide on the connector until it locks
Sliding on the connector
Note
z A rag should be placed between the secondary air pump and the
design cover to prevent the cover from being scratched.
Sliding the design cover onto the

secondary air pump
10. Then press in the two rubber mountings on the support. The rubber
mountings must be felt to engage.
Rubber mounting on support

11. Tighten the 4 fastening screws on the ignition coils. → Tightening torque: 3.5 ftlb.
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Fastening screws on the ignition coils

Subsequent work
Subsequent work
1. Install engine compartment cover on the right and rear. → 700219 Removing and reinstalling front cover
as of MY 2003
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28 39 19 Removing and installing hall sender - as of MY 2003

- Preliminary work
- Removing hall sender
- Installing hall sender
- Subsequent work
Preliminary work
Preliminary work
"Removing"
Removing hall sender
Note
z The hall sensors are located behind the camshaft housing and point towards the intake system.
Note
Replace all seals and O-rings.
1. Disconnect connector on hall sender. To do so, push the button and remove.
2. Loosen the fastening screw on the hall sender. Use a socket wrench with 1/4 inch drive and a joint.
3. Pull the hall sender out of the camshaft housing.
Installing hall sender

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Fastening screw on hall sender

1. Push the hall sender into the camshaft housing and tighten the
2. Push on electric connector. The connector must engage audibly.
Subsequent work
Subsequent work
as of MY 2003
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28 70 55 Replacing spark plugs - as of MY 2003

- Preliminary work
- Replacing spark plugs
Tools

spark plug wrench special tool 3122 B
Preliminary work
Preliminary work
Removing design cover of cylinder bank 1 -4

1. Remove engine compartment cover on the right and rear. To do this, undo the four bayonet screws and the
fastening screw on the washer-fluid reservoir. → 700219 Removing and installing front cover (engine
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compartment) - chapter on "removing"
2. Detach the torque support. To do this, unscrew the fastening screw

on the torque support bracket and pull it out.

Torque support on body

4. Detach the secondary air pump from cylinder bank 1 -4. To do this,
unscrew the three fastening screws, pull the pump out of the bracket
and lay it aside.

pump of cylinder bank 1 - 4
Note
5. Unscrew the four fastening screws on the ignition coil cover

(illustration shows side 5 - 8).
Removing fastening screws of ignition

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coil cover
Removing design cover from cylinder

bank 1 - 4
6. Remove design cover from cylinder bank 1 - 4. Lift the cover slightly with both hands on the edge pointing
towards the intake system until it snaps out of the fastening points.
the front.
Removing cover
8. Remove torque arm bracket. To do so, undo the four fastening
screws and set bracket aside.
Tightening fastening screws of torque

support bracket
Note
1. Unscrew the four fastening screws on the ignition coil cover.

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Design cover of cylinder bank 5 -8 Fastening screws of ignition coil cover

1. Pull off lower hose from secondary air pump 5 - 8.
2. Separate the eight ignition coils from the wire harness. To do this,
press on the button and, at the same time, pull off the plug.
Separating ignition coils from wire

harness
3. Undo ignition coil. To do this, unscrew the fastening screw on the valve cover.
4. Pull out ignition coil and lay it aside.
5. Undo spark plugs using special tool spark plug wrench 3122 B
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Ignition coil Fastening screw on valve cover
ATTENTION
Broken spark plug electrodes can damage the engine!
z 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.
Loosening spark plugs using spark

plug wrench
6. Check electrode gap in V8 naturally aspirated engine. → Control
value: 1.6 mm
Electrode gap of spark plug in V8

7. Check electrode gap in V8 turbo engine. → Control value: 0.8 mm
+/-0.05 mm

turbo engine
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Note
z Use only spark plugs approved by Porsche AG!
z Check electrode gap before screwing in a new spark plug.
8.
Tighten spark plugs using special tool spark plug wrench 3122 B.
→ Tightening torque: 25 (19 ftlb.) Nm , → Tightening torque: 30
(22 ftlb.) Nm
Tightening spark plugs using spark
plug wrench
9. Reconnect the ignition coil. Tighten the fastening screws. →
Fastening screw on valve cover

10. Connect ignition coil. To do this, push on the connector until it locks
11. Push lower hose onto secondary air pump 5 - 8.
Connecting ignition coil
Note
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Pressing down rubber mountings on Sliding design cover under secondary

bracket air pump
3. Tighten the four fastening screws on the ignition coils. → Tightening
torque: 3.5 ftlb.
Fastening screws of ignition coil cover

Note
1. Install bracket for the torque support. The M8 x 45 Torx screws are
tightened at the upper screw points. → Tightening torque: 23 ftlb.
At the lower screw-mounting points (centre of valve cover) the M6 x
40 are first tightened to → Initial tightening: 3.5 ftlb. and then to →
Final tightening: 7.5 ftlb. .

support bracket
2. Slide the design cover of cylinder bank 1 - 4 under the secondary air pump bracket as shown in the
illustration and then slide the cover of the second ignition coil through underneath the torque support bracket.
4. Tighten the four fastening screws on the ignition coils (illustration shows side 5 - 8). → Tightening torque:
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Pressing down rubber mountings on Inserting cover

bracket
3.5 ftlb.
5. Reinstall secondary air pump. Tighten the three fastening screws. →


6. Reinstall torque support. Install the fastening screw (M10 x 85) with a
new lock nut on the bracket. → Tightening torque: 44 ftlb.
7. Tighten torque support fastening screw on the body (M10 x 70) . →

8. Install the engine compartment cover at the right and rear. To do this,
tighten the four bayonet screws and the sheetmetal screw on the
washer-fluid reservoir. → 700219 Removing and installing front cover
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as of MY 2003
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28 72 19 Removing and installing knock sensor - as of MY 2003

- Preliminary work
- Removing knock sensor
- Installing knock sensor
- Subsequent work
Preliminary work
Preliminary work
"Removing"
2. Remove and fold up cover for coolant regulator (thermostat). → 195819 Removing and installing coolant
regulator (thermostat) - chapter on "Removing"
Removing knock sensor
1. Mark and note the installation position of the knock sensor and pull
off cable plug.
2. Unscrew fastening screw and take knock sensor out of the
crankcase.
Pulling off cable plug
Installing knock sensor

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Note
z The knock sensor and the cable plug must be aligned so that they never touch!
ATTENTION
Engine damage and changed exhaust behaviour due to incorrectly
mounted knock sensors!
→ The precise tightening torque for the knock-sensor screw must be

observed, otherwise the proper function of the knock sensor is not
ensured.
→ The knock sensors must a aligned so that the sensor housing and
the cable plug do not touch anywhere, otherwise proper functioning
of the knock sensor is not ensured.
Knock sensor, cylinder row 1-4
1. Install knock sensor. Make sure that the knock sensors are aligned according to the illustrations
-longer arrow points to alignment, smaller arrow points to fastening screw- .
2. Tighten fastening screws. → Tightening torque: 17 ftlb.

3. Push on cable plug and ensure that the cable plug does not touch.
Pushing on cable plug
Subsequent work
Subsequent work
1. Install cover for coolant regulator (thermostat). → 195819 Removing and installing coolant regulator
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(thermostat) - chapter on "Installing"
"Installing"
"Filling"
as of MY 2003
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20 02 01 Checking fuel pressure - as of MY 2003

- Information
- Checking fuel pressure
Tools

available tool
Porsche System Tester ll commercially 9588

available tool

available tool
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available tool
pressure gauge commercially p378

available tool
Pressure gauge commercially p378a

available tool
Tools and materials
Special tools
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Special tools

-B- Pressure gauge p378a For fuel pressure test.
interchange with -G- . There is a sheetmetal
clip in the connecting piece for the fuel
gallery which opens the scavenging valve
during the test procedure.
Must not be impinged with
under/overpressure.
interchanged with -C- . There are no metal
clips in the connecting piece for the fuel
gallery.
Information
Test conditions

Checking fuel pressure

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Design cover
3. Connect connection line 9559 to the pressure gauge p378 .
Screw the other end onto the fuel gallery.
Connection line
4. Switch on the ignition and start the engine. Read off fuel pressure
on pressure gauge. The value must be 4.0 ± 0.2 bar at idle
speed.
Pressure gauge
DANGER
Danger of fire due to incorrect or faulty scavenging valves!
→ Replace scavenging valves after removing.

→ Only use the special, Porsche-approved valves in the fuel
gallery.
Connection line
Note
z The steady-state pressure must be greater than 2.0 bar after 1 hour.
5. Unscrew connection line and close the fuel gallery with a new plastic cap.
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Design cover
as of MY 2003
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20 10 21 Removing fuel tank - as of MY 2003

- Preliminary work
- Removing fuel tank
Tools

available tool .gif
Preliminary work
Preliminary work for removing fuel tank

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2. Remove the carbon canister. Details for loosening in installation location (wheel housing) see → 202521
Removing carbon canister. The degassing tank is removed with the fuel tank connected (joined).
3. Remove rear axle (spring struts and rear axle housing) push it aside on the lifting platform (scope of work
without further disassembly of rear axle) → 420519 Removing and installing rear axle housing - chapter
on "Removing"
Tools and materials
Required tools

-1- Lifting platform Can be found in For removing and installing the rear
Workshop Equipment axle.
Manual, 3.0.13 "WE 1206"
DANGER
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longer periods.
DANGER

→ Do not smoke.
Note
Removing fuel tank
Removing fuel tank

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Note
z The repair procedure may vary depending on engine type and country equipment. This relates in
particular to components in the right wheel housing.
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Fuel tank mount

Fuel tank 1 Do not damage fuel tank and Do not damage fuel tank and
connected lines. Lines connected lines. Lines
cannot be replaced cannot be replaced
individually. individually.
that the tank cannot fall
down.
down.
down.
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down.
2. Screw the tank cap down. Then remove the rubber sleeve
around the fuel filler neck, loosen the two fastening screws M6 x
25 and remove the ground cable.
Tank filler neck

3. Remove the fuel supply -1- at the connection unit and disconnect
the 2 connection points -2 and 3- .
Connection unit
4. Pull fuel filler neck and degassing tank out of the wheel housing
and secure with a piece of wire arrow -arrow- (picture shows
degassing tank with carbon canister).
Wire protection for degassing tank

5. Then, loosen the stone guard on the right side. Unscrew screws -2- .
6. Remove line holder under the stone shield by pressing on the centre plug -arrow- . Replace holder.
7. Remove the centre underbody cover at the left and right of the longitudinal side members. → 519319
Removing and installing centre cover - chapter on "removing"
8. Remove rear heat shield. To do so, undo the three speed nuts and the two screws.
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Holder Stone guard
DANGER
Danger of injury due to
heavy filled tank!
→ For safety reasons, the

tank should only be
removed and installed
when empty!
9. Loosen the tank Tank attachment band Heat protection shield

attachment band, which
runs in the direction of
travel -arrows- . Then,
position a transmission
jack under the tank and
secure the tank from
falling using a belt. When
doing so, make sure that
the fuel lines are not
damaged.
ATTENTION
Risk of damaging to fuel lines!

→ A second person should hold the carbon canister during
removal.
10. Undo and remove the remaining restraining straps with the help Tank on lever
of a second worker. Slowly lower the tank with the transmission
jack. Also carefully guide the degassing tank in the right wheel
housing.
as of MY 2003
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20 10 23 Installing fuel tank - as of MY 2003

- Installing fuel tank
- Subsequent work
Tools

available tool .gif
Tools and materials
Required tools
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-1- Lifting platform Can be found in For removing and installing the rear
Workshop Equipment axle.
Manual, 3.0.13 "WE 1206"
DANGER
longer periods.
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DANGER

→ Do not smoke.
Note
Note

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Fuel tank mount

-1- Fuel tank 1 Do not damage fuel tank and Do not damage fuel tank and
connected lines. Lines connected lines. Lines
cannot be replaced cannot be replaced
individually. individually.
down.
down.
down.
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down.
Note
z The top left cover must be fitted before the tank is installed.
z When installing the tank and rear axle, make sure that cables and
lines are not damaged and are in the correct installation position.
z When introducing the tank into the body, a second person should
guide the degassing tank and safeguard it against damage using
wire.
1. Raise the tank with a transmission jack. Make sure to secure the tank with a tension strap to prevent it
from falling.
2. With the help of a second worker, put the tank into the installation position. A second person should
carefully guide the degassing tank.
Note
z Note direction arrow stamped on the restraining straps and install
these in the direction of travel.
3. Attach lower covers and fit the four restraining straps, which run
at right angles to the direction of travel. Make sure that the
stamped arrow is pointing forwards in the direction of travel.
Tighten fastening screws to the specified tightening torque. →
Tightening torque: 17 ftlb. Secure fuel filler neck and degassing
tank again with a wire -arrow- .
Figure shows secured degassing tank
(shown here with carbon canister
attached)
4. Lower the transmission jack and fit the centre restraining strap.
The arrow must be pointing forwards. Tighten fastening screws to
the specified torque. → Tightening torque: 17 ftlb.
Centre fuel tank restraining strap

5. Fit the exhaust system heat shield. If the shield is cracked or damaged, it must be replaced. Tighten the
3 sheetmetal nuts and the 2 screws.
6. Mount the underbody panel of the side member on the left and right. → 519319 Removing and installing
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middle cover
7. Replace holder and attach to side member. Clip in lines.
Holder
8. Then, fit the stone guard on the right side. Mount nuts -arrows-
and tighten to the specified torque. → Tightening torque: 7.5
ftlb.
Stone guard
9. Mount the fuel supply -1- to the connection unit and connect the
2 connection points -2 and 3- .
Connection unit
Subsequent work
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Subsequent work
1. Fit cover. Tighten the 4 fastening nuts. → Tightening torque: 7.5

ftlb. Refit carpeted floor and fix with double-sided adhesive tape.

2. Tighten the seat-belt buckle fastening plates. Use 3 new
fastening screws for this and tighten. For tightening torque see
→ 692519 Removing and installing rear belt lock
4. Mount rear axle (spring struts and rear axle housing). → 420519
Removing and installing rear axle housing - chapter on
"Installing"
5. Mount carbon canister. → 202523 Installing carbon canister

6. Fill fuel tank (refuel). → Filling with fuel Fastening screws for retaining
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g g

20 15 19 Removing and installing fuel level sensor - as of MY

2003
- Information
- Preliminary work
- Removing fuel level sensor
- Installing fuel level sensor
- Subsequent work
Tools

Information
Note
z The two senders have different shapes and may not be switched.
z The float installed in the left direction of travel is flat, while the float installed in the right direction of travel
is spherical.
z 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.
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Both fuel level sensors
Jammed fuel-level sensor
The effect of fuel and various tolerances means that the left fuel level sensor can become jammed under fuel
lines or the sensor's electric cable. The instrument cluster would then display an incorrect fuel level.
To prevent this, the two fuel lines coming from the left pump and the
electric cable should be tied together with a tie-wrap following repairs.
Tie-wrap fixed electric cable
Preliminary work
Opening the tank
Note
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3. Fold up the retaining brackets of the (right and left) seat-belt

buckles. To do so, loosen the four fastening screws and fold up
the bracket with the seat-belt buckle. Do not use the fastening
screws again.

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DANGER
→ Inhaling vapours can cause irritation of the mucous membranes
and eyes.
Fuel supply and disconnection points
→ Wear protective gloves that are fuel-resistant. at right connection unit
→ Wear a breathing mask with active charcoal filter; do not breathe
in any fuel vapours.
→ Ensure that there is adequate ventilation and extract all fuel
vapours.
→ Before opening the fuel lines or fuel hoses, relieve the fuel
pressure.
→ Collect escaping fuel, absorb it if necessary with a suitable
binding material and dispose of properly.
DANGER

→ Do not smoke.
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Note
6. Carefully remove the fuel supply -1- at the relevant connection unit (right connection unit here) and
loosen the two disconnection points -2 and 3- . Also remove line (not shown here) in vehicles with
auxiliary heating (auxiliary heater). Do the same at the left connection unit. Disconnect all connections on
the connection unit.
7. Open the relevant cap with the key T10202 and lift up the
connection unit (cap).
Cap
Preliminary work
1. Disconnect electric connectors -1 and 2- . Then pull off the fuel

lines -3 and 4- and remove the connection unit.
Connection unit

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1. Reach carefully past the fuel pump and feel for the sender. This is located in front of the pump, pointing
diagonally outwards.
2. Press the retaining spring on the sender by hand while at the

same time pulling the sender up.
1. Install a new tank gauge. Press the sender into its mounting. The
retaining spring must engage audibly.
View shows the left sender
View shows the right sender
Subsequent work
Subsequent work

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Connection unit Seal for opening of tank
2. Connect connection unit. Connect the electric connectors for the tank gauge and fuel pump. Then push
on the fuel lines. The connectors must engage audibly.
3. Fit connection unit into tank opening. When doing so, make sure that the plastic lug is pointing forwards.
Closing the tank
1. Close the tank. To do so, fit the sheetmetal ring and tighten using
the key T10202. → Tightening torque: 104 ftlb.
Cap
2. Fit all connections (fuel lines, ventilation tubes and electric
plugs).

electric plugs
3. Fit the lid. Then tighten the four fastening nuts. → Tightening torque: 7.5 ftlb. Refit carpeted floor and
fix with double-sided adhesive tape.

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as of MY 2003
Country C00, C02, C05, C07,
C08, C09, C10, C11, C12,
C13, C14, C15, C16, C18,
C19, C20, C21, C22, C23,
C24, C25, C26, C27, C28,
C32, C33, C34, C35, C36,
C37, C38, C39, C45, C46,
Fastening screws for retaining Fastening nuts for cap
C98, C99
g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g

20 25 21 Removing carbon canister - as of MY 2003

- Preliminary work
- Information
- Removing carbon canister
Preliminary work
Preliminary work
1. Take up the vehicle at the jacking points provided using a platform lift. → Lifting the vehicle [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1] → Lifting the vehicle [9PAAJ1]
3. Screw the tank cap down. Then remove the rubber sleeve
around the tank filler neck, loosen the 2 M6 x 20 fastening
screws and remove the ground cable.
4. Remove right rear wheel. → 440519 Removing and installing
wheel - chapter on "Removing".
Tank filler neck

5. Remove right rear wheel housing liner. → 536919 Removing and installing rear wheel housing liner -
DANGER
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→ Inhaling vapours can
cause irritation of the Rear wheel housing liner
mucous membranes and
eyes.
represents a serious risk
to health when inhaled,
touched or swallowed
over longer periods.
→ Only work on the fuel
system in well-ventilated
rooms.
→ Wear protective gloves
that are fuel-resistant. Mud flap
→ Wear a breathing mask
with active charcoal filter;
do not breathe in any fuel
vapours.
→ Ensure that there is
adequate ventilation and
extract all fuel vapours.
→ Before opening the fuel
lines or fuel hoses, relieve
the fuel pressure.
→ Collect escaping fuel,
absorb it if necessary with
a suitable binding
material and dispose of
properly.
→ Pay attention to
cleanliness when working
on the fuel system.
DANGER

→ Do not smoke.
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Note
Information
ATTENTION
Risk of damage!
z There is a risk of leaks if the overflow line on the fuel filler neck is above the valve.

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Note
The following exploded drawing shows the attachment of the tank filler neck and carbon canister in the right
wheel housing.
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3- Fastening screw
5- Fastening nut M6
6- Carbon canister
7- Degassing tank

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ATTENTION
Risk of damage!

→ A second person should hold the carbon canister during
removal.
1. Loosen the 5 fastening screws on the carbon canister and the Fastening screws
two on the degassing tank in the right wheel housing -arrows- .
Note
z In USA vehicles, the rubber hose -2- of the leak diagnosis pump
is extremely tight. If the hose is pulled, the connection piece can
break off at the leak diagnosis pump.
2. Carefully remove the 2 electric connectors -3- on the carbon

canister and on the leak diagnosis pump and the hose on the
connection piece -2- of the leak diagnosis pump (USA). There is
always a risk of damage. Then, disconnect plastic line -1- .

3. Cut through the tie-wraps of the ground cable on the carbon
canister and take the carbon canister out of the wheel housing.
Replace tie-wraps.
Cutting tie-wraps
4. Remove hose connection on the degassing tank.
ATTENTION
Risk of damage!
g g
z Lines can become

kinked or can crack.
→ Never leave carbon

canister hanging freely on
the lines.
→ A second person should
hold the carbon canister
during removal.
5. Pull fuel filler neck and

degassing tank out of the
wheel housing and secure Wire protection Hose connection on the degassing
with a piece of wire tank
-arrow- (figure shows
degassing tank with
carbon canister).
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g

20 25 23 Installing carbon canister - as of MY 2003

- Installing carbon canister
- Subsequent work
DANGER
longer periods.
DANGER

→ Do not smoke.
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Note
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Note
The following exploded drawing shows the attachment of the tank filler neck and carbon canister in the right
wheel housing.
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3- Fastening screw
5- Fastening nut M6
6- Carbon canister
7- Degassing tank

1. Replace the ground cable tie-wraps on the carbon canister and pre-assemble the ground cable. Lift the
carbon canister into the wheel housing.
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2. Join all lines on the carbon canister and degassing tank at the plug connections.
3. Carefully mount the 2 electric connectors -3- on the carbon

canister and on the leak diagnosis pump and the hose on the
connection piece -2- of the leak diagnosis pump (USA). Then
connect plastic line -1- .

4. Insert the hose on the degassing tank.
ATTENTION
Risk of damage!
z There is a risk of leaks if the overflow line on the fuel filler
neck is above the valve.
Degassing tank
5. Swivel carbon canister down into installation position from
behind. Make sure that the fuel overflow line -1- is below the
solenoid valve -2- . If the line is not routed correctly, this will
cause damage during subsequent operation.
Picture shows the correct position of the line. View from above without rear side panel.
Fuel overflow line and solenoid valve
1 - Overflow line
2 - Solenoid valve
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6. Tighten the 5 fastening screws on the carbon canister and the 2

on the degassing tank in the right wheel housing -arrows- . →
Fastening screws
Subsequent work
Subsequent work
1. Install the right rear wheel housing liner. → 536919 Removing

and installing rear wheel housing liner - chapter on "Installing"

2. Mount rear wheel. → 440519 Removing and installing wheel - chapter on "Installing"
3. Connect ground cable to fuel filler neck. Screw down the 2 fastening screws and mount rubber sleeve
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Mud flap
around the tank filler neck. → Tightening torque: 7.5 ftlb.
4. Screw on tank cap.

5. Activate air suspension.
as of MY 2003
g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g

20 43 02 Fuel filter lines checked (in tank) - as of MY 2003

- Information
Information
g
Overview - lines for fuel filter

g
1- Fuel pump, left

2- Connection to fuel filter
3- Fuel supply line connection
5- Fuel pump, right
7- Connection to fuel pressure regulator
8- Connection point for left fuel pump and pressure regulator
9- Sucking jet pump of left pump
as of MY 2003
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g g g g p p g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g g g p p g

20 48 19 Removing and installing leakage diagnosis pump

(LDP) - as of MY 2003
- Preliminary work
- Information
- Removing leakage diagnosis pump (LDP)
- Installing leakage diagnosis pump (LDP)
- Subsequent work
DANGER
longer periods.
DANGER

→ Do not smoke.
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Note
Preliminary work
Preliminary work
1. Remove carbon canister and place it on a clean surface. → 202521 Removing carbon canister
Information
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Overview of active carbon filter
1 - Degassing tank
2 - Filler neck
3 - Pressure control valve
4 - Carbon canister
5 - Leakage diagnosis pump
→ Installation position of leakage diagnosis pump
Installation position of leakage

diagnosis pump
1. Loosen three fastening screws on plastic support for pressure control valve. -Arrows-
To remove the top fastening screw, carefully press the pressure control valve hose aside using a
screwdriver and screw out the fastening screw. → Pressure control valve
2. Turn the pressure control valve to the side and remove the three fastening screws on the leakage
diagnosis pump. → Pressure control valve and leakage diagnosis pump mount
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Pressure control valve Leakage diagnosis pump mount

3. Carefully lever the leakage diagnosis pump out of the bracket on
the active carbon filter using a screwdriver. → Levering out
leakage diagnosis pump
Levering out leakage diagnosis pump

4. Carefully lever the leakage diagnosis pump out of the rubber
flange on the housing using a screwdriver. → Rubber flange
Rubber flange
5. Pull off the air hose. → Pulling off air hose
6. If the rubber flange slips out of the housing and remains on the connection piece of the leakage
diagnosis pump while you are removing the leakage diagnosis pump, check the rubber flange for
damage and insert it back flush into the carbon canister housing if it is OK. → Rubber flange → Inserted
rubber flange
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Rubber flange Pulling off air hose
1. If the rubber flange slips out of the housing and remains on the
connection piece of the leakage diagnosis pump while you are
removing the leakage diagnosis pump, check the rubber flange
for damage and insert it back flush into the carbon canister
housing if it is OK. → Rubber flange → Inserted rubber flange
Rubber flange

2. Lightly lubricate the connection piece of the leakage diagnosis pump and rubber flange with KLUEBER
Syntheso Glep 1 (000 043 204 68 status 12/05) and carefully move leakage diagnosis pump into
g g g g p p g
Fitting leakage diagnosis pump

installation position. Make sure that the rubber flange is not pushed into the housing.
3. Ensure that the leakage diagnosis pump is seated correctly in the

bracket for the active carbon filter. Fit the three fastening screws
for the leakage diagnosis pump → Tightening torque: 3 (2 ftlb.)
Nm and turn pressure control valve back into installation position.
→ Pressure control valve and leakage diagnosis pump mount

4. Fit air hose. → Fitting air hose on leakage diagnosis pump
Fitting air hose on leakage diagnosis

pump
5. Fit three fastening screws on the plastic support for the pressure
control valve → Tightening torque: 3 (2 ftlb.) Nm . -Arrows-
Leakage diagnosis pump mount

To fit the top fastening screw, carefully press the pressure control valve hose aside using a screwdriver
and screw in the fastening screw. → Pressure control valve
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Pressure control valve

Subsequent work
Subsequent work
1. Install carbon canister. → 202523 Installing carbon canister
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g g

20 60 19 Removing and installing fuel filter - as of MY 2003

- Preliminary work
- Information
- Removing fuel filter
- Installing fuel filter
- Subsequent work
Tools

Preliminary work
Preliminary work
Note
Opening the tank
Note
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3. Fold up the retaining brackets of the (right and left) seat-belt

buckles. To do so, loosen the four fastening screws and fold up
the bracket with the seat-belt buckle. Do not use the fastening
screws again.

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DANGER
and eyes.
vapours.
pressure.
DANGER

→ Do not smoke.
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Note
Cap
Information
Component overview
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Component overview of left connection unit (fuel filter)
1- Adapter for bleeding

2- Filter feed from left pump
3- Fuel supply to pressure regulator
4- Electric connection for fuel pump
5- Electric connection for fuel level sensor
6- Filter feed from right pump
1. Disconnect electric connectors -1 and 2- . Then pull off the fuel

lines -3 and 4- and remove the filter unit.
Connection unit

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2. Connect filter unit. Mount

the electric connector
-1 and 2- and the hose
connections -3 and 4- .
3. Place the connection unit

into the tank. When doing
so, make sure that the
plastic lug is pointing
forwards.
Connection unit Seal
Subsequent work
Closing the tank
Cap
plugs).

electric plugs
adhesive tape.
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Subsequent work
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
gq y g

20 66 01 Checking quantity of fuel delivered - as of MY 2003

- Information
- Checking quantity of fuel delivered
Tools

Pressure gauge special tool 378a

available tool

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measurement tool set commercially 9684

available tool

available tool

available tool
Tools and materials
Special tools
gq y g
Tool illustration for fuel pressure

-B- Pressure gauge 378a For fuel pressure test.
interchange with -F- . There is a sheetmetal
clip in the connecting piece for the fuel
gallery which opens the scavenging valve
during the test procedure.
Must not be impinged with
under/overpressure.
interchanged with -C- . There is no metal clip
in the connecting piece for the fuel gallery.
Information
Test conditions

Checking quantity of fuel delivered

gq y g
Checking fuel delivery rate

Throttle body cover
WARNING
Danger of fire and injury!
z Danger of fire due to escaping fuel, e.g. on hot engine
components or due to electrostatic charge.
z Danger of fire due to naked flames and sparks, e.g. during

Test hose/measuring adapter
→ Ensure that there is adequate ventilation and extract all fuel connection
vapours.
pressure.
Note
z The fuel gallery is pressurised! Place a cloth near the front of the fuel gallery to prevent fuel dripping onto
hot engine parts.
3. Join the test hose to the measuring adapter and connect the other end to the scavenging valve on the
fuel gallery.
Note
z For the delivery rate check, a second person should clock the time.
4. Place the open hose end from the pressure regulator in the measuring beaker.
5. Connect jumper lead 26 to two test leads 16 taken from measurement tool set 9684 and use these to
bridge the fuel pump. The exact assignment of the contacts can be obtained from → Fuse
carrier [9PAAJ1]→ Fuse carrier [9PAAE1 9PAAE7 9PAAF1].
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Note
z To avoid incorrect readings, make sure that the hose lines are
already full of fuel at the start of the test.
6. Keep fuel pump switched on until fuel emerges from the end of
the hose. Then empty the measuring beaker.
7. Switch on fuel pump I (left pump) for one minute. Then monitor
the fuel delivered and note the quantity. Now repeat the process
with pump II (right pump).
Test setup
Fuel pump Delivery rate

Fuel pump I (left) > 1.6 l/min
Fuel pump II (right) > 1.3 l/min
If the test delivery rate produced in the test is too low, repeat it at the right scavenging valve of the fuel gallery.
8. On completion of the test, switch off the ignition and remove test tool.
DANGER
Danger of fire due to faulty scavenging valves!
→ Only use the special, Porsche-approved valves in the fuel

gallery.
9. Press the four rubber elements in the cover onto the four ball Cover
socket holders. The mounts must be felt to engage.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g p p g

20 66 19 Removing and installing fuel pump - as of MY 2003

- Preliminary work
- Information
- Removing fuel pump
- Installing fuel pump
- Subsequent work
Tools

Preliminary work
Preliminary work
Information
General note
Note
z The fuel pumps have different hose connections and must not be confused.
z The connections should be marked for identification when removing.

g g p p g
z In order that the connections do not fall in the fuel tank, they should be secured using tie-wraps.
The following overview is used as an orientation for connecting fuel pumps:
1- Fuel pump, left

5- Fuel pump, right
7- Connection to fuel pressure regulator
8- Connection point for left fuel pump and pressure regulator
9- Sucking jet pump of left pump
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Removing fuel pump
Opening the tank
Note
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DANGER
and eyes.
vapours.
pressure.
DANGER

→ Do not smoke.
g g p p g

Note
Cap
Removing left fuel pump
1. Pull off electric connectors -1 and 2- on the left connection unit.

Then pull off the fuel lines -3 and 4- and remove the connection
unit (filter unit).

2. Disconnect the sucking jet pump at the fuel pump. To do this, press on the left and right and pull off the
connection.
3. Raise the right connection unit slightly and disconnect the fuel pump line at the Y-piece (on the right
side).
g g p p g

fuel pump
4. Turn the pump approx. 90° to the left until it disengages at the
tank floor. Remove the pump from the tank.
Turning the pump

Removing right fuel pump
1. Disconnect the electric connectors for the fuel pump and fuel
level sensor. Then pull off the fuel lines on the pressure regulator
and remove the connection unit.

2. Disconnect the sucking jet pump at the fuel pump. To do this,
press on the left and right and pull off the connection.
3. Disconnect the hose for the right fuel pump at the Y-piece.

fuel pump
4. Turn the pump approx. 90° to the left until it disengages at the tank floor. Remove the pump from the
tank.
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Turning the pump

Installing fuel pump
Installing left 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.
2. Connect the fuel line from the pump to the Y-piece (right side of the tank).
3. Attach the sucking jet pump connection. This must engage

audibly.

fuel pump
4. Replace both seals on the connection units.

5. Connect connection unit. Connect the electric connectors for the tank gauge and fuel pump. Then push
on the fuel lines. The connectors must engage audibly.
6. Place the connection unit into the tank. When doing so, make sure that the plastic lug is pointing
forwards.
Installing right 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.
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2. Connect the fuel line from the right pump to the Y-piece.

3. Attach the sucking jet pump connection. This must engage
audibly.

fuel pump
4. Replace connection unit seal.
5. Connect connection unit. Connect the electric connectors for the

tank gauge and fuel pump. Then push on the fuel lines. The
6. Place the connection unit into the tank. When doing so, make
sure that the plastic lug is pointing forwards.

Closing the tank
Cap
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electric plugs


Subsequent work
Subsequent work
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g g

20 03 Draining and filling fuel - as of MY 2003

- Information
- Draining fuel (emptying fuel tank)
- Filling with fuel (filling fuel tank)
Tools

adapter special tool 9479
Tools and materials
Tools and materials

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Special tool
A - Fuel transfer unit (This tool has been tested and approved by PORSCHE.); see Workshop
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.); see Workshop Equipment
Manual 3.2.2 "WE 1262"
C - Porsche adapter (This adapter fits 8-mm to 10-mm fuel lines (986; 996 and Cayenne.);
see Workshop Equipment Manual 3.2.2 "WE 1262"
D - Connecting piece between Porsche adapter and suction line (This is screwed into suction
line E and connected to the Porsche adapter.); see Workshop Equipment Manual 3.2.2
"WE 1262"
E - Suction line with venting device (Always attach venting device (rubber taper with
transparent hose) to the filler neck. This minimises the amount of escaping fuel vapours.);
see Workshop Equipment Manual 3.2.2. "WE 1262"
ohne - Adapter adapter 9479 (For controlling the fuel pumps); see Workshop Equipment Manual,
Bezeichnung Chapter 2.2.2
Information
Using equipment
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Overview of fuel transfer system
1 - Air connection (connection for unlubricated/oil-free compressed air)

2 - Fuel tank (capacity: 110 litres), (Tank can be changed. The scale at the side starts at approx. 10 litres.
Other markings are shown in 5-litre 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.
2. Connect the suction hose (or fuel nozzle) to the connection -1-
and then connect the venting device -2- .
Fuel transfer system

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.
Earth cable attached to vehicle

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Note
z Fuel can be removed directly through the fuel filler neck on older
vehicles or vehicles from other manufacturers by removing the
connecting piece.
Connecting piece
Draining fuel (emptying fuel tank)
Draining fuel (emptying the fuel tank)
DANGER
longer periods.
DANGER

→ Do not smoke.
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ATTENTION
Damage to the fuel tank!
→ Please observe the general warning notes and working regulations. → 10 The most important working
regulations and warning notes.
→ The tank can only be drained using the vehicle's own fuel pumps.
→ It is not possible to extract fuel via the fuel filler opening and doing so may cause damage.
Note
z All windows should be opened for better ventilation in the passenger compartment.
2. Fold up the retaining brackets of the right-hand belt anchor. To

do so, undo the three fastening screws and fold up the bracket
with the belt anchors. Do not use the fastening screws again.
Retaining brackets of the right-hand

belt anchor
3. Undo the right cap. To do so, cut out the carpeted floor along the
perforated lines using a carpet knife and fold it over. Then
unscrew the four fastening nuts and remove the lids. View shows
both lids.
4. Reduce the fuel pressure in the fuel line. To do so, screw down
the protective cap on the fuel gallery and carefully press the
valve. Collect emerging fuel with a cloth.
Cap
5. Carefully pull off the fuel line -1- . Collect emerging fuel with a
cloth.
Fuel line
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6. Connect earth cable to the vehicle.
Earth cable attached to vehicle

7. Attach Porsche adapter to the connection piece. Twist top and
bottom part of adapter in opposite directions until it is tight.
Porsche adapter
8. Screw the connecting piece into the suction hose and tighten it
hand tight.
Connecting piece
9. Connect the connecting piece to the adapter.
Connecting piece connected to

adapter
10. Open lid of central electrics box. To do this, loosen the four fastening screws.
ATTENTION
Risk of damage to fuel pumps!
z The Porsche adapter can slip from the tank connection.
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→ Only switch fuel pumps on after the extraction pump has been
switched on.
→ Always set extraction pump to suction mode - never refill mode -
when the vehicle pump is running.
Note
z Use special tool adapter 9479 from the measurement tool box to
activate the fuel pump.
z Alternatively, adapters 26 and 25 can be connected and the fuel

Lid of central electrics box
relay can be bridged. A fault is stored in the engine control
module during this procedure.
11. Remove fuel pump relays -1- and -2- . The pump can be activated by bridging the relevant contacts. The
contact assignment is printed on the corresponding relay. No faults are stored in the engine control
module when special tool adapter 9479 is used. Both pumps should be activated. As soon as the tank is
empty, fit the fuel pump relays again and close the electrics box.
Fuel pump relay
12. Carry out any necessary repair work on the tank. Please observe the warning notes in the chapter
entitled → 10 The most important working regulations and warning notes.
plugs).
Connections
14. Fit the lid. Then tighten the four fastening nuts → Tightening torque: 10 (7.5 ftlb.) Nm . Refit carpeted
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Cap
floor and fix with double-sided adhesive tape.
fastening screws for this and tighten. For tightening torque see
→ 692519 Removing and installing rear belt lock


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.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
p g g

24 24 55 Replacing air-cleaner element - as of MY 2003

- Preliminary work
- Replacing air-cleaner element - Cayenne S (type M48/00)
- Subsequent work
Preliminary work
Preliminary work
1. Remove throttle-housing cover. → 243519 Removing and installing throttle-housing cover (Y-shaped
pipe)
2. Remove engine compartment covers on the left and right over the air cleaner housing. → 700219
Replacing air-cleaner element - Cayenne S (type M48/00)
Note
z In vehicles with air suspension, the compressor air tube on the air cleaner cover must be removed and
installed.
Note
z Under particularly difficult conditions (dusty environments) it may be necessary to change the filter
element outside the maintenance intervals.
z The description only applies to changing one filter element. The second element is changed in the same
way.
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Air guide for V8 S
1. Remove the air tube on the right air cleaner cover. To do this,
unclip the green cap. Insert a screwdriver into the notch of the
cap and lever the cap off. → Air line
Air line
2. Push the circlip into the flange -1- and then pull it off together
with the flange -2- .
Connection
3. Clip the green cap on again after disassembly.
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4. The coolant bleeder hose Cover cap

on the coolant expansion
tank should be unclipped
from the air cleaner
housing cover of the
cylinder bank 1 - 4.

5. Open the two upper fastening clips on the air cleaner housing.
Clamps
6. Press the cover of the air cleaner housing in the direction of the
engine, pulling it upwards at the same time.
Cover for air filter housing

7. Remove the air-cleaner element from the air cleaner housing.
Air cleaner element

8. Insert filter element in the housing.
9. Place the cover on the air cleaner housing and run in from top to bottom. Make sure that the three
fastening lugs run into the mounting points on the underside. The figure gives a clearer view of the
dismantled air cleaner housing.
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Fastening lugs on underside Filter element inserted correctly
Clamps
10. Push cover up against the air cleaner housing and release the 2 fastening clips
11. Push the air suspension line onto the right air cleaner cover.
Air suspension line

12. The coolant bleeder hose and the coolant overflow hose must be
clipped back onto the cylinder bank 1 - 4 on the air cleaner
housing.
Subsequent work
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Subsequent work
1. Install throttle-housing cover. → 243519 Removing and installing throttle-housing cover (Y-shaped pipe)
2. Install engine compartment covers on the left and right over the air cleaner housing. → 700219 Removing
9PAAE1, 9PAAE7
as of MY 2003
g g g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g g g

24 25 19 Removing and installing air cleaner housing - as of MY

2003
- Preliminary work
- Removing air cleaner housing - Cayenne S (type M48/00)
- Installing air cleaner housing - Cayenne S (type M48/00)
- Subsequent work
Preliminary work
Preliminary work
Note
z The description relates to one cylinder row. The air cleaner housing on the other cylinder row is removed
and installed in the same way.
1. Perform the steps required to replace the air-cleaner element. → 242455 Replacing air cleaner element
2. Remove the relevant wheel-housing liner. → 505619 Removing and installing front wheel housing liner.
Component overview
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Installation position for air guide for V8 S
Installation position for air guide for V8 Biturbo
Removing air cleaner housing - Cayenne S (type M48/00)
1. Pull the air guide of the air cleaner housing out of the wheel well.
To do this take hold of the air guide in one hand and pull it
forwards at an angle.
Air guide
2. Unscrew the fastening screw on the air cleaner housing.
Fastening screw
3. Unclip the electric cable from the coolant expansion tank on the cylinder bank 1 - 4. The cable is clipped
in at 2 points.
4. Lift the air cleaner housing, tip it towards the engine and remove it from the engine compartment.
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Air cleaner housing Electric cable

Installing air cleaner housing - Cayenne S (type M48/00)
1. Insert the air cleaner housing into the engine compartment at an

angle from above.
Air cleaner housing

2. Introduce the 2 retaining bolts on the underside into the take-up
bores in the body. Check the wheel well to make sure that the
blue rubber discs are present and ensure that the bolts are
properly fitted.
Fastening bolts and rubber washers

3. Tighten the fastening screw on the air cleaner housing. →
Fastening screw
4. Unclip the electric cable from the coolant expansion tank on cylinder bank 1 - 4. The cable is clipped in at
two points.
5. Replace the air guide on the air cleaner housing from the wheel well. Check that the elements are
installed correctly.
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Air guide Electric cable
Subsequent work
Subsequent work
1. The steps required to replace the air-cleaner element are to be performed in the same way. → 242455
Replacing air cleaner element
2. Install the relevant wheel-housing liner. → 505619 Removing and installing front wheel housing liner.
9PAAE1, 9PAAE7
as of MY 2003
g g pp g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g pp g

24 30 19 Removing and installing fuel pipe - as of MY 2003
Removing and installing fuel pipe

1. The steps involved in removing and installing the fuel pipe (fuel distributor pipe, pressure pipe) are
identical to those involved in removing and installing the fuel injectors. → 244019 Removing and installing
injection valve
as of MY 2003
g g g p pp g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g g p pp g

24 35 19 Removing and installing cowl for throttle housing (Y-

shaped pipe) - as of MY 2003
- Removing cowl for throttle housing (Y-shaped pipe) - Cayenne S (type M48/00)
- Installing cowl for throttle housing (Y-shaped pipe) - Cayenne S (type M48/00)
Removing cowl for throttle housing (Y-shaped pipe) - Cayenne S (type M48/00)
Installation position for V8 S
1. Remove front engine compartment cover. → 700219 Removing and installing front cover (engine

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Front design cover

bolts through 45° in an anti-clockwise direction. The spot on the
bolts must lie as shown in the picture. → Fastening bolts
Fastening bolts
Removing fastening bolts

bellows off the air flow sensors.
Bellows
8. Remove the hose on the Y pipe. To do this, press the button and disconnect the vacuum line.
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Installing cowl for throttle housing (Y-shaped

pipe) - Cayenne S (type M48/00)
Vacuum line
Vacuum line
clamps.
Bellows
left and right fastening bolts. Turn the bolts 45° clockwise.
→ Fastening bolts
Fastening bolts
4. Connect the throttle adjuster. The plug must engage audibly. Clip the connecting cable into the
sheetmetal holder.
5. Press the 4 rubber elements in the cover onto the 4 ball head supports. The mounts must be felt to
engage.
6. Install front engine compartment cover. → 700219 Removing and installing front cover (engine
compartment) - "Installing" section
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Front design cover Cable plug for throttle housing
9PAAE1, 9PAAE7
as of MY 2003
g g j g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g j g

24 40 19 Removing and installing fuel injector - as of MY 2003

- Preliminary work
- Removing fuel injector
- Installing fuel injector
- Subsequent work
Preliminary work
Preliminary work: Installing fuel injectors

1. Remove engine compartment lining at the rear and on the right-hand side. → 700219 Removing and
installing front cover (engine compartment) - "Removing" section
2. Remove design covers from engine. → 108319 Removing and installing engine cover - "Removing"
section
Component overview
Installation position for suction module and fuel injectors

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Fuel pipe and fuel injectors
1 - Intake-air distributor
2 - Positive crankcase ventilation (T flange)
3 - K50 x 12 lens-head screw → Tightening torque: 1.6 ftlb.
4 - Cap; replace
5 - Valve insert
7 - Fuel gallery; do not bend
8 - Fuel injector
9 - Safety clip
Removing fuel injector
Removing injection valve

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DANGER
and eyes.
Fuel connections
vapours.
pressure.
DANGER

→ Do not smoke.
Note

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1. Disconnect fuel line -1- and line -2- from the carbon canister on the radiator tank splash panel.
2. Disconnect the electric connectors to the eight fuel injectors. To

do this, press the metal clip on the plug and pull off the plug.
Metal clip on plug

3. Unscrew the four fastening screws on the fuel distribution pipe.
4. Remove fuel distribution pipe with the fuel injectors.

pipe
5. Pull off the clamp on the fuel injector -A- and pull the fuel injector
out of the fuel distribution pipe -B - .
Fuel injector
Installing fuel injector
Note
z If the fuel injectors are to be reused, the sealing rings should be replaced.
1. Replace sealing rings on the injection valves. Take care not to damage the fuel injector when removing
the sealing rings.
2. Insert injection valve into the fuel distribution pipe and align. The electric connector must be positioned
opposite the lug on the distributor. Then fit sheetmetal clips -arrow- .
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View shows fitting Valve alignment

3. Insert the fuel injector into the fuel distribution pipe -A- and insert the clamp on the fuel injector -B - .
4. Check that the sheetmetal clip is correctly fitted. The sheetmetal

clip must engage in the flanged edge on the fuel distribution pipe.
5. Insert fuel injectors into the openings in the intake module and
press the fuel gallery down.
Installation position for sheetmetal clip

6. Tighten the four fastening screws to the specified torque. →

pipe
Fuel injector clamp

9. Switch on ignition and check the system for leaks.
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Subsequent work
Fuel connections
Work subsequent to installing injection valves
1. Install design covers for engine. → 108319 Removing and installing engine cover - "Installing" section
2. Install engine compartment cover at the rear and on the right-hand side. → 700219 Removing and
installing front cover (engine compartment) - "Installing" section
as of MY 2003
g g y g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g y g

24 42 19 Removing and installing throttle body - as of MY 2003

- Preliminary work
- Removing throttle body
- Installing throttle body
- Subsequent work
Preliminary work
Preliminary work
1. Remove Y-shaped pipe (intake manifold in front of throttle housing). → 243519 Removing and installing
air box for throttle housing (Y-pipe) - section on "Removing" [9PAAF1 9PAAJ1]→ 243519 Removing and
installing air box for throttle housing (Y-pipe) - section on "Removing" [9PAAE1 9PAAE7]
Removing throttle body
Removing throttle housing

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Suction module
1- Intake-air distributor and throttle housing

2- Seals for intake-air distributor; replace
3- Seal for throttle adjuster; replace
4- Throttle adjuster; do not actuate by hand
5- Support for throttle body cover; secure with the fastening screws for the throttle adjuster
7- Fastening screws
1. Pull off cable plug on the throttle housing and pull cable out of the
clip -Arrows- .

2. Undo four screws on the throttle housing -Arrows- . Loosen sheetmetal reinforcement around the throttle
housing. Remove throttle housing.
3. Check condition of sealing ring. Replace sealing ring if necessary → Sealing ring for throttle housing .
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Sealing ring for throttle housing Loosening throttle adjuster
Installing throttle body
Installing throttle housing


2. Move throttle housing into installation position and place
sheetmetal reinforcement around the throttle housing. Insert and
screw in four screws -Arrows- . → Tightening torque: 8 (6 ftlb.)
Nm
Throttle adjuster mount

3. Attach cable plug to throttle housing and insert cable into clip
-Arrows- .

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Subsequent work
Subsequent work
1. Install Y-shaped pipe (intake manifold in front of throttle housing). → 243519 Removing and installing air
box for throttle housing (Y-pipe) - section on "Installing" [9PAAF1 9PAAJ1]→ 243519 Removing and
installing air box for throttle housing (Y-pipe) - section on "Installing" [9PAAE1 9PAAE7]
as of MY 2003
g g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g g

24 45 19 Removing and installing air flow sensor - as of MY

2003
- Information
- Removing air flow sensor - Cayenne S (type M48/00)
- Installing air flow sensor - Cayenne S (type M48/00)
Information
Suction routes for V8 S

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Suction routes for V8 Turbo
Removing air flow sensor - Cayenne S (type M48/00)

1. Remove left and right engine compartment cover. → 700219 Removing and installing front cover (engine
2. Separate electric connections on the air flow sensor.

meter
Bellows
4. Pull out retaining clip on the air flow sensor. → Clamp for hot-film mass air flow meter
5. Pull out air flow sensor.
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Installing air flow sensor - Cayenne S (type M48/00)
1. Insert air flow sensor in the pipe on the air cleaner housing cover.
When doing so, observe the flow direction. There is a small arrow
on the housing which must point towards the engine. Then
connect the retaining clip.

2. Connect the bellows and tighten the hose clamps.
Bellows
3. Connect electric connector to the air flow sensor.
4. Fit engine compartment cover. → 700219 Removing and


meter
9PAAE1, 9PAAE7
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as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g

24 46 01 Checking the intake-air distributor for leaks - as of MY

2003
- Leak test
Tools

Tools and materials
Required tools
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-A- Compressed-air reducer Commercially available, see Workshop
Equipment Manual. Set it to a maximum
operating pressure of 1.2 bar.
-B- Plug 9264/7
-C- Leak-locating spray Commercially available, see Workshop
Equipment Manual.
Leak test
Note
z The specified description can be used to check the intake system from the air cleaner outlet to the
injection valves for leaks.
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Suction routes for V8
Cylinders must not be located in the overlapping TDC. This happens only if the crankshaft was turned
manually.
1. Remove engine compartment cover. → 700219 Removing and installing front cover (engine
2. Separate connections on the air cleaner covers. To do this, turn

the pins by 180° and pull them out. Then pull off the intake
manifolds.
Fastening bolts
3. Connect the plugs 9264/7 to the two air cleaner connections and
push in the securing clip.
WARNING
Danger of damaging the intake system if pressure is too high!
z Intake system can burst.
z Danger of injury from flying components.
→ Do not subject intake system to excessive air pressure (max. 1.2

bar of absolute pressure).
Plugs on intake manifold
WARNING
Danger of injury from flying components.
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→ Do not pull out the oil dipstick or open the engine during the test procedure.
4. Set compressed-air reducer to 0.2 bar (approx. 1.2 bar absolute pressure).
5. Push a compressed-air hose onto the connection from the plug 9264/7 and connect the other end to the
pressure reducer.
6. Spray the intake system systematically with a leak-locating spray.

Bubbles can be seen clearly at the locations where there are
leaks (e.g. -arrow- ).
Note
z Any leaks that exist between the air cleaner cover and the intake
distributor seal can be located using this method.
z Proceed systematically with the check.
7. Seal defective areas.

View shows a leaking Y pipe
8. Remove special tool.
9. Push the connections onto the cover of the air cleaner housing
and mount and lock the fastening pins.
10. Fit engine compartment cover. → 700219 Removing and

as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g g

24 46 19 Removing and installing intake-air distributor - as of

MY 2003
- Preliminary work
- Information
- Removing intake-air distributor
- Installing intake-air distributor
- Subsequent work
Preliminary work
Preliminary work for removing intake distributor
1. Remove design cover → 108319 Removing and installing engine cover - "Removing" section.
Information
Component overview
Installation location for intake-air distributor

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I - Curved hose
II - Check valve
III - Hose
A - Vacuum line closed
B - Vacuum line closed
Vacuum line
Suction module
1- Intake-air distributor and throttle housing

2- Seals for intake-air distributor; replace
3- Seal for throttle adjuster; replace
4- Throttle adjuster; do not actuate by hand
5- Support for throttle body cover; secure with the fastening screws for the throttle adjuster
7- Fastening screws
Removing intake-air distributor
Note

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1. Separate the electric connection from the throttle adjuster. To do

this, press on the plug at the top and bottom and, at the same
time, pull it off. Unclip the cable from the sheetmetal holder.
ATTENTION
direction.

the right and left pin through 45° in an anti-clockwise direction. Direction of rotation for fastening bolts

Fastening bolts
Bellows
6. Remove the vacuum line on the Y-shaped pipe. To do this, press the button and disconnect the vacuum
line.
7. Disconnect the vacuum line on the rear of the intake system.

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Vacuum line on rear side of suction Vacuum line connection

module
Positive crankcase ventilation
8. Disconnect positive crankcase ventilation line on the two valve covers. To do this press the plastic ring
and pull the connections. Then remove the positive crankcase ventilation line from the retaining clip.
Positive crankcase ventilation line

connection
9. Then remove the line between the oil mist collector and the
intake distributor.
Line for oil mist separator

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DANGER

→ Do not smoke.
→ Danger of fire due to naked flames and sparks, e.g. during
→ Danger of fire due to escaping fuel, e.g. on hot engine Fuel lines
components or due to electrostatic charge. Allow engine to cool
down.
DANGER
longer periods.
Note
z Before the lines are opened, place a cloth or a suitable container underneath them!
z Collect escaping fuel.
10. Disconnect fuel line -1- and line -2- to the carbon canister on the radiator tank splash panel.
11. Disconnect the electric connectors to the eight fuel injectors. To do this, press the metal clip on the plug
and pull off the plug.
12. Unscrew the fastening screws on the intake distributor in the sequence shown below. → Loosening order
for suction module
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Loosening order for suction module
13. Remove intake distributor from the engine in an upward direction.
Installing intake-air distributor
Note
1. Replace intake distributor gaskets.

2. Place intake-air distributor on the engine and tighten the screws in the sequence shown below.
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Installation position for seals

→ Tightening sequence for suction module → Initial tightening: 7.5 ftlb. → Final tightening: 11 ftlb.
Tightening sequence for suction module


4. Install positive crankcase ventilation line. The 2 connections must audibly engage. Then close the
mounting clip.
5. Install line between intake distributor and oil mist collector.
DANGER
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Line for oil mist separator Positive crankcase ventilation

and eyes.
vapours. Fuel lines
pressure.
DANGER

→ Do not smoke.
7. Connect vacuum line to the rear of the intake distributor. The plug must engage audibly.
9. Slide the bellows onto the air flow sensors and tighten the hose clamps.
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Vacuum line connection Vacuum line on rear side of suction

module
Bellows
ATTENTION
direction.
left and right fastening bolts. Turn the right and left bolts 45° Direction of rotation for fastening bolts
clockwise.

Subsequent work
Subsequent work for installing intake distributor

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1. Install design cover → 108319 Removing and installing engine cover - "Installing" section.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g p g g

24 58 19 Removing and installing fuel pressure regulator - as of

MY 2003
- Preliminary work
- Information
- Removing fuel pressure regulator
- Installing fuel pressure regulator
- Subsequent work
Tools

Preliminary work
Preliminary work
Note
Opening the tank
Note
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g g p g g

DANGER
Danger of poisoning from
fuels!
→ Inhaling vapours can
cause irritation of the
mucous membranes and
eyes.
→ It can be carcinogenic. It Fuel supply and disconnection points
represents a serious risk at right connection unit
to health when inhaled,
touched or swallowed
over longer periods.
→ Only work on the fuel
system in well-ventilated
rooms.
→ Wear protective gloves
that are fuel-resistant.
→ Wear a breathing mask
with active charcoal filter;
do not breathe in any fuel
vapours.
→ Ensure that there is
adequate ventilation and
extract all fuel vapours.
→ Before opening the fuel
lines or fuel hoses, relieve
the fuel pressure.
→ Collect escaping fuel,
absorb it if necessary with
a suitable binding
material and dispose of
properly.
→ Pay attention to
cleanliness when working
on the fuel system.
DANGER
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→ Do not smoke.
Note
Cap
Information
Component overview
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Connecting flange with pressure regulator
1 - Fuel pressure line

2 - Electric connection for fuel pump
3 - Connection to fuel delivery unit right and left (unpressurised)
4 - Pressure regulator input from fuel filter
5 - Electric connection for fuel level indicator
6 - Fuel pressure regulator; 4 bar supply pressure
1. Pull off electric connectors -1 and 2- . Then pull off the fuel lines
-3 and 4- and remove the connection unit (pressure regulator).
Connection unit (pressure regulator)
Note
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z The pressure regulator is integrated into the connection unit.
z The connection unit together with integrated pressure regulator is replaced as a complete unit and not
disassembled.
Seal
2. Connect the connection unit. Fit electric connector -1 and 2- and
3. Place the connection unit into the tank. When doing so, make
sure that the plastic lug is pointing forwards.
Connection unit
Subsequent work
Closing the tank
Cap
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electric plugs

Subsequent work
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g yg y g

24 69 19 Removing and installing oxygen sensors in front of

- Preliminary work
- Removing oxygen sensors in front of catalytic converter - Cayenne S (M48/00)
- Installing oxygen sensors in front of catalytic converter - Cayenne S (M48/00)
- Subsequent work
Tools

Torque wrench, commercially NR.90 Only in
signal-transmitting available tool combination with
with changeover wrench inserts
ratchet

wrench: Open ring available tool lengths, e.g.
wrench angled Hazet 4681-1 to 3

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assembly
Preliminary work
Preliminary work for removing oxygen sensors in front of catalytic converter - Cayenne S
(M48/00)
1. Remove front wheel → 440519 Removing and installing wheel.
2. Remove front wheel housing liner → 505619 Removing and installing front wheel housing liner -
"Removing" section.
3. Remove engine compartment cover above the oxygen sensor plugs → 700219 Removing and installing
front cover (engine compartment) - "Removing" section.
4. Disconnect oxygen sensor plug for the oxygen sensor in front of

catalytic converter at the right of the water splash panel and
unclip the cable from the holder.
5. Remove air cleaner housing → 242519 Removing and installing
air cleaner housing - "Removing" section.
ATTENTION

Cable plugs for oxygen sensors
6. Release oxygen sensor wire from the cable guide and leave it at the oxygen sensor.
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Tools and materials
sensors
sensors
sensors NR.98
sensors
ATTENTION
→ Always release oxygen sensor cable so that the wire can turn when unscrewing or screwing in the
sensor.
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1- Exhaust manifold, cylinders 1 -4

3- Seal for exhaust manifold; replace
4- M8 hexagon nut; replace, coat thread of bolts with Microgleit
7- Seal; replace
8- M8 hexagon nut; replace
9- Catalytic converter, front
11 - Support
12 - Support
15 - Stud M8 x 25
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17 - Seal; replace
20 - Screw
21 - Bracket
22 - Bracket
23 - Bracket
1. Remove the oxygen sensor in the exhaust manifold using a mirror. To do this, screw out the oxygen
sensor with an open-ended wrench SW 22.
ATTENTION
→ Always expose oxygen sensor cable so that the wire can turn
when unscrewing or screwing in the sensor.
Oxygen sensor for exhaust manifold

1. Preassemble the oxygen sensor in the exhaust manifold by hand
using a mirror. Tighten oxygen sensor using a special tool.
→ 246919 Removing and installing oxygen sensor ahead of
catalytic converter - "Tools and materials" section → Tightening
torque: 33 ftlb. +/-3.5 ftlb.
Tool on exhaust manifold oxygen

sensor
Subsequent work
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Touching up for installing oxygen sensors in front of catalytic converter - Cayenne S

(M48/00)
1. Push oxygen sensor wire into the cable guide.
2. Connect the oxygen sensor plug for the oxygen sensor in front of
catalytic converter at the right of the water splash panel and clip
the wires into the guide. Fit cable plug.
3. Install air cleaner housing → 242519 Removing and installing air

cleaner housing - chapter on "installing".
4. Fit engine compartment cover above the oxygen sensor plugs

→ 700219 Removing and installing front cover (engine
compartment) - "Installing" section.
5. Install front wheel housing liner → 505619 Removing and

installing front wheel housing liner - "Installing" section. Cable plugs for oxygen sensors
6. Fit front wheel → 440519 Removing and installing wheel.
9PAAE1, 9PAAE7
as of MY 2003
g g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g g

24 70 19 Removing and installing DME control module - as of

MY 2003
- Information
- Obtaining read-out and saving vehicle data from DME control module
- Removing DME control module
- Installing DME control module
- Programming new DME control module
- Programming DME control module
Information
Note
z If the DME control module is replaced, it must be programmed using the Porsche System Tester. Thus,
the DME control module can be adapted to the vehicle, the national variant and the equipment. The DME
control module is located in the radiator tank near the right fender.
z If possible, before the DME control module is removed and replaced, a read-out of the vehicle data
should be obtained from the Porsche System Tester.
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Overview of the DME control module
Exhaust-gas standard
ME 7.1.1 min
Type Version Explanation
Low Emission Vehicle, USA
OBD 2 LEV
Rest of world
RoW EU2
European On-Board
EOBD EU4 Diagnosis.
Obtaining read-out and saving vehicle data from DME control module
Continue.
3. Using the →| key, move from the vehicle type to the control modules.
4. Select DME with the cursor keys and press the >> key.
5. Select Control unit programming with the cursor keys and press the >> key.
6. Select Read out control unit (vehicle data) with the cursor keys and press the >> key.
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7. The message Vehicle data read-out complete will appear on the screen of the Porsche System Tester.
8. After replacement of the DME control module, the vehicle data is installed in the menu Program control
module (see Section 6).
Removing DME control module
ATTENTION
Risk of short circuit!
→ Before removing the control unit, switch off the ignition.
Note
z Unscrew the two fastening screws for the cowl panel cover and lift up the cover in this area. → 664419
Removing and installing cowl panel cover
1. Push the two retaining clips aside -arrows- and remove control
unit to the front.

2. Pull out latch on both connectors in -direction of arrow- and
remove the connectors.
Installing DME control module
1. Insert both connectors into the control unit and push in latch in -direction of arrow- .
2. Insert control unit and secure with the two retaining clips -arrow- .
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Retaining clips for control unit Latch for connectors

Programming new DME control module
Note
z If a new DME control module is to be installed in a vehicle, the immobiliser code specified in IPAS must
be entered in the DME control module.
z You can get the codes from IPAS or from your importer by specifying the vehicle identification number.
z During DME programming, it is essential to guarantee the power supply for the Porsche System Tester. It
is essential to connect a battery charger with a current rating of at least 40 A to the vehicle battery.
z Symbol for the Tab key = →| .
z The procedure described here has been structured in general terms; different text or additions may
appear in the Porsche System Tester.
1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on ignition. Read
out DME control module. → 247019 Removing and installing DME control module - "Reading out" section
2. Switch off ignition and replace DME control module with a new unit. → 247019 Removing and installing
DME control module - "Removing" section
3. Change to the Control module programming menu and press >> .
4. Program control module and press >> .
6. Select vehicle type and press >> .
11. The System Tester indicates whether the control unit is programmable and the approximate
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programming time.
Note
z During programming, the electric radiator fans may start.
12. Once the DME control module has been programmed successfully, switch to the Program immobiliser
code menu and press >> .
13. Enter the new immobiliser code (IPAS), confirm with the >> key, check the code again and confirm with
the F7 key.
Note
z In some countries (currently USA, Canada) the Ready status must be obtained following a test drive
and/or by using the Porsche System Tester after a DME control module is programmed. If in doubt about
this, contact the relevant importer.
z With all DME systems, the engine must run for several minutes before the engine control unit can relearn
the idle speed and mixture adaptation values!
15. For the learning and adaptation routine of the throttle (E-gas), switch the ignition on for 30 seconds
without starting the engine. Do not actuate accelerator pedal. This completes the adaptation of the
throttle adjusting unit and the programming sequence is complete.
16. Read out the fault memory and delete the DME control module fault on every control unit connected to
the CAN.
Note
z If faults are present, proceed in accordance with the DME 7.1.1 Manual. See On-Board Diagnosis
Manual (DME 7.1.1)
Programming DME control module
Note
z If a DME control module from a different vehicle with ME 7.1.1 is being used, proceed as follows. As a
check, the immobiliser code of the vehicle in which the control unit is being installed (NEW) and of the
vehicle from which the control unit has been removed (OLD) are required.
z During DME programming, it is essential to guarantee the power supply for the Porsche System Tester. It
is essential to connect a battery charger with a current rating of at least 40 A to the vehicle battery.
z You can get the necessary codes from IPAS or from your importer by specifying the vehicle identification
number.

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z The procedure described here has been structured in general terms; different text or additions may
appear in the Porsche System Tester.
1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on ignition. Read
out DME control module. → 247019 Removing and installing DME control module - "Reading out" section
2. Switch off ignition and replace DME control module with a new unit. → 247019 Removing and installing
DME control module - "Removing" section
3. Change to the Control unit programming menu and press >> .
4. Program control module >> .
6. Select vehicle type >> .
11. The System Tester indicates whether the control unit is programmable and the approximate
programming time.
12. Once the DME control module has been programmed successfully, switch to the Program immobiliser
code menu and press >> .
13. Enter the old immobiliser code (IPAS, vehicle - OLD), continue with the >> key, check the code again
and confirm with F7 .
14. Enter the new immobiliser code (IPAS, vehicle - NEW), continue with the >> key, check the code again
and confirm with F7 .
Note
z In some countries (currently USA, Canada) the Ready status must be obtained following a test drive
and/or by using the Porsche System Tester after a DME control module is programmed. If in doubt about
this, contact the relevant importer.
z With all DME systems, the engine must run for several minutes before the engine control unit can relearn
the idle speed and mixture adaptation values!
16. For the learning and adaptation routine of the throttle (E-gas), switch the ignition on for 30 seconds
without starting the engine. Do not actuate accelerator pedal. This completes the adaptation of the
throttle adjusting unit and the programming sequence is complete.
17. Read out the fault memory and delete the DME control module fault on every control unit connected to
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the CAN.
Note
z If faults are present, proceed in accordance with the DME 7.1.1 Manual. See On-Board Diagnosis
Manual (DME 7.1.1)
as of MY 2003
g g yg y g
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g g yg y g

24 73 19 Removing and installing oxygen sensors behind

- Preliminary work
- Removing oxygen sensors behind catalytic converter - Cayenne S (M48/00)
- Installing oxygen sensors behind catalytic converter - Cayenne S (M48/00)
- Subsequent work
Tools

Torque wrench, commercially NR.90 Only in
signal-transmitting available tool combination with
with changeover wrench inserts
ratchet


g g yg y g

assembly
Preliminary work
Preliminary work: Removing oxygen sensors behind catalytic converter
ATTENTION

1. Loosen and bend primary catalytic converter (primary catalytic

converter does not need to be removed completely). For details
see → 267619 Removing and installing primary catalytic Mount for primary catalytic converter in
converter - "Removing" section. Turbo
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Tools and materials
sensors
sensors
sensors NR.98
sensors
Removing oxygen sensors behind catalytic converter - Cayenne S (M48/00)

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1- Exhaust manifold, cylinders 1 -4

3- Seal for exhaust manifold; replace
4- M8 hexagon nut; replace, coat thread of bolts with Microgleit
7- Seal; replace
8- M8 hexagon nut; replace
9- Catalytic converter, front
11 - Support
12 - Support
15 - Stud M8 x 25
g g yg y g

17 - Seal; replace
20 - Screw
21 - Bracket
22 - Bracket
23 - Bracket
ATTENTION
→ Always expose oxygen sensor cable so that the wire can turn when unscrewing or screwing in the
sensor.
1. Carefully unscrew oxygen sensors on primary catalytic converter.
Installing oxygen sensors behind catalytic converter - Cayenne S (M48/00)

1. Position the oxygen sensor by hand and screw in as far as possible.
2. Tighten oxygen sensor using special tool → 247319 Removing and installing oxygen sensors behind
catalytic converter - "Tools and materials" section. → Tightening torque: 33 ftlb. +/-3.5 ftlb.
Subsequent work
Subsequent work: Installing oxygen sensor behind catalytic converter
1. Install primary catalytic converter→ 267619 Removing and

installing primary catalytic converter - "Installing" section.

Turbo
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9PAAE1, 9PAAE7
as of MY 2003
C15, C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28,
C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99

g y g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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g y g

26 01 01 Checking exhaust system for leaks - as of MY 2003

- Preliminary work
- Leak test
- Subsequent work
Tools

plugs special tool 9710/3
Preliminary work
Preliminary work
Leak test
ATTENTION
→ Allow components to cool down.

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Note
correctly.
z The general warning notes must be observed. → 10 The most important working regulations and warning
notes
1. Remove tailpipes. To do this, loosen the fastening screws and

pull the tailpipes out of the rear silencer by swivelling them gently
to the side.
2. Insert plugs 9710/3 on both sides of the rear silencer and twist
these by folding over the lever.

3. Remove the protective cap of the test valve on one side and
apply excess pressure of approx. 0.3 bar using a tyre-inflating
device.
Note
z The exhaust system must be completely sealed between the
engine and the catalytic converters.
4. Check exhaust system for leaks and repair if necessary.
5. Remove the plugs and insert the tailpipes into the rear silencer.
Tyre-inflating device on test valve
Subsequent work
Subsequent work
1. Align tailpipes with the bumper and secure them. → 263415 Aligning tailpipes [9PAAD1 9PAAD7
9PAAE1 9PAAE7]→ 263415 Aligning tailpipes [9PAAF1 9PAAJ1]

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as of MY 2003
g g y g
WARNUNG
WARNING
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g g y g

26 01 19 Removing and installing exhaust system - as of MY

2003
- Information
- Removing exhaust system
- Installing exhaust system
Tools

available tool
Information
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separate at the central with 2 exhaust straps.
notch with chain pipe Position the straps
cutters NR.166. horizontally. (Nut pointing
downwards)
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retainer
mount
mount
Removing exhaust system
Note
The exhaust system in the V6 is designed as a single strand. Repair instructions and notes apply to both
exhaust systems.
WARNING
→ Only remove the exhaust system when it has cooled down!

1. Release connecting straps between the catalytic converters and

the exhaust system. Then push the straps backwards onto the
exhaust system. The exhaust straps must not be reused.
Exhaust clamps
WARNING
Danger of injury from heavy exhaust system!
→ Before loosening the exhaust system, it should be secured to

prevent it from falling.
2. Release the front and middle retainers. To do this, loosen the 2

fastening screws.
Note
z Before the rear silencer is released, the exhaust system must be supported with a transmission jack or
held by another person.
3. Unscrew the fastening screws on the left and right of the rear silencer.
4. Remove exhaust system.

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Figure shows exhaust system on Mount for rear silencer

transmission jack
Installing exhaust system
1. Position exhaust system under the vehicle supported by a

transmission jack or another person.

transmission jack
2. Tighten the fastening screws of the rear muffler. For tightening
torques see → 263355 Replacing rear silencer - "Replacing"
section.
Mount for rear silencer

3. Tighten the front and middle supports -arrows- . → Tightening
torque: 17 ftlb.

4. Install new exhaust clamps. The bolts must be pointing downwards. → Adjustment value: 10 ° →
g g y g
as of MY 2003
C15, C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28,
C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
g g g
WARNUNG
WARNING
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ATTENZIONE
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g g g

26 10 19 Removing and installing exhaust manifold - as of MY

2003
- Preliminary work
- Removing exhaust manifold — Cayenne S (type M48/00)
- Installing exhaust manifold — Cayenne S (type M48/00)
- Subsequent work
Preliminary work
Preliminary work for removing exhaust manifold
Removing exhaust manifold — Cayenne S (type M48/00)
Removing exhaust manifold - Cayenne S (type M48/00)
Overview of exhaust manifold

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1. Loosen starter catalyst from exhaust manifold. To do this, loosen

the three fastening screws -arrows- .
2. Unclip the oxygen sensor cable from all holders. Remove oxygen
sensor when replacing exhaust manifold.
3. Loosen the 12 fastening nuts in the sequence shown below.
Remove the exhaust manifold.

manifold
Fastening nuts
Installing exhaust manifold — Cayenne S (type M48/00)
Installing exhaust manifold - Cayenne S (type M48/00)
Note
z Visually inspect exhaust manifold for cracks and distortion.
z A cracked or distorted exhaust manifold may not be reinstalled.
z As a matter of principle, replace seals on manifold.
z If the studs in the cylinder head are damaged, they must be replaced. → 157356 Replace mount for
exhaust manifold (stud) - "Replacing" section
1. Clean sealing surfaces. The surfaces must be free from foreign objects.
2. Use a new seal. The seal must be positioned so that the part number is visible from the outside.
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3. Push the manifold across the studs and fit it with 12 new fastening nuts. The fastening nuts are tightened
in two stages in accordance with the tightening sequence → Tightening sequence for fastening nuts →
Tightening torque: 19 ftlb. and → Tightening torque: 24 ftlb. .
Tightening sequence for fastening nuts
4. Fit oxygen sensor when replacing exhaust manifold. For details see → 246919 Removing and installing
oxygen sensor ahead of catalytic converter - "Installing" section. Clip oxygen sensor cable into the
holders.
5. Fit starting catalytic converters with new gaskets. For details see
"Installing" section.

manifold
Subsequent work
Subsequent work for installing exhaust manifold
9PAAE1, 9PAAE7
as of MY 2003
g g g
g y g
WARNUNG
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g y g

26 28 01 Checking exhaust system mount - as of MY 2003

Tools

available tool
Checking exhaust system mount
ATTENTION
→ Do not touch the exhaust system until it has cooled down!

Note
z Check the rubber-metal mounts between the body and the exhaust system for cracks and elongation and
check overall condition.
z During the life of the vehicle, the rubber-metal mounts must not soften to such an extent that the exhaust
system starts to hit against adjacent components or the body.
z Check the exhaust system for contact with adjacent parts by shaking it manually.
z Examine the metal mount for corrosion and damage and check that it is positioned correctly.
z Damaged components must be replaced.
z The exhaust system must be moved to the correct installation position or damaged components must be
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replaced if necessary.

downwards)
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retainer
mount
mount
Main catalytic converter V6 and V8 are of the same design -10-
Exhaust manifold and catalytic converters V6
1 - Cylinder head
2 - Exhaust manifold seal
3 - M8 fastening nut; replace
4 - Exhaust manifold
5 - Flange gasket; replace
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10 - (Main) catalytic converter (of same design as V8)
11 - Fastening screws M8
14 - Heat shield
15 - Fastening screw M8
16 - Fastening screws M8 for intake distributor
17 - Support for intake distributor
18 - Side fastening screws M8 for intake distributor
as of MY 2003
p g g
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26 33 55 Replacing rear silencer - as of MY 2003

- Information
- Detaching rear silencer
- Replacing rear silencer
Tools

available tool
Information
Component overview
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Component overview for V8
Component overview for V6 (single-strand exhaust system)

I Repair separation point 2 When carrying out repairs, Link up the separation point
downwards)
A Gap dimension Max. 5 mm
B Exhaust strap length 95 mm
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C Inclination Maximum inclination: 10 °

D Offset of rear silencer retainer 2 10 mm
E Off-centre position of central 1 4 mm
holder
F Off-centre position of front 1 2 mm
holder
Detaching rear silencer

1. Use a transmission jack to prevent the rear silencer from falling.
2. There is a small notch on the underside of the exhaust pipes that

is level with the rear axle transmission. The notch marks the
disconnection point.
View shows the disconnection point

3. Place the pipe cutter chain around the exhaust pipe near the
notch and engage in the other end of the pipe cutter. Then clamp
the chain firmly by twisting the handle.
Laying chain of pipe cutter around

exhaust pipe
4. Swivel the pipe cutter to and fro in large movements until the pipe is cut through. While doing this, keep
tightening the chain by twisting the handle.
Note
exhaust systems.
5. Then cut through the second exhaust pipe.

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Cutting through pipe with pipe cutter
Note
z Before the rear silencer is released, the exhaust system must be
supported with a transmission jack or held by another person.
6. Undo the four fastening screws to the left and right on the rear
silencer and remove the rear silencer from the vehicle.
Fastening screws for rear silencer
Replacing rear silencer

1. Remove the tailpipes on the old rear silencer and attach them to the new one. Fit new attaching rubbers.
Note
exhaust systems.
2. Push the two new connecting clamps onto the exhaust pipes on the rear silencer . Then install the rear
silencer using a transmission jack. Tighten the four fastening screws to the specified tightening torque. →
3. Push connecting clamps over the exhaust system and align them
→ 263355 Replacing rear muffler - "Information" section. Tighten
Connecting clamps on exhaust system

p g g
as of MY 2003
j g pp g
WARNUNG
WARNING
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j g pp g

26 34 15 Adjusting tailpipes - as of MY 2003

- Adjusting tailpipes
Adjusting tailpipes
Adjusting tailpipes - Cayenne S (type M48/00) and V6
Overview of tailpipes
j g pp g
Component overview
1 - Rear muffler
2 - 2 mounts (align during installation)
3 - 2 tailpipe clamps
4 - 2 tailpipes (align during installation)

2. Align tailpipes. The circumferential gap -A- should be →
Adjustment value: 31 mm +/-1 mm .
Aligning tailpipes
3. Tighten bolt on tailpipe clamp. → Tightening torque: 44 ftlb. .

j g pp g
as of MY 2003
C15, C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28,
C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99

g g pp g
WARNUNG
WARNING
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ATTENZIONE
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g g pp g

26 34 19 Removing and installing tailpipes - as of MY 2003

- Removing and installing tailpipes
Tailpipes (1/2 page)

g g pp g
Component overview for Cayenne naturally-aspirated engine
1 - Rear muffler
Component overview for Cayenne Turbo
1 - Rear muffler
2. Loosen tailpipes by turning and pulling off.

g g pp g
3. Clean extension positions and replace tailpipe clamp if necessary depending on the condition.
4. Put tailpipes in installation position and align → 263415 Aligning tailpipes [9PAAD1 9PAAD7 9PAAE1
9PAAE7]→ 263415 Aligning tailpipes [9PAAF1 9PAAJ1].
5. Tighten the bolt on the tailpipe clamp. → Tightening torque: 60

(44 ftlb.) Nm .
as of MY 2003
g g y p p g
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26 65 19 Removing and installing secondary air pump - as of

MY 2003
- Preliminary work
- Removing secondary air pump
- Installing secondary air pump
- Subsequent work
Preliminary work
Preliminary work for removing secondary air pump

1. Remove engine compartment cover on left, right and rear. → 700219 Removing and installing front cover
(engine compartment) - chapter on "removing"
Note
z The description only relates to one secondary air pump.
z The second pump is removed in a similar way.
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Overview of secondary air pump

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Component overview
1 - Bracket for secondary air pump

3 - Secondary air pump valve
4 - Spring band clamp
5 - Connecting hose
7 - Seal (replace during installation)
9 - Secondary air pump
1. Remove hose from secondary air pump. Then separate the electric connector on the secondary air
pump.
2. Unscrew the 3 fastening screws on the secondary air pump.
3. Remove pump from support.

g g y p p g
Removing bracket for

secondary air pump
Note
On the right secondary air
pump also unclip the cooling
water hose and vacuum hose.
1. Undo the three fastening

screws for the bracket and
remove the bracket.
Fastening screws for secondary air Hose and electric connector on
pump secondary air pump
Installing bracket for secondary air pump
Note
1. Install bracket and tighten with the three fastening screws. → Tightening torque: 7.5 ftlb.
Installing secondary air pump

1. Push electric connector together and insert pump into the bracket. Then connect the hose to the
secondary air pump connection piece.
2. Tighten the three fastening screws. → Tightening torque: 7.5

ftlb.

pump
Subsequent work
Subsequent work for installing secondary air pump

1. Install engine compartment cover on left, right and rear. → 700219 Removing and installing front cover
as of MY 2003
g g y p p g
g g y g
WARNUNG
WARNING
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ATTENZIONE
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g g y g

26 73 19 Removing and installing (main) catalytic converter - as

of MY 2003
- Preliminary work
- Removing (main) catalytic converter
- Installing (main) catalytic converter
- Subsequent work
Preliminary work
Preliminary work
1. Remove the engine guard . → 108019 Removing and installing engine guard - chapter on "removing"
2. Lift the vehicle. → 03 Entire vehicle - General
Removing (main) catalytic converter
ATTENTION

Note
z Cover the right wing and guide through a ratchet from above using several extensions in order to loosen
the top nut between the primary and main catalytic converters.
Note
z If the working height of the vehicle has to be changed due to further work, the transmission support must
be re-fitted using the old bolts.
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11 - Support
12 - Support
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19 - 6 screws
20 - Bracket
21 - 2 brackets
22 - Bracket
Cayenne S (M48/00)

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11 - Support
12 - Support
15 - 6 studs M8 x 25
20 - 6 screws
21 - Bracket
22 - 2 brackets
23 - Bracket
1. Remove transverse strut. Undo screws (including the centre

ones) -arrows- .
Transverse strut
exhaust system. Then push the clamps backwards onto the
exhaust system. The exhaust clamps must not be reused.

4. Remove cardan shaft between front-wheel drive and transfer box -see figure- . → 390219 Removing and
installing front cardan shaft - chapter on "removing" [9PAAE1 9PAAF1 9PAAJ1]→ 390219 Removing and
installing front cardan shaft - chapter on "removing" [9PAAE7]
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Cardan shaft between front-wheel Fastening screws to body and cross

drive and transfer box member

5. Support transmission with transmission jack. Let main catalytic converter hang down. Unscrew the three
nuts connecting the primary and main catalytic converters. Remove main catalytic converter. Remove
flange gasket.
6. Re-fit transmission support using old screws so that the transmission jack can be removed from under
the vehicle.
ATTENTION


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11 - Support
12 - Support
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19 - 6 screws
20 - Bracket
21 - 2 brackets
22 - Bracket
Cayenne S (M48/00)

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11 - Support
12 - Support
15 - 6 studs M8 x 25
20 - 6 screws
21 - Bracket
22 - 2 brackets
23 - Bracket
1. Remove transverse strut. Undo the screws -arrows- (do not

forget the centre screw).
Transverse strut
exhaust system. Then push the clamps backwards onto the
exhaust system. The exhaust clamps must not be reused.

4. Unscrew the three nuts connecting the primary and main catalytic converters and guide out the main
catalytic converter. Remove flange gasket.
Installing (main) catalytic converter

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Nuts connecting primary and main Fastening screws to body and cross
catalytic converters member
1. Transmission support removed and transmission supported with jack.
Note
z Gaskets and self-locking nuts and bolts must always be replaced!
4. Replace flange gasket and push over the studs of the main

5. Put main catalytic converter in the installation position and fit new
nuts and bolts.
6. Tighten nuts connecting primary and main catalytic converters to

the specified tightening torque. → Tightening torque: 17 ftlb.

Note
z To fit the cardan shaft, the transmission must be supported again
and the transmission support removed. Then fit the transmission
support with new screws. → 390219 Removing and installing front
cardan shaft - chapter on "installing" [9PAAE1 9PAAF1 9PAAJ1]
→ 390219 Removing and installing front cardan shaft - chapter on
7. Re-install cardan shaft between front-wheel drive and transfer

box. Make sure that the main catalytic converter is also
Cardan shaft between front-wheel
positioned with the cardan shaft over the transmission
drive and transfer box
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support.→ 390219 Removing and installing front cardan shaft -

chapter on "installing" [9PAAE1 9PAAF1 9PAAJ1]→ 390219
Removing and installing front cardan shaft - chapter on
9. Fit exhaust clamps. For installation position and tightening

torque, see → 260119 Removing and installing exhaust system -

10. Install transverse strut. Tighten the screws -arrows- (do not
forget the centre screw). → Tightening torque: 7.5 ftlb.
Transverse strut

3. Replace flange gasket and push over the studs of the main

4. Put main catalytic converter in the installation position and fit new nuts and bolts.
5. Tighten nuts connecting primary and main catalytic converters to the specified tightening torque. →
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7. Fit exhaust clamps. For installation position and tightening
torque, see → 260119 Removing and installing exhaust system -

8. Install transverse strut. Tighten the screws -arrows- (do not
forget the centre screw). → Tightening torque: 7.5 ftlb.
Transverse strut
Subsequent work
Subsequent work
as of MY 2003
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WARNUNG
WARNING
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ATTENZIONE
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g gp y y g

26 76 19 Removing and installing primary catalytic converter -

as of MY 2003
- Preliminary work
- Removing primary catalytic converter
- Installing primary catalytic converter
- Subsequent work
Preliminary work
Preliminary work
1. Remove engine compartment cover above the oxygen sensor connectors. → 700219 Removing and
installing front cover (engine compartment) - chapter on "removing"
3. Remove front wheel housing liner. → 505619 Removing and installing front wheel housing liner - chapter
on "removing"
4. Remove air cleaner housing. → 242519 Removing and installing air cleaner housing - chapter on
"removing"
5. Remove main catalytic converter. → 267319 Removing and installing (main) catalytic converter - chapter
on "removing"
Removing primary catalytic converter
ATTENTION

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Note

3 - Exhaust manifold gasket; replace
4 - Hexagon nut M8; replace nut and coat threads of studs with Microgleit
7 - Gasket; replace
8 - Hexagon nut M8; replace
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11 - Support
12 - Support
15 - Stud M8 x 25
20 - Screw
21 - Bracket
22 - Bracket
23 - Bracket
1. At the water splash panel, disconnect the connector for the

oxygen sensor behind catalytic converter and unclip cable from
support.
Oxygen sensor connector at water

splash panel
2. With the aid of a mirror, remove the fastening screw on the
catalytic converter bracket -arrow lower right- .

bracket
3. Remove the three fastening nuts between the exhaust manifold
and primary catalytic converter.
4. Release oxygen sensor cable and remove primary catalytic
converter in a downward direction. Remove flange gasket.
Fastening nuts for securing exhaust

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manifold to primary catalytic converter
ATTENTION

Note

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3 - Exhaust manifold gasket; replace
4 - Hexagon nut M8; replace nut and coat threads of studs with Microgleit
7 - Gasket; replace
8 - Hexagon nut M8; replace
11 - Support
12 - Support
15 - Stud M8 x 25
20 - Screw
21 - Bracket
22 - Bracket
23 - Bracket
1. At the water splash panel, disconnect the connector for the

oxygen sensor behind catalytic converter and unclip cable from
support.
Disconnecting oxygen sensor

connector at the splash panel and
unclipping cable
2. With the aid of a mirror, remove the fastening screw on the
catalytic converter bracket -arrow lower right- .

bracket
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Fastening nuts between exhaust

manifold and primary catalytic
converter
4. Release oxygen sensor cable and remove oxygen sensor.
5. Lower starter catalyst clear. Remove flange gasket.
Installing primary catalytic converter
Note
4. Through the wheel housing, position fastening screw on catalytic converter bracket.
5. Position the three fastening nuts between the exhaust manifold

ATTENTION
manifold. Positioning fastening nuts for securing
converter
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8. At the water splash panel, connect the connector for the oxygen
sensor behind catalytic converter.

Note
3. Install oxygen sensor.
5. Position the three fastening nuts between the exhaust manifold

Positioning fastening nuts for securing

converter
6. Through the wheel housing, position fastening screw on catalytic converter bracket -lower right screw- .
7. Tighten fastening screw to catalytic converter bracket and nuts to specified tightening torque. →
Tightening torque: 17 ftlb. → Tightening torque: 17 ftlb.
ATTENTION
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Positioning fastening screw on

catalytic converter bracket
→ Lay the oxygen sensor cable so that it cannot touch the exhaust manifold.
9. At the water splash panel, connect the connector for the oxygen
sensor behind catalytic converter.

Subsequent work
Subsequent work
1. Install main catalytic converter. → 267319 Removing and installing (main) catalytic converter - chapter on
"installing"
2. Install air cleaner housing. → 242519 Removing and installing air cleaner housing - chapter on "installing"
3. Install front wheel housing liner. → 505619 Removing and installing front wheel housing liner - chapter on
"installing"
4. Mount wheel. → 440519 Removing and installing wheel - chapter on "installing"
5. Fit engine compartment cover above the oxygen sensor connectors. → 700219 Removing and installing
9PAAE1, 9PAAE7
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
g g y g

27 06 19 Removing and installing battery - as of MY 2003

- Removing battery
- Installing battery
Removing battery
Removing battery
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Main illustration showing battery installation position in the vehicle
DANGER
z Do not disconnect battery with engine running.
z Disconnect and reconnect battery with extreme caution. Risk of short circuit and explosion.
z Do not tilt battery when removing it. Risk of acid burns as a result of emerging acid.
z Do not rub the battery with a dry cloth. Risk of explosion as a result of static charge.
Note
z The battery is located in the battery case under the left front seat.
z 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 completely discharged. → External power connection, jump lead starting
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Observe the warning notes and safety regulations for lead-acid batteries.→ Warning notes and safety
regulations for lead-acid batteries [9PAAD1 9PAAD7]→ Warning notes and safety regulations for lead-acid
batteries [9PAAE1 9PAAE7 9PAAF1]
Note
For vehicles with a Vehicle Tracking System (VTS), please read the
→ 906323 Vehicle Tracking System (VTS) TI!
1. Move front left seat back and up as far as possible. Move

backrest fully forward.
2. Detach front seat trim towards the front -Arrow A- .
3. Fold the carpet sections forward and remove the two fastening
screws -1- .
4. Fold the seat back as far as possible -Arrow B- . With the seat in
its folded position, move the seat forward again using the fore-
and-aft adjustment -Arrow C- .
5. Open the four tension hooks on the battery case cover using a
screwdriver.
6. Remove the battery case cover and air duct.
7. Risk of short circuit! First connect the negative cable -2- , then
the positive -3- .
8. Unscrew the fastening screw on the sheetmetal bracket and remove the sheetmetal bracket.
9. Unscrew the screw on the battery mount and remove the battery mount.
10. Pull off the vent hose on the battery.
Installing battery
Installing battery
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1. Risk of contact with caustic fluid Position the battery in the

battery case below the stops, if at all possible without tilting it.
2. Position the battery mount and tighten with the fastening screw.
→ Tightening torque: 17.5 ftlb.
3. Position the sheetmetal bracket and secure it with the fastening

4. Insert the vent hose on the battery.
Note
z Make sure that the two ends of the vent hose are routed and inserted correctly.
5. Risk of short circuit! First connect the positive cable -3- , then the
negative cable -2- . → Tightening torque: 3.5 ftlb.
6. Replace the battery box cover carefully. The cover must be

mounted properly.
7. Attach the four tension hooks on the battery case cover and
close using the screwdriver.
ATTENTION
Risk of material damage to screw connections for seat and seat
frame!
→ The fastening screws for seat and seat frame are coated and
must be replaced after being unscrewed.
→ Before screwing in the new fastening screws, clean the thread
holes with an M10 x 1.5 tap!
8. Move the seat in its folded position towards the rear -arrow A- and then tip forward -arrow B- .
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9. Screw in fastening screws -1- . → Tightening torque: 33 ftlb.

Carry out work instructions after disconnecting the battery.→ Work

as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
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27 06 IN General information on the vehicle battery - as of MY

2003
- Information
Note
z To prevent contact corrosion, only approved bolts, nuts, washers, etc. should be used. These elements
have a special surface coating and must be stored separately.
The battery is one of the most important electrical components in the vehicle. Fault-free functioning of the
battery contributes greatly to customer satisfaction. To guarantee long and efficient operation, the battery
must be checked and maintained according to the description in this chapter.
Besides the start function, the battery also has the tasks of buffer and supplier of electrical power for the
entire vehicle electrical system.
Information
Treatment of the battery
Maintenance-free battery:
Note
battery.
Low-maintenance battery:
Note
z Battery terminals do not need to be greased.
z The battery terminal clamps must only be attached manually without using excessive force to prevent
damage to the battery housing.
battery.
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z To ensure that the battery does not leak, it is essential to ensure that the original plugs supplied with the
battery are screwed into the battery openings.
z In the event of loss or damage, only original plugs of the same design should be used.
z The plugs must be fitted with an O-ring seal.
Warning notes and safety regulations for lead-acid batteries

1. -1- Fire, sparks, naked flames and smoking are forbidden:
– Avoid sparking when using cables and electrical devices.
– Avoid short circuits.
– In batteries with central venting, there is an increased

concentration of detonating gas at the hose opening. The venting
hose must not be bent or blocked by dirt.
2. -2- Wear eye protection
3. -3- Keep children away from acids and batteries.
4. -4- Risk of causticisation!
– Battery acid is highly caustic, therefore wear protective gloves.

– Do not tip battery; acid can emerge from the vent opening.
Battery symbols
Note
z First aid: Rinse acid splashes in the eyes immediately with clean water for a few minutes. Consult a
doctor immediately. Neutralise acid splashes on the skin or clothing immediately with soap suds and
rinse again with plenty of water. If acid has been drunk unintentionally, consult a doctor immediately.
5. -5- Observe information on the battery in the Technical Manual and in the Driver's Manual.
6. -6- Risk of explosion:
– A highly explosive detonating gas mixture occurs when charging batteries.
7. -7- Waste disposal:
– Hand in old batteries at a collection point.
8. -8- Never dispose of old batteries in the domestic rubbish!
Notes on removing and installing the battery
Note
z The battery is located under the left front seat.
z In order to avoid triggering the siren in vehicles with an additional alarm siren, the battery must be
disconnected while the ignition is on!
z All loads must be switched off beforehand! Remove ignition key!
z Never disconnect battery with engine running!

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z Never start engine without a securely connected battery!
z The battery terminal clamps must only be attached by hand without using excessive force to prevent
damage to the battery housing.
z Check that the battery is seated correctly after installation. Otherwise, a loose battery presents risks such
as: - Reduced service life due to vibration damage. - Possible damage to the grid plates of the battery. -
Damage to the battery housing from mounting parts (possible acid leakage, with high subsequent costs).
- Inadequate crash safety.
Principle of operation of central venting
Note
z State of the art batteries are fitted with central venting -A- .
z The gas generated during charging emerges centrally through an

opening on the upper cover side. The backfire protection is
integrated at the same position, which prevents the ignition of the
combustible gas present in the battery.
Central venting
z In batteries with hose/pipe -A- for the central venting, ensure that
the hose is not pinched. Only then can the battery be freely
vented.
Central venting
Visual inspection
Before measurements such as open-circuit voltage, acid density or the battery load test are carried out, a
visual inspection of the battery must be performed.
Through this check, it can be determined:
z Whether the housing of the battery is damaged. Acid can leak out due to damage of the housing.
z Whether the battery terminals (battery line connections) are damaged. Contact of the line connections
cannot be guaranteed if the battery terminals are damaged. This can cause a line fire and malfunctions in
the electrical system.
Note
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Central venting
Checking acid level
1. Switch ignition off and remove ignition key.
2. Move front left seat back and up as far as possible. Move

backrest fully forward.
3. Detach front seat trim forwards -Arrow A- .
4. Fold the carpet cut-outs forwards and remove the two fastening
screws -Arrows 1- .
5. Fold the seat back completely -Arrow B- . With the seat in its
folded position, move the seat forward again using the fore-and-
aft adjustment -Arrow C- .
Folding back the front left seat

6. Open the four tension hooks on the battery box lid using a
screwdriver.
7. Remove battery box lid with vent duct.
Opening tension hook

Low-maintenance battery
WARNING
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→ Only use a torch to illuminate the inside of the battery. Never illuminate the inside of the battery with a
naked flame.
Note
z The correct acid level of the battery is an important factor for long and efficient operation of the battery.
z When the acid level is too low, a capacity loss (performance loss) of the battery occurs, which is caused
by the cell plates drying out. If the cell plates are not surrounded by electrolyte (battery acid), this will
lead to corrosion of the lead plates, the plate bridges and the cell connectors. The result of the corrosion
is that battery functioning cannot be guaranteed. The battery will become unserviceable.
z If the acid level is too high, damage can occur by the battery acid (sulphuric acid/water mixture) leaking
out of the battery.
2. Shine a torch into the battery. The acid level of the battery must be at the protruding lug.
– If the acid level is too low, refill with distilled water using the battery filling bottle.
4. Remount battery cover.
Note
z The charge state and acid level of the battery can be checked through the inspection glass -B- .
z If a battery is more than 5 years old and the indicator of the inspection glass is colourless, replace the
battery.
z If the battery has been charged, air bubbles can form under the
inspection glass. Before carrying out a visual inspection, tap
carefully on the inspection glass with something like the handle of
a screwdriver.
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Green The battery charge is satisfactory.
Battery will start reliably.
Dark grey The battery has no charge or the charge is too low.
Recharge battery.
Transparent/clear Acid level has become critical.
Replace battery.
Checking acid density
WARNING
→ Only use a torch to illuminate the inside of the battery. Never illuminate the inside of the battery with a
naked flame.
Note
z Only for low-maintenance batteries.
Note
z Use commercially available battery acid tester.
z The acid density test provides information about the state of the battery in conjunction with the battery
load test.
z The temperature of the battery acid must be at least 10°C .
The density of the acid must be checked as follows in all battery cells (low-maintenance battery) :
2. Unscrew all battery plugs (plugs of the battery cells).

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3. Dip the acid siphon or the pipette into the battery cell and take up the battery acid.
4. Read off the density of the acid in kg/dm³ on the scale of the battery acid tester and compare with the
following table.
Battery charge state in normal climatic zones Density in kg/dm³

discharged 1.12
half charged 1.20
well charged 1.28
Battery charge state in tropical climatic zones (hot countries) Density in kg/dm³
discharged 1.08
half charged 1.16
well charged 1.23
The acid density must be at least 1.24 kg/dm³ in normal climatic zones.
– If the acid density is too low, charge battery.
– After charging the battery, repeat the acid density test.
The measured values for the acid density of the individual battery cells must not differ by more than 0.03
kg/dm³ from each other.
Examples of non-permissible acid density deviations:

Battery cell: 1 2 3 4 5 6
Acid density per cell in kg/dm³
Example 1: 1.24 1.25 1.25 1.10 1.24 1.25
Example 2: 1.26 1.26 1.25 1.14 1.18 1.24
Example 1: The acid density in cell 4 is too low.
Example 2: The acid density in cells 4 and 5 is too low. The acid density deviations between the battery cells
is greater than 0.03 kg/dm³.
– If the nominal values are not achieved, replace battery.
– If the nominal values are achieved, screw in the original plugs again.
ATTENTION
5. Move the seat in its folded position towards the rear -Arrow A- and then tip forward -Arrow B- .
6. Screw in fastening screws -Arrow 1- . → Tightening torque: 33 ftlb.

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7. Clip in front seat trim -Arrow C- .
Folding seat back and screwing down

Open-circuit voltage measurement
Note
z Use a hand-held multimeter to measure the battery voltage.
2. Disconnect ground strap on the battery.
Note
z After charging and waiting for at least 2 hours, during which time the battery should neither be loaded nor
charged:
3. Measure the battery voltage with a hand-held multimeter.
– The battery open-circuit voltage should not fall below 12.5V.
– If the hand-held multimeter shows 12.5V or more, the battery voltage is OK.
– If the hand-held multimeter shows a battery voltage below 12.5V: Charge battery.
Battery load test
Note
z The acid density test provides information about the state of the battery in conjunction with the battery
load test.
z A battery test device is required for the load test.
z The battery need not be removed or disconnected.
z The battery must be charged before the load test is performed.
Carry out battery load test:

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2. Observe the information in the operating instructions of the battery test device.
3. Connect the clamps of the test lines to the battery terminals as described in the operating instructions of
the test device.
– As the load current varies, the current must be set depending on the battery capacity (operating
instructions of test device).
4. Perform the battery load test in accordance with the operating instructions.
– The result of the battery load test is a voltage value that must be compared with the specified minimum
voltage (limit value).
Table:
Battery capacity: 70 Ah 95 Ah 110 Ah
Cold test current 340 A 450 A 520 A
Load current See tester instructions
Minimum voltage (limit value) See tester instructions
5. If the minimum voltage is not attained, replace battery.
Remarks on battery load test:
The battery voltage sinks during this test due to the severe load on the battery.
If the battery is in order, the voltage value only decreases to the minimum voltage.
If the battery is faulty, the battery voltage will sink very quickly below the specified minimum voltage.
After the test has taken place, the low voltage value remains over a long period of time; the voltage increases
again slowly.
Charging battery
WARNING
Danger of fire and explosion
→ The battery plugs must always be screwed in correctly when charging and during voltage measurement
and load measurement.
→ Rooms in which batteries are being charged should not be entered with a naked flame or when smoking.
Gases form through the charging process in the batteries which are highly flammable.
Note
z A battery charging device is required.
z Observe charging device operating instructions.
z The battery must have a minimum temperature of 10°C.
z If possible, do not fast charge batteries as this can damage them.
z If exhaustively discharged batteries are charged quickly, they will not take up a charge current or they will
be identified too early as full due to the so-called "surface charge".
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3. First disconnect the ground strap of the battery, then the positive battery line.
4. Connect positive line of the battery charging device to the positive terminal of the battery.
5. Connect negative line of the battery charging device to the negative terminal of the battery.
Procedure for charging exhaustively discharged batteries:
Batteries which are not in operation for a long period of time discharge.
A battery is exhaustively discharged if the open-circuit voltage has sunk below 11.6 V.see open-circuit
voltage measurement
In exhaustively discharged batteries, the battery acid (sulphuric acid and water mixture) consists of virtually
only water, as the sulphuric acid proportion is considerably reduced.
Exhaustively discharged batteries sulphatise, i.e. the entire plate surfaces of the batteries harden.
If exhaustively discharged batteries are immediately recharged after an exhaustive discharge, the
sulphatisation recedes again.
If these batteries are not recharged, the plates continue to harden and charge take-up ability is limited. A
reduction in the battery performance is the result.
Exhaustively discharged batteries must be charged with a low charge current as follows:
– Set maximum charge current at 10% of battery capacity; i.e. with a 95 Ah battery the maximum charge
current is 9.5 A.
8. Charge battery.
Note
z When working or carrying out tests on the Cayenne, or when it is in the workshop, a battery charging
device with a rated current of at least 40 A must be connected.
z 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.
4. Open protective cover on the positive terminal -+- -A- .
5. First, connect the positive cable from the charging device to the positive terminal for jump lead starting
-+- . → Tightening torque: 3.5 ftlb.
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Opening protective cover Removing cover for jump lead starting

terminal
6. Connect the negative cable from the charging device to the ground point for jump lead starting - - - . →
Connecting the battery for trickle charging
A suitable battery charging device must be connected to the vehicle electrical system when
performing the following tasks. All unnecessary 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
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g y y g

27 07 19 Removing and installing auxiliary battery - as of MY

2003
- Removing auxiliary battery
- Installing auxiliary battery
Removing auxiliary battery
Note
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Overview of auxiliary battery
DANGER
→ Do not disconnect battery with engine running.

→ Disconnect and reconnect battery with extreme caution. Risk of short circuit and explosion.
→ Do not tilt battery when removing it. Risk of acid burns as a result of emerging acid.
→ Do not rub the battery with a dry cloth. Risk of explosion as a result of static charge.
1. Switch off all loads and remove ignition key.
2. Observe the warning notes and safety regulations for hydrocyanic acid batteries → 2706 Battery

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3.1. Remove knob -A- and position it on bolt -B- .

3.2. Unscrew the bolt -B- and remove it together with the collapsible
spare wheel.
Removing collapsible spare wheel

4.1. Remove tyre sealant -1- if present.
4.2. Unscrew the two fastening nuts -2- .
4.3. Undo fastening screw -3- and washer.
Mount for subwoofer

5. Disconnect plug connection and remove subwoofer:
5.1. Remove plug connection from retaining bracket on the

subwoofer and disconnect the plug connection.
Disconnecting plug connection on

subwoofer and removing subwoofer
6. Removing cover for housing:
6.1. Unscrew the four fastening nuts -arrows A- .
6.2. Unclip the four fastening clips -arrows B- using a screwdriver.
7. Disconnecting and removing the battery:
7.1. Risk of short circuit! First disconnect the negative cable -arrow 1- , then the positive cable -arrow 2- .
7.2. Pull off vent hose -arrow 4- on the battery.

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Disconnecting and removing battery Removing cover for housing
7.3. Unscrew the battery mount nut and remove the retaining bracket for the battery mount -arrow 5- .
7.4. Risk of causticisation! Remove battery from the battery case by the folding handles, if at all possible
without tilting it.
Installing auxiliary battery
1. Inserting and connecting battery:
1.1. Risk of causticisation! Position the battery in the battery case

below the stops, if at all possible without tilting it.
1.2. Position retaining bracket and tighten with fastening nut

-arrow 5- . → Tightening torque: 17 ftlb.
Note
z Make sure that the two ends of the vent hose are routed and
inserted correctly.
1.3. Insert vent hose -arrow 4- on battery.
1.4. Risk of short circuit! First connect the positive cable -arrow 1- ,
then the negative cable -arrow 2- . → Tightening torque: 3.5
ftlb. Position and tighten retaining strip,
insert breather hose, connect poles
2. Positioning battery case cover and screwing it on:
2.1. Put on the battery case cover, position it and clip in the four fastening clips -arrows A- onto the cover.
2.2. Push the retraining straps across the four fastening bolts on the body floor and screw on the four
fastening nuts -arrows B- . → Tightening torque: 4.5 ftlb.
3. Install subwoofer:

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Installing subwoofer Positioning cover for housing and

screwing it on
3.2. Push the electrical plug connection together until the plug is felt to engage.
Note
4.1. Insert fastening screw -3- with washer and tighten. →

4.2. Position both fastening nuts -2- and tighten them. → Tightening
Mount for subwoofer
torque: 1.5 ftlb.
4.3. If present, place tyre sealant -1- in well.
4.2. Screw in fastening screw -B- .

4.3. Position twist grip -A- and tighten fastening screw -B- .
Installing collapsible spare wheel
as of MY 2003
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g g p g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g p g g

27 22 19 Removing and installing three-phase generator - as of

MY 2003
- Preliminary work
- Removing the three-phase generator
- Installing the three-phase generator
- Perform additional assembly work when replacing the three-phase generator
- Subsequent work
Tools

repair kit for wiring special tool NR.155-
harnesses 1
repair kit for Cayenne wiring special tool NR.155-

harnesses 2
Preliminary work
Preliminary work
1. Before the three-phase generator can be removed, the battery must be disconnected and the terminal
g g p g g
covered. → 90 Work instructions after disconnecting the battery
2. Remove right wheel housing liner. → 505619 Removing and installing front wheel housing liner - chapter
on "removing"
3. Remove right air cleaner housing. → 242519 Removing and installing air cleaner housing - chapter on
"removing"
5. Drain coolant . → 193817 Draining and filling in coolant (includes bleeding) - chapter on "draining"
6. Remove drive belt. → 137819 Removing and installing drive belt - chapter on "removing"
Removing the three-phase generator
Note
z When the engine is being cleaned with high-pressure cleaning equipment, make sure that the high
pressure blast is not directed directly onto the three-phase generator (risk of bearing damage).
Overview of three-phase generator
Note
z If the impact bracket is used, the routing of the wires may differ from this description!
1. Unscrew the three fastening screws -8- for the impact bracket and remove the impact bracket.
2. Unscrew fastening screw -3- of ground lead and lay ground lead to one side.
3. Lever out fastening clips -4- for the electrical lead using a screwdriver.
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Unscrewing fastening screw of ground Unscrewing the fastening screws for

lead. the impact bracket
4. Seal the coolant hoses -A and B- with a hose clamp to prevent
them from leaking.
Sealing coolant hoses with hose clip

5. Unscrew fastening screws -A and B- of coolant hoses.
Unscrewing fastening screws of

coolant hoses.
Note
z If the protective cap cannot be removed, use a knife to carefully
cut if off the three-phase generator. Make sure that the plug
connection and the electrical lead are not damaged and that
there is no more than minimal damage to the protective cap.
6. Pull off protective cap for electrical plug connection from

receptacle on three-phase generator.
Pulling off protective cap for electrical

generator
7. Release -a- and pull off plug.
8. Unscrew fastening nut for B+ lead and remove the B+ lead.

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9. Unscrew the three

fastening screws
-1 and 2- and support the
three-phase generator
with your hand.
10. Remove the three-phase
generator through the
opening - wheel housing
liner with air-cleaner box
removed.
Unscrewing fastening screws of three- Pulling plug off three-phase generator

phase generator
Installing the three-phase generator
Note
Additional assembly operations must be performed if a new three-phase generator has to be fitted. → 272219
Removing and installing new three-phase generator - chapter on "completing"
1. Insert the three-phase generator through the opening - wheel

housing liner with air-cleaner box removed - -Arrow A- and
position it on the engine -Arrow B- .
Position three-phase generator on the

engine
3. Additional assembly operations must be performed if a new
three-phase generator has to be fitted.
Tightening the fastening screws of the

three phase generator
4. Insert the plug -6- until the locking tab -A- is felt to engage.
5. Clip the line into the two retaining clips -7- .
6. Tighten electrical B+ lead with fastening nut -5- . → Tightening torque: 11 ftlb.
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Note
z Check condition of
protective cap; if it is
damaged it must be
repaired using body
sealant.
7. Position protective cap

and press it on, ensuring
it fits securely and is
sealed against moisture. Positioning protective cap for electrical Tightening fastening nut for B + lead
generator
8. Replace sealing rings. Push in coolant connections on the three-
phase generator and screw into place using fastening screws
-A and B- . → Tightening torque: 7.5 ftlb.
9. Connect coolant lines and position holding clamps.
Tightening coolant connections to

three phase generator
10. Secure ground lead to three-phase generator with fastening
screw -3- . → Tightening torque: 15 ftlb.
11. Attach clip -4- of the electrical lead to the three-phase generator.
Tightening fastening screw of ground

lead to three phase generator
12. Position the impact bracket and screw into place with the
fastening screws -8- . → Tightening torque: 7.5 ftlb.
Perform additional assembly work when replacing the three-phase generator
Additional assembly work when replacing three-phase generator

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Note
The parts pack of a new three-phase generator contains all the parts required (insulator, PIN and socket).
1. Lay the lead of the new three-phase generator as for the old lead
and clip into the three retaining clips -Arrows A- .
2. Trim the lead (with 2-pole plug) included in the engine wiring
harness to the three-phase generator -arrow- such that, together
with the new lead already laid from the three-phase generator, it
can be joined without tension and without too much slack.
3. In the wiring harness, insulate and immobilise the wire to PIN 2 of

the plug that was cut off.
Laying and trimming lead of three-

phase generator
4. In the wiring harness, remove the insulation of the wire to PIN 1
of the plug that was cut off and push new insulator -1- onto the
wire.
5. Crimp new PIN -2- using repair kit for wiring harnesses
NR.155-1 and repair kit for Cayenne wiring harnesses
NR.155-2 .
6. Insert wire with new PIN into the new socket -3- and lock.
Crimping plug to wiring harness

8. Tie the plug connection with a tie-wrap -2- to the nearby wiring
harness.
9. Clip line holder -3- to the shaft tube.

clipping the line holder
Subsequent work
Subsequent work
1. Install drive belt. → 137819 Removing and installing drive belt - chapter on "installing"
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2. Fill in coolant. → 193817 Draining and filling in coolant (includes bleeding) - chapter on "filling in"
3. Install right air-cleaner box. → 242519 Removing and installing air cleaner housing - chapter on
"installing"
4. Install right wheel housing liner. → 505619 Removing and installing front wheel housing liner - chapter on
"installing"
battery
9PAAE1, 9PAAE7
as of MY 2003
g g g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g g g

27 22 19 Removing and installing the generator - as of MY 2006

- Preliminary work
- Subsequent work
Preliminary work
Preliminary work
3. Remove right wheel housing liner. → 505619 Removing and installing front wheel housing liner - section
on "Removing"
"Removing"
Note
This description applies to engine numbers as of M48/00 816 09867.
Note
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1. Unscrew the three fastening screws -8- for the impact bracket
and remove the impact bracket.

the impact bracket
2. Unscrew fastening screw -3- on ground lead and lay ground lead
to one side.
3. Lever out fastening clips -4- for the electric line using a
screwdriver.
Unscrewing fastening screw on ground

lead.
5. Unscrew fastening screw -4- on the return connection piece.
6. Unscrew fastening screw -2- on the supply connection piece -1- .

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Unscrewing fastening screw on the Sealing coolant hoses with hose clip
return connection piece
Unscrewing fastening screw on heat Unscrewing fastening screw on the

protection shield for generator lines supply connection piece
7. Unscrew fastening screw -2- on the heat protection shield for generator lines.

9. Unclip wire harness for the generator at the three retaining clips
-Arrows A- .
Unclipping wire harness for generator

10. Cut both tie-wraps -3- on the wire harness for the generator -2- .
11. Release plug connection for generator -1- ( -Arrow A- ) and disconnect it -Arrows B- .
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Disconnecting plug connection for

generator

generator
1. Insert the generator through the opening - wheel housing liner

with air-cleaner box removed - -Arrow A- and position it on the
engine -Arrow B- .

engine
2. Position the three fastening screws -1 and 2- and tighten them. → Tightening torque: 23 (17 ftlb.) Nm

4. Secure wire harness -2- to the wire harness running parallel using two tie-wraps -3- .
5. Secure the heat protection shield with the generator lines to the generator using the fastening screw -2- .
6. Clip wire harness for the generator in at the three retaining clips -Arrows A- .
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Pushing plug connection together and Tightening fastening screws on the

clipping in the line holder generator

Clipping in wire harness for generator

7. Secure B+ line with the fastening nut -5- . → Tightening torque:
15 (11 ftlb.) Nm
Securing B+ line to generator

8. Screw on supply connection piece -1- .
8.1. Grease the new seal on the supply connection piece -1- with Vaseline.
8.2. Press supply connection piece -1- as far as it will go into the supply coolant bore on the generator and
secure with the new fastening screw -2- . → Tightening torque: 10 (7.5 ftlb.) Nm
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Screwing on supply connection piece


11. Secure ground lead to the generator with the fastening screw -3-
. → Tightening torque: 20 (15 ftlb.) Nm

13. Position the impact bracket and secure with the fastening screws
-8- . → Tightening torque: 10 (7.5 ftlb.) Nm

impact bracket
Subsequent work
Subsequent work
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"Installing"
"Installing"
battery
9PAAE1, 9PAAE7
as of MY 2006
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
p g g g

27 22 55 Replacing the generator - as of MY 2006

- Preliminary work
- Subsequent work
Tools

Repair kit for wire special tool NR.155-
harnesses 1
Repair kit for Cayenne wire commercially NR.155-

harnesses available tool 2
Preliminary work
Preliminary work
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3. Remove right wheel housing liner. → 505619 Removing and installing front wheel housing liner - section
on "Removing"
"Removing"
Note
This description applies to engine numbers up to M48/00 816 09866.
Note
1. Unscrew the three fastening screws -8- for the impact bracket and remove the impact bracket.
2. Unscrew fastening screw -3- on ground lead and lay ground lead to one side.
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Unscrewing fastening screw on ground Unscrewing the fastening screws for

lead. the impact bracket
4. Seal the coolant hoses -A and B- with a hose clamp to prevent

them from leaking.
Sealing coolant hoses with hose clamp

5. Unscrew fastening screws -A and B- on coolant connections.

coolant hoses.
6. Cut off the electric line directly behind the protection cap -Arrow-
on the generator.
Cutting off electric line behind the

protection cap on the generator
7. Unscrew fastening nut -5- on the B+ line. Unclip the B+ line at the two retaining clips -6- and remove it.
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8. Unscrew fastening screw -2- on the heat protection shield for
generator lines.
Unscrewing fastening screw on heat

protection shield for generator lines
Unscrewing fastening screws on the

generator
Note
The following parts are required for installing the Hitachi generator.
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Range of spare parts for the Hitachi generator
1- Generator
2- Return connection piece
3- Supply connection piece
5- 1x hose clamp
6- Heat protection shield
8- 1x line
9- 1x connector
10 - 1x shrink-fit hose
11 - 1x cable connection
Parts -1 to 7- are available as spare parts.
Parts -8 to 11- are included in the Repair kit for Cayenne wire harnesses NR.155-2.
1. Fit return connection piece -4- on the new generator -1- .
1.1. Pull off both caps for the coolant bores -2- on the new generator -1- ( -Arrows A- ).
1.2. Grease the seal -3- on the new return connection piece -4- with Vaseline.
1.3. Press return connection piece -4- as far as it will go into the return coolant bore on the new generator
-1- ( -Arrow B- ) and secure with the new fastening screw -5- . → Tightening torque: 10 (7.5 ftlb.) Nm
2. Insert the generator through the opening - wheel-housing liner with air-cleaner box removed - -Arrow A-
and position it on the engine -Arrow B- .
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engine
Fitting return connection piece on the

new generator
Tightening fastening screws on the

generator
4. Secure the heat protection shield with the generator lines to the
generator using the fastening screw -2- . → Tightening torque:
10 (7.5 ftlb.) Nm

5. Secure B+ line with the fastening nut -5- . → Tightening torque:
15 (11 ftlb.) Nm
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6. Remove old supply Securing B+ line to generator

connection piece -1- .
6.1. Press hose clamp -2-

together and pull supply
connection piece -1- out
of the coolant hose.
Removing old supply connection piece

7. Install new supply connection piece -1- .
7.1. Grease the seal -2- on the new supply connection piece -1-
with Vaseline.
7.2. Press supply connection piece -1- as far as it will go into the
supply coolant bore on the new generator -Arrow A- and
secure with the new fastening screw -3- . → Tightening torque:
10 (7.5 ftlb.) Nm
7.3. Fit the coolant hose -4- with a new hose clamp -5- and push it
onto the supply connection piece -1- ( -Arrow B- ).
Installing new supply connection piece

8. Lay the line for the new generator in the same way as the old line
and clip it into the three retaining clips -Arrows A- .
Laying generator line

9. Join the new line -1- to the new connector -2- .
9.1. Push new line -1- with the PIN fully into the connector housing -2- ( -Arrow A- ).
9.2. Lock connector -2- ( -Arrow B- ) until it engages audibly.

Check that connector -2- is locked correctly.
Note
Select a place for the joint where there is enough space to join all the lines present.
Do not cut the lines too short in case they have to be laid in a different position if there is insufficient space in
the area of the joint.
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Note
The electric lines are located in the splash water area and are thus
exposed to the highest demands.
The greatest care must be taken in the individual work steps for
stripping insulation from, crimping, and shrinking/insulating the electric
lines.
The procedure for stripping insulation from, crimping, and

shrinking/insulating the electric lines must be complied with and
observed. The procedures are described in detail in the Repair kit for
Cayenne wire harnesses NR.155-2.
Crimping samples are to be prepared before beginning work.
Note Joining connector to new line

Allocation of lines - see wiring diagram.
10. Crimp the line from the new generator -1- with the line from the
engine wire harness -4- .
10.1. Trim the line from the engine wire harness -4- so that it can be
joined to the new line that was already laid from the generator
-1- without tension and without too much slack.
10.2. In the engine wire harness -4- , insulate and immobilise the
wire to PIN 2 of the connector that was cut off.
10.3. In the engine wire harness -4- , strip 10 mm of the line to PIN 1
of the connector that was cut off and push new shrink-fit hose
-3- onto the line.
Joining line from new generator to line
10.4. Crimp both lines -1 and 4- using a new crimping sleeve -2- and from engine wire harness
the hand crimping pliers from the Repair kit for wire
harnesses NR.155-1.
10.5. Slide new shrink-fit hose -3- over the crimp connection and carefully shrink it to make it watertight using
the hot-air blower with special nozzle (recommended accessories for the repair kit for wire
harnesses).
11. Wrap commercially available PVC tape all around the area of the connection point.
13. Secure wire harness -2- to the wire harness running parallel
using two tie-wraps -3- .

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14. Grease new sealing ring with Vaseline. Attach return connection piece to the generator and secure with
fastening screws -4- . → Tightening torque: 10 (7.5 ftlb.) Nm
16. Secure ground lead to the generator with the fastening screw -3-
. → Tightening torque: 20 (15 ftlb.) Nm

18. Position the impact bracket and secure with the fastening screws
-8- . → Tightening torque: 10 (7.5 ftlb.) Nm

impact bracket
Subsequent work
Subsequent work
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"Installing"
"Installing"
battery
9PAAE1, 9PAAE7
as of MY 2006
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
g g g

27 60 19 Removing and installing starter - as of MY 2003

- Preliminary work
- Removing the starter
- Installing the starter
- Subsequent work
Preliminary work
Preliminary work
"Removing"
2. Disconnect battery. → 270619 Removing and reinstalling battery - chapter on "Removing"; → 90 Work
Removing the starter
WARNING
Risk of damage to starter
→ The battery must be properly disconnected before the electric lines are detached on the starter.
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Overview of starter
1. Unscrew fastening nuts -1- and -2- on the starter, remove the
lines and lay them to one side.
Fastening nuts on starter

2. Unscrew the two fastening screws -3- .
Fastening screws
3. Pull starter forward in the direction of travel -arrow A- , turn slightly -arrow B- and remove in an upward
direction -arrow C- .
Installing the starter
1. Place the starter from above on the engine -arrow C- , turn slightly -arrow B- and position in the
mounting -arrow A- on the engine.
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Positioning the starter Removing starter
Screwing in fastening screws in engine

housing
2. Insert fastening screws -3- on starter, screw into the engine housing and tighten. → Tightening torque:
33 ftlb.
3. Position electric lines on the starter and tighten with fastening

nuts -1- and -2- . → Tightening torque: 11 ftlb. , → Tightening
torque: 6 ftlb.
Positioning and tightening electric lines

to starter
Subsequent work
Subsequent work
"Installing"
2. Connect the battery . → 270619 Removing and reinstalling battery - chapter on "Installing"; → 90 Work

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as of MY 2003
p j p g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
p j p g g

27 06 External power connection, jump lead starting - as of MY

2003
- Information
Information
Note
z 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
Risk of damage and injury as a result of a short circuit.
→ Use only standard jump leads with a sufficiently wide cross section and fully insulated terminal clamps.
Observe the cable manufacturer's specifications.
→ Route the jump leads so that they cannot become entangled in moving parts in the engine compartment.
→ No contact is allowed between the vehicles, otherwise electricity could flow as soon as the positive
terminal is connected.
The flat battery must be properly connected to the vehicle electrical system.
2. Open protective cover on the positive terminal -+- for jump lead starting -arrow A- .
3. Connect the positive cable to the positive terminal for jump-lead starting -+- , then to the positive terminal
of the battery supplying the power.
4. First, connect the negative cable to the negative terminal of the battery supplying the power, 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.
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7. Disconnect the two jump

leads in reverse sequence
when the engine is
running.
8. Close protective cover

-arrow B- .
Protective cover on positive terminal Removing the cover.

for jump-lead starting
9. Position the cover.
Positioning the cover
as of MY 2003
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WARNING
AVERTISSEMENT
ATTENZIONE
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g g g g

28 04 19 Removing and installing ignition switch - as of MY

2003
- Preliminary work
- Removing ignition switch
- Installing ignition switch
- Subsequent work
- Information
Tools

wrench special tool T10152
Preliminary work
Preliminary work
1. Remove trim panel under dashboard on left. → 701919 Removing and reinstalling trim panel under
dashboard - chapter on "Removing"
Removing ignition switch
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Overview of ignition starter switch
1. Carefully lift rubber sleeve on the ignition starter switch -arrow A-

using a screwdriver, for example, and remove it.
2. Carefully unclip moulding for dashboard -arrow B- with a plastic
spatula. Observe the two upper lugs when doing do.
Rubber sleeve on ignition starter

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3. Turn union nut using a switch

narrow plastic spatula, for
example, or using the
special wrench T10152
tool and unscrew the ring
from the ignition starter
switch.
4. Press ignition switch

inwards and remove
towards the bottom.
Union nut
5. Press connector -arrow- and pull off from ignition starter switch.
Removing ignition starter switch
Installing ignition switch
1. Connect the connector to the ignition starter switch until it

engages firmly.
Pushing connector onto ignition starter

switch
2. Position ignition starter switch in the dashboard. Position union
nut, re-adjust switch and tighten union nut using wrench T10152.
Positioning the union nut

3. Check clips on the moulding for the dashboard for damage and replace if necessary.
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Clips on moulding for dashboard
4. Position moulding and press onto the dashboard until the clips engage.
Subsequent work
Subsequent work
1. Install cover under instrument panel on left. → 702219 Removing and reinstalling cover under dashboard
- chapter on "Installing"
Information
Emergency operation of the ignition key lock
Note
z In the event of insufficient or non-existent battery positive voltage, the ignition key can be removed using
the emergency operation.
1. Push a ball-point pen, for example, into the opening next to the
key, turn the ignition key to position 0 and pull out.
Ignition key
2. Key in position 0, press release -arrow- and pull key out.
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as of MY 2003
C15, C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28,
C32, C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
Keyless Entry and Drive

p g g g
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WARNING
AVERTISSEMENT
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p g g g

28 20 55 Replacing ignition coils - as of MY 2003

- Preliminary work
- Replacing ignition coils
- Subsequent work
Preliminary work
Preliminary work
1. Switch ignition off and remove ignition key
2. Remove engine compartment cover on the right and rear. → 700219 Removing and reinstalling front
cover (engine compartment) - chapter on "Removing"
Replacing ignition coils
1. Loosen the torque support. To do this unscrew the fastening

screw on the torque support bracket.

bracket
2. Loosen the torque support on the body and swivel upwards.
3. Loosen the secondary air pump from cylinder row 1-4. To do this, unscrew the 3 fastening screws, pull
the pump out of the support and lay it aside.
Note
z Place a cloth between design cover and support for secondary air pump to avoid scratching cover.
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Fastening screws for secondary air Torque support to body

pump
4. Loosen the 4 fastening screws on the ignition coil cover (picture
shows side 5-8).

5. Remove design cover from cylinder bank 1-4. Lift the cover
slightly with both hands on the side pointing towards the intake
system until it snaps out of the fastening points.

6. Lift the cover at the front edge and slide the ignition coil cover of
the second cylinder out of the torque support bracket. Pull out
cover to the front.
Pulling out cover to the front

7. Remove torque support bracket. To do so, undo the 4 fastening screws and set bracket aside.
8. Disconnect the ignition coil. To do this, press the button on the connector and pull off the connector.
9. Loosen ignition coil. To do this, unscrew the fastening screw on the valve cover.
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Pulling off plug Fastening screws for torque support

bracket
Fastening screws on valve cover

Ignition coil
11. Reconnect the new ignition coil. Tighten the fastening screws. →

12. Connect ignition coil. To do this slide on the connector until it locks with an audible click.
13. Install bracket for torque support. The M8 x 45 Torx screws are tightened on the upper screw points. →
Tightening torque: 17 ftlb. The M6 x 40 screws are tightened on the lower screw fastening points
(centre of the valve cover) → Initial tightening: 3.5 ftlb. → Final tightening: 7.5 ftlb.
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Fastening screws for torque support Sliding on the connector

bracket
Note
z A rag should be placed between the secondary air pump support
and the design cover to prevent the cover from being scratched.
14. Slide the design cover of cylinder row 1-4 under the secondary
air pump support as shown in the illustration and then slide the
support bracket.
Install cover
15. Press down the two rubber mountings on the support. The rubber
mountings must be felt to engage.
Rubber mounting on support

16. Tighten the four fastening screws on the ignition coils (illustration
shows side 5-8). → Tightening torque: 3.5 ftlb.
Fastening screws on the ignition coils

17. Reinstall secondary air pump. Tighten the 3 fastening screws. → Tightening torque: 7.5 ftlb.
18. Reinstall torque support. Install the fastening screw (M10 x 85) with a new fastening nut on the bracket.
19. Tighten torque support fastening screw on the body (M10 x 70) . → Tightening torque: 44 ftlb.
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Fastening screw on the torque support Fastening screws for secondary air
bracket pump
Note
z A rag should be placed between the secondary air pump and the design cover to prevent the cover from
being scratched.
1. Unscrew the 4 fastening screws on the ignition coil cover.

2. Remove design cover of cylinder bank 5-8. To do this, lift the
cover slightly with both hands at the side pointing towards the
intake system until it is released from its bracket.

4. Disconnect the ignition coil. To do this, press the button on the connector and pull off the connector.
5. Loosen ignition coil. To do this, unscrew the fastening screw on the valve cover.
7. Reconnect a new ignition coil. Tighten the fastening screws. → Tightening torque: 7.5 ftlb.
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Pulling off plug Removing the design cover
Pulling the ignition coil out and Fastening screws for ignition coil
replacing it
Sliding on the connector Fastening screws for ignition coil
8. Connect ignition coil. To do this slide on the connector until it locks with an audible click.
Note
z A rag should be placed between the secondary air pump and the
design cover to prevent the cover from being scratched.
9. Slide the design cover under the secondary air pump as

illustrated.
Sliding the design cover onto the

secondary air pump
10. Then press in the two rubber mountings on the support. The rubber mountings must be felt to engage.
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Fastening screws on the ignition coils Rubber mounting on support
11. Tighten the 4 fastening screws on the ignition coils. → Tightening torque: 3.5 ftlb.
Subsequent work
Subsequent work
1. Install engine compartment cover on the right and rear. → 700219 Removing and reinstalling front cover
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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g g g

28 39 19 Removing and installing hall sender - as of MY 2003

- Preliminary work
- Removing hall sender
- Installing hall sender
- Subsequent work
Preliminary work
Preliminary work
"Removing"
Note
z The hall sensors are located behind the camshaft housing and point towards the intake system.
Note
Replace all seals and O-rings.
1. Disconnect connector on hall sender. To do so, push the button and remove.
2. Loosen the fastening screw on the hall sender. Use a socket

wrench with 1/4 inch drive and a joint.
3. Pull the hall sender out of the camshaft housing.
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1. Push the hall sender into the camshaft housing and tighten the
2. Push on electric connector. The connector must engage audibly.
Subsequent work
Subsequent work
"Installing"
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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p g p p g g

28 70 55 Replacing spark plugs - as of MY 2003

- Preliminary work
- Replacing spark plugs
Tools

spark plug wrench special tool 3122 B
Preliminary work
Preliminary work
Removing design cover of cylinder bank 1 -4

1. Remove engine compartment cover on the right and rear. To do this, undo the four bayonet screws and
the fastening screw on the washer-fluid reservoir. → 700219 Removing and installing front cover (engine
compartment) - chapter on "removing"
2. Detach the torque support. To do this, unscrew the fastening screw on the torque support bracket and
pull it out.
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Torque support on body Fastening screw for torque support
4. Detach the secondary air pump from cylinder bank 1 -4. To do

this, unscrew the three fastening screws, pull the pump out of the
bracket and lay it aside.

Note
5. Unscrew the four fastening screws on the ignition coil cover

(illustration shows side 5 - 8).
Removing fastening screws of ignition

coil cover
6. Remove design cover from cylinder bank 1 - 4. Lift the cover
slightly with both hands on the edge pointing towards the intake
system until it snaps out of the fastening points.
Removing design cover from cylinder

bank 1 - 4
7. Lift the cover at the front edge and slide the ignition coil cover of the second cylinder out of the torque
support bracket. Pull out cover to the front.
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Removing cover
8. Remove torque arm bracket. To do so, undo the four fastening
screws and set bracket aside.

support bracket
Note
1. Unscrew the four fastening screws on the ignition coil cover.

2. Remove design cover of cylinder bank 5 - 8. To do this, lift the
cover slightly with both hands at the edge pointing towards the
intake system until it is released from its holder.
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Design cover of cylinder bank 5 -8


1. Pull off lower hose from secondary air pump 5 - 8.
2. Separate the eight ignition coils from the wire harness. To do

this, press on the button and, at the same time, pull off the plug.
Separating ignition coils from wire

harness
3. Undo ignition coil. To do this, unscrew the fastening screw on the
valve cover.

4. Pull out ignition coil and lay it aside.
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Ignition coil
Loosening spark plugs using spark

plug wrench
5. Undo spark plugs using special tool spark plug wrench 3122 B
ATTENTION
Broken spark plug electrodes can damage the engine!
z 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.
6. Check electrode gap in V8 naturally aspirated engine. → Control

value: 1.6 mm

7. Check electrode gap in V8 turbo engine. → Control value: 0.8
mm +/-0.05 mm

turbo engine
Note
z Use only spark plugs approved by Porsche AG!
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z Check electrode gap before screwing in a new spark plug.
8.
Tighten spark plugs using special tool spark plug wrench 3122
B. → Tightening torque: 25 (19 ftlb.) Nm , → Tightening
Tightening spark plugs using spark

plug wrench
9. Reconnect the ignition coil. Tighten the fastening screws. →

10. Connect ignition coil. To do this, push on the connector until it
locks with an audible click.
11. Push lower hose onto secondary air pump 5 - 8.
Connecting ignition coil
Note
3. Tighten the four fastening screws on the ignition coils. → Tightening torque: 3.5 ftlb.

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Pressing down rubber mountings on Sliding design cover under secondary

bracket air pump
Note
z Place a cloth between secondary air pump bracket and design
cover to avoid scratching the cover.

1. Install bracket for the torque support. The M8 x 45 Torx screws
are tightened at the upper screw points. → Tightening torque:
23 ftlb. At the lower screw-mounting points (centre of valve
cover) the M6 x 40 are first tightened to → Initial tightening: 3.5
ftlb. and then to → Final tightening: 7.5 ftlb. .

support bracket
2. Slide the design cover of cylinder bank 1 - 4 under the secondary
air pump bracket as shown in the illustration and then slide the
support bracket.
Inserting cover
4. Tighten the four fastening screws on the ignition coils (illustration shows side 5 - 8). → Tightening
torque: 3.5 ftlb.
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Fastening screws of ignition coil cover Pressing down rubber mountings on

bracket

5. Reinstall secondary air pump. Tighten the three fastening screws. → Tightening torque: 7.5 ftlb.
6. Reinstall torque support. Install the fastening screw (M10 x 85)

with a new lock nut on the bracket. → Tightening torque: 44 ftlb.
7. Tighten torque support fastening screw on the body (M10 x 70) .

8. Install the engine compartment cover at the right and rear. To do

this, tighten the four bayonet screws and the sheetmetal screw
on the washer-fluid reservoir. → 700219 Removing and installing
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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g g g

28 72 19 Removing and installing knock sensor - as of MY 2003

- Preliminary work
- Removing knock sensor
- Installing knock sensor
- Subsequent work
Preliminary work
Preliminary work
"Removing"
2. Remove and fold up cover for coolant regulator (thermostat). → 195819 Removing and installing coolant
regulator (thermostat) - chapter on "Removing"
Removing knock sensor
1. Mark and note the installation position of the knock sensor and
pull off cable plug.
2. Unscrew fastening screw and take knock sensor out of the
crankcase.
Pulling off cable plug
Installing knock sensor
Note
z The knock sensor and the cable plug must be aligned so that they never touch!
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ATTENTION
Engine damage and changed exhaust behaviour due to
incorrectly mounted knock sensors!
→ The precise tightening torque for the knock-sensor screw must

be observed, otherwise the proper function of the knock sensor
is not ensured.
→ The knock sensors must a aligned so that the sensor housing
and the cable plug do not touch anywhere, otherwise proper
functioning of the knock sensor is not ensured.
1. Install knock sensor. Make sure that the knock sensors are aligned according to the illustrations
-longer arrow points to alignment, smaller arrow points to fastening screw- .
2. Tighten fastening screws. → Tightening torque: 17 ftlb.

3. Push on cable plug and ensure that the cable plug does not
touch.
Pushing on cable plug
Subsequent work
Subsequent work
1. Install cover for coolant regulator (thermostat). → 195819 Removing and installing coolant regulator
(thermostat) - chapter on "Installing"
"Installing"
"Filling"
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as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
32 47 19 Removing and installing torque converter sealing ring -

as of MY 2003
- Preliminary work
- Removing the torque converter sealing ring
- Installing the torque converter sealing ring
- Subsequent work
Tools

slide hammer kit commercially 168
available tool
assembly sleeve special tool 3295

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Preliminary work
Preliminary work for sealing ring for torque converter

1. Remove transmission. → 373519 Removing and installing transmission - chapter on "removing" [9PAAJ1]
→ 373519 Removing and installing transmission - chapter on "removing" [9PAAE1 9PAAF1]→ 373519
Removing and installing transmission - chapter on "removing" [9PAAD1]
2. Remove torque converter. → 325019 Removing and installing torque converter - chapter on
"removing" [9PAAD1]→ 325019 Removing and installing torque converter - chapter on "removing" [9PAAE1
9PAAF1 9PAAJ1]
Removing the torque converter sealing ring
Removing the torque-converter sealing ring
Torque converter overview
1. Using the bolt adapter from the slide hammer kit 168, screw
countersunk head bolt into sealing ring -direction of arrow- .
WARNING
Danger of scalding and chemical burns from hot ATF
→ Allow ATF to cool down

→ Wear personal protective gear (goggles, gloves)
Preliminary work for removing sealing

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ring
Removing the torque-converter sealing

ring
2. Screw on slide hammer from slide hammer kit 168 and remove sealing ring.
Installing the torque converter sealing ring
Installing the torque-converter sealing ring
Torque converter overview
1. Position new sealing ring on special tool assembly sleeve 3295.
2. Drive in sealing ring with special tool assembly sleeve 3295 -arrow- until special tool touches transmission
housing.
Subsequent work
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Installing sealing ring

Reworking sealing ring for torque converter
1. Install torque converter. → 325019 Removing and installing torque converter - chapter on
"installing" [9PAAD1]→ 325019 Removing and installing torque converter - chapter on "installing" [9PAAE1
9PAAF1 9PAAJ1]
2. Install transmission. → 373519 Removing and installing transmission - chapter on "installing" [9PAAJ1]
→ 373519 Removing and installing transmission - chapter on "installing" [9PAAE1 9PAAF1]→ 373519
Removing and installing transmission - chapter on "installing" [9PAAD1]
9PAAD1, 9PAAE1, 9PAAF1, 9PAAJ1
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
32 50 19 Removing and installing torque converter - as of MY 2003

- Preliminary work
- Removing torque converter
- Installing torque converter
- Subsequent work
Tools

dowel pin special tool 95950
Preliminary work
Preliminary work for torque converter

1. Remove Tiptronic gears. → 373519 Removing and installing transmission - section on "Removing" [9PAAJ1]
→ 373519 Removing and installing transmission - section on "Removing" [9PAAE1 9PAAF1]
Removing torque converter
Removing the torque converter

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Torque converter
WARNING

1. Place oil collection pan under the converter bell housing.
Note
z ATF can leak out when removing the torque converter.
z Place torque converter with transmission side pointing upwards.
Installing torque converter
Installing the torque converter
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Torque converter
Note
z Ensure that converter is seated correctly.
1. Clean any emerging oil off converter bell housing.
2. Push torque converter as far as it will go on to the transmission shaft.
3. The correct installation position is achieved when the special tool

dowel pin 95950 can be inserted through the opening in the
converter bell housing in front of the converter -inset- .
Installation position of torque converter
Subsequent work
Reworking the torque converter
1. Install Tiptronic transmission. → 373519 Removing and installing transmission - section on

"Installing" [9PAAJ1]→ 373519 Removing and installing transmission - section on "Installing" [9PAAE1
9PAAF1]
2. Check and if necessary, top up the ATF. → 370235 Checking and topping up the ATF
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as of MY 2003
g pp g p g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
37 02 35 Checking and topping up the ATF - as of MY 2003

- Information
- Checking ATF
- Filling in ATF
Tools

material special tool 00000 oil filler for ATF / VW 1924 and
1924/01 / Workshop
Equipment Manual No. 3
Information
Test conditions with cooler lines closed
ATF cooler line was not opened between thermostat and ATF cooler.
For example: changing transmission, replacing sealing ring on transmission, changing ATF filter, general checks.
z Warm up transmission in lower load range. Switch all transmission ranges several times while doing so.
z Read out ATF temperature with Porsche System Tester (PST) 2.
z ATF temperature: 40 °C.
z Selector lever is in position P.
z Test and filling process at idle speed.
Test conditions after opening cooler lines

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ATF cooler line was opened between thermostat and ATF cooler.
For example: replacing ATF, changing ATF line, changing ATF cooler, changing ATF thermostat.
z Warm up transmission in lower load range. Switch all transmission ranges several times while doing so.
z Read out ATF sump temperature with Porsche System Tester (PST) 2.
z The ATF temperature must be 90 °C (coolant circuit open).
z Let ATF cool down to 40 °C.
z Selector lever is in position P.
z Test and filling process at idle speed.
Checking ATF
Checking ATF
Note
z Always avoid oil leaks after unscrewing the oil inspection plug. This is caused by a certain amount of oil
which remains on the screw in the lifting tube.
1. Remove engine guard . → 108019 Removing and installing engine guard - section on "Removing"
2. Remove cover of ATF pan. To do this, loosen the two fastening

screws.
Note
z Secure vehicle to prevent it rolling away.
z Vehicle must be horizontal in order to check ATF.
3. Move selector lever to position N and continue the test process at

idle speed.
Shield to transmission
WARNING

Note
z Note the test conditions → Test conditions with cooler lines closed→ ATF check screws
Test conditions after opening cooler lines for the following steps.
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Note
z Undo oil inspection plug -A- only when temperature reaches 40 °C.
4. Unscrew oil inspection plug -A- .
5. The oil level is correct when oil emerges at the lifting tube. If this is
not the case, add more ATF. → 370235 Checking and topping up
ATF - section on "Refilling"
6. Screw in oil inspection plug -A- . → Tightening torque: 52 ftlb.

Check screw and oil drain plug
7. Install cover of ATF pan. To do this, tighten the two fastening screws.
8. Move selector lever to position P and switch off engine.

Filling in ATF
Topping up ATF

screws.
Note
z Vehicle must be horizontal in order to check ATF.
3. Start engine, move selector lever to position N and continue at idle

speed.
WARNING

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Note
z Note the test conditions → Test conditions with cooler lines closed→
Test conditions after opening cooler lines for the following steps.
Note
z Undo oil inspection plug only when temperature reaches 40 °C.

5. Fill with ATF using material 00000 until oil emerges at the lifting pipe.
6. Screw in oil inspection plug -A- . → Tightening torque: 70 (52 ftlb.)

Nm
7. Move selector lever to position P and switch off engine.

8. Install cover of ATF pan. To do this, tighten the two fastening screws.
Transmission shield
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
37 02 55 Changing ATF - as of MY 2003

- Preliminary work
- Changing ATF
- Subsequent work
Tools

(material) special tool 00000 discharge chute
Preliminary work
Preliminary work for replacing ATF

Changing ATF
Replacing ATF
1. Remove cover of ATF pan. To do this, loosen the two fastening screws -arrows- .
2. Place oil collecting container underneath the vehicle.
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WARNING

Note
z ATF must be changed when the engine/transmission is cold. Check screw and oil drain plug
Note
z Only part of the total change quantity can be filled because of the test specifications stipulated for the ATF.
z The rest must then be filled as described in the Checking ATF chapter.
3. Unscrew oil drain plug -B- and drain ATF.
4. Screw in oil drain plug -B- with new sealing ring. → Tightening torque: 28 (21 ftlb.) Nm
Note
z Counter when loosening the ATF lines.
5. Undo ATF line screw connection on cooler side -arrow- at the

thermostat.
ATF line to ATF thermostat

6. Unscrew bolt -arrow- on ATF thermostat holder.
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WARNING
Danger of scalding and chemical
burns from hot ATF

→ Wear personal protective
gear (goggles, gloves)
7. Hold shop-made tool

(material) 00000 -Figure- Drip tray ATF thermostat holder to cooler
under ATF thermostat.
8. Drain ATF from ATF cooler.
Note
z Counter when fastening the ATF lines.
9. Tighten ATF line screw connection on cooler side -arrow- at the

thermostat. → Tightening torque: 30 (22 ftlb.) Nm
ATF line to ATF thermostat

10. Screw in bolt -arrow- on ATF thermostat holder. → Tightening
torque: 3.5 (2.5 ftlb.) Nm
ATF thermostat holder to cooler

11. Unscrew ATF inspection plug/filler screw -A- . → Tightening torque:
70 (52 ftlb.) Nm
Note
z Modified ATF filling capacity in the transmission in combination with
new control units.
z Observe → " Technische Information Ti 01/04 Gruppe 3" and

numbers on transmission and control unit.
12. Fill with ATF using material 00000 until oil emerges at the lifting
pipe. → Change quantity: 8.5 l or → Change quantity: 9.6 l Check screw and oil drain plug
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13. Screw in ATF inspection plug/filler screw -A- .

14. Install cover of ATF pan. To do this, tighten the two fastening screws
-arrows- . → Tightening torque: 10 (7.5 ftlb.) Nm
Subsequent work
Reworking for replacing ATF

9PAAD1, 9PAAE1
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g g g
ADVERTENCIA
37 04 19 Removing and installing selector knob - as of MY 2003

- Removing selector knob
- Installing selector knob
Removing selector knob
Removing selector knob
Overview of selector knob
1. Selector lever in position D.
Note
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z The button -inset- at the front

must not be pressed down
when the selector knob is
pulled.
2. Pull selector lever up and off.
Removing selector knob Removing selector knob
Installing selector knob
Installing selector knob
Overview of selector knob
1. Selector lever in position D.
ATTENTION
Overstretch the spring in selector knob.
z Unlocking button does not return to the initial position.
→ Only move the selector knob as far forward until the tool can be inserted. Avoid any further overstretching.
2. The unlocking hook in the selector knob must retract to the -Hebel grau- . Lock the hook under the button,
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Section of selector knob
using short screwdriver -A- for example.
Note
z The button must not be pressed down when the selector knob is
installed.
3. Push on the selector knob until it audibly engages in the selector

support. The sleeve is then inserted in the selector lever cover.
4. Remove the tool on the handle.
5. Functional test of gear selecting system:

Pushing off selector knob
z Will the vehicle start?
z Do all the selector lever positions work?
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
37 08 19 Removing and installing selector support - as of MY 2003

- Preliminary work
- Removing selector support
- Installing selector support
- Subsequent work
Tools

unlocking hook special tool 9713
special inserts model AB special tool NR.170
accessory for the torque special tool NR.98-1

wrench: open ring wrench
insert a/f 13 + adapter
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Preliminary work
Preliminary work for selector frame

1. Remove selector knob. → 370419 Removing and installing selector knob - removing
Removing selector support
Removing selector frame
Overview of selector frame
1. Remove cover of centre console. To do this unscrew two screws -right arrows- , separate plug connection
-inset- , tip cover up -curved arrow- and back and remove.
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Releasing the selector lever cover Removing centre console cover
2. Remove selector lever cover with special tool unlocking hook 9713. To do this hook into the left and right of
the unlocking bracket -inset- from the front and press outwards. Pull the cover upwards slightly at the same
time.
3. Unlock the rear unlocking brackets in the same way.
4. Remove selector lever cover and separate cable connection.
Cable plug for selector lever cover

5. Pull off electrical plug connections.
Cable plug for selector frame

6. Remove the transverse strut of the centre console.
7. Unscrew selector frame screws -arrows- .
8. Unscrew cable fastening screw -right arrow- on the cable adjustment using special tool special inserts
model AB NR.170 and remove retaining clip -left arrow- .
9. Remove selector frame.
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Screw connection of selector frame Transverse strut of selector frame
Selector lever cable connection

Installing selector support
Removing and installing cable adjustment
Note
z When a new selector support is used, the cable adjustment of the selector cable must be modified.
1. Remove pins -direction of arrow- and take out cable adjustment.
Removing the cable adjustment

2. Insert cable adjustment on the new selector support and install pins -direction of arrow- .
3. When doing so, ensure that the opening for the adjusting screw -arrow- is turned upwards.
Installing selector frame

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Cable adjustment Installing the cable adjustment
Overview of selector frame
1. Push selector lever cable into cable adjustment.
2. Push on retaining clip -left arrow- and screw in fastening screw

-right arrow- using the special inserts model AB NR.170 tool and
the accessory for the torque wrench: open ring wrench insert a/f
13 + adapter NR.98-1 on the cable adjustment. → Tightening
torque: 7.5 ftlb.
3. Adjust selector lever cable . → 371515 Adjusting selector lever
cable [9PAAE1 9PAAF1 9PAAJ1]→ 371515 Adjusting selector lever
cable [9PAAD1]

4. Position selector frame and screw in screws -arrows- . → Tightening torque: 4.5 ftlb.
5. Install the transverse strut of the centre console.
6. Position electric plug connections -arrow- on the selector frame.

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Transverse strut of selector frame Selector frame to body
Cable plug for selector frame
7. Position cable connection on the underside of the selector lever cover.
8. Install selector lever cover. Make sure that the wiring harness
-arrows- is not pinched in the selector frame.
Cable lead to selector frame

9. Position cable connection -inset- on the underside of the centre
console cover.
Fitting centre console cover

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10. Insert centre console cover at the front and tip backwards -curved arrow- . Screw in two screws
-right arrows- .
Subsequent work
Reworking selector frame

1. Install selector knob. → 370419 Removing and installing selector knob - installing
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g y g
ADVERTENCIA
37 08 IN Selector lever emergency release - as of MY 2003

- Preliminary work
- Operating emergency release
- Subsequent work
Preliminary work
Preliminary work for emergency release
→ 681919 Removing and installing cover for centre console - "Removing" chapter
Operating emergency release
Operating emergency release
1. Using a screwdriver, push the locking lever on the front of the

selector frame -arrow- towards the driver's side -direction arrow- .
2. Move selector lever to position N.
Centre console without cover
Subsequent work
Subsequent work on emergency release

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→ 681919 Removing and installing cover for centre console - "Installing" chapter
9PAAD1, 9PAAE1, 9PAAF1
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
37 12 37 Disassembling and assembling cover for selector lever -

as of MY 2003
- Preliminary work for cover for selector lever
- Disassembling cover for selector lever
- Assembling cover for selector lever
- Subsequent work
Tools

Preliminary work for cover for selector lever
Preliminary work for cover for selector lever

1. Remove selector knob. → 370419 Removing and installing selector knob - section on "Removing"
2. Remove cover of centre console. To do this, unscrew two screws -arrows on right- , separate plug
connection -inset- , tip cover up -curved arrow- and back, and remove.
time.
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Releasing the selector lever cover Removing centre console cover
4. Release the rear release plates in the same way.
Cable plug for selector lever cover
Disassembling cover for selector lever
Disassembling cover for selector lever
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Overview of cover for selector lever
Note
z Use a clean and soft working surface to disassemble the cover for the selector lever.
Note
z Only press the retaining lugs until the shade loosens from the upper part.
z Otherwise, the retaining lugs can break.
1. Release the lugs -arrows- on one side on the underside of the cover
for the selector lever.
Releasing the shade

2. Tip shade up on this side → Removing the shade and remove.
Assembling cover for selector lever
Assembling cover for selector lever

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Note
z Use a clean and soft working surface to disassemble the cover for the
selector lever.
Removing the shade

1. Before assembly, the printed circuit board is to be inserted correctly
-arrows- .
Fastening the printed circuit board

2. The shade must be inserted in the correct position, sliding contact -1-
on grinding track -2- .
Position of upper part to lower part

3. Fasten shade on the one side with the retaining lugs -arrows- .
Inserting the shade

4. Push shade onto the upper part → Fastening the shade , until it locks with an audible click.
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Subsequent work
Fastening the shade

Subsequent work for cover of selector lever
1. Connect cable connection on underside of selector lever cover.
-arrows- is not pinched in the selector frame.
Cable lead to selector frame

3. Position cable connection -inset- on the underside of the centre
console cover.

4. Insert centre console cover at the front and tip backwards
-curved arrow- . Screw in two screws -arrows on right- .
5. Install selector knob. → 370419 Removing and installing selector

knob - section on "Installing"

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as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
j g g
ADVERTENCIA
37 15 15 Adjusting selector lever cable - as of MY 2003

- Preliminary work for selector lever cable
- Adjusting selector lever cable
- Subsequent work for selector lever cable
Tools

special inserts model AB special tool NR.170
accessory for the torque special tool NR.98-1

wrench: open ring wrench
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Preliminary work for selector lever cable
1. Remove selector knob. → 370419 Removing and installing selector knob - chapter on "removing"
Adjusting selector lever cable
Adjusting selector lever cable

1. Pull latch (plastic pin) up and move selector lever to position P.
2. Remove cover of centre console. To do this unscrew two screws

-arrows- , separate plug connection -inset- , tip cover up and back
and remove.
Centre console cover

time.
4. Unlock the rear unlocking brackets in the same way.
5. Remove selector lever cover and separate cable connection.
6. Remove the transverse strut of the centre console -arrows- .

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Cable plug for selector frame cover Releasing selector frame cover
Cable connection for centre console Transverse strut for centre console
7. Pull off electrical plug connections -arrow- .
8. Unscrew selector frame screws -arrows- .
Screw connection of selector frame

9. Undo selector lever cable screw connections on the selector frame
-arrow- using the special inserts model AB NR.170 tool.
Selector lever cable to selector frame

10. Remove shield on the transmission. To do this, unscrew three fastening screws -arrows- .
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Shield to left of transmission
11. Move shift lever on the transmission to position P, the highest position.
12. Screw in selector lever cable screw connections on the selector

frame -arrow- using the special inserts model AB NR.170 tool and
the accessory for the torque wrench: open ring wrench insert a/f
13 + adapter NR.98-1. → Tightening torque: 7.5 ftlb.
Selector lever cable to selector frame

13. Screw in selector frame screws -arrows- . → Tightening torque: 4.5
ftlb.
Screw connection of selector frame

14. Position electric plug connection -arrow- on the selector frame.
Centre console cable

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15. Install the transverse strut of the centre console -arrows- .
16. Position cable connection on the underside of the selector lever

cover.
Transverse strut for centre console

-direction of arrow- is not pinched in the selector frame.
Wiring harness to selector frame

18. Position cable connection on the underside -inset- of the centre
console cover.
19. Insert centre console cover at the front and tip backwards. Screw in
two screws -right arrows- .

Centre console cover

21. Install shield on the transmission. To do this, screw in three fastening
screws -arrows- . → Tightening torque: 7.5 ftlb.
Subsequent work for selector lever cable

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Reworking selector lever cable
2. Install selector knob. → 370419 Removing and installing selector knob - chapter on "Installing"
as of MY 2003
g g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g g g
ADVERTENCIA
37 15 19 Removing and installing selector lever cable - as of MY

2003
- Preliminary work for selector lever cable
- Removing selector lever cable
- Installing selector lever cable
- Subsequent work for selector lever cable
Tools

universal disassembly tool special tool NR.21

1. Move selector lever to position D.
2. Remove selector frame. → 370819 Removing and installing selector frame - removing
Removing selector lever cable

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Removing selector lever cable
Note
z When a new selector lever cable is used, this should be connected
directly to the old cable when it is removed. This ensures that it is
routed correctly.
1. Remove shield on the transmission. To do this, unscrew three

fastening screws -arrow- .

2. Remove tab washer -A- on the cable.
Selector lever cable connection to

transmission
3. Unscrew selector lever cable from the ball joint with universal
disassembly tool NR.21.
4. Pull selector lever cable up and out through the lower part of the
selector frame.
Removing selector lever cable on

transmission
Installing selector lever cable
Removing and installing cable adjustment
Note
z When a new selector support is used, the cable adjustment of the selector cable must be modified.
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1. Remove pins -direction of arrow- and take out cable adjustment.
Removing the cable adjustment

2. Insert cable adjustment on the new selector support and install pins
Installing the cable adjustment

3. When doing so, ensure that the opening for the adjusting screw
-arrow- is turned upwards.
Cable adjustment
Installing selector lever cable
Note
z When a new selector lever cable is used, this should be connected to the old cable immediately during
removal. This ensures that it is routed correctly.
Note
z The cable adjustment must be changed when a new selector lever cable is used.
1. Install selector lever cable through the lower part of the selector frame.
2. Press rubber sleeve on the selector lever cable into the lower part of the selector frame.
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Note
z Ensure that the tab washer is seated correctly.
3. Attach tab washer -A- to the cable holder on the transmission side.

transmission
4. Attach cable to the ball joint -arrow- .

transmission
screws -arrow- .
Subsequent work for selector lever cable
Reworking selector lever cable

1. Install selector frame. → 370819 Removing and installing selector frame - installing
as of MY 2003
g g p g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g g p g
ADVERTENCIA
37 30 19 Removing and installing the Tiptronic control unit - as of

MY 2003
- Preliminary work
- Removing Tiptronic control unit
- Installing Tiptronic control unit
- Coding Tiptronic control unit
- Subsequent work
Preliminary work
Preliminary work
1. The ignition key must be removed before removing the connector from the control unit.
2. Move right front seat all the way back and up.
Removing Tiptronic control unit
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Installation position
Note
z The control unit is located under the right front seat.
1. If the Tiptronic control unit is replaced, observe the points under coding the control unit. → 373019 Removing
and installing Tiptronic control unit - chapter on "Coding"
2. Unclip right front seat trim and remove drawer.
3. Unscrew the fastening screw for the support.
Note
z Only for vehicles with telephone
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4. Unscrew the three fastening

nuts and remove support for
telephone control unit.
5. Move seat all the way forward

and remove ignition key.
Unscrewing fastening nuts Unscrewing fastening screw for

support
6. Release the two connectors -A- and remove them -B- .
7. Remove support with the two control units -C- .
Releasing and removing connector
Release locking tabs and remove

control unit
Installing Tiptronic control unit
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Installation position
1. Insert control unit into the support -A- until the locking tabs -B- are felt
to engage.
Inserting and locking control unit

2. Connect the two connectors -A- and push in the locking mechanism -B- until it is felt to engage.
3. Place the support with the two control units in installation position -C- .
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Connecting and locking the connectors

4. Move seat all the way back and tighten the support with the fastening
screw.
5. If the Tiptronic control unit is replaced, observe the points under

coding the control unit. → 373019 Removing and installing Tiptronic
control unit - chapter on "Coding"
Tightening fastening screw
Note
6. Position the support for the telephone control unit and screw down
using the three fastening nuts.
Tightening fastening nuts
Coding Tiptronic control unit
Note
z The adaptation values must be reset using the Porsche System Tester when the transmission is
renewed/replaced.
z If a new control unit is installed, it must adapt first. Poor shifting quality can therefore be expected in the
adaptation phase.
z After the test drive, let the engine run for 10 minutes at idle speed. This ensures that all adaptation values are
stored in the control unit.
z The instructions of the Porsche System Tester have highest priority.

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z The procedure described here has been structured generally; changes or additions may be made. It is based
on Tester Software 16.0.
z During coding, it is essential to guarantee the power supply for the Porsche System Tester. It is essential to
connect a battery charger with a current rating of at least 40 A to the vehicle battery.
Continue.
3. Using the >> key, move from the vehicle type to the list of control units. Perform the automatic control unit
search.
4. Select Tiptronic with the cursor keys and press the >> key.
5. Select Control unit replacement with the cursor keys and press the >> key.
6. Select Read out values (codings) and press the >> key.
7. The message Coding read-out complete will appear on the screen of the Porsche System Tester >> .
8. Switch off ignition and replace Tiptronic control unit. → 373019 Removing and installing Tiptronic control unit -
9. Switch on ignition.
10. After replacement of the control unit, the vehicle data is installed under the menu Write in data read out (see
Section 6). Press the >> key.
11. System Tester displays Coding write-in complete. Press the >> key.
12. Exit the menu, switch off ignition, lock vehicle and read out fault memory once more.
Note
z If the data cannot be read out with the Porsche System Tester, the versions listed must be coded using the
menu item "Codings" .
Version Coding Note

Countries RoW/USA Country-specific
Asia Japan, Korea, Taiwan
Subsequent work
Subsequent work
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1. For vehicles with a telephone, install the telephone control unit. → 919019 Removing and installing control
unit for telephone - chapter on "installing"
2. Clip in right front seat trim and install drawer.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
37 31 15 Adjusting multi-functional switch - as of MY 2003

- Preliminary work for multi-functional switch
- Adjusting multi-functional switch
- Subsequent work
Tools

adjustment tool special tool T10173
Preliminary work for multi-functional switch
Adjusting multi-functional switch
Adjusting multi-functional switch
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Overview of multi-functional switch
Note
z To unscrew the cardan shaft bolts, a second fitter should sit in the vehicle and block the drive harness by
actuating the foot brake.
z The colour markings, match points -arrows- , on the cardan shaft and on the all-wheel final drive flange must
be aligned. This will neutralise the residual imbalance of the components.
z Apply another colour marking if necessary.
Note
z Screws which are tightened with a torque angle must be replaced with
new ones.
Front cardan shaft match points

2. Remove three shield screws -arrows- on the all-wheel final drive.
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3. Remove cardan shaft from the Shield on final four-wheel drive

front-axle final drive.
Cardan shaft to four-wheel final drive

5. Pull out compact connector on multi-functional switch.
Shield to right side of transmission

6. Remove cap nut, cap, nut with tab washer and rubber washer on the
multi-functional switch.
Assembling multi-functional switch

7. Loosen the fastening screws -arrow- .
Fastening screws for multi-functional

switch
8. Position special adjustment tool T10173 on the shaft and fix to the shaft with screws -arrow- .
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Fastening screws for multi-functional Adjustment tool to multi-function

switch switch
9. Screw in fastening screws -arrow- and remove special adjustment tool T10173. → Tightening torque: 3.5
ftlb.
10. Install cap nut, cap, nut with tab washer and rubber washer on the
multi-functional switch. → Tightening torque: 5 ftlb. → Tightening
torque: 11 ftlb.
11. Position compact connector on multi-functional switch.
Note
z When installing the shield, ensure that all fastening parts → Mounting
element shield are present and inserted correctly.
Mounting element shield

screws -arrow- . → Tightening torque: 7.5 ftlb.

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13. Fix cardan shaft with new screws to the front-axle final drive. → Initial tightening: 22 ftlb. → Final
tightening: 90 Winkel-Grad
14. Install shield fastening screws -arrows- on all-wheel final drive. →


Shield on final four-wheel drive
Subsequent work
Reworking multi-function switch
1. Fit engine guard. → 108019 Removing and installing engine guard - installing
9PAAE1, 9PAAF1
as of MY 2003
g g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g g g
ADVERTENCIA
37 31 19 Removing and installing multi-functional switch - as of

MY 2003
- Preliminary work
- Removing multi-functional switch
- Installing multi-functional switch
- Subsequent work
Preliminary work
Removing multi-functional switch
Removing multi-functional switch
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Note
z To unscrew the cardan shaft bolts, a second fitter should sit in the vehicle and block the drive harness by
z The colour markings, match points -arrows- , on the cardan shaft and on the all-wheel final drive flange must
Front cardan shaft match points

2. Remove three shield screws -arrows- on the all-wheel final drive.
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3. Remove cardan shaft from the Final four-wheel drive shield

front-axle final drive.

5. Pull off the cable plug on the multi-functional switch.

6. Remove cap nut, cap, nut with tab washer and rubber washer on the
multi-functional switch.

7. Unscrew fastening screws on the multi-functional switch -arrow- and
remove switch.
Fastening screws for multi-functional

switch
Installing multi-functional switch

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Installing multi-functional switch
Note
z The colour markings, match points -arrows- , on the cardan shaft and
on the all-wheel final drive flange must be aligned. This will neutralise
the residual imbalance of the components.
Note
z Screws which are tightened with a torque angle must be replaced with
new ones.
1. Put multi-functional switch on the selector shaft.
2. Adjust multi-functional switch . → 373115 Adjusting multi-functional switch
Note
z When installing the shield, ensure that all fastening parts → Mounting
element shield are present and inserted correctly.
3. Connect cable plug to multi-functional switch.

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Mounting element shield
4. Install shield on the transmission. To do this, screw in three fastening screws -arrow- . → Tightening torque:
7.5 ftlb.
5. Fix cardan shaft with new screws to the front-axle final drive. → Initial
tightening: 22 ftlb. → Final tightening: 90 Winkel-Grad

6. Install shield fastening screws -arrows- on all-wheel final drive. →

Final four-wheel drive shield
Subsequent work
Reworking multi-function switch
1. Fit engine guard. → 108019 Removing and installing engine guard - installing
9PAAE1, 9PAAF1
g g g
as of MY 2003
g g g g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g g g g g
ADVERTENCIA
37 33 19 Removing and installing sealing ring for selector shaft -

as of MY 2003
- Preliminary work
- Removing sealing ring for selector shaft
- Installing sealing ring for selector shaft
- Subsequent work
Tools

pressure sleeve special tool T10174

g g g g g
Preliminary work
Preliminary work for sealing ring for right selector shaft
1. Remove multi-functional switch. → 373119 Removing and installing multi-functional switch - section on
"Removing" [9PAAE1 9PAAF1]→ 373119 21 Removing and installing multi-functional switch - section on
"Removing" [9PAAJ1]
Preliminary work for sealing ring for left selector shaft
Removing sealing ring for selector shaft
Removing sealing ring for right selector shaft
1. Remove sealing ring with sharp tool, such as a scriber. -Graphic-
Removing sealing ring for selector

shaft
Removing sealing ring for left selector shaft

fastening screws -Arrow- .
Left transmission shield

2. Remove tab washer -A- on the cable.
3. Unscrew selector lever cable from the ball joint with universal disassembly tool NR.21.
4. Push a sharp tool, e.g. scriber, into the sealing ring and remove it. -Arrow-
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Removing selector cable from Selector lever cable to transmission

transmission
Removing left sealing ring

Installing sealing ring for selector shaft
Installing sealing ring for right selector shaft
1. Press new sealing ring with special tool pressure sleeve T10174 as
far as the pressure sleeve on the transmission housing.
Installing sealing ring for selector shaft

Installing sealing ring for left selector shaft
1. Position new sealing ring -arrow- .
2. Press new sealing ring with special tool pressure sleeve T10174 as far as the pressure sleeve on the
transmission housing. -arrow-
3. Position selector lever on selector shaft and screw in fastening nut. → Tightening torque: 11 ftlb.
g g g g g
Installing sealing ring Positioning sealing ring

4. Attach tab washer -A- to the cable holder on the transmission side.
5. Press cable on the ball joint -arrow- .
Selector lever cable to transmission
Left transmission shield
Note
z When installing the shield, ensure that all fastening parts -figure- are
present and inserted correctly.

screws -arrow- . → Tightening torque: 7.5 ftlb.
Sheetmetal panel screws
Subsequent work
g g g g g
Reworking for sealing ring for right selector shaft
1. Install multi-functional switch. → 373119 Removing and installing multi-functional switch - section on
"Installing" [9PAAE1 9PAAF1]→ 373119 23 Removing and installing multi-functional switch - section on
"Installing" [9PAAJ1]
Reworking for sealing ring for left selector shaft
as of MY 2003
g g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g g g
ADVERTENCIA
37 35 19 Removing and installing transmission - as of MY 2003

- Preliminary work
- Removing transmission
- Installing transmission
- Subsequent work
Tools

(material) special tool 00000 wooden block
fixing pin special tool 95950

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insert special tool 96870
insert bit special tool 96880
centring pin special tool 96890

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Preliminary work
Preliminary work for removing transmission

1. Remove covers in engine compartment to the right and rear. → 700219 Removing and reinstalling front
cover (engine compartment) - chapter on "Removing"
2. Remove Y-shaped pipe. → 243519 Removing and installing air box for throttle housing (Y-shaped pipe) -
chapter on "Removing" [9PAAF1]→ 243519 Removing and installing air box for throttle housing (Y-shaped
pipe) - chapter on "Removing" [9PAAE1]
4. Remove exhaust system. → 260119 Removing and installing exhaust system - chapter on "removing"
5. Remove rear cardan shaft. → 393519 Removing and reinstalling rear cardan shaft - chapter on "Removing"
6. Remove front cardan shaft. → 390219 Removing and installing front cardan shaft - chapter on "Removing"
7. Remove catalytic converter on left side. → 267619 Removing and installing primary catalytic converter -
chapter on "Removing" [9PAAE1]→ 267619 Removing and installing primary catalytic converter - chapter on
"Removing" [9PAAF1]→ 267619 Removing and installing primary catalytic converter - Cayenne Turbo -
chapter on "Removing" [9PAAE1]→ 267619 Removing and installing primary catalytic converter - Cayenne
Turbo - chapter on "Removing" [9PAAF1]
Removing transmission
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Note
z The line connections on the transmission and the ends of the ATF lines must be closed off after the lines
have been separated from the transmission!
1. Moving selector lever to position N
2. Remove torque converter support on engine side.
Torque converter support screw
3. Remove shield on the left of the transmission. To do this, unscrew three fastening screws -Arrow- .
4. Remove shield on the right of the transmission. To do this, unscrew three fastening screws -Arrow- .
5. Remove transfer box. → 396519 Removing and installing transfer box - chapter on "Removing"
6. Support engine transmission aggregate on converter bell housing with a (material) 00000 on the suspension
subframe.
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Left shield Torque converter support
Right shield
Shield panel to steering gear Supporting the engine/transmission

7. Remove shield panel on the steering gear. aggregate
8. Remove plug connections on the Tiptronic transmission -1,2,3- .
Tiptronic plug connections

9. Remove reference mark sender on the converter bell housing -Arrow- .
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10. Unscrew coolant pipe holder

bolts -Arrows- on the
converter bell housing.
Coolant pipes to converter bell Reference mark sender

housing
11. Remove retaining clip -A- on the holder.

12. Unscrew selector lever cable from the ball joint with universal
disassembly tool NR.21.
Removing selector cable
Note
z A second fitter is required to unscrew or screw in the converter
screws.
z The converter screws must be replaced.
13. Remove converter screws. Observe the following steps for this
purpose.
14. Turn crankshaft clockwise with special tool socket wrench insert
97140. Disconnecting converter screws
15. Insert special tool fixing pin 95950 into the front bore on the converter bell housing -Arrow- and hold
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upwards with light pressure until it engages when the crankshaft is turned.
16. Position special tool insert bit 96880 on converter screw through
opening in the engine block, connect bit snap-on head and special
insert 96870 one after the other.
17. Remove special tool fixing pin 95950 before undoing the converter
screws.
18. Unscrew converter screw and twist out.

19. Complete the steps described above for the other five screws.
Opening for converter screws
WARNING

20. Release ATF lines and lock connections.
21. Lift transmission with transmission jack and mounting plate on the
ATF pan and secure with belts. ATF line to transmission
22. Remove (material) 00000 base.
Supporting the engine/transmission

aggregate
23. Unscrew engine transmission flange screws -Arrow- and two screws
on the underside.
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24. Unhinge bleeder line on the Fastening screws for securing

upper side of the transfer box transmission to engine
whilst lowering.
25. Gradually extend

transmission.
Tool recommendation
Installing transmission
Note
z A second fitter is required to unscrew or screw in the converter screws.
z The converter screws must be replaced.
Note
renewed/replaced. → Removing and installing Tiptronic control unit
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Note
z Because of the limited space between the engine and the radiator,
the fixing pin can only be inserted at one point.
z Insert special tool in front of the fixing point in the belt pulley and then
turn towards the fixing point. To remove, turn engine back slightly and
remove fixing pin.
1. Fix crankshaft with special tool fixing pin 95951.
Disconnecting the crankshaft

2. Insert special tool centring pin 96890 in converter.
3. Gradually run in transmission. Thread centring pin through and

replace bleeder line.
Converter centring pin

4. Screw in engine transmission flange screws -Arrow- and two screws
on the underside. → Tightening torque: 59 ftlb.

transmission to engine
5. Remove special tool centring pin 96890 through opening in the
engine block.
Tool recommendation
6. Support transmission with a (material) 00000 between converter bell housing and suspension subframe.
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ATTENTION
Damage to converter screws due to excessive tightening torque.
→ Observe adjusting value for torque wrench. 65 Nm (48 ftlb.) on

torque wrench = 85 Nm (63 ftlb.) on the screw.
7. Screw in new converter screws:
Supporting the engine/transmission

aggregate
8. Place screws on special tool insert bit 96880 and screw in first
screw.
9. Position bit snap-on head and special tool insert 96870 and tighten
screws. → Tightening torque : 63 ftlb.
10. Remove special tool fixing pin 95951 on the crankshaft.

97140.

12. Insert special tool fixing pin 95950 into the opening on the converter
bell housing -Arrow- and hold with light pressure until it engages
when the crankshaft is turned.
13. Pull out special tool fixing pin 95950 before tightening to the
specified tightening torque.
14. Complete the steps described above for the other screws.
Disconnecting converter screws
WARNING

15. Position ATF lines on transmission and screw on tightly. →

ATF line to transmission

16. Replace converter lever cable on holder and insert safety clip -A- .
17. Press selector lever cable on to ball head -Arrow- .
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18. Screw in fastening screws for coolant pipe holder -Arrow- on the
converter bell housing. → Tightening torque: 6.5 ftlb.
Coolant pipes to converter bell

housing
19. Install reference mark sender on the converter bell housing -Arrow- .
20. Install catalytic converters on left side. → 267619 Removing and

installing primary catalytic converter - chapter on
"Installing" [9PAAE1]→ 267619 Removing and installing primary
catalytic converter - chapter on "Installing" [9PAAF1]→ 267619
Removing and installing primary catalytic converter - Cayenne Turbo
- chapter on "Installing" [9PAAE1]→ 267619 Removing and installing
primary catalytic converter - Cayenne Turbo - chapter on
"Installing" [9PAAF1]
21. Move oxygen sensor cable behind catalytic converter upwards.
Reference mark sender to converter
bell housing
22. Install shield panel on the steering gear. → Tightening torque: 7.5
ftlb.
Shield panel to steering gear

23. Connect plug connections on the Tiptronic transmission -1,2,3- .
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24. Install transfer box → Removing and installing transfer box.
Tiptronic plug connections

25. Install shield on the right of the transmission. To do this, screw in
three fastening screws -Arrow- . → Tightening torque: 7.5 ftlb.
Right shield
26. Install shield on the left of the transmission. To do this, screw in three
fastening screws -Arrow- . → Tightening torque: 7.5 ftlb.
Left shield
27. Connect oxygen sensor cable to the radiator tank.
Cable for oxygen sensors

28. Flange torque converter support on engine side. → Tightening torque: 44 ftlb.
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WARNING
Danger of scalding and chemical
burns from hot ATF

→ Wear personal protective
gear (goggles, gloves)
29. Unscrew ATF control screw

-A- and fill in ATF until a ATF pan check screw/filler screw Torque converter support screw
constant discharge is visible
at the lifting tube.
30. Screw in ATF check screw -A- . → Tightening torque: 52 ftlb.
Subsequent work
Reworking for installing transmission
2. Install front cardan shaft. → 390219 Removing and installing front cardan shaft - chapter on "Installing"
3. Install rear cardan shaft. → 393519 Removing and reinstalling rear cardan shaft - chapter on "Installing"
4. Install the exhaust system. → 260119 Removing and installing exhaust system - chapter on "Installing"
5. Install engine compartment cover on right and rear. → 700219 Removing and reinstalling front cover (engine
9PAAE1, 9PAAF1
as of MY 2003
g g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g g g
ADVERTENCIA
37 35 27 Removing and refitting transmission - as of MY 2003

- Preliminary work
- Refitting transmission
- Subsequent work
Tools

suspending device special tool 2024 A
counterer special tool 3435

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insert special tool 9687
Insert bit special tool 9688
centring pin special tool 9689

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Preliminary work
Preliminary work for removing the transmission
Note
renewed/replaced. → 373019 Removing and installing Tiptronic control unit - chapter on "removing"
1. Unscrew two screws on the underside of the converter bell housing in the installed transmission.
g g g
Overview of removing/refitting the transmission
Note
z Shift lever on the transmission is in position P. Move lever up fully.
Note
z A second fitter is required!
1. Unscrew cardan shaft bolts -Arrow- to the transfer box. Counter with
special counterer 3435 on triangular flange -A- .
Front cardan shaft to transfer box

2. Remove shield fastening screws on the right of the transmission.
WARNING

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Note
z The line connections on the
transmission and the ends of
the ATF lines should be
closed off after the lines have
been separated from the
transmission!
3. Disconnect ATF lines from the

transmission. To do this,
unscrew screw -Arrow- and ATF line to transmission Right shield
remove lines.
4. Release bleeder lines from the retainers -Arrow- on the engine.

5. Remove catalytic converter on left side. → 267619 Removing and
installing starting catalytic converter - chapter on
"Removing" [9PAAE1]→ 267619 Removing and installing starting
catalytic converter - chapter on "Removing" [9PAAF1 9PAAJ1]
Vent lines
6. Remove reference mark sender on the converter bell housing
-Arrow- .
Reference mark sender

7. Unscrew two coolant pipe screws on converter bell housing -Arrow- .
8. Remove converter bolts:

9714.

housing
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Disconnecting converter screws
10. Insert special tool fixing pin 9595 into the front bore on the converter bell housing -Arrow- and hold
upwards with light pressure until it engages when the crankshaft is turned.
11. Insert special tool Insert bit 9688 through opening in the engine
block on converter screw. Connect special tool insert 9687.

12. Unscrew converter screw and twist out.
13. Complete the steps described above for the other five screws.
Fastening converter screws

14. Attach transmission with holder suspending device 2024 A on
workshop crane.
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Transmission to workshop crane
Transmission cross member
15. Raise transmission a few centimetres and notch transmission cross member B -A- .
16. Unscrew engine transmission flange screws -Arrows- and two

screws on the underside.

Refitting transmission
g g g
Overview of removing/refitting the transmission
WARNING

Note
z Since locking is not possible after removal, the cardan shaft can only be tightened to the specified torque
after the engine has been installed.
z Screws which are tightened with a torque angle must be replaced with new ones.
1. Fix engine to the crankshaft with special tool fixing pin 9595.
Disconnecting the crankshaft

2. Attach transmission with holder suspending device 2024 A on workshop crane.
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Torque converter centring pin Transmission to workshop crane
3. Insert special tool centring pin 9689 in converter.
4. Fit the transmission onto the engine.
5. Screw in engine transmission flange screws -Arrows- . →

Note
z Screws which are tightened with a torque angle must be replaced
with new ones.
Transmission to engine screw

connection
6. Raise transmission a few centimeters and install transmission cross
member on holder -A- . → Initial tightening: 37 ftlb. → Final
tightening: 90 Winkel-Grad
7. Disassemble workshop crane and holder suspending device 2024

A.
8. Remove special tool centring pin 9689 through opening in the

engine block.
Note
z A second fitter is required. Transmission cross member
z Replace converter screws.
9. Screw in new converter screws:
10. Place screw on special tool insert bit 9688 and screw in screw.
11. Position bit snap-on head and special tool insert 9687 and screw in screw, but do not tighten.
12. Turn crankshaft clockwise with special tool socket wrench insert 9714.
g g g
13. Insert special tool fixing pin

9595 into the front bore on
the converter bell housing
-Arrow- and hold with light
pressure until it engages
when the crankshaft is
turned. This sets the position
for the next screw.
14. Complete the steps described

above for the other five
screws.
15. Remove special tool fixing Disconnecting converter screws Opening for converter screw on engine
pin 9595 before tightening
the converter screws to the
specified torque. →
16. Fasten coolant pipe on the converter bell housing -Arrow- . →


housing
17. Install reference mark sender on the converter bell housing -Arrow- .
18. Install catalytic converters on left side. → 267619 Removing and

installing primary catalytic converter - Cayenne Turbo - chapter on
"Installing" [9PAAE1]→ 267619 Removing and installing primary
catalytic converter - Cayenne Turbo - chapter on "Installing" [9PAAF1
9PAAJ1]→ 267619 Removing and installing primary catalytic
converter - chapter on "Installing" [9PAAE1]→ 267619 Removing and
installing primary catalytic converter - chapter on "Installing" [9PAAF1
9PAAJ1]

19. Press bleeder lines in the retainers -Arrow- on the engine.
20. Tighten the fastening screws in cardan shaft -Arrow- to the transfer box.
21. Fasten ATF lines with new sealing rings on the transmission. → Tightening torque: 19 ftlb.
Subsequent work
g g g
Front cardan shaft to transfer box Bleeder lines to engine holder
ATF line to transmission

Reworking for refitting
Note
renewed/replaced. → 373019 Removing and installing Tiptronic control unit - chapter on "removing"
1. Install engine → 100123 Installing M48/00 engine
2. Screw in two screws on the underside of the converter bell housing in the installed transmission.
3. Screw in front cardan shaft bolts. → Initial tightening: 22 ftlb. → Final tightening: 90 Winkel-Grad
4. Check and if necessary, top up the ATF. → 370235 Checking and topping up ATF - chapter on "refilling"
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
p p g
ADVERTENCIA
37 35 TW Technical data on 6-speed Tiptronic transmission - as of

MY 2003
- Technical values
Technical values
Technical data
Note
z In order to protect the converter components against excessive centrifugal forces when idle, the engine
speed in the selector lever positions P and N is limited to 4,000 rpm.
TypeA 48.00 / A 48.50 / A 48.20
Equipment6-speed / 6-speed / 6-speed
Installed inCayenne S / Cayenne Turbo / Cayenne
Model year2003 / 2003 / 2004
DesignFully automatic 6-speed planetary gear set
Transmission ratios
1st gear4.148
2nd gear2.370
3rd gear1.556
4th gear1.155
5th gear0.859
6th gear0.686
Reverse gear3.394
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Filling capacities A 48.00
Note
z Modified ATF filling capacities in the transmission in combination with new control units.
z Observe → " Technische Information 01/04 Gruppe 3" and numbers on transmission and control unit.
Location Explanation Type Basic value Tolerance 1 Tolerance 2

Automatic transmission New filling for transmission Filling capacity 9 litre
Automatic transmission Change quantity Filling capacity 8.5 litre
Filling capacities A 48.00
Note

Automatic transmission New filling for transmission Filling capacity 10.1 litre
Automatic transmission Change quantity Filling capacity 9.6 litre
9PAAE1
as of MY 2003
g g p g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g g p g
ADVERTENCIA
37 55 19 Removing and installing ATF pan - as of MY 2003

- Preliminary work
- Removing ATF pan
- Installing ATF pan
- Subsequent work
Preliminary work
Preliminary work for ATF pan
Removing ATF pan
Removing ATF pan
g g p g
Overview of ATF pan
WARNING


screws -arrows- .
2. Place collection pan under the transmission. Unscrew oil drain plug -B- and drain ATF.
3. Screw in oil drain plug -B- with new sealing ring. → Tightening torque: 21 ftlb.
4. Unscrew screws -arrows- on the ATF pan and remove pan.
Installing ATF pan

g g p g
Installing ATF pan
ATF pan Check screw and oil drain plug

Overview of ATF pan
Note
z Make sure that the gasket has been positioned correctly on the bulb of the oil pan edge.
1. Place new gasket on the ATF pan.
2. Check position of the magnets -arrows- in the oil pan.

g g p g
Magnets in the ATF pan
ATF pan
3. Position ATF pan and screw in screws -arrows- . → Tightening torque: 4.5 ftlb.
WARNING

4. Unscrew oil inspection plug -A- and fill ATF until constant emission is
visible.
5. Screw in oil inspection plug again -A- with new sealing ring. → Oil inspection plug and oil drain plug
Subsequent work
Reworking ATF pan
Note
2. Install shield on ATF pan. To do this, tighten the two fastening screws -arrows- . → Tightening torque: 7.5
ftlb.
as of MY 2003
g g p g
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
g g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g g g
ADVERTENCIA
37 58 19 Removing and installing ATF filter - as of MY 2003

- Preliminary work
- Removing ATF filter
- Installing ATF filter
- Subsequent work
Preliminary work
Preliminary work for ATF filter
1. Remove ATF pan. → 375519 Removing and installing ATF pan - "Removing" chapter
Removing ATF filter
Removing ATF filter
1. Unscrew three screws -arrows- on the ATF filter and remove filter.
Fastening of ATF filter
Installing ATF filter

g g g
ATTENTION
Leaks between ATF filter and hydraulic control unit
z Sealing ring of ATF filter is being pinched.
→ Turn slightly when installing the filter.
1. Coat new sealing ring -arrow- with ATF and insert in the hydraulic
control unit.
Inserting the sealing ring for ATF filter

2. Position ATF filter using a turning motion -arrow movement- .

3. Position ATF filter and screw in screws -arrows- . → Tightening
torque: 7.5 ftlb.
Fastening of ATF filter
Subsequent work
Reworking ATF filter

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1. Install ATF pan. → 375519 Removing and installing ATF pan - installing
as of MY 2003
g g g
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g g g
ADVERTENCIA
38 18 19 Removing and installing wire harness in transmission -

as of MY 2003
- Information about wire harness
- Preliminary work for wire harness
- Removing wire harness in transmission
- Installing wire harness in transmission
- Subsequent work
Information about wire harness
Information about wiring harness
Overview of wiring harness
-1- - Shift solenoid valve (S1)

-2- - Plug connection for output shaft speed inductive pickup
-2a- - Cable routing for output shaft speed inductive pickup
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-3- - Oil pressure switch 2 for transmission (omit in MY 2006)

-4- - Oil pressure switch 1 for transmission (omit in MY 2006)
-5- - Shift solenoid valve UK (modulation pressure)
-6- - Input shaft speed (turbine speed) inductive pickup
-7- - ATF temperature sensor
-8- - Modulation pressure solenoid valve (main)
-9- - Shift solenoid valve C1 (modulation pressure)
-11- - Shift solenoid valve B1 (modulation pressure)
-13- - Shift solenoid valve (S2)
Preliminary work for wire harness
Preliminary work for wiring harness

1. Remove ATF filter. → 375819 Removing and installing ATF filter - chapter on "Removing"
Removing wire harness in transmission
Removing wire harness in transmission
Overview of wire harness

g g g
Note
z The adaptation values of the Tiptronic control unit must be reset
using the Porsche System Tester when replacing/renewing the wire
harness. → 373019 Removing and installing Tiptronic control unit
1. Remove fastening screw from both connectors -Arrow- .
Connector installation
2. Pull off connectors -Arrows- on the solenoid valves -8-12- .
3. Pull off cable plugs -1,5,13- .
Solenoid valves
4. Remove wire harness for solenoid valves through opening in the
housing -Arrow- .
Removing wire harness

5. Pull off plug -Arrow- for input shaft inductive pickup -6- .
6. Pull off cable plugs from the oil pressure switches -4,3- .
Cable plug for input shaft inductive

pickup
7. Unscrew fastening screw -Arrow- for ATF temperature sensor -7- and remove sensor.
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Cable plug for output shaft inductive ATF temperature sensor

pickup
8. Pull off cable plug -2- for output shaft speed inductive pickup -Arrow- .
9. Remove wire harness for sensors through opening in the housing

-Arrow- .
Removing wire harness

10. Remove electrohydraulic control unit. To do this, unscrew fastening
screws -Arrows- and take out the control unit.
Fastening screws for control unit

11. Remove output shaft speed inductive pickup. To do this, unscrew
fastening screw -Arrow- .
Output shaft inductive pickup

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Installing wire harness in transmission
Installing wiring harness in transmission
Overview of wiring harness
Note
using the Porsche System Tester when replacing/renewing the wire
harness. → 373019 Removing and installing Tiptronic control unit
1. Install output shaft speed inductive pickup. To do this, screw in

fastening screw -arrow- . → Tightening torque: 7.5 ftlb.
Output shaft inductive pickup
Note
with new ones.
2. Install electrohydraulic control unit and screw in new fastening

screws -arrows- . → Initial tightening: 6 ftlb. → Final tightening:
90 Winkel-Grad
Fastening screws for control unit

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3. Plug in cable plug -2- for output shaft speed inductive pickup. -arrow-
4. Install wire set for sensors through opening in the housing.
Cable plug for output shaft inductive

pickup
5. Insert ATF temperature sensor -7- and screw in fastening screw
-arrow- . → Tightening torque: 7.5 ftlb.
ATF temperature sensor

6. Plug in cable plug for oil pressure switch -3,4- and inductive pickup
for input shaft -6- -arrow- .
7. Install wire set for solenoid valves through opening in the housing.
8. Push in the cable plug for the solenoid valves -1,5,8-13- .
Cable plug for input shaft inductive

pickup
9. Screw in the fastening screw from both plugs -arrow- . →
Plug installation
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Subsequent work
Reworking wiring harness

1. Install ATF filter. → 375819 Removing and installing ATF filter - chapter on "Installing"
2. Unscrew ATF control screw -A- and fill in ATF until a constant
discharge is visible at the lifting tube.
3. Screw in ATF control screw with a new sealing ring. → Tightening

torque: 52 ftlb.
4. Check and if necessary, top up the ATF. → 370235 Checking and
topping up the ATF
Oil inspection plug and oil drain plug
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
38 45 19 Removing and installing oil pressure switch - as of MY

2003
- Preliminary work for oil pressure switch
- Removing oil pressure switch
- Installing oil pressure switch
- Touching up the oil pressure switch
Preliminary work for oil pressure switch
Preliminary work oil pressure switch

1. Remove ATF filter. → 375819 Removing and installing ATF filter - chapter on "Removing"
Removing oil pressure switch
Removing oil pressure switch
1. Pull off cable plugs from the two oil pressure switches.
2. Remove oil pressure switch.
Oil pressure switch
Installing oil pressure switch

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Installing oil pressure switch
1. Install oil pressure switch -arrows- . → Tightening torque: 3.25 ftlb.
2. Connect and engage cable plugs on the oil pressure switches.
Oil pressure switch
Touching up the oil pressure switch
Reworking oil pressure switch

1. Install ATF filter. → 375819 Removing and installing ATF filter - chapter on "Installing"
3. Screw in ATF control screw -A- with new sealing ring. → tightening
torque: 51.8 ftlb.
Note
z Observe test conditions after opening cooler lines.
4. Check and top up the ATF. → 370235 Check and top up the ATF -
Chapter "Checking"
ATF inspection plug/drain plug
9PAAD1, 9PAAE1, 9PAAF1
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
38 60 19 Removing and installing ATF cooler - as of MY 2003

- Preliminary work
- Removing ATF cooler
- Installing ATF cooler
- Subsequent work
Preliminary work
Preliminary work for ATF cooler

Removing ATF cooler
Removing ATF cooler
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Overview of ATF cooler
1. Remove the front transverse strut under the radiator. To do this,

loosen the two fastening screws (M8 x 25) to the left and right.
2. Place oil collection pan under the ATF thermostat.
Transverse strut to body
WARNING

3. Unscrew nut on ATF line to thermostat -arrow- and drain ATF.
4. Close off line ends.

ATF cooler
5. Remove retaining clip -arrow- on ATF cooler.
6. Remove ATF cooler.
Installing ATF cooler

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Retaining clip for ATF cooler

Installing ATF cooler
WARNING

Overview of ATF cooler
1. Position ATF cooler.
2. Install retaining clips -arrow- on ATF cooler.
3. Screw in ATF line nuts on thermostat -arrow- . → Tightening torque: 22 ftlb.
4. Install the front cross member under the radiators. To do this, tighten the four fastening screws. →
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ATF cooler Retaining clip for ATF cooler
Transverse strut to body

6. Screw in ATF control screw with a new sealing ring. → Tightening

torque: 52 ftlb.
Subsequent work
Reworking ATF cooler

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as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
38 62 19 Removing and installing line for ATF cooling - as of MY

2003
- Preliminary work
- Removing line for ATF cooling
- Installing line for ATF cooling
- Subsequent work
Preliminary work
Preliminary work for line for ATF cooling

Removing line for ATF cooling
Removing line for ATF cooling
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Overview of ATF line
1. Place collecting pan underneath the vehicle.
WARNING

2. Unscrew fastening screw -arrow- which fastens ATF line to the ATF
thermostat and remove line.
3. Unscrew ATF line screw connection to engine oil pan and to ATF line to ATF filter
transmission.
WARNING

4. Unscrew fastening screw securing ATF line to transmission -arrow-

and remove lines.
5. Remove ATF line. ATF line to transmission
Installing line for ATF cooling

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Installing line for ATF cooling
Overview of ATF line
1. Install ATF line.
2. Screw in ATF line screw connection to engine oil pan → Tightening torque: 7.5 ftlb. and to transmission
bell housing → Tightening torque: 7.5 ftlb. .
3. Screw in fastening screw -arrow- which fastens ATF line to ATF

thermostat. → Tightening torque: 7.5 ftlb.
ATF line to ATF filter

4. Screw in fastening screw for securing ATF line to transmission -arrow- . → Tightening torque: 19 ftlb.
5. Unscrew ATF control screw -A- and fill in ATF until a constant discharge is visible at the lifting tube.
6. Screw in ATF control screw with a new sealing ring. → Tightening torque: 52 ftlb.
Subsequent work
Reworking for line for ATF cooling

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1. Install engine carrier .

installing engine carrier -
2. Install front cardan shaft.

installing front cardan shaft -
3. Check and if necessary, top

up the ATF. → 370235
Checking and topping up the
ATF Check screw and oil drain plug ATF line to transmission
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
38 70 19 Removing and installing sealing ring for output shaft - as

of MY 2003
- Preliminary work
- Removing sealing ring for output shaft
- Installing sealing ring for output shaft
- Subsequent work
Tools

slide hammer kit special tool NR.168
pressure piece special tool T10180
protective sleeve special tool T10186

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Preliminary work
Preliminary work for sealing ring for output shaft

Removing sealing ring for output shaft
Overview of sealing ring
1. Screw countersunk head bolt and bolt adapter from slide hammer kit NR.168 into sealing ring
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Removing sealing ring Screwing screws into sealing ring
2. Screw on slide hammer from slide hammer kit NR.168 and remove sealing ring -Bild- .
Installing sealing ring for output shaft
Overview of sealing ring
1. Push special tool protective sleeve T10186 -arrow- onto output shaft.
2. Push on sealing ring.
3. Remove special tool protective sleeve T10186 and drive in sealing ring flush using special tool pressure
piece T10180 -arrow- arrow .
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Subsequent work
Driving in the sealing ring Putting on protective sleeve

Reworking sealing ring for output shaft
1. Install transfer box. → 396519 Removing and installing transfer box - chapter on "Installing"
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
38 75 19 Removing and installing ATF thermostat - as of MY 2003

- Preliminary work
- Removing ATF thermostat
- Installing ATF thermostat
- Subsequent work
Tools

material special tool 00000 discharge chute
Preliminary work
Preliminary work for ATF thermostat
Removing ATF thermostat
Removing ATF thermostat
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Overview of ATF thermostat
WARNING

Note
z Counter when loosening the ATF lines. ATF cooler line at thermostat
Note
z To prevent oil from spreading into the body front section, a material 00000 should be held underneath.
2. Undo ATF line screw connection on cooler side -Arrow- at the thermostat.
3. Unscrew ATF line fastening screw -Arrow- to thermostat
4. Unscrew ATF thermostat fastening screw -Arrow- to cooler.
Note
z To prevent oil from spreading into the body front section, a material 00000 should be held underneath.
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ATF thermostat on cooler ATF line to thermostat
Discharge chute
5. Hold shop-made tool (material) 00000 -figure- under ATF thermostat.
6. Disconnect ATF lines from thermostat and drain off ATF.
Installing ATF thermostat
Installing ATF thermostat
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Overview of ATF thermostat
Note
z The sealing rings at the ends of the ATF lines on the transmission and cooler sides must be replaced before
installation.
1. Replace sealing rings on the ATF lines and coat with ATF.
2. Connect transmission-side ATF lines to thermostat. Insert the upper line first.
3. Insert ATF cooler lines.
4. Tighten ATF thermostat fastening screw -Arrow- to cooler. →

ATF thermostat on cooler

5. Tighten ATF line fastening screw -Arrow- to thermostat. → Tightening torque: 7.5 ftlb.
Note
z Counter when fastening the ATF lines.
6. Tighten ATF line screw connection on cooler side -Arrow- at the thermostat. → Tightening torque: 22 ftlb.
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ATF cooler lines at thermostat ATF line to thermostat

7. Insert locking clip -1- on charge air cooler suction line and push line
on until it engages.
Disconnecting ambient air valve

9. Screw in ATF inspection plug -A- with new sealing ring. →

Subsequent work
Subsequent work for ATF thermostat
9PAAD1, 9PAAE1
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g g y g
ADVERTENCIA
38 77 19 Removing and installing electrohydraulic control unit - as

of MY 2003
- Preliminary work
- Removing the electrohydraulic control unit
- Installing the electrohydraulic control unit
- Subsequent work
Preliminary work
Preliminary work for electrohydraulic control mechanism
1. Remove pipe set in transmission. → 381819 Removing and installing pipe set in transmission - chapter on
"removing"
Removing the electrohydraulic control unit
1. Remove electrohydraulic control unit. To do this, unscrew fastening

screws -arrows- and remove the control unit.
Control unit fastening screws
Installing the electrohydraulic control unit
Installing the electrohydraulic control unit

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Note
with new ones.
Note
using the Porsche System Tester when replacing/exchanging the
electrohydraulic control unit. → Removing and installing the Tiptronic
control unit Control unit fastening screws
1. Install electrohydraulic control unit. To do this, screw in new fastening screws -Pfeil- . → Initial tightening: 6
ftlb. → Final tightening: 90 degree angle
Subsequent work
Subsequent work for electrohydraulic control mechanism
1. Install pipe set in transmission. → 381819 Removing and installing pipe set in transmission - chapter on
"installing"
3. Screw in ATF inspection plug -A- with new sealing ring. →

4. Check and if necessary, top up the ATF. → 370235 Checking and

topping up the ATF
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
39 01 19 Removing and installing rear final drive - as of MY 2003

- Preliminary work for rear final drive
- Removing rear final drive
- Installing rear final drive
- Subsequent work for rear final drive
Tools

centring tool commercially 9680
available tool
Preliminary work for rear final drive
Preliminary work: Rear final drive


2. Remove longitudinal interlock servo motor. → 397719 Removing and installing rear-differential lock servo
motor - "Removing" section
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Removing rear final drive
Overview of rear cardan shaft
2. Loosen fastening screws for fixing cardan shaft centre bearing holder
to body.
Cardan shaft support to body

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Centre bearing to cardan shaft holder
Tying up rear cardan shaft
Note
z The colour marking, match point, on the cardan shaft and on the
flange of the rear final drive must be installed in alignment -arrows- .
This will neutralise the residual imbalance of the components.
Note
z To loosen the cardan shaft on the rear axle transmission, a second
fitter should counter the fastening screws on the triangular flange of
the transfer box. Match points on the cardan shaft
4. Remove cardan shaft from rear axle transmission and tie it up.
Note
z To loosen the drive shaft bolts on the rear axle transmission, a
second fitter should sit in the vehicle and block the rear-axle final
drive by actuating the foot brake.
5. Remove both drive shafts on transmission side and tie up.
6. Support transmission jack and rear axle transmission with retaining

band.
Removing rear drive shaft

7. Unscrew fastening screws for final drive. To do this, counter with ring
wrench.
Mount for rear final drive

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8. Tip drive flange upwards -arrow- and gradually drain rear axle transmission. Remove bleeder line at the
same time.
9. Remove transmission and pull off bleeder line → Removing bleeder

line .
Removing bleeder line
Installing rear final drive
Note
with new ones.
Note
z The colour marking, match point, on the cardan shaft and on the flange of the rear final drive must be
installed in alignment -arrows- . This will neutralise the residual imbalance of the components.
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1. Secure rear axle transmission on transmission jack with retainer

band.
Match points on the cardan shaft

2. Run in rear axle differential by gradually tipping the drive flange
upwards -arrow- . Connect bleeder line at the same time.
3. Screw in new fastening screws on final drive. To do this, counter with

ring wrench. → Initial tightening: 67 ftlb. → Final tightening: 67 °
Note
z To tighten the drive shaft bolts on the rear final drive, a second fitter
should sit in the vehicle and block the rear-wheel drive assembly by
4. Attach drive shafts with new screws. → 42 Tightening torques for Installing transmission
rear axle
ATTENTION
Cardan shaft can be damaged by imbalance.
→ Cardan shaft and flange not installed in original position.

→ The colour marking, match point, on the cardan shaft and on the
flange of the rear final drive must be installed in alignment. This will
neutralise the residual imbalance of the components.
Note Cardan shaft to rear final drive
z To attach the cardan shaft to the rear final drive, a second fitter should counter the fastening screws on the
triangular flange of the transfer box.
5. Attach cardan shaft with new screws.
6. Screw in fastening screws for fixing cardan shaft centre bearing holder to body. → Tightening torque: 44
ftlb.
Note
z Centre bearing must be installed without tension.
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Alignment of special tool 9680 Cardan shaft support to body

z Fit special tool centring tool 9680 -Werkzeug in Einbaulage- in the
order specified.
7. Position special tool centring tool 9680.
Installation position for special tool

8. Press on special tool centring tool 9680 in sequence according to
numbering -1, 2- .
Installation of special tool 9680

9. Tighten threaded joints -arrow- connecting support to centre
bearing. → Tightening torque: 15 ftlb.
Cardan shaft support to centre bearing

10. Remove special tool centring tool 9680.
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Subsequent work for rear final drive
Removal of special tool 9680

Subsequent work: Rear final drive

2. Install servo motor for rear-differential lock. → 397719 Removing and installing rear-differential lock servo
motor - "Installing" section
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g g g
ADVERTENCIA
39 02 19 Removing and installing front cardan shaft - as of MY

2003
- Preliminary work for front cardan shaft
- Removing front cardan shaft
- Installing front cardan shaft
- Subsequent work for front cardan shaft
Tools

material special tool 00000 transmission jack
Preliminary work for front cardan shaft

Removing front cardan shaft

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Overview of cardan shaft
Note
z To unscrew the cardan shaft bolts, a second fitter should sit in the
vehicle and block the drive train by actuating the foot brake.
z The colour markings, match points -arrows- on the cardan shaft and
Fastening of cardan shaft to transfer

box
1. Remove cardan shaft from the transfer box -arrow- .
Match points of front cardan shaft to

front final drive
Note
z To unscrew the cardan shaft bolts, a second fitter should sit in the vehicle and block the drive train by
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Front cardan shaft to all-wheel final

drive
2. Detach cardan shaft from final four wheel drive → Front cardan shaft
to all-wheel final drive .
3. Support transmission with material 00000 and secure with retaining

band.

front final drive
4. Unscrew four exhaust system screws from cross member
-centre arrow- and unscrew holder screws from body -right arrow- .
Exhaust system at cross member

5. Unscrew transmission cross member bolts from body -A- .
6. Unscrew two screws fastening cross member -B- to transfer box

support and remove transmission cross member.

7. Undo exhaust clamp on the right side -arrows- and push it in the direction of the catalytic converter.
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Note
If the cardan shaft is to remain
removed, the transmission cross-
member must be refitted.
8. Remove cardan shaft

between ATF pan and
exhaust system support
-arrow- .
Removing cardan shaft Exhaust clamp
Installing front cardan shaft
Note
z The transmission cross member must be disassembled before the cardan shaft is installed.
1. Install cardan shaft between ATF pan and exhaust system support.
2. Fit new exhaust clamps -arrows- . The bolts must point downwards. Note tightening torque. → 260119
Removing and installing exhaust system
3. Support transmission with transmission jack.

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Note
z Screws which are tightened
with a torque angle must be
replaced with new ones.
4. Screw in new screws

fastening cross member -B- to
transfer box support. → Initial
tightening: 37 ftlb. → Final
tightening: 90 degree angle
Transmission cross member Exhaust clamp
Note
5. Screw new cross member screws into body -A- . → Initial tightening: 37 ftlb. → Final tightening: 90
degree angle
6. Fasten exhaust system to transmission cross member

-centre arrow- and body -outer arrow- . Observe torques for
exhaust system → 260119 Removing and installing exhaust system

drive
Note
z The colour markings, match points -arrows- on the cardan shaft and on the all-wheel final drive flange must
Note
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z To tighten the cardan shaft bolts, a second fitter should sit in the
vehicle and block the drive train by actuating the brake.
Note
with new ones.
7. Fix cardan shaft with new screws → Front cardan shaft to all-wheel
final drive to the all-wheel final drive. → Initial tightening: 22 ftlb. →
Final tightening: 90 degree angle
front final drive
8. Fix cardan shaft with new screws -arrow- to the transfer box. →
Initial tightening: 22 ftlb. → Final tightening: 90 degree angle
Subsequent work for front cardan shaft

as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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39 13 19 Removing and installing transfer box control module - as

of MY 2003
- Removing transfer box control module
- Installing transfer box control module
Removing transfer box control module
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Note
3. For vehicles with a telephone, remove the telephone control unit. → 919019 Removing and installing control
unit for telephone - chapter on "removing"

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Note
z Only for vehicles with
telephone


8. Release the two connectors -A- and pull them off -B- .
9. Remove the support with the two control units -C- .
Installing transfer box control module
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1. Insert the control unit -A- until the locking tabs -B- are felt to engage.
2. Insert the two connectors -A- and press in the locking mechanism -B- until it is felt to engage.
3. Place the support with the two control units in the installation position -C- .
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4. Move seat all the way back

and tighten the support with
the fastening screw.
Note
6. For vehicles with a telephone, install the telephone control unit.

→ 919019 Removing and installing control unit for telephone -
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
39 22 19 Removing and installing sealing ring for output flange -

as of MY 2003
- Preliminary work for sealing ring for output flange
- Removing sealing ring for output flange
- Installing sealing ring for output flange
- Subsequent work
Tools

shop-made tool commercially
available tool .gif
pressure piece commercially t10181

available tool
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striker commercially vw
available tool 771/1
extraction tool commercially vw

Preliminary work for sealing ring for output flange
Preliminary work sealing ring for output flange
Removing sealing ring for output flange
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Overview of sealing rings
1. Remove output flange with special tool striker vw 771/1 and shop-
made tool .
Removing output flange
Removing sealing ring
Installing sealing ring for output flange
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1. Replace circlip on flange shaft.
Replacing circlip
2. Drive in new sealing ring with special tool pressure piece t10181
until the special tool touches the transmission housing.
3. Install output flange.
Subsequent work
Reworking sealing ring for output flange

1. Install rear final drive. → 390119 Removing and installing rear final drive - "Installing" section [9PAAD1
g g g g p g g
9PAAD7]→ 390119 Removing and installing rear final drive - "Installing" section [9PAAE1 9PAAE7 9PAAF1
9PAAJ1]
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
39 35 19 Removing and installing rear cardan shaft - as of MY

2003
- Preliminary work for rear cardan shaft
- Removing rear cardan shaft
- Installing rear cardan shaft
- Subsequent work
Tools

available tool
Preliminary work for rear cardan shaft
Preliminary work - rear cardan shaft

1. Remove exhaust system after catalytic converter. → 260119 Removing and installing exhaust system -
Removing rear cardan shaft

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Note
z If the cardan shaft or transfer box has to be replaced, please ignore the next step.
z Marking the position of the cardan shaft with respect to the transfer box triangular flange serves only to
prevent possible humming noises.
Note
fitter should counter the fastening screws -arrows- at the triangular
flange of the transfer box.
Rear cardan shaft to transfer box

2. The position of the cardan shaft -arrows- with respect to the rear axle transmission flange is marked with a
white dot, match point, on both components.
Note
z The colour marking, match point, on the cardan shaft and on the rear final drive flange must be aligned. This
will neutralise the residual imbalance of the components.
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3. Mark the position of the

cardan shaft -arrow- with
respect to the transfer box
flange with a coloured pen.
Mark for rear cardan shaft to transfer Match points for cardan shaft to final
box drive
4. Loosen fastening screws -arrow- securing cardan shaft support to
centre bearing.

5. Unscrew fastening screws on the cardan shaft at the rear axle
transmission → Cardan shaft to rear final drive .
Cardan shaft to rear final drive
ATTENTION
Noises caused by damage in the drive line
→ Faulty centre bearing; replace cardan shaft

→ Do not loosen cardan shaft bolts using rubber/metal disc.
6. Unscrew fastening screws -arrows- on the cardan shaft at the

transfer box. Counter with an open-ended wrench.
Cardan shaft to transfer box

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ATTENTION
Cardan shaft can be damaged if not handled correctly
→ Avoid repeated sagging or significant vertical traction.

→ When one of the two flanges on the cardan shaft has been released,
the centre bearing must be relaxed!
→ Do not leave cardan shaft hanging. All three fastening points for
transfer box, centre bearing and rear final drive must always be
screwed in.
→ The recommended procedures must be followed during installation, Cardan shaft centre bearing to body
otherwise the position of the cardan shaft in its original place is no
longer guaranteed. Possible result: premature failure of the centre
bearing resulting in subsequent cardan shaft replacement.
7. Release cardan shaft centre bearing holder. To do this, unscrew six fastening screws -arrows- .
8. Carefully separate cardan shaft from transfer box → Removing

cardan shaft and press backwards.
Note
z To prevent the cardan shaft from being damaged, a second mechanic
is required to remove the equipment.
Removing cardan shaft
Installing rear cardan shaft
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ATTENTION

→ When one of the two flanges on the cardan shaft has been released, the centre bearing must be relaxed!
→ Do not leave cardan shaft hanging. All three fastening points for transfer box, centre bearing and rear final
drive must always be screwed in.
→ The recommended procedures must be followed during installation, otherwise the position of the cardan
shaft in its original place is no longer guaranteed. Possible result: premature failure of the centre bearing
resulting in subsequent cardan shaft replacement.
ATTENTION
Leakage due to damage to centring sleeve
→ Ensure that no damage occurs during removal and installation.

→ Centring sleeve should be greased slightly.
→ Transfer box journal must be clean.
Note
z There is no colour marking on the flange to the transfer box for installing new components, transfer box or
cardan shaft. As a result, positioning is not an issue.
z If none of the components are replaced, the mark you apply is a precautionary measure in order to avoid
humming noises from the drive line.
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Note
z To prevent the cardan shaft from being damaged, a second mechanic is required to install the equipment.
1. Install cardan shaft.
2. Pull cardan shaft joints apart so that they sit in the transmission flanges.
3. Screw in six screws -arrow- on the centre bearing holder but do not
tighten.
Cardan shaft centre bearing to body

4. Position the cardan shaft at the colour markings -arrow- again.
Marking on transfer box flange/cardan

shaft
Note
z The colour marking, match point -arrow- , on the cardan shaft and on the flange of the rear final drive must
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Note
z To attach the cardan shaft to the rear axle transmission, a second
the transfer box.

with new ones.
5. Screw in new screws for cardan shaft flange at the rear axle
transmission. → Initial tightening: 22 ftlb. → Final tightening: 90 °
Match points for cardan shaft to final
drive
6. Tighten bolts connecting cardan shaft triangular flange to transfer
box -arrows- . Counter with an open-ended wrench. → Tightening
torque: 56 ftlb.

7. Screw in fastening screws for securing cardan shaft centre bearing
holder to body -arrows- . → Tightening torque: 44 ftlb.
Note
Mounting special tool 9680

z Fit special tool centring tool 9680 → Special tool in installation position in the specified sequence.
8. Mount special tool centring tool 9680 -arrow,inset- .

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Special tool in installation position

numbering -1, 2- .
Pressing on special tool 9680

10. Tighten bolts -arrow- connecting holder to centre bearing. →

11. Remove special tool centring tool 9680. -arrows-
Removing special tool 9680
Subsequent work
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Subsequent work - rear cardan shaft

as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
39 55 19 Removing and installing sealing ring for cardan flange -

as of MY 2003
- Preliminary work for cardan flange sealing ring
- Removing sealing ring for cardan flange
- Installing sealing ring for cardan flange
- Subsequent work for sealing ring for cardan flange
Tools

available tool .gif
counterer commercially 3435

available tool
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torque screwdriver for commercially 89

measuring friction moment available tool

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Preliminary work for cardan flange sealing ring

2. Remove front cardan shaft → 390219 Removing and installing front cardan shaft - chapter on
"Removing" [9PAAE1 9PAAF1 9PAAJ1]→ 390219 Removing and installing front cardan shaft - chapter on
"Removing" [9PAAD1 9PAAD7 9PAAE7].
Removing sealing ring for cardan flange
Overview of cardan flange sealing ring

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1. Mark nut on drive flange with a coloured pen -arrow- .
Marking nut
2. Determine rolling moment of axle transmission with special tool
torque screwdriver for measuring friction moment 89. Push stop
on special tool to zero and turn transmission several times. Note the
displayed value.
3. Unscrew nut on drive flange. To do this, use the special tool

counterer 3435 to block the transmission → Measuring rolling
moment .
Measuring rolling moment

4. Remove drive flange with special tool striker vw 771/1 and shop-
made tool → Removing drive flange .
Removing drive flange

5. Remove sealing ring with special tool striker vw 771/1 and
extraction tool vw 771/37.
Installing sealing ring for cardan flange

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1. Fill space between dust and sealing lips with grease.
Greased sealing ring

2. Drive sealing ring in as far as the mounting face with special tool
pressure piece T10183.
3. Push in drive flange and tighten nut.
Driving in the sealing ring

4. Position marking on nut and drive shaft -arrow- again so that the rolling moment determined prior to removal
is attained once again.
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Note
z If the rolling moment has to be corrected, this should be done via the
tightening torque of the nut.
5. Check rolling moment with special tool torque screwdriver for

measuring friction moment 89.
Marking nut
Rolling moment Adjustment value 2.0 (1.5 ftlb.) Nm +0.5 (0.5 ftlb.) Nm
Subsequent work for sealing ring for cardan flange
Subsequent work on sealing ring for cardan flange

1. Install front cardan shaft → 390219 Removing and installing front cardan shaft - chapter on
"Installing" [9PAAE1 9PAAF1 9PAAJ1]→ 390219 Removing and installing front cardan shaft - chapter on
"Installing" [9PAAD1 9PAAD7 9PAAE7].
2. Carry out oil check. → 399035 Checking and topping up oil for all-wheel final drive - chapter on "Checking"
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA

as of MY 2003
- Preliminary work for output flange sealing ring
- Removing sealing ring for left and right output flange
- Installing sealing ring for left and right output flange
- Subsequent work for output flange sealing ring
Tools

available tool .gif

available tool
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Preliminary work for output flange sealing ring
Removing sealing ring for left and right output flange
Removing sealing ring for left-hand output flange
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Overview of left sealing ring
1. Remove flanged shaft with special tool striker vw 771/1 and shop-
made tool .
Removing flanged shaft

Removing sealing ring for right-hand output flange
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Overview of right sealing ring
made tool .

extraction tool vw 771/37 attachment.
Installing sealing ring for left and right output flange
Installing sealing ring for left-hand output flange

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1. Drive in sealing ring with special tool pressure piece t10032

→ Installing sealing ring until the special tool touches the
transmission housing.

2. Replace circlip on end of long flanged shaft.
Example using the short flanged shaft

Installing sealing ring for right-hand output flange
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2. Replace circlip on flanged shaft → Replacing circlip .
3. Push flanged shaft into transmission until it engages.
Replacing circlip
Subsequent work for output flange sealing ring

1. Install four-wheel final drive → 398819 Removing and installing four-wheel final drive - chapter on
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"Installing".
2. Check oil for four-wheel final drive. → 399035 Checking and topping up oil for four-wheel final drive - chapter
on "Checking"
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
39 61 19 Removing and installing rubber mounting for four-wheel

final drive - as of MY 2003
- Preliminary work for rubber mounting on four-wheel final drive
- Removing rubber mounting for four-wheel final drive
- Installing rubber mounting for four-wheel final drive
- Subsequent work for four-wheel final drive
Tools

workshop caliper gauge commercially 139
available tool
assembly fixture special tool 9716

a/b
assembly fixture commercially 9716

available tool a/b/c
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Preliminary work for rubber mounting on four-wheel final drive
Preliminary work, rubber mounting on four-wheel final drive

1. Remove four-wheel final drive. → 398819 Removing and installing four-wheel final drive - "Removing"
section
Removing rubber mounting for four-wheel final drive
Removing rubber mounting for four-wheel final drive, drive side
Rubber mounting, drive side -1-
1. Mark rubber mounting for transmission housing at the installation position -arrow- .
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Removing rubber mounting, drive side Marking for rubber mounting
2. Position special tool assembly fixture 9716 a/b on rubber mounting → Removing rubber mounting, drive
side .
3. Remove rubber mounting on drive side -arrow- .
Removing rubber mounting for four-wheel final drive, right output side
Rubber mounting for right output side -2-
2. Position special tool assembly fixture 9716 a/b on rubber mounting → Removing right rubber mounting .
Removing rubber mounting for four-wheel final drive, left output side
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Removing right rubber mounting Marking for rubber mounting
Rubber mounting for left output side -3-
1. Mark rubber mounting for transmission housing at the installation

position -arrow- .
Marking for rubber mounting

2. Position special tool assembly fixture 9716 a/b on rubber mounting → Removing left rubber mounting .
3. Remove left rubber mounting -arrow- .
Installing rubber mounting for four-wheel final drive

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Removing left rubber mounting

Installing rubber mounting for four-wheel final drive, drive side
Note
Noises in drive line
z Installation position of rubber mounting bulge is incorrect Rubber

mounting bulge must be installed vertically into housing
z Installation position of mount in housing is incorrect Pay attention to

installation dimension of mount to housing
1. Mark centre of bulge in rubber mounting → Marking for centre of

rubber mounting . Marking for centre of rubber mounting
2. Position rubber mounting in housing using special tool assembly fixture 9716 a/b/c.
3. Pull in rubber mounting in direction of travel until installation position is reached. Measure distance between
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Installation position of rubber mounting

assembly fixture ring and housing using workshop caliper gauge 139. → Distance: 7.5 mm +/-0.1 mm
Installing rubber mounting for four-wheel final drive, right output side
Note


Note Marking for centre of rubber mounting

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z Installation position of rubber mounting bulge is incorrect Rubber mounting bulge must be installed vertically
into housing
z Installation position of mount in housing is incorrect Pay attention to installation dimension of mount to
housing
1. Mark centre of bulge in rubber mounting → Marking for centre of rubber mounting .
2. Position special tool assembly fixture 9716 a/b on rubber mounting.
3. Pull in rubber mounting until installation position is reached.
Installing rubber mounting

Installing rubber mounting for four-wheel final drive, left output side
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Note



into housing
housing
1. Mark centre of bulge in rubber mounting. -arrows-
2. Position special tool assembly fixture 9716 a/b/c on rubber mounting → Positioning bearing .
3. Press rubber mounting flush into housing. -direction of arrow-
Subsequent work for four-wheel final drive
Touching up, rubber mounting on four-wheel final drive

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1. Install four-wheel final drive. → 398819 Removing and installing four-

wheel final drive - "Installing" section
Positioning bearing
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g g g g
ADVERTENCIA
39 61 19 Removing and installing rubber mounting for rear final

drive - as of MY 2003
- Preliminary work
- Removing rubber mounting for rear final drive
- Installing rubber mounting for rear final drive
- Subsequent work
Tools

material special tool 00000 shop-made tool

available tool a/b

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striker workshop VW
equipment 771/1
Preliminary work
Preliminary work, rubber mounting on rear final drive
Removing rubber mounting for rear final drive
Removing rubber mounting for rear final drive, drive side
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position -arrow- .
Marking for rubber mounting for

housing
2. Position special tool assembly fixture 9716 a/b on rubber mounting
→ Removal on drive side .
Removal on drive side

Removing rubber mounting for rear final drive, output side
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Rubber mounting for output side -2-
1. Remove output flange with special tool striker VW 771/1 and

material 00000 -direction of arrow- .

position -arrow- .

3. Position special tool assembly fixture 9716 a/b on rubber mounting → Removing rubber mounting .
4. Remove rubber mounting -direction of arrow- .
Installing rubber mounting for rear final drive

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Removing rubber mounting

Installing rubber mounting for rear final drive, output side
Note


1. Position special tool assembly fixture 9716 a/b/c on rubber

mounting and align the markings.
2. Press rubber mounting flush → see figure into housing.

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Note


Installing rubber mounting for rear final drive, drive side
Note



mounting → Installing rubber mounting on drive side and align the Installing rubber mounting on drive
markings. side
Note
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into housing
housing
2. Press rubber mounting flush -direction of arrow- into housing.
Subsequent work
Touching up, rubber mounting on rear final drive

9PAAJ1]
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g g g
ADVERTENCIA
39 65 19 Removing and installing transfer box - as of MY 2003

- Preliminary work for transfer box
- Removing transfer box
- Installing transfer box
- Subsequent work for transfer box
Preliminary work for transfer box
Preliminary work transfer box

Removing transfer box
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Overview of removing and installing transfer box
Note
1. Remove front cardan shaft on the transfer box and tie it up.

2. Remove cable plug on the servo motor -1 , 2- and release cable
holder.
Note
Always observe the exact work sequence when installing/removing the
transmission cross member.
3. Remove transmission cross member.
4. Support transmission with transmission jack and secure with

retaining band.
Cable plug on servo motor
5. Unscrew bolts on body -A- .
6. Unscrew two transmission cross member screws -B- on transfer box holder.
7. Place a wooden block -arrow- between the converter bell housing and suspension subframe.
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Supporting transmission Transmission cross member
Tiptronic line holder
8. Unscrew fastening nut and push holder with Tiptronic line -A- away to the side.
9. Unscrew fastening screws -arrows- securing transfer box to main

transmission.
Transfer box to main transmission

10. Separate transfer box from main transmission.
11. Gradually drain transfer box. Pull out vent line -arrows- and remove it from the retainers on the upper side.
Installing transfer box

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Vent line support Removing transfer box

1. Support main transmission on converter bell housing with a wooden

block -arrow- .
Supporting transmission
2. Gradually run in transfer box. Press vent line into holder -arrow- and
attach to transfer box.
Vent line support

3. Screw in fastening screws on main transmission. → Tightening
torque: 33 ftlb.

4. Tighten holder -A- for Tiptronic line using fastening nut -arrow- . → Tightening torque: 7.5 ftlb.
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Transfer box
5. Support transfer box with transmission jack and remove wooden
block between converter bell housing and suspension subframe.
Note
Note
with new ones. Supporting transmission
6. Install transmission cross member.
7. Screw in two cross member screws -B- on transfer box holder. →

8. Screw in fastening screws for securing transmission cross member to
body -A- . → Initial tightening: 37 ftlb. → Final tightening: 90 °
Note
9. Connect front cardan shaft to transfer box. → Initial tightening: 22 ftlb. → Final tightening: 90 °
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10. Connect cable plugs -1 , 2- to

the transfer box and secure
the cable holder.
Cable plug on servo motor Front cardan shaft to transfer box
Subsequent work for transfer box
Reworking transfer box

1. Install cardan shaft. → 393519 Removing and installing rear cardan shaft - chapter on "Installing" [9PAAE1
9PAAE7 9PAAF1]→ 393519 Removing and installing rear cardan shaft - chapter on "Installing" [9PAAD1]
→ 393519 23 Removing and installing rear cardan shaft - chapter on "Installing" [9PAAJ1]→ 393519
Removing and installing rear cardan shaft - chapter on "Installing" [9PAAD7]
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g g g
ADVERTENCIA
39 77 19 Removing and installing transverse lock servo motor - as

of MY 2003
- Removing transverse lock servo motor
- Installing transverse lock servo motor
- Subsequent work
Removing transverse lock servo motor
Overview of transverse lock servo motor
1. Pull cable plug -1, 2- off the servo motor.

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Cable lead fastening Electric plug on servo motor
2. Pull off fastening element -arrow- for cable lead and place lead aside.
3. Unscrew four fastening screws -arrows- on the servo motor.
ATTENTION
Emerging oil is harmful to the eyes.
→ Wear personal protective gear (e.g. safety goggles).
Note
z Avoid minor oil leaks when removing the servo motor. Servo motor fastening
4. Place oil collection container underneath.
Installing transverse lock servo motor
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1. Replace sealing ring -arrow- on servo motor.
2. Install servo motor.
Sealing ring on servo motor

3. Screw in four screws -arrows- on servo motor. → Tightening
torque: 7.5 ftlb.
Servo motor fastening

4. Install fastening element -arrow- for cable lead.
5. Connect cable plug -1, 2- to servo motor.
Subsequent work
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Electric plug on servo motor Cable lead fastening

Subsequent work for servo motor for differential lock
1. Check the oil in the final drive. → 399035 Checking and topping up oil for rear final drive
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g g g
ADVERTENCIA
39 78 19 Removing and installing servo motor on transfer box - as

of MY 2003
- Removing servo motor on transfer box
- Installing servo motor on transfer box
Removing servo motor on transfer box
Overview of servo motor
1. Before beginning to work on the servo motor for the transfer box, engage the Low Range offroad driving
program.
2. Disconnect Low Range cable plug -arrow- on the servo motor and loosen cable holder -A- .
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Low Range cable plug

3. Pull centre-differential lock cable plug -arrow- off the servo motor.
Centre-differential lock cable plug

4. Unscrew servo motor threaded joint on the transfer box.
Threaded joint for servo motor
Installing servo motor on transfer box
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Note
z If a new servo motor is installed, it is supplied in Low Range position,
offroad driving program.
1. Connect servo motor to the shaft on the transfer box. Position cutout
of the shaft -right inset- to the servo motor -left inset- .
2. Screw in servo motor threaded joint -arrows- on the transfer box. →

Positioning the servo motor

3. Screw in servo motor threaded joint support -arrows- on the transfer
box. → Tightening torque: 7.5 ftlb.

4. Connect centre-differential lock cable plug -2- , Low Range -1- and secure cable holder.
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Cable plug for servo motor
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g g g g g g
ADVERTENCIA
39 82 19 Removing and installing sealing ring for cardan flange

(rear final drive) - as of MY 2003
- Preliminary work for sealing ring for cardan flange
Tools

shop made tool special tool 00000
torque screwdriver for commercially NR.89

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striker workshop VW
equipment 771/1
extraction tool workshop VW

equipment 771/37
Preliminary work for sealing ring for cardan flange

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1. Remove rear cardan shaft. → 390119 Removing and installing rear final drive - chapter on
"Removing" [9PAAD1 9PAAD7]→ 390119 Removing and installing rear final drive - chapter on
"Removing" [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]
1. Mark position of nut on drive flange -arrow- at shaft.
Marking of nut on drive flange

2. Check rolling moment of rear final drive with special tool torque screwdriver for measuring friction
moment NR.89 -picture- and note value.
Note
z A second fitter is required for loosening/tightening the flange
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3. Unscrew nut on drive flange.

To do this, block flange with
special tool arm bracket
3435.
Loosening nut on drive flange Checking rolling moment

4. Remove drive flange with special tool shop made tool 00000 and
striker VW 771/1.
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1. Drive in sealing ring with special tool pressure piece T10182

-picture- until special tool touches transmission housing.
2. Push in flange and screw in nut.
Note
3. Position marking on nut and drive shaft -arrow- again so that the
rolling moment determined prior to removal is reached once again.
Marking nut on drive flange
Note
z If the rolling moment has to be corrected, this should be done via the tightening torque of the nut.
4. Check rolling moment with special tool torque screwdriver for measuring friction moment NR.89. →
Rolling moment: 2.0 ftlb. -0.2 ftlb. +0.2 ftlb.
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Checking rolling moment
Touching up sealing ring for cardan flange

1. Install rear cardan shaft. → 390119 Removing and installing rear final drive - chapter on "Installing" [9PAAD1
9PAAD7]→ 390119 Removing and installing rear final drive - chapter on "Installing" [9PAAE1 9PAAE7
9PAAF1 9PAAJ1]
2. Check the oil in the final drive. → 399035 Inspecting and adding oil for rear final drive - chapter on
"Checking"
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g g g
ADVERTENCIA
39 88 19 Removing and installing four-wheel final drive - as of MY

2003
- Preliminary work for all-wheel final drive
- Removing four-wheel final drive
- Installing four-wheel final drive
Tools

multiple-tooth socket wrench commercially NR.31
spring compressor workshop VW 552

equipment
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Preliminary work for all-wheel final drive
Preliminary work final four wheel drive

1. Remove right engine compartment cover → 700219 Remove and install front cover (engine compartment) -
Chapter "Removing".
2. Support engine. → Support engine on the body [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]→ Support engine on
the body [9PAAD1 9PAAD7] or → Supporting engine on the body [9PAAD1 9PAAD7]→ Supporting engine
on the body [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]
3. Remove front wheels. → 440519 Remove and install wheel - Chapter "Removing"
4. Remove engine guard → 108019 Removing and installing engine guard - Chapter "Removing".
5. Remove front cardan shaft → 390219 Install and remove front cardan shaft - Chapter "Removing" [9PAAE1
9PAAF1 9PAAJ1]→ 390219 Install and remove front cardan shaft - Chapter "Removing" [9PAAD1 9PAAD7
9PAAE7].
Removing four-wheel final drive
Overview of front-wheel drive
1. Clamp steering wheel in centre position with steering wheel holder -figure- .
2. Unscrew plastic nuts -arrows- on front right wheel housing liner.
3. Engage special tool spring compressor VW 552 in top of wheel housing, behind wheel housing liner, and
support the spring strut.
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Wheel housing liner mount
Steering wheel holder
Installation position of spring

compressor
4. Remove cover plate on the steering -arrows- .
5. Pull Servotronic plug off the steering gear.
Cover plate on steering

6. Unscrew bolted connection -arrow- securing universal joint to
steering gear. Remove universal joint from steering gear.
7. Remove left and right drive shafts from four-wheel final drive using
multiple-tooth socket wrench insert M12 NR.31.
Universal joint bolted connection

8. Undo fastening screws for four-wheel final drive and screw on drive flange.
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Note
z Supports 1, 2 and 3 must be fitted to the unit lifting platform.
9. Raise unit lifting platform until it bears against the front-axle carrier.
VAG bolts
Bolts on front-axle carrier
Note
z Fastening screw -left arrow- at front right cannot be removed until
the front-axle carrier is lowered.
10. Unscrew bolts -arrows- on front-axle carrier.
VAG bolts
11. Undo bolt connecting spring strut to trailing arm -arrow- .
Bolt connecting spring strut to trailing

arm
12. Unscrew servo line holders -arrow- from air-conditioning compressor and remove the line.
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Servo line holders Servo line holders

13. Disengage servo line from the front-axle carrier at the three holders -arrows- .
14. Loosen holders for coolant pipes -arrow- at the body.
ATTENTION
Over-extension of drive shafts on running gear!
→ Do not pull front-axle carrier downwards.
15. Lower front-axle carrier with the unit lifting platform. Remove vent line
from the final drive at the same time.
Coolant pipe holders
ATTENTION
Risk of damage to ATF lines and pressure line for power steering.
→ Protect ATF lines with water hose or similar.

→ The servo line must not be crushed or stretched.
Note
z A second fitter is required for removing/installing the four-wheel final Pressing out drive shaft
drive.
16. Press left drive shaft out of flange on final drive.
17. Lift transmission and press to the left.
18. Tilt forward the transmission housing together with drive flange.
19. Remove four-wheel final drive downwards through the front-axle carrier.
Installing four-wheel final drive

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Removing four-wheel final drive Movement sequence for four-wheel

final drive
Installing the four-wheel final drive
ATTENTION

Note
z A second fitter is required for removing/installing the four-wheel final drive.
1. Swivel left flange of final drive in over the front-axle carrier.

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2. Rotate drive flange upwards and install final drive through the front-axle carrier.
3. Insert right drive shaft into output flange and place final drive into the
mounts on the front-axle carrier.
Movement sequence for installing four-

wheel final drive
4. Fit left drive shaft by lifting the final drive output flange.
Fitting left drive shaft
VAG bolts
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Note
z The front right fastening screw for the four-wheel final drive
-left arrow- can only be screwed in with the front-axle carrier
lowered.
5. Insert fastening screws -arrows- for four-wheel final drive and screw
for drive flange.
Note
z Supports 1, 2 and 3 must be fitted to the unit lifting platform. VAG bolts
6. Raise front-axle carrier with unit lifting platform until it bears against the body. Position vent line at the same
time.
Note
z For details of tightening torques for running gear parts, see Group 4
(Running gear) → 40 Tightening torques for front axle.
7. Screw in bolts -arrows- on front-axle carrier.

8. Screw in bolt -arrow- connecting spring strut to trailing arm.

arm
9. Fit holders -arrow- for coolant pipes to the body.
10. Engage servo line in the three holders -arrows- on the front-axle carrier.
11. Screw servo line holders -arrow- on to air-conditioning compressor and clip in the line.
Note
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Servo line holders Coolant pipe holders
Holder on air-conditioning compressor
12. Tighten fastening screw for four-wheel final drive. → Initial tightening: 67 ftlb. → Final tightening: 90 °
Note
z For details of tightening torques for running gear parts, see Group 4 (Running gear) → 40 Tightening
torques for front axle.
13. Screw in drive shaft screws.
14. Connect steering column to steering gear. Screw in new screw.
Steering column mounting

15. Install cover plate on the steering.
16. Connect Servotronic plug to the steering gear.
17. Remove special tool spring compressor VW 552 from spring strut.
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Installation position of spring Cover plate on steering

compressor
18. Screw in plastic nuts -arrows- on front right wheel housing liner.

19. Remove steering-wheel holder -figure- .
Note
20. Tighten bolts -arrows- on front-axle carrier.

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Subsequent work - final four wheel drive
1. Install front cardan shaft → 390219 Install and remove front cardan shaft - Chapter "Installing" [9PAAE1
9PAAF1 9PAAJ1]→ 390219 Install and remove front cardan shaft - Chapter "Installing" [9PAAD1 9PAAD7
9PAAE7].
2. Remove engine support. → Support engine on the body [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]→ Support
engine on the body [9PAAD1 9PAAD7] or → Supporting engine on the body [9PAAD1 9PAAD7]
→ Supporting engine on the body [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]
3. Install right engine compartment cover → 700219 Remove and install front cover (engine compartment) -
4. Mount front wheels. → 440519 Remove and install wheel - Chapter "Installing"
5. Calibrate steering angle sensor → 456005 Initialise and calibrate steering angle sensor
6. Align front axle and adjust as required. → Suspension alignment complete
7. Install engine guard → 108019 Install and remove engine guard - Chapter "Installing".
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
39 90 35 Checking and topping up oil for transfer box - as of MY

2003
- Checking oil for transfer box
- Topping up oil for transfer box
Tools

ATF filling device for filling commercially NR.161
transmission available tool
Checking oil for transfer box
WARNING
Risk of scalding from hot oil
→ Let the oil cool down

Note
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z The vehicle must stand horizontally. Inspection/drain plug
Note
The oil level can only be checked after the vehicle has been idle for 45 minutes.
The engine must not be started during this time.
2. The oil level is correct if the oil reaches the lower edge of the inspection window.
Note
Use only oil approved by Porsche.
3. If this is not the case, top up the oil. → 399035 Inspecting and adding oil for transfer box - chapter on "Filling"
4. Screw in oil inspection plug -A- with new sealing ring. → Tightening torque: 15 ftlb.
Topping up oil for transfer box
Filling oil for transfer box
WARNING

Note
The oil level can only be checked after the vehicle has been idle for 45 Inspection/drain plug
minutes.
Note
z The vehicle must stand horizontally!
Note
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2. Fill with oil using the ATF filling device for filling transmission NR.161 to the lower edge of inspection
plug -A- . Raise filling device.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g pp g p g
ADVERTENCIA
39 90 35 Checking and topping up oil for rear final drive - as of MY

2003
- Checking oil for rear final drive
- Topping up oil for final drive
Tools

Checking oil for rear final drive
WARNING

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Note
z Vehicle must be horizontal in order to check fluid level in rear final
drive.
2. The oil level is correct if the oil reaches the lower edge of the
inspection window.
Note Control/drain plug for rear final drive

3. If this is not the case, top up the oil. → 399035 Inspecting and adding oil for rear final drive - chapter on
"Filling"
4. Screw in oil inspection plug -A- with new sealing ring. → Tightening
torque: 26 ftlb.
Control/drain plug for rear final drive
Topping up oil for final drive
WARNING

Note
z Vehicle must be horizontal in order to fill rear final drive. Control/drain plug for rear final drive

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Note
plug -A- .
torque: 26 ftlb.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
39 90 35 Checking and topping up oil for four-wheel final drive -

as of MY 2003
- Preliminary work for oil for four-wheel final drive
- Checking oil for four-wheel final drive
- Topping up oil for four-wheel final drive
- Subsequent work for oil for four-wheel final drive
Tools

ATF filling device for filling commercially 161
special inserts mod. AB commercially 170

available tool
accessory for the torque commercially 98-1

wrench: open ring wrench available tool
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Preliminary work for oil for four-wheel final drive
Preliminary work for oil for all-wheel final drive
Checking oil for four-wheel final drive
Checking oil for all-wheel final drive
WARNING

Note
z Vehicle must be horizontal to check oil level in all-wheel final drive. Oil inspection plug-filler screw
1. Unscrew oil inspection plug -A- with tool special inserts mod. AB 170.
3. If this is not the case, top up the oil. → 399035 Checking and topping up oil for all-wheel final drive - chapter
on "Filling"
4. Screw in oil inspection plug -A- with new sealing ring. To do this, use the special tool special inserts model
AB 170 and accessory for the torque wrench: open ring wrench insert a/f 13 + adapter 98-1. →
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Topping up oil for four-wheel final drive
Tightening to the specified torque

Filling oil for all-wheel final drive
WARNING

Note
z Vehicle must be horizontal in order to fill final drive. Oil inspection plug-filler screw
Note
z Use only oil approved by Porsche.
2. Fill with oil using the ATF filling device for filling transmission 161 to the lower edge of inspection plug
-A- .
3. Screw in oil inspection plug -A- with new sealing ring. To do this, use
the special tool special inserts model AB 170 and accessory for
the torque wrench: open ring wrench insert a/f 13 + adapter 98-
1. → Tightening torque: 26 ftlb.
Subsequent work for oil for four-wheel final drive

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Touch up for oil for all-wheel final drive

1. Remove engine guard. → 108019 Removing and installing engine guard - chapter on "Installing"
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
39 90 55 Changing oil for four-wheel final drive - as of MY 2003

- Changing oil for four-wheel final drive
Tools

special inserts model AB commercially 170

available tool
accessory for torque wrench: commercially 98-1

open ring wrench insert a/f 13 available tool
+ adapter
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Preliminary work oil for four-wheel final drive

Changing oil for four-wheel final drive

WARNING

2. Unscrew oil drain plug -B- and drain the oil.
3. Screw in oil drain plug -B- with a new sealing ring. → Tightening
torque: 26 ftlb. Oil inspection and drain plug
4. Unscrew oil inspection plug using the special inserts model AB 170
tool.
Tool for oil inspection plug

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Note
5. Using the ATF filling device for filling transmission 161, fill with oil
up to the lower edge of the oil inspection plug -A- .
Oil inspection and drain plug

6. Unscrew oil inspection plugs -A- using the special inserts model
AB tool 170 accessory for torque wrench: open ring wrench
insert a/f 13 + adapter 98-1 and screw in a new sealing ring. →
Reworking oil for four-wheel final drive

as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
39 90 55 Changing oil for rear final drive - as of MY 2003

- Changing oil for rear final drive
Tools

Changing oil for rear final drive

WARNING

2. Unscrew oil drain plug -B- and drain oil.

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WARNING

Note
z Vehicle must be horizontal in order to fill rear final drive.
opening -A- . → Tightening torque: 1.25 l +0.35 l
torque: 26 ftlb.
7. Check oil for rear final drive → 399035 Checking and topping up oil
for rear final drive - chapter on "Checking"
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
39 90 55 Changing oil for transfer box - as of MY 2003

- Changing oil for transfer box
- Subsequent work for oil for transfer box
Tools

Changing oil for transfer box

1. Slide oil collecting container under the vehicle.
WARNING


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3. Screw in oil drain plug -B- with new sealing ring. → Tightening
torque: 15 ftlb.

Note
Vehicle must be horizontal in order to fill the transfer box.
Note
5. Fill with oil to the lower edge of the inspection plug opening -A- using
the ATF filling device for filling transmission 161. Raise filling Oil inspection and drain plug
device.
6. Screw in oil inspection plug -A- with a new sealing ring. →

Subsequent work for oil for transfer box
Reworking oil for transfer box

1. Check oil for transfer box. → 399035 Check and top up oil for transfer box - Chapter "Checking"
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
39 92 19 Removing and installing sealing ring for rear transfer box

(output flange) - as of MY 2003
- Preliminary work sealing ring for transfer box
- Removing sealing ring for rear transfer box (output flange)
- Installing sealing ring for rear transfer box (output flange)
- Reworking sealing ring for transfer box
Tools

shop made tool commercially
available tool .gif

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socket special tool T10204
hook workshop VW 681

equipment
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Preliminary work sealing ring for transfer box

[9PAAE1 9PAAE7 9PAAF1]→ 393519 Removing and reinstalling rear cardan shaft - chapter on "Removing"
[9PAAD1]→ 393519 21 Removing and reinstalling rear cardan shaft - chapter on "Removing" [9PAAJ1]
→ 393519 Removing and reinstalling rear cardan shaft - chapter on "Removing" [9PAAD7]
Removing sealing ring for rear transfer box (output flange)
Removing sealing ring for rear output drive (output flange)
1. Remove nut of output flange with special tool socket T10204. To do

this, secure with special tool arm bracket 3435 .
Output flange nut

2. Remove round seal on output flange.
3. Remove flange with shop made tool and striker vw 771/1.
ATTENTION
Leakage due to scores on the sealing face.
→
When removing the sealing ring, place the tip of the hook on the sealing ring only and not on the sealing
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Removing output flange Rubber ring for rear output drive
Removing sealing ring for rear output

drive
face.
4. Remove sealing ring with special tool hook VW 681.
Installing sealing ring for rear transfer box (output flange)
Installing sealing ring at rear of transfer box (output flange)
1. Drive in new sealing ring with special tool pressure piece T10185
2. Install output flange and, if necessary, drive in with a plastic hammer.
Note
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z Ensure that the round seal is

inserted.
z Replace nut on output flange.
z Fit nut using screw locking

device.
3. Screw in output flange nut

using special tool socket
T10204. To do this, counter
the flange with special tool
arm bracket 3435. → Rubber ring for rear output drive Output flange nut
4. Caulk nuts at the recesses in the output shaft.
Caulking nuts
Reworking sealing ring for transfer box
Subsequent work for sealing ring for transfer box

as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
39 92 19 Removing and installing sealing ring for front transfer

box output - as of MY 2003
- Preliminary work for transfer box sealing ring
- Removing sealing ring for front transfer box output
- Installing sealing ring for front transfer box output
- Subsequent work for transfer box sealing ring
Tools

available tool .gif

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arm bracket commercially 3435

available tool
socket commercially t10204

available tool

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hook commercially vw 681

available tool
Preliminary work for transfer box sealing ring

[9PAAE1 9PAAF1 9PAAJ1]→ 390219 Removing and installing front cardan shaft - chapter on "Removing"
[9PAAD1 9PAAD7 9PAAE7]
2. Support transfer box with transmission jack.
3. Support transmission with material 00000 and secure with retaining band.
4. Unscrew four exhaust system screws on the cross member -centre arrow- and unscrew screw connection
holder on body -right arrow- .
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Transmission cross member Exhaust system at cross member
5. Unscrew transmission cross member on body -A- .
6. Unscrew two screws on the cross member -B- on the transfer box holder and remove transmission cross
member.
Removing sealing ring for front transfer box output
Overview of sealing ring for front transfer box output
1. Unscrew collar nut of output flange with special tool socket t10204. To do this, block flange with special tool
arm bracket 3435.
3. Remove output flange with shop made tool and striker vw 771/1.
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Round seal on output flange Countering flange
Installing sealing ring for front transfer box output
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Note
z Ensure that the round seal -arrow- is inserted.
z Fit nut using screw-locking compound, e.g. Loctite 648.
→ Driving in the sealing ring until the special tool touches the
Round seal on output flange
Note
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z Fit nut using screw-locking

compound, e.g. Loctite 648.
3. Screw in new nut on output

flange using special tool
socket T10204. To do this,
counter the flange with special
tool arm bracket 3435. →
Round seal on output flange Tightening nut on output flange

Caulking nuts
Subsequent work for transfer box sealing ring

[9PAAE1 9PAAF1 9PAAJ1]→ 390219 Removing and installing front cardan shaft - chapter on "Installing"
2. Screw in new transmission cross member screws -B- on transfer box

holder. → initial tightening: 37 ftlb. → final tightening: 90 degree
of angle
3. Screw in new cross member screws on body . -A- → initial

tightening: 37 ftlb. → final tightening: 90 degree of angle

4. Fix exhaust system to transmission cross member -centre arrow- and body -outer arrow- . Observe
torques → 260119 Remove and install exhaust system

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as of MY 2003
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99

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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
39 92 19 Removing and installing sealing ring for transfer box

input shaft - as of MY 2003
- Preliminary work sealing ring for input shaft transfer box
- Removing sealing ring for transfer box input shaft
- Installing sealing ring for transfer box input shaft
- Subsequent work
Tools

available tool

available tool
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Preliminary work sealing ring for input shaft transfer box
Removing sealing ring for transfer box input shaft
ATTENTION
Damage to input shaft bearing.
→ Drive bevelled attachment in by approx. 2 mm.

→ Screw sheetmetal screw max. two turns into the sealing ring.
1. Using the bevelled attachment from the slide hammer kit 168, make
a small hole -figure- in the sealing ring.
Preparing for removal

2. Screw a suitable sheetmetal screw in by two turns.
Screwing in sheetmetal screw

3. Remove sealing ring using special tool slide hammer kit 168.
Installing sealing ring for transfer box input shaft

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1. Fill the space between the dust and sealing lips on the new sealing
ring with grease.
Preparing the sealing ring

2. Drive new sealing ring in flush using special tool pressure piece
t10184.
Fitting sealing ring
Subsequent work

as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
39 IN Information - as of MY 2003
Porsche Traction Management
Porsche Traction Management, or PTM, is a system which guarantees or improves the traction of the vehicle.
Two controllable locks are available in the system.
It operates permanently and receives values from different sensors (e.g. steering-angle sensor, lateral
acceleration sensor) from which the corresponding lock controls are obtained. In this way the optimum power is
distributed to the drive wheels.
The locks are:
z Longitudinal lock (in the transfer box): Distributes the moment released by the gear via the cardan shafts to
the front or rear axle gear.
z Longitudinal interlock (depending on the equipment in the rear final drive): Distributes the moment to the two
rear driving wheels.
Two locks available in the system can be activated.
acceleration sensor) from which the corresponding lock activations are obtained. In this way the optimum power is
The locks are:
z Centre-differential lock (in the transfer box): Distributes the moment released by the gear via the cardan
shafts to the front axle final drive or rear axle differential.
z Rear-differential lock (depending on the equipment in the rear final drive): Distributes the moment to the two
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The locks are:
as of MY 2003
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WARNUNG
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AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
39 Technical data - as of MY 2003

- Technical data on transfer box
- Technical data on four-wheel final drive
- Technical data on rear final drive
Technical data on transfer box
View of transfer box
z Type: Z 48.20
Installed in: Cayenne
Model year: 2004
Low Range gearing: i = 2.70

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Type: Two-stage planetary differential; planetary set
Filling capacity (new filling): → Filling capacity: 0.85 l
Filling capacity (change quantity): → Filling capacity: 0.75 l
z Type: Z 48.00
Installed in: Cayenne S
Model year: 2003
z Type: Z 48.50
Installed in: Cayenne Turbo
Model year: 2003
Technical data on four-wheel final drive
g
Overall view of front-axle final drive
z Type: V 48.20
Model year: 2004
Type: Bevel wheel gear
Transmission ratio for Tiptronic: i = 4.56
Transmission ratio for manual transmission: i = 4.10
Bearing rolling moment: 2.0 - 2.4
Filling capacity (new filling): → Filling capacity: approx. 1.0 l
z Type: V 48.00
Model year: 2003
z Type: V 48.50

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Model year: 2003
Technical data on rear final drive
Overall view of rear axle transmission
z Type: H 48.20
Model year: 2004
Bearing rolling moment: → Bearing rolling moment: 1.7 ftlb. +0.2 ftlb.
Filling capacity for Tiptronic: → Filling capacity: approx. 1.4 l

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Filling capacity for manual transmission: → Filling capacity: approx. 1.25 l
Filling capacity with rear-differential lock: → Filling capacity: approx. 1.6 l
z Type: H 48.00
Model year: 2003
z Type: H 48.50
Model year: 2003
as of MY 2003
WARNUNG
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AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
30 01 07 Bleeding the clutch system - as of MY 2003

- Notes
- Procedure for bleeding
Notes
Note
z The clutch system and brake system share a common reservoir.
z The clutch slave cylinder is located to the left of the transmission, at the top of the clutch bell-housing.
z The brake fluid change interval is 2 years in conjunction with Super DOT 4 brake fluid.
z This brake fluid is available under the following part numbers: Container quantity: 1 litre = 000.043.203.66. 30
litres = 000.043.203.67.
Procedure for bleeding
The shared reservoir for the brake and clutch systems is located in the
engine compartment, on the left under the cowl panel cover -arrow- in the
plenum panel.
1. Open the reservoir and connect the bleeding device → see figure . Switch on the bleeding device and set the
bleeding pressure to approx. 2.0 bar.
2. Remove engine guard. → 108019 Removing and installing engine guard.

freedom from air bubbles and to determine the brake fluid used. Attach the hose of the collecting bottle to the
bleeder valve.
4. Open the bleeder valve -arrow- (approx. three turns!) until brake fluid
emerges. Press the clutch pedal three times and wait for approx. 30
seconds. Press the clutch pedal three times again (2 workers
required).
5. Repeat the procedure as often as required until clear, bubble-free

brake fluid emerges.
6. Tighten the bleeder valve to the specified tightening torque (3.5 ± 0.5)
ftlb.) and remove the bleeder hose from the clutch slave cylinder. Fit
dust cap and remove bleeder hose from reservoir.
7. Screw cap on reservoir. Once the vehicle has been filled and bled, the
brake fluid level in the reservoir must be between the MIN and MAX
markings. Adjust the brake fluid level if necessary. → see figure
8. Fit engine guard → 108019 Removing and installing engine guard.
9PAAD7, 9PAAE7
as of MY 2003
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ADVERTENCIA
30 05 19 Removing and installing the clutch pedal - as of MY 2004

- Preliminary work
- Removing
- 23
- Subsequent work
Tools

pliers special tool T10206
Preliminary work
Note
For better accessibility, remove the lower cover on the driver's side under the steering column.
1. Move the driver's seat back. Pull the steering wheel all the way out and put it in the highest position (better
access to pedals).
2. Remove and install cover under dashboard. → 702219 Removing and installing cover under dashboard
3. Remove and install trim panel under dashboard. → 701919 Removing and installing trim panel under
dashboard
Removing
Removing clutch pedal
Overview of pedals
1- Seal
2- Hexagon nut
3- Mounting saddle
4- Pin
5- Hexagon nut
6- Hexagon-head bolt
7- Seal
8- Fixing clip
9- Master cylinder
10 - Mounting
11 - Bolt
12 - Clutch pedal
13 - Cap
14 - Lock (mechanical)
15 - Clutch power spring
16 - Bearing shell
17 - Rubber stop
19 - Pin
21 - Mounting saddle for clutch pedal
22 - Switch
23 - Switch
1. Remove the -clutch power spring from clutch pedal (arrows)- .

Compress the clutch power spring (depress pedal lightly). As it
becomes free, secure the hole in the bolt of the clutch power spring
with a cotter pin or similar.
Mount for clutch power spring

2. Depress the pedal and pivot the clutch power spring from front to
rear through 180° (against direction of travel) -arrow- and unclip from
the bearings. -Item 15-
Pivoting out clutch power spring

3. Remove -lock on bolt of clutch power spring (arrow)- . If necessary, carefully drive the bolt out with a
hammer and drift and take out the clutch power spring. -Item 11-
4. Remove lock on pin (clutch pedal shaft) -arrow- . -Item 20-
5. The left lock remains on the pin (clutch pedal shaft). -arrow- Push the pin all the way to the left. If necessary,
release and lay aside the wiring harness. -Item 18, 19-
Right lock on pin, clutch pedal Left lock of clutch power spring
Disengaging clutch pedal Left lock on pin, clutch pedal
6. Detach pushrod of master cylinder from pedal. To do this, insert the pliers T10206 into cut-outs on clutch
pedal. Remove clutch pedal. -Item 12-
23
Installing clutch pedal

Overview of pedals
1- Seal
2- Hexagon nut
3- Mounting saddle
4- Pin
5- Hexagon nut
7- Seal
8- Fixing clip
9- Master cylinder
10 - Mounting
11 - Bolt
12 - Clutch pedal
13 - Cap
16 - Bearing shell
17 - Rubber stop
19 - Pin
22 - Switch
23 - Switch
Installation is in reverse order.
1. When the clutch pedal locks into place, the lugs on the right and left
must click in audibly. To do this, push the clutch pedal firmly in the
direction of travel on the mounting. -Position 10- Now turn the pedal
to the right and left (2 x click). → Locking the clutch pedal into place
Locking the clutch pedal into place

2. Insert the pin (clutch pedal shaft) -item 19- from the left. Make sure
that the lock is inserted in the correct position in order to prevent
twisting the shaft in the mounting saddle/clutch pedal. -arrow-
Pin for left lock, clutch pedal

3. Mount the lock of the pin from the clutch pedal -item 20- on the right
(the brake pedal is removed in the picture here for the sake of
clarity).
4. The lock must be able to be inserted in the right groove. → Locks for clutch pedal pins
Clutch power spring Locks for clutch pedal pins
5. Insert clutch power spring. → Clutch power spring Insert the bolt in the correct position so that the hexagon
cannot twist. The lock must be inserted into the groove from the bolt.
6. Press the clutch pedal and the swivel the clutch power spring 180° to
the front and insert in the bearing. -arrows- Remove cotter pin.
Clutch power spring mount
Subsequent work
1. → 701919 Removing and reinstalling trim panel under dashboard
2. → 702219 Removing and reinstalling cover under dashboard diagnostic socket, clip in the connector.
9PAAD7, 9PAAE7
as of MY 2004
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
30 20 19 Removing and installing master cylinder - as of MY 2003

-
-
-
-
Tools

bonnet stay special tool 9704
pliers VW-tool T10005
Preliminary work
Note
The clutch master cylinder is installed under the brake booster, accessible from the plenum panel in the engine
compartment.
1. Disconnect the battery → 90 Work instructions after disconnecting the battery.
2. Open bonnet and position it with the bonnet stay 9704 → 664419 Removing and installing cowl panel
cover .
3. Remove engine design cover → 700219 Removing and installing front cover (engine compartment).
4. Remove cowl panel cover → 664419 Removing and installing cowl panel cover.
5. Remove left plenum panel partition.
6. Partly remove fuse carrier, including six connectors, on the left in the
plenum panel and lay to one side -arrow- → 9784 fuse carrier.
Warning notes
ATTENTION
Increased risk of accidents when working with brake fluid.
z Possible danger of damage or injury.
z Brake fluid on electrical contacts (even thinned brake fluid) leads to corrosion and may cause faults
in the system.
→ Wear protective goggles and gloves.

→ IMMEDIATELY remove any escaped brake fluid. CAREFULLY rinse again with water and dry if necessary.
Look out for fuse carrier!
Removing
Overview of pedals
Overview of pedals excluding stop light switch
-1- - Seal
-2- - Hexagon nut
-3- - Mounting saddle
-4- - Pin
-5- - Hexagon nut
-6- - Hexagon-head bolt
-7- - Seal
-8- - Fixing clip/screw
-9- - Master cylinder
-10- - Mounting
-11- - Bolt
-12- - Clutch pedal
-13- - Cap
-14- - Lock (mechanical)
-15- - Clutch power spring
-16- - Bearing shell
-17- - Rubber stop
-19- - Pin
-21- - Mounting saddle for clutch pedal
-22- - Switch (clutch pedal switch)
-23- - Switch (interlock)
Installation position of clutch master cylinder
Clutch master cylinder
-A- - Pressure line connection to clutch slave cylinder

-B- - Supply
-C- - Dust boot
-D- - Pushrod
1. Remove brake fluid by suction below MIN mark in reservoir.
Note
Brake fluid is hygroscopic! Seal all lines immediately with suitable plugs.
Brake fluid will flow from the lines. Protect body in the area under the clutch master cylinder (e.g. with a cleaning
cloth).
2. Loosen pressure line from clutch master cylinder to slave cylinder -A- . To do this, remove safety clip to the
stop using a screwdriver -direction of arrow- .
Opening safety clip for pressure line Removing safety clip for pressure line
connection of clutch master cylinder connection from clutch master cylinder
3. Open safety clip. The pressure line can now be pulled off -arrow- .
4. Remove lines on brake fluid reservoir and clutch master cylinder -B- (pull strongly!).
5. Remove clutch pedal → 300519 Removing and installing clutch

pedal . To do this, detach pushrod of master cylinder from pedal.
Insert pliers T10005 in the cut-outs on clutch pedal. Remove clutch
pedal -12- .
6. Remove fixing clips on clutch master cylinder. Carefully remove
clutch master cylinder with a cleaning cloth (soiling of passenger
compartment with brake fluid!).
Disengaging clutch pedal
Installing
Note
Use a new line from the brake fluid reservoir to the clutch slave cylinder.
If the switches -22 - 23- have been removed from the mounting saddle of the clutch pedal -21- they must be
replaced and their operation checked.
Replace all seals and sealing rings.
z Remove plugs from the lines.
Overview of pedals
1- Seal
2- Hexagon nut
3- Mounting saddle
4- Pin
5- Hexagon nut
7- Seal
8- Fixing clip/screw
9- Master cylinder
10 - Mounting
11 - Bolt
12 - Clutch pedal
13 - Cap
16 - Bearing shell
17 - Rubber stop
19 - Pin
22 - Switch (clutch pedal switch)
23 - Switch (interlock)
1. Fit master cylinder with fixing clip.
2. Fit clutch pedal → 300519 Removing and installing clutch pedal .
3. Fit pressure line to clutch master cylinder. Engage safety clip

4. Connect line between brake fluid reservoir and clutch master cylinder
(top and bottom).
5. Fill brake fluid reservoir with brake fluid. The brake fluid level must
not exceed the MAX mark.
Engaging safety clip for pressure line

connection from clutch master cylinder
Subsequent work
1. Fit fuse box and clip in the six connectors. -arrow-
2. Fit left plenum panel partition, ensuring correct seating of gaskets

and correct routing of wiring harness.
3. Fit cowl panel cover → 664419 Removing and installing cowl panel
cover.
4. Install engine design cover → 700219 Removing and installing front

cover (engine compartment).
5. Bleed the clutch → 300107 Bleeding the clutch system.

6. Connect the battery → 90 Work instructions after disconnecting the
battery.
Note
If clutch switches 22-23 on the mounting saddle for clutch pedal 21 have been removed, they must be replaced.
Afterwards check operation of new clutch switches.
Check operation of both clutch switches -22-23- (see below: first switch (clutch pedal switch), second switch
(interlock).
1- Seal
2- Hexagon nut
3- Mounting saddle
4- Pin
5- Hexagon nut
7- Seal
8- Fixing clip/screw
9- Master cylinder
10 - Mounting
11 - Bolt
12 - Clutch pedal
13 - Cap
16 - Bearing shell
17 - Rubber stop
19 - Pin
22 - Switch (clutch pedal switch)
23 - Switch (interlock)
1. First switch (clutch pedal switch) -22-
Connect System Tester and select >> PSM << system. In the menu >> Input signals/clutch switches << read out
the switch states.
From end-position 1 of the clutch pedal (pedal not depressed!) to a pedal

travel of 11 mm -A- the switch (clutch pedal switch) must be at >> Not
actuated << in the System Tester. Measured using a steel rule at the tread
plate of the clutch pedal - second worker required.
Depress clutch pedal over (!) 11 mm pedal travel:
z Now the switch (clutch switch) must switch to >> Actuated << .
If the switch (clutch pedal switch) does not operate, the installation
position must be checked. If that does not succeed, then follow the
troubleshooting procedure in the Technical Manual >> Group 0,
Diagnostic Repair Group 40-66, PSM Fault Code 650 << .
2. Second switch (interlock) -23-
Connect System Tester and select >> Kessy << system. In the menu >>
Input signals/clutch switches (interlock) << read out the switch states.
Depress clutch pedal (rest position) up

to 11 mm from end-position 1
From end-position 2 of the clutch pedal (pedal fully depressed!) minus 20 mm -B- the switch (interlock) must be at
>> Actuated << in the System Tester. Measured using a steel rule at the tread plate of the clutch pedal - second
worker required.
Depress clutch pedal up to 20 mm before (!) end-position2:
z Up to that point the switch (interlock) must be at >> Not actuated << in the System Tester.
If the switch (interlock) does not switch over, the installation position must be checked. If that does not succeed,
then follow the troubleshooting procedure in the Technical Manual >>
Group 0, Diagnostic Repair Group 91-97, Kessy Fault Code 650 << .
Clutch pedal end-position 2 (fully

depressed) minus 20 mm depression
9PAAD7, 9PAAE7
as of MY 2003
WARNUNG
WARNING
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30 30 19 Removing and installing clutch slave cylinder - as of MY

2003
- Preliminary work
- Technical values
- Removing clutch slave cylinder
- Installing clutch slave cylinder
- Subsequent work
Preliminary work
Preliminary work for clutch slave cylinder

1. Raise the vehicle.→ 40 Lifting the vehicle
2. Remove engine guard. → 108019 Removing and installing engine guard - chapter on "removing"
Technical values
Tightening torques
Removing clutch slave cylinder
The clutch slave cylinder -arrow- is located to the left of the transmission,
at the centre section of the clutch bell-housing (shown here on removed
transmission).
Note
z Once the lead is separated from the clutch slave cylinder, the clutch
pedal must not be pressed until re-installation is complete.
z During removal, do not bend the clutch slave cylinder more than 3°
from the installation position. Greater deflections of the pushrod can
damage the clutch slave cylinder and cause brake fluid to run into the
bellows.
1. Unclip the line -arrow- on the clutch slave cylinder (remove retaining
spring) and seal using a suitable plug. Pay attention to the seal on
the line. This can remain stuck in the clutch slave cylinder. Carefully
remove the seal and replace with a new one, if necessary.
2. Remove the fastening screw -arrow- of the clutch slave cylinder.
3. Press the clutch slave cylinder carefully outwards -Arrow 1- . During removal, do not bend the clutch slave
cylinder more than 3° from the installation position.
4. Remove the clutch slave cylinder to the rear -Arrow 2- without tilting it. Wipe off any emerging brake fluid
with a lint-free cloth.
Installing clutch slave cylinder
Note
z Drain the clutch slave cylinder fully before installation. Check the bellows for ingress of fluid and clean with a
lint-free cloth if necessary.
z Pay attention to the seal of the clutch slave cylinder. This may have been left behind in the clutch slave
cylinder during removal.
z During installation, do not bend the pushrod of the clutch slave cylinder more than 3° from the installation
position. Greater deflections of the pushrod can damage the clutch slave cylinder.
z Make sure the clutch slave cylinder is positioned correctly during installation.
z Check that the pushrod of the clutch slave cylinder is definitely centred in the release lever.
z Ensure that the cap is seated correctly on the pushrod.
1. Remove the seal from the clutch slave cylinder and fit it in the correct position on the line. Use a new seal, if
necessary.
2. Insert the clutch slave cylinder carefully (do not tilt) and mount with
the fastening screw. Tightening torque: 17 ± 1.5 ftlb.
3. Remove the plug from the line and clip the line into the clutch slave
cylinder. Ensure the retaining spring is seated correctly.
4. Bleed the clutch system → 300107 Bleeding the clutch system.
Subsequent work
Subsequent work for clutch slave cylinder

1. Remove engine guard. → 108019 Removing and installing engine guard - chapter on "installing"
9PAAD7, 9PAAE7
as of MY 2003
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30 50 19 Removing and installing clutch - as of MY 2003

- Preliminary work for clutch
- Removing clutch
- Installing clutch
- Subsequent work for clutch
Tools

2-hole nut turner commercially 3212
available tool
centring mandrel special tool 3434
Preliminary work for clutch

Preliminary work for clutch
1. Remove manual transmission. → 343519 Removing and installing transmission - chapter on
"removing" [9PAAD7]→ 343519 Removing and installing transmission - chapter on "removing" [9PAAE7]
Removing clutch
1. Mark position of clutch adjuster on the clutch pressure plate using a

coloured pen -arrow- .
Clutch adjuster marking
ATTENTION
Clutch grabbing
z Clutch pressure plate may warp if screws are not loosened and
tightened evenly.
→ Loosen and tighten the clutch pressure plate in the specified order.
2. Unscrew the fastening screws on the clutch in the specified order

-1 to 6- in several stages. Loosen each screw by half a turn at a time.
Clutch tightening sequence
3. Remove clutch.
Installing clutch
Installing clutch
Note
When installing the clutch plate, observe the correct installation position. Please note marking -arrow inset- on
clutch plate.
Note
Clutch plate marking Centring the coupling plate
z If the marking -arrow- for the clutch adjuster no longer lines up after
reassembly, the clutch must be replaced.
Marking the clutch adjuster
Note
z The clutch pressure plate must be positioned on the three dowel pins
→ Fitting clutch plate of the double-mass flywheel.
1. Position clutch plate and pressure plate on engine using special tool
centring mandrel 3434 -arrow- .
Fitting clutch plate
Note
z Replace clutch fastening screws.
Note
z If the marking -arrow- for the clutch adjuster no longer lines up after reassembly, the clutch must be
replaced.
2. Screw in clutch fastening screws in the specified order -1 to 6- in

several stages. Tighten each screw by half a turn at a time. →
3. Remove special tool centring mandrel 3434.
Marking the clutch adjuster

Installing a new clutch
ATTENTION
Danger of injury from releasing clutch set.
z Due to preloading of the clutch set, parts of the coupling may fly
out.
→ Locking hook on new clutch set was removed prematurely.

→ Secure clutch pressure plate. Then remove locking hook.
Centring the coupling plate
Note
When installing the clutch plate, observe the correct installation position.
Please note marking -arrow inset- on clutch plate.
Clutch plate marking
Note
z The clutch pressure plate must be positioned on the three dowel pins
→ Fitting clutch plate of the double-mass flywheel.
1. Position new clutch set on engine using special tool centring

mandrel 3434 -arrow- .
Fitting clutch plate

Note
z Replace clutch fastening screws.
2. Screw in clutch fastening screws in the specified order -1 to 6- in

several stages. Tighten each screw by half a turn at a time. →
ATTENTION
Danger of injury from releasing clutch set.
z Due to preloading of the clutch set, parts of the coupling may fly
out.
→ Locking hook on new clutch set was removed prematurely.

→ Secure clutch pressure plate. Then remove locking hook.
3. Unscrew locking hook with special tool 2-hole nut turner 3212 in an
anti-clockwise direction -arrow- and remove it. Removing locking hooks
4. Remove special tool centring mandrel 3434.
Subsequent work for clutch
Subsequent work for clutch

1. Install manual transmission. → 343519 Removing and installing transmission - chapter on
"installing" [9PAAD7]→ 343519 Removing and installing transmission - chapter on "installing" [9PAAE7]
9PAAD7, 9PAAE7
as of MY 2003
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30 56 01 Checking clutch for wear - as of MY 2003

- Preliminary work
- Checking clutch for wear
Tools

material special tool 00000
Preliminary work
Preliminary work for clutch wear

1. Remove transmission. → 343519 Removing and installing transmission - chapter on "removing" [9PAAD7]
→ 343519 Removing and installing transmission - chapter on "removing" [9PAAE7]
Checking clutch for wear
1. Measure clutch wear at one of the three clutch adjusters. To do this, measure using material 00000 between
adjuster and clutch pressure plate -arrow inset- .
z Distance when new: ? 16 mm.

z Replace clutch if distance ≤ 8 mm.
Clutch is OK:
2. Install transmission. → 343519 Removing and installing transmission

- chapter on "installing" [9PAAD7]→ 343519 Removing and installing
transmission - chapter on "installing" [9PAAE7]
Clutch is defective:
3. Replace clutch. → 300519 Removing and installing the clutch pedal
Measuring clutch wear
9PAAD7, 9PAAE7
as of MY 2003
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34 01 35 Checking and topping up transmission oil - as of MY

2003
- Preliminary work
- Checking transmission oil
- Topping up transmission oil
- Subsequent work
Tools

oil filler for ATF commercially
available tool .gif
Preliminary work
Preliminary work for transmission oil

Checking transmission oil
Checking transmission oil
WARNING

Note
z Secure vehicle to prevent it rolling away. Oil inspection plug
z To check transmission oil the vehicle must be horizontal.
1. Unscrew oil inspection plug -arrow- .
If this is not the case, add more transmission oil. → 340135 Checking and topping up transmission oil -
chapter on "refilling"
3. Screw in oil inspection plug -arrow- with new sealing ring. →

Oil inspection plug
Topping up transmission oil
Topping up transmission oil
WARNING

Note
z To check transmission oil the vehicle must be horizontal.
Note
Oil inspection plug
2. Fill in oil using oil filler for ATF up to lower edge of oil inspection plug -arrow- .
3. Screw in oil inspection plug -arrow- with new sealing ring. → Tightening torque: 26 ftlb.
Subsequent work
Subsequent work for transmission oil

9PAAD7, 9PAAE7
as of MY 2003
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34 01 55 Changing transmission oil - as of MY 2003

- Preliminary work
- Changing transmission oil
- Subsequent work
Tools

oil filler for ATF commercially
available tool .gif
Preliminary work
Preliminary work for transmission oil

Changing transmission oil

Changing transmission oil
WARNING

Note
z Secure vehicle to prevent it rolling away. Oil drain plug
z Vehicle must be horizontal in order to change transmission oil.
2. Unscrew oil drain plug -arrow- and drain transmission oil.
3. Screw in oil drain plug -arrow- with new sealing ring. → Tightening torque: 26 ftlb.
Note
5. Fill in oil using oil filler for ATF up to lower edge of inspection
window -arrow- . → Change quantity: 1.8 litre
6. Screw in oil inspection plug -arrow- with new sealing ring. →

Oil inspection plug
Subsequent work
Subsequent work for transmission oil

9PAAD7, 9PAAE7
as of MY 2003
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34 04 19 Removing and installing shift lever knob - as of MY 2003

- Removing shift lever knob
- Installing shift lever knob
Removing shift lever knob
Removing shift lever knob
Overview of shift-lever knob
1. Put shift-lever knob in neutral position.
2. Unscrew fastening screws on centre console cover -right arrows- , tip cover up and back -curved arrow-
and separate cable connection -inset- .
Leather boot Centre console cover
3. Press leather boot out of centre console cover from below -arrows- .
4. Unlock shift-lever knob. To do this, turn the grooved end piece on the
gearshift lever clockwise by a quarter of a turn until it engages.
Unlocking the shift-lever knob
Note
z Do not pull shift-lever knob off by pulling on the leather boot.
Removing the shift-lever knob
Installing shift lever knob
Installing shift lever knob
Overview of shift-lever knob
1. Insert the shift lever knob from above until it engages.
Assembling the shift-lever knob

2. Lock shift-lever knob. To do this, turn the grooved end piece on the
gearshift lever anti-clockwise by a quarter of a turn until it engages.
Locking the shift-lever knob

3. Fit leather boot into centre console cover from above.
4. Position cable connection -inset- on the underside of the centre console cover.
5. Tip centre console cover backwards -curved arrow- and screw in fastening screws -right arrows- .
9PAAD7, 9PAAE7
as of MY 2003
Centre console cover Leather boot

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34 08 19 Removing and installing top section of gearshift bracket -

as of MY 2003
- Preliminary work for top section of gearshift bracket
- Removing top section of gearshift bracket
- Installing top section of gearshift bracket
- Subsequent work for top section of gearshift bracket
Tools

locking bridge commercially 9619
available tool
Preliminary work for top section of gearshift bracket
Preliminary work for top section of gearshift bracket
1. Remove shift lever knob. → 340419 Removing and installing shift lever knob - chapter on "removing"
Removing top section of gearshift bracket
Removing top section of gearshift bracket

1. Remove centre console trim panel.
2. Remove foam mat → Foam mat .
Foam mat
3. Lock gearshift lever in neutral position using special tool locking
bridge 9619 -arrow- .
Locking the gearshift lever

4. Remove transverse strut on centre console -arrows- .
ATTENTION
Plate on fastening part breaks off.
→ Unlocking causes plate to become overstretched.

→ Only bend fastening part as far as release.
5. Pull shift and selector cable off gearshift bracket. To do this, release
the fastening parts using a screwdriver -arrows- .
6. Remove special tool locking bridge 9619. Removing shift and selector cables
Gearshift bracket
7. Unscrew fastening screws -arrows- on top section of gearshift bracket.
8. Remove top section of gearshift bracket.
Installing top section of gearshift bracket
Installing top section of gearshift bracket
Note
z Transmission must be in neutral position!
1. Install top section of gearshift bracket. Insert shift and selector cable
into fastening part -arrows- .
Inserting shift and selector cables

2. Screw in fastening screws -arrows- on top section of gearshift
bracket. → Tightening torque: 6.5 ftlb.
Gearshift bracket
3. Lock shift and selector cable by pressing on the fastening parts -arrows- .
4. Function test for shift mechanism:

z Position of gearshift lever?
z Possible to shift through all gears, including reverse gear?
Locking the shift and selector cable

5. Install the transverse strut of the centre console -arrows- .

6. Insert foam mat → Foam mat .
7. Insert centre console trim panel.
Foam mat
Subsequent work for top section of gearshift bracket
Touching up top section of gearshift bracket
1. Install shift lever knob. → 340419 Removing and installing shift lever knob - chapter on "installing"
9PAAD7, 9PAAE7
as of MY 2003
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34 12 19 Removing and installing shift and selector cables - as of

MY 2004
- Preliminary work for shift and selector cables
- Removing shift and selector cables
- Installing shift and selector cables
- Subsequent work
Tools

material special tool 00000 transmission
jack
disassembly tool, commercially 21

universal available tool
Preliminary work for shift and selector cables
Preliminary work for shift and selector cables

2. Remove rear cardan shaft. → 393519 Removing and reinstalling rear cardan shaft - chapter on
"Removing" [9PAAE7]→ 393519 Removing and reinstalling rear cardan shaft - chapter on
"Removing" [9PAAD7]
3. Remove top section of gearshift bracket. → 340819 Removing and reinstalling top section of gearshift
bracket - chapter on "Removing"
Removing shift and selector cables
Overview of shift and selector cables
1. Unscrew threaded joint on bottom section of gearshift bracket

-arrows- .
Mount of gearshift bracket to body
Attaching the cardan shaft
2. Remove front cardan shaft on the transfer box and tie it up at the side -arrow- .
3. Lower the transmission:
4. Loosen fastening screws securing exhaust system support

-centre arrows- to transmission cross member.
5. Support transfer box with material 00000.
Catalytic converter
6. Unscrew four screws -A- on transmission cross member.

7. Lower transmission cross member by approx. 55 mm -arrow- .
8. Remove safety clips -arrows- on support.

Removing safety clips for manual Distance from transmission cross
transmission member to body
9. Release shift and selector cable attachment using disassembly tool, universal 21 on gearshift lever
-arrows- .
10. Guide the shift and selector cables out of the support.
11. Remove bottom section of gearshift bracket with installed shift and
selector cables backwards over the transfer box → Removing bottom
section of gearshift bracket .
Removing bottom section of gearshift

bracket
12. Remove safety clips on bottom section of gearshift bracket -1st arrow- , then remove operating cables
-2nd arrow- .
Installing shift and selector cables
Installing shift and selector cables

Removing operating cables from
bottom section of gearshift bracket
Overview of shift and selector cable
Installing safety clips
Note
z If present: remove assembly aids from production -arrow- . These were only needed for the first installation
in order to align the gearshift bracket.
1. Insert shift and selector cables in bottom section of gearshift bracket
-1st arrow- , then fit safety clips -2nd arrow- .
Assembly aid on bottom section of

gearshift bracket
2. Insert bottom section of gearshift bracket with installed shift and
selector cables over the transfer box → Installing gearshift bracket .
3. Guide the shift and selector cables into the support.
Installing gearshift bracket

4. Pressing the ends of the shift and selector cables onto the ball head
joint on the selector lever -arrows-
Assembly of shift and selector cable at

transmission
5. Press rubber boots into the support and fit safety clips -arrow- .
Assembly of safety clips on

transmission
Positioning the bottom section of
gearshift bracket
6. Lift up transfer box with cross member. Position bottom section of gearshift bracket in transmission tunnel
-arrow- .
Note
with new ones.
7. Screw in new fastening screws -A- for transmission cross member.

Transmission cross member to body Initial tightening 37 ftlb.
Transmission cross member to body Final tightening 67 °
8. Screw in two fastening screws to secure exhaust system support to

transmission cross member -centre arrows- . → Tightening torque:
17 ftlb.
Note
with new ones.
9. Fix front cardan shaft to transfer box with new screws. → Initial
tightening: 22 ftlb. → Final tightening: 90 °
Catalytic converter
Mount of gearshift bracket to body
10. Screw in threaded joint on bottom section of gearshift bracket -arrows- . → Tightening torque: 18 ftlb.
Subsequent work
Touching up for shift and selector cables
1. Install rear cardan shaft. → 393519 Removing and reinstalling rear cardan shaft - chapter on
"Installing" [9PAAE7]→ 393519 Removing and reinstalling rear cardan shaft - chapter on
"Installing" [9PAAD7]
3. Install top section of gearshift bracket. → 340819 Removing and reinstalling top section of gearshift bracket -
4. Function test for shift mechanism:
z Position of gearshift lever?

z Possible to shift through all gears, including reverse gear?
9PAAD7, 9PAAE7
as of MY 2004
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ADVERTENCIA
34 35 19 Removing and installing transmission - as of MY 2003

- Preliminary work for transmission
- Installing transmission
- Subsequent work for transmission
Tools

plate commercially
available tool .gif
plate commercially 9725

available tool
removal tool, universal commercially nr.21
available tool
Preliminary work for transmission
Preliminary work for transmission

1. Disconnect battery. → Work instructions after disconnecting battery
2. Remove centre console cover. → 681719 Removing and installing centre console - "Removing" chapter
3. Remove shift lever knob. → 340419 Removing and installing shift lever knob - chapter on "removing"
7. Remove clutch slave cylinder. → 303019 Removing and installing clutch slave cylinder - "Removing" chapter
Note
z The cables do not have to be separated from the transmission in order to remove the transmission.
1. Remove insulating mat.
2. Unscrew fastening screws for securing bottom section of gearshift bracket to body.
3. Remove reference mark sender on the transmission bell housing.
4. Unscrew coolant pipe support threaded joint on the transmission bell housing.
5. Pull off cable plug for neutral switch.

Threaded joint on bottom section of Centre console sound absorber
gearshift bracket
Support for coolant pipes Reference mark sender
6. Pull off cable plug for back-up light switch.
7. Remove transfer box → 396519 Removing and installing transfer box - chapter on "Removing".
8. Remove breather pipe. To do so, undo the fastening screws

-1 and 2- on the transmission.
Clutch bell-housing breather pipe

9. Support manual transmission with special tool plate and transmission jack .
10. Unscrew fastening screws -arrows- for securing transmission to engine.
11. Push out transmission. Pull off vent line for the transfer box.
12. Remove circlips -inset- on support on the transmission.
13. Remove shift and selector cables from support using special tool removal tool, universal nr.21. Remove
Fastening points for securing Plate
Disassembly of circlips Vent line support
Removal
selector support with cables.
Note
z If present: Remove assembly aids from production on the bottom section of the selector console -arrow- .
These were only needed for the first installation in order to align the shift console.
Assembly aid on bottom section of
gearshift bracket
1. Fasten the shift and selector cables to the ball head joint on the
support.
Assembly of shift and selector cables

2. Install snap rings -enlarged view- on support bracket on the
transmission.
Assembly of circlips
3. Raise manual transmission with special tool plate and transmission
jack .
Transmission on transmission jack

4. Run in transmission. Connect vent line for the transfer box.
Mount engine to transmission Vent line support
5. Screw in fastening screws for securing transmission to engine. → Tightening torque: 59 ftlb.
6. Support transmission with a wooden block on the suspension

subframe.
7. Remove special tool plate 9725.
Plate
8. Install breather pipe. To do so, screw in the fastening screws -1,2- on
the transmission. → Tightening torque: 17 ftlb. → Tightening
torque: 6.5 ftlb.
Clutch bell-housing breather pipe

9. Install transfer box. → 396519 Removing and installing transfer box - chapter on "Installing" Insert gearshift
Inserting gearshift bracket
bracket into the opening in the centre tunnel from below.
10. Attach cable plug for back-up light switch.

11. Push on cable plug for neutral switch.
12. Screw in fastening screws for coolant pipe support to the

transmission bell housing.
Support for coolant pipes

13. Install reference mark sender on the transmission bell housing.

14. Screw in fastening screws for securing bottom section of gearshift bracket to body. → Tightening torque:
18 ftlb.
15. Install insulating mat.

16. Install centre console trim. → 681719 Removing and installing centre console - "Installing" chapter
Subsequent work for transmission

Insulating mat for centre console Threaded joint on bottom section of
gearshift bracket
Touch up for transmission
1. Install clutch slave cylinder. → 303019 Removing and installing clutch slave cylinder - "Installing" chapter
3. Install rear cardan shaft. → 393519 Removing and reinstalling rear cardan shaft - chapter on "Installing"
5. Install shift lever knob. → 340419 Removing and installing shift lever knob - section on "Installing"
6. Connect the battery. → Work instructions after disconnecting the battery
9PAAE7
as of MY 2003
WARNUNG
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ADVERTENCIA
34 35 27 Removing and refitting transmission - as of MY 2003

- Preliminary work
- Refitting transmission
- Subsequent work
Tools

suspending device commercially 2024 a
available tool
removal tool, universal commercially nr.21

available tool
Preliminary work
Preliminary work for removing the transmission
1. Remove engine. → 100121 Removing engine
Disassembly of circlips
2. Remove shift and selector cables from support using special tool
removal tool, universal nr.21. Remove selector support with
cables.
Disassembly of shift and selector

cables
3. Loosen vent line from supports and remove.
Vent line support

4. Fasten transmission with support suspending device 2024 a on workshop crane.
5. Raise transmission a few centimetres and notch transmission cross member. -A-
Transmission cross member Transmission to workshop crane
6. Unscrew fastening screws for securing transmission to engine.
7. Uncouple transmission from engine.
8. Unscrew fastening screws for transfer box and remove the

transmission.
Transmission to engine threaded joint

point
Disassembly of circlips
2. Remove shift and selector cables from support using special tool
removal tool, universal nr.21. Remove selector support with
cables.
Disassembly of shift and selector

cables
Vent line support

3. Loosen vent line from supports and remove.
4. Attach transmission with support suspending device 2024 a on

workshop crane.
Transmission to workshop crane

5. Raise transmission a few centimetres and notch transmission cross
member B -A- .

6. Unscrew fastening screws for securing transmission to engine. This
involves unscrewing four screws on the engine side and six on the
transmission side.
7. Remove transmission
Transmission to V6 engine threaded

joint points
1. Refit the transfer box onto the transmission.
2. Fasten the shift and selector cables to the ball head joint on the
support.
Assembly of shift and selector cables

3. Install circlips -inset- on support on the transmission.
Assembly of circlips
4. Connect the vent line for the transfer box on the transmission.
Vent line support

5. Fasten transmission with support suspending device 2024 a on workshop crane.
6. Fit the transmission onto the engine.
7. Screw in fastening screws for securing transmission to engine. → Tightening torque: 59 ftlb.
Note
Transmission to engine threaded joint Transmission to workshop crane
point
8. Raise transmission a few centimetres and install transmission cross
member on support. -A- → Initial tightening: 37 ftlb. → Final
tightening: 90 °
9. Remove support suspending device 2024 a from the transmission.
Subsequent work
Touching up for removing transmission

1. Install engine. → 100123 Installing engine.
9PAAE7
as of MY 2003
WARNUNG
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ADVERTENCIA
34 35 IN Technical data on manual transmission - as of MY 2003

- Technical data on manual transmission
Technical data on manual transmission
Technical data
TypeG 48.00 / G48.20
Installed inCayenne / Cayenne S
Model yearas of 2004
Type6-speed manual transmission
Transmission ratios
1. gear4.68
2. gear2.53
3. gear1.69
4. gear1.22
5. gear1.00
6. gear0.84
Reverse gear4.27
Manual transmission filling capacities

Filling capacity New filling Filling capacity 1.8 l
Filling capacity Change quantity Filling capacity 1.8 l
9PAAD7, 9PAAE7
as of MY 2003
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34 49 19 Removing and installing countershaft cap - as of MY

2003
- Preliminary work for countershaft cap
- Removing countershaft cap
- Installing countershaft cap
- Touching up countershaft cap
Tools

slide hammer kit commercially nr.168
available tool

available tool
Preliminary work for countershaft cap
Preliminary work countershaft cap

1. Remove transmission. → 343519 Removing and installing transmission - chapter on "removing" [9PAAD7]
→ 343519 Removing and installing transmission - chapter on "removing" [9PAAE7]
Removing countershaft cap
Removing countershaft cap
Overview of cap
1. Drive two small holes -figure- - offset by 180 degrees - into the
sealing ring.
Preparatory work for removing sealing

ring
2. Screw two sheetmetal screws into the holes in the cap.
3. Remove cap using slide hammer kit nr.168.

Removing sealing ring Screwing in sheetmetal screws
Installing countershaft cap
Installing countershaft cap
Overview of cap
1. Drive new cap in flush using special tool pressure piece t10180.
Touching up countershaft cap
Reworking countershaft cap

1. Install transmission. → 343519 Removing and installing transmission - chapter on "installing" [9PAAD7]
→ 343519 Removing and installing transmission - chapter on "installing" [9PAAE7]
2. Check transmission oil . → 340135 Check and top up transmission oil - Chapter "Checking"
9PAAD7, 9PAAE7
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
35 50 19 Removing and installing sealing ring for drive shaft - as

of MY 2003
- Preliminary work for drive shaft
- Removing sealing ring for drive shaft
- Installing sealing ring for drive shaft
- Touching up for sealing ring for drive shaft
Tools

sheetmetal screws commercially
available tool .gif

available tool
available tool
Preliminary work for drive shaft
Preliminary work for sealing ring for manual transmission

1. Remove transmission. → 343519 Removing and installing transmission - chapter on "Removing" [9PAAD7]
→ 343519 Removing and installing transmission - chapter on "Removing" [9PAAE7]
Removing sealing ring for drive shaft
Removing sealing ring for drive shaft
1. Remove clutch lever with release bearing. To do this, press the

retaining spring -arrow- out of the opening in the clutch lever.
Clutch lever
Guide tube screws
2. Remove guide tube for release bearing. To do this, unscrew four fastening screws -arrow- .
Note
z There are two depressions in the sealing ring -arrows- . The
sheetmetal screws for removing the sealing ring are screwed in here.
3. Screw two sheetmetal screws into the sealing ring.
Depression in sealing ring

4. Remove sealing ring using slide hammer kit nr.168.
Installing sealing ring for drive shaft
Installing sealing ring for drive shaft
1. Fill the space between the dust and sealing lips on the new sealing ring with grease).
2. Drive new sealing ring in flush with special tool pressure piece t10180.
3. Install guide tube for release bearing. To do this, screw in four fastening screws -arrow- .
Guide tube screws Preparing sealing ring
Clutch lever
4. Install clutch lever with release bearing. To do this, the retaining spring -arrow- must be engaged in the
opening in the clutch lever.
Touching up for sealing ring for drive shaft
Subsequent work for sealing ring for drive shaft

1. Install transmission. → 343519 Removing and installing transmission - chapter on "installing" [9PAAD7]
→ 343519 Removing and installing transmission - chapter on "installing" [9PAAE7]
9PAAD7, 9PAAE7
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
35 53 19 Removing and installing sealing ring for output shaft - as

of MY 2003
- Preliminary work for sealing ring for output shaft
- Removing sealing ring for output shaft
- Installing sealing ring for output shaft
- Subsequent work
Tools

sheetmetal screws commercially
available tool .gif

available tool
available tool
protective sleeve commercially t10186

available tool
Overview of output-shaft sealing ring
Note
z There are two depressions in the sealing ring. -arrows- The
sheetmetal screws for removing the sealing ring are screwed in here.
Depression in sealing ring

1. Screw two sheetmetal screws into the sealing ring.
Preliminary work for removing the

sealing ring
2. Remove sealing ring using slide hammer kit nr.168.


Overview of output-shaft sealing ring
ring with grease).
Preparing sealing ring

2. Push special tool protective sleeve t10186 -arrow- onto the output shaft.
3. Push on sealing ring.
4. Remove special tool protective sleeve t10186 and drive sealing ring in flush using special tool pressure
Installing sealing ring Protective sleeve on output shaft
piece t10180 -arrow- .
Subsequent work
Subsequent work for sealing ring for output shaft

2. Check transmission oil. → 340135 Checking and topping up transmission oil - chapter on "Checking"
9PAAD7, 9PAAE7
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
39 01 19 Removing and installing rear final drive - as of MY 2003

- Preliminary work for rear final drive
- Removing rear final drive
- Installing rear final drive
- Subsequent work for rear final drive
Tools

available tool
Preliminary work for rear final drive


2. Remove longitudinal interlock servo motor. → 397719 Removing and installing rear-differential lock servo
motor - "Removing" section
2. Loosen fastening screws for fixing cardan shaft centre bearing holder
to body.
Cardan shaft support to body

Centre bearing to cardan shaft holder
Tying up rear cardan shaft
Note
z The colour marking, match point, on the cardan shaft and on the
flange of the rear final drive must be installed in alignment -arrows- .
This will neutralise the residual imbalance of the components.
Note
the transfer box. Match points on the cardan shaft
4. Remove cardan shaft from rear axle transmission and tie it up.
Note
z To loosen the drive shaft bolts on the rear axle transmission, a
second fitter should sit in the vehicle and block the rear-axle final
drive by actuating the foot brake.
5. Remove both drive shafts on transmission side and tie up.
6. Support transmission jack and rear axle transmission with retaining

band.

7. Unscrew fastening screws for final drive. To do this, counter with ring
wrench.

8. Tip drive flange upwards -arrow- and gradually drain rear axle transmission. Remove bleeder line at the
same time.
9. Remove transmission and pull off bleeder line → Removing bleeder

line .
Removing bleeder line
Note
with new ones.
Note
z The colour marking, match point, on the cardan shaft and on the flange of the rear final drive must be
installed in alignment -arrows- . This will neutralise the residual imbalance of the components.
1. Secure rear axle transmission on transmission jack with retainer
band.
Match points on the cardan shaft

2. Run in rear axle differential by gradually tipping the drive flange
upwards -arrow- . Connect bleeder line at the same time.
3. Screw in new fastening screws on final drive. To do this, counter with

ring wrench. → Initial tightening: 67 ftlb. → Final tightening: 67 °
Note
z To tighten the drive shaft bolts on the rear final drive, a second fitter
should sit in the vehicle and block the rear-wheel drive assembly by
4. Attach drive shafts with new screws. → 42 Tightening torques for Installing transmission
rear axle
ATTENTION
Cardan shaft can be damaged by imbalance.
→ Cardan shaft and flange not installed in original position.

→ The colour marking, match point, on the cardan shaft and on the
flange of the rear final drive must be installed in alignment. This will
neutralise the residual imbalance of the components.
Note Cardan shaft to rear final drive
z To attach the cardan shaft to the rear final drive, a second fitter should counter the fastening screws on the
triangular flange of the transfer box.
5. Attach cardan shaft with new screws.
6. Screw in fastening screws for fixing cardan shaft centre bearing holder to body. → Tightening torque: 44
ftlb.
Note
Alignment of special tool 9680 Cardan shaft support to body
z Fit special tool centring tool 9680 -Werkzeug in Einbaulage- in the
order specified.
7. Position special tool centring tool 9680.
Installation position for special tool

numbering -1, 2- .
Installation of special tool 9680

9. Tighten threaded joints -arrow- connecting support to centre
bearing. → Tightening torque: 15 ftlb.

10. Remove special tool centring tool 9680.
Subsequent work for rear final drive
Removal of special tool 9680


2. Install servo motor for rear-differential lock. → 397719 Removing and installing rear-differential lock servo
motor - "Installing" section
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
39 02 19 Removing and installing front cardan shaft - as of MY

2003
- Preliminary work for front cardan shaft
- Removing front cardan shaft
- Installing front cardan shaft
- Subsequent work for front cardan shaft

Note

drive
1. Detach cardan shaft from final four wheel drive → Front cardan shaft to all-wheel final drive .
front final drive
Note

2. Remove cardan shaft from the transfer box → Front cardan shaft to
transfer box .
3. Swivel the cardan shaft forwards over the suspension subframe and
remove it.

front final drive
Note
z To tighten the cardan shaft bolts, a second fitter should sit in the vehicle and block the drive train by actuating
the brake.
Note
1. Swivel the cardan shaft over the suspension subframe and install it.

front final drive
2. Fix cardan shaft with new screws -arrow- to the transfer box. → Initial
tightening: 22 ftlb. → Final tightening: 90 degree angle

3. Fix cardan shaft with new screws → Cardan shaft to all-wheel final
drive to the all-wheel final drive. → Initial tightening: 22 ftlb. → Final
tightening: 90 degree angle
Cardan shaft to all-wheel final drive

9PAAD1, 9PAAD7, 9PAAE7
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
39 13 19 Removing and installing transfer box control module - as
of MY 2003
- Removing transfer box control module
- Installing transfer box control module
Removing transfer box control module
Note
3. For vehicles with a telephone, remove the telephone control unit. → 919019 Removing and installing control
unit for telephone - chapter on "removing"

Note
z Only for vehicles with
telephone


8. Release the two connectors -A- and pull them off -B- .
9. Remove the support with the two control units -C- .
Installing transfer box control module
1. Insert the control unit -A- until the locking tabs -B- are felt to engage.
2. Insert the two connectors -A- and press in the locking mechanism -B- until it is felt to engage.
3. Place the support with the two control units in the installation position -C- .
4. Move seat all the way back
and tighten the support with
Note
6. For vehicles with a telephone, install the telephone control unit.

→ 919019 Removing and installing control unit for telephone -
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA

as of MY 2003
- Preliminary work for sealing ring for output flange
- Removing sealing ring for output flange
- Installing sealing ring for output flange
- Subsequent work
Tools

available tool .gif

available tool

Preliminary work for sealing ring for output flange
Preliminary work sealing ring for output flange
Removing sealing ring for output flange
1. Remove output flange with special tool striker vw 771/1 and shop-
made tool .
Installing sealing ring for output flange
1. Replace circlip on flange shaft.
Replacing circlip
2. Drive in new sealing ring with special tool pressure piece t10181
Subsequent work
Reworking sealing ring for output flange

9PAAJ1]
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
39 35 19 Removing and installing rear cardan shaft - as of MY

2003
- Preliminary work for rear cardan shaft
- Removing rear cardan shaft
- Installing rear cardan shaft
- Subsequent work
Tools

available tool
Preliminary work for rear cardan shaft
Preliminary work - rear cardan shaft

1. Remove exhaust system after catalytic converter. → 260119 Removing and installing exhaust system -

Note
z If the cardan shaft or transfer box has to be replaced, please ignore the next step.
z Marking the position of the cardan shaft with respect to the transfer box triangular flange serves only to
prevent possible humming noises.
Note
fitter should counter the fastening screws -arrows- at the triangular
flange of the transfer box.
Rear cardan shaft to transfer box

2. The position of the cardan shaft -arrows- with respect to the rear axle transmission flange is marked with a
white dot, match point, on both components.
Note
z The colour marking, match point, on the cardan shaft and on the rear final drive flange must be aligned. This
will neutralise the residual imbalance of the components.
3. Mark the position of the
cardan shaft -arrow- with
respect to the transfer box
flange with a coloured pen.
Mark for rear cardan shaft to transfer Match points for cardan shaft to final
box drive
4. Loosen fastening screws -arrow- securing cardan shaft support to
centre bearing.

5. Unscrew fastening screws on the cardan shaft at the rear axle
transmission → Cardan shaft to rear final drive .
ATTENTION
Noises caused by damage in the drive line
→ Faulty centre bearing; replace cardan shaft

→ Do not loosen cardan shaft bolts using rubber/metal disc.
6. Unscrew fastening screws -arrows- on the cardan shaft at the

transfer box. Counter with an open-ended wrench.

ATTENTION

→ When one of the two flanges on the cardan shaft has been released,
the centre bearing must be relaxed!
→ Do not leave cardan shaft hanging. All three fastening points for
transfer box, centre bearing and rear final drive must always be
screwed in.
→ The recommended procedures must be followed during installation, Cardan shaft centre bearing to body
otherwise the position of the cardan shaft in its original place is no
longer guaranteed. Possible result: premature failure of the centre
bearing resulting in subsequent cardan shaft replacement.
7. Release cardan shaft centre bearing holder. To do this, unscrew six fastening screws -arrows- .
8. Carefully separate cardan shaft from transfer box → Removing

cardan shaft and press backwards.
Note
z To prevent the cardan shaft from being damaged, a second mechanic
is required to remove the equipment.
Removing cardan shaft
ATTENTION

→ When one of the two flanges on the cardan shaft has been released, the centre bearing must be relaxed!
→ Do not leave cardan shaft hanging. All three fastening points for transfer box, centre bearing and rear final
drive must always be screwed in.
→ The recommended procedures must be followed during installation, otherwise the position of the cardan
shaft in its original place is no longer guaranteed. Possible result: premature failure of the centre bearing
resulting in subsequent cardan shaft replacement.
ATTENTION
Leakage due to damage to centring sleeve
→ Ensure that no damage occurs during removal and installation.

→ Centring sleeve should be greased slightly.
→ Transfer box journal must be clean.
Note
z There is no colour marking on the flange to the transfer box for installing new components, transfer box or
cardan shaft. As a result, positioning is not an issue.
z If none of the components are replaced, the mark you apply is a precautionary measure in order to avoid
humming noises from the drive line.
Note
z To prevent the cardan shaft from being damaged, a second mechanic is required to install the equipment.
1. Install cardan shaft.
2. Pull cardan shaft joints apart so that they sit in the transmission flanges.
3. Screw in six screws -arrow- on the centre bearing holder but do not
tighten.

4. Position the cardan shaft at the colour markings -arrow- again.
Marking on transfer box flange/cardan

shaft
Note
z The colour marking, match point -arrow- , on the cardan shaft and on the flange of the rear final drive must
Note
z To attach the cardan shaft to the rear axle transmission, a second
the transfer box.

with new ones.
5. Screw in new screws for cardan shaft flange at the rear axle
transmission. → Initial tightening: 22 ftlb. → Final tightening: 90 °
Match points for cardan shaft to final
drive
6. Tighten bolts connecting cardan shaft triangular flange to transfer
box -arrows- . Counter with an open-ended wrench. → Tightening
torque: 56 ftlb.

7. Screw in fastening screws for securing cardan shaft centre bearing
holder to body -arrows- . → Tightening torque: 44 ftlb.
Note
Mounting special tool 9680

z Fit special tool centring tool 9680 → Special tool in installation position in the specified sequence.
8. Mount special tool centring tool 9680 -arrow,inset- .

Special tool in installation position
numbering -1, 2- .
Pressing on special tool 9680

10. Tighten bolts -arrow- connecting holder to centre bearing. →

11. Remove special tool centring tool 9680. -arrows-
Removing special tool 9680
Subsequent work
Subsequent work - rear cardan shaft
as of MY 2003
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ADVERTENCIA
39 55 19 Removing and installing sealing ring for cardan flange -

as of MY 2003
- Preliminary work for cardan flange sealing ring
Tools

available tool .gif
counterer commercially 3435

available tool
torque screwdriver for commercially 89


2. Remove front cardan shaft → 390219 Removing and installing front cardan shaft - chapter on
"Removing" [9PAAD1 9PAAD7 9PAAE7].

1. Mark nut on drive flange with a coloured pen -arrow- .
Marking nut
2. Determine rolling moment of axle transmission with special tool
torque screwdriver for measuring friction moment 89. Push stop
on special tool to zero and turn transmission several times. Note the
displayed value.
3. Unscrew nut on drive flange. To do this, use the special tool

counterer 3435 to block the transmission → Measuring rolling
moment .
Measuring rolling moment

4. Remove drive flange with special tool striker vw 771/1 and shop-
made tool → Removing drive flange .

extraction tool vw 771/37.

1. Fill space between dust and sealing lips with grease.
Greased sealing ring

2. Drive sealing ring in as far as the mounting face with special tool
pressure piece T10183.
3. Push in drive flange and tighten nut.

4. Position marking on nut and drive shaft -arrow- again so that the rolling moment determined prior to removal
is attained once again.
Note
z If the rolling moment has to be corrected, this should be done via the
tightening torque of the nut.
5. Check rolling moment with special tool torque screwdriver for

measuring friction moment 89.
Marking nut
Rolling moment Adjustment value 2.0 (1.5 ftlb.) Nm +0.5 (0.5 ftlb.) Nm
Subsequent work on sealing ring for cardan flange

1. Install front cardan shaft → 390219 Removing and installing front cardan shaft - chapter on
"Installing" [9PAAE1 9PAAF1 9PAAJ1]→ 390219 Removing and installing front cardan shaft - chapter on
"Installing" [9PAAD1 9PAAD7 9PAAE7].
2. Carry out oil check. → 399035 Checking and topping up oil for all-wheel final drive - chapter on "Checking"
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA

as of MY 2003
- Preliminary work for output flange sealing ring
- Removing sealing ring for left and right output flange
- Installing sealing ring for left and right output flange
- Subsequent work for output flange sealing ring
Tools

available tool .gif

available tool

Removing sealing ring for left and right output flange
Removing sealing ring for left-hand output flange
made tool .

Removing sealing ring for right-hand output flange
made tool .

extraction tool vw 771/37 attachment.
Installing sealing ring for left and right output flange
Installing sealing ring for left-hand output flange



2. Replace circlip on end of long flanged shaft.
Example using the short flanged shaft

Installing sealing ring for right-hand output flange


2. Replace circlip on flanged shaft → Replacing circlip .
3. Push flanged shaft into transmission until it engages.
Replacing circlip

1. Install four-wheel final drive → 398819 Removing and installing four-wheel final drive - chapter on
"Installing".
2. Check oil for four-wheel final drive. → 399035 Checking and topping up oil for four-wheel final drive - chapter
on "Checking"
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
39 61 19 Removing and installing rubber mounting for four-wheel

final drive - as of MY 2003
- Preliminary work for rubber mounting on four-wheel final drive
- Removing rubber mounting for four-wheel final drive
- Installing rubber mounting for four-wheel final drive
Tools

workshop caliper gauge commercially 139
available tool
assembly fixture special tool 9716

a/b

Preliminary work for rubber mounting on four-wheel final drive
Preliminary work, rubber mounting on four-wheel final drive

1. Remove four-wheel final drive. → 398819 Removing and installing four-wheel final drive - "Removing"
section
Removing rubber mounting for four-wheel final drive
Removing rubber mounting for four-wheel final drive, drive side
Removing rubber mounting, drive side Marking for rubber mounting
2. Position special tool assembly fixture 9716 a/b on rubber mounting → Removing rubber mounting, drive
side .
3. Remove rubber mounting on drive side -arrow- .
Removing rubber mounting for four-wheel final drive, right output side
2. Position special tool assembly fixture 9716 a/b on rubber mounting → Removing right rubber mounting .
Removing rubber mounting for four-wheel final drive, left output side
Removing right rubber mounting Marking for rubber mounting

position -arrow- .

2. Position special tool assembly fixture 9716 a/b on rubber mounting → Removing left rubber mounting .
3. Remove left rubber mounting -arrow- .
Installing rubber mounting for four-wheel final drive

Removing left rubber mounting
Installing rubber mounting for four-wheel final drive, drive side
Note


1. Mark centre of bulge in rubber mounting → Marking for centre of

rubber mounting . Marking for centre of rubber mounting
2. Position rubber mounting in housing using special tool assembly fixture 9716 a/b/c.
3. Pull in rubber mounting in direction of travel until installation position is reached. Measure distance between
assembly fixture ring and housing using workshop caliper gauge 139. → Distance: 7.5 mm +/-0.1 mm
Installing rubber mounting for four-wheel final drive, right output side
Note



into housing
housing
1. Mark centre of bulge in rubber mounting → Marking for centre of rubber mounting .
2. Position special tool assembly fixture 9716 a/b on rubber mounting.
3. Pull in rubber mounting until installation position is reached.
Installing rubber mounting

Installing rubber mounting for four-wheel final drive, left output side
Note



into housing
housing
1. Mark centre of bulge in rubber mounting. -arrows-
2. Position special tool assembly fixture 9716 a/b/c on rubber mounting → Positioning bearing .
3. Press rubber mounting flush into housing. -direction of arrow-
Touching up, rubber mounting on four-wheel final drive

1. Install four-wheel final drive. → 398819 Removing and installing four-
wheel final drive - "Installing" section
Positioning bearing
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
39 61 19 Removing and installing rubber mounting for rear final

drive - as of MY 2003
- Preliminary work
- Removing rubber mounting for rear final drive
- Installing rubber mounting for rear final drive
- Subsequent work
Tools

material special tool 00000 shop-made tool

available tool a/b

striker workshop VW
equipment 771/1
Preliminary work
Preliminary work, rubber mounting on rear final drive
Removing rubber mounting for rear final drive
Removing rubber mounting for rear final drive, drive side

position -arrow- .
Marking for rubber mounting for

housing
2. Position special tool assembly fixture 9716 a/b on rubber mounting
→ Removal on drive side .
Removal on drive side

Removing rubber mounting for rear final drive, output side
1. Remove output flange with special tool striker VW 771/1 and

material 00000 -direction of arrow- .

position -arrow- .

3. Position special tool assembly fixture 9716 a/b on rubber mounting → Removing rubber mounting .
4. Remove rubber mounting -direction of arrow- .
Installing rubber mounting for rear final drive

Removing rubber mounting
Installing rubber mounting for rear final drive, output side
Note



mounting and align the markings.
2. Press rubber mounting flush → see figure into housing.

Note


Installing rubber mounting for rear final drive, drive side
Note



mounting → Installing rubber mounting on drive side and align the Installing rubber mounting on drive
markings. side
Note
into housing
housing
2. Press rubber mounting flush -direction of arrow- into housing.
Subsequent work
Touching up, rubber mounting on rear final drive

9PAAJ1]
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
39 65 19 Removing and installing transfer box - as of MY 2003

- Preliminary work for transfer box
- Removing transfer box
- Installing transfer box
- Subsequent work for transfer box
Preliminary work for transfer box
Preliminary work transfer box

Overview of removing and installing transfer box
Note
1. Remove front cardan shaft on the transfer box and tie it up.

2. Remove cable plug on the servo motor -1 , 2- and release cable
holder.
Note
3. Remove transmission cross member.
4. Support transmission with transmission jack and secure with

retaining band.
Cable plug on servo motor
5. Unscrew bolts on body -A- .
6. Unscrew two transmission cross member screws -B- on transfer box holder.
7. Place a wooden block -arrow- between the converter bell housing and suspension subframe.
Supporting transmission Transmission cross member
Tiptronic line holder
8. Unscrew fastening nut and push holder with Tiptronic line -A- away to the side.
9. Unscrew fastening screws -arrows- securing transfer box to main

transmission.

10. Separate transfer box from main transmission.
11. Gradually drain transfer box. Pull out vent line -arrows- and remove it from the retainers on the upper side.

Vent line support Removing transfer box
1. Support main transmission on converter bell housing with a wooden

block -arrow- .
2. Gradually run in transfer box. Press vent line into holder -arrow- and
attach to transfer box.
Vent line support

3. Screw in fastening screws on main transmission. → Tightening
torque: 33 ftlb.

4. Tighten holder -A- for Tiptronic line using fastening nut -arrow- . → Tightening torque: 7.5 ftlb.
Transfer box
5. Support transfer box with transmission jack and remove wooden
block between converter bell housing and suspension subframe.
Note
Note
with new ones. Supporting transmission
6. Install transmission cross member.
7. Screw in two cross member screws -B- on transfer box holder. →

8. Screw in fastening screws for securing transmission cross member to
body -A- . → Initial tightening: 37 ftlb. → Final tightening: 90 °
Note
9. Connect front cardan shaft to transfer box. → Initial tightening: 22 ftlb. → Final tightening: 90 °
10. Connect cable plugs -1 , 2- to
the transfer box and secure
the cable holder.
Cable plug on servo motor Front cardan shaft to transfer box
Subsequent work for transfer box
Reworking transfer box

as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
39 77 19 Removing and installing transverse lock servo motor - as

of MY 2003
- Removing transverse lock servo motor
- Installing transverse lock servo motor
- Subsequent work
1. Pull cable plug -1, 2- off the servo motor.

Cable lead fastening Electric plug on servo motor
2. Pull off fastening element -arrow- for cable lead and place lead aside.
3. Unscrew four fastening screws -arrows- on the servo motor.
ATTENTION
Emerging oil is harmful to the eyes.
→ Wear personal protective gear (e.g. safety goggles).
Note
z Avoid minor oil leaks when removing the servo motor. Servo motor fastening
4. Place oil collection container underneath.
1. Replace sealing ring -arrow- on servo motor.
2. Install servo motor.
Sealing ring on servo motor

3. Screw in four screws -arrows- on servo motor. → Tightening
torque: 7.5 ftlb.
Servo motor fastening

4. Install fastening element -arrow- for cable lead.
5. Connect cable plug -1, 2- to servo motor.
Subsequent work
Electric plug on servo motor Cable lead fastening
Subsequent work for servo motor for differential lock
1. Check the oil in the final drive. → 399035 Checking and topping up oil for rear final drive
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
39 78 19 Removing and installing servo motor on transfer box - as

of MY 2003
- Removing servo motor on transfer box
- Installing servo motor on transfer box
1. Before beginning to work on the servo motor for the transfer box, engage the Low Range offroad driving
program.
2. Disconnect Low Range cable plug -arrow- on the servo motor and loosen cable holder -A- .
Low Range cable plug
3. Pull centre-differential lock cable plug -arrow- off the servo motor.
Centre-differential lock cable plug

4. Unscrew servo motor threaded joint on the transfer box.
Note
z If a new servo motor is installed, it is supplied in Low Range position,
offroad driving program.
1. Connect servo motor to the shaft on the transfer box. Position cutout
of the shaft -right inset- to the servo motor -left inset- .
2. Screw in servo motor threaded joint -arrows- on the transfer box. →

Positioning the servo motor

3. Screw in servo motor threaded joint support -arrows- on the transfer
box. → Tightening torque: 7.5 ftlb.

4. Connect centre-differential lock cable plug -2- , Low Range -1- and secure cable holder.
Cable plug for servo motor
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
39 82 19 Removing and installing sealing ring for cardan flange

(rear final drive) - as of MY 2003
- Preliminary work for sealing ring for cardan flange
Tools

shop made tool special tool 00000
torque screwdriver for commercially NR.89

striker workshop VW
equipment 771/1
extraction tool workshop VW

equipment 771/37

1. Remove rear cardan shaft. → 390119 Removing and installing rear final drive - chapter on
"Removing" [9PAAD1 9PAAD7]→ 390119 Removing and installing rear final drive - chapter on
"Removing" [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]
1. Mark position of nut on drive flange -arrow- at shaft.
Marking of nut on drive flange

2. Check rolling moment of rear final drive with special tool torque screwdriver for measuring friction
moment NR.89 -picture- and note value.
Note
3. Unscrew nut on drive flange.
To do this, block flange with
special tool arm bracket
3435.
Loosening nut on drive flange Checking rolling moment

4. Remove drive flange with special tool shop made tool 00000 and
striker VW 771/1.
1. Drive in sealing ring with special tool pressure piece T10182

-picture- until special tool touches transmission housing.
2. Push in flange and screw in nut.
Note
3. Position marking on nut and drive shaft -arrow- again so that the
rolling moment determined prior to removal is reached once again.
Marking nut on drive flange
Note
z If the rolling moment has to be corrected, this should be done via the tightening torque of the nut.
4. Check rolling moment with special tool torque screwdriver for measuring friction moment NR.89. →
Rolling moment: 2.0 ftlb. -0.2 ftlb. +0.2 ftlb.
Checking rolling moment
Touching up sealing ring for cardan flange

1. Install rear cardan shaft. → 390119 Removing and installing rear final drive - chapter on "Installing" [9PAAD1
9PAAD7]→ 390119 Removing and installing rear final drive - chapter on "Installing" [9PAAE1 9PAAE7
9PAAF1 9PAAJ1]
2. Check the oil in the final drive. → 399035 Inspecting and adding oil for rear final drive - chapter on
"Checking"
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
39 88 19 Removing and installing four-wheel final drive - as of MY

2003
- Preliminary work for all-wheel final drive
- Removing four-wheel final drive
- Installing four-wheel final drive
Tools

multiple-tooth socket wrench commercially NR.31

equipment
Preliminary work for all-wheel final drive
Preliminary work final four wheel drive

1. Remove right engine compartment cover → 700219 Remove and install front cover (engine compartment) -
Chapter "Removing".
2. Support engine. → Support engine on the body [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]→ Support engine on
the body [9PAAD1 9PAAD7] or → Supporting engine on the body [9PAAD1 9PAAD7]→ Supporting engine
on the body [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]
3. Remove front wheels. → 440519 Remove and install wheel - Chapter "Removing"
4. Remove engine guard → 108019 Removing and installing engine guard - Chapter "Removing".
5. Remove front cardan shaft → 390219 Install and remove front cardan shaft - Chapter "Removing" [9PAAE1
9PAAF1 9PAAJ1]→ 390219 Install and remove front cardan shaft - Chapter "Removing" [9PAAD1 9PAAD7
9PAAE7].
1. Clamp steering wheel in centre position with steering wheel holder -figure- .
2. Unscrew plastic nuts -arrows- on front right wheel housing liner.
3. Engage special tool spring compressor VW 552 in top of wheel housing, behind wheel housing liner, and
support the spring strut.
Installation position of spring

compressor
4. Remove cover plate on the steering -arrows- .
5. Pull Servotronic plug off the steering gear.
Cover plate on steering

6. Unscrew bolted connection -arrow- securing universal joint to
steering gear. Remove universal joint from steering gear.
7. Remove left and right drive shafts from four-wheel final drive using
multiple-tooth socket wrench insert M12 NR.31.
Universal joint bolted connection

8. Undo fastening screws for four-wheel final drive and screw on drive flange.
Note
z Supports 1, 2 and 3 must be fitted to the unit lifting platform.
9. Raise unit lifting platform until it bears against the front-axle carrier.
VAG bolts
Note
z Fastening screw -left arrow- at front right cannot be removed until
the front-axle carrier is lowered.
10. Unscrew bolts -arrows- on front-axle carrier.
VAG bolts
11. Undo bolt connecting spring strut to trailing arm -arrow- .

arm
12. Unscrew servo line holders -arrow- from air-conditioning compressor and remove the line.
Servo line holders Servo line holders
13. Disengage servo line from the front-axle carrier at the three holders -arrows- .
14. Loosen holders for coolant pipes -arrow- at the body.
ATTENTION
Over-extension of drive shafts on running gear!
→ Do not pull front-axle carrier downwards.
15. Lower front-axle carrier with the unit lifting platform. Remove vent line
from the final drive at the same time.
Coolant pipe holders
ATTENTION

Note
z A second fitter is required for removing/installing the four-wheel final Pressing out drive shaft
drive.
16. Press left drive shaft out of flange on final drive.
17. Lift transmission and press to the left.
18. Tilt forward the transmission housing together with drive flange.
19. Remove four-wheel final drive downwards through the front-axle carrier.

Removing four-wheel final drive Movement sequence for four-wheel
final drive
Installing the four-wheel final drive
ATTENTION

Note
z A second fitter is required for removing/installing the four-wheel final drive.
1. Swivel left flange of final drive in over the front-axle carrier.

2. Rotate drive flange upwards and install final drive through the front-axle carrier.
3. Insert right drive shaft into output flange and place final drive into the
mounts on the front-axle carrier.
Movement sequence for installing four-

wheel final drive
4. Fit left drive shaft by lifting the final drive output flange.
Fitting left drive shaft
VAG bolts
Note
z The front right fastening screw for the four-wheel final drive
-left arrow- can only be screwed in with the front-axle carrier
lowered.
5. Insert fastening screws -arrows- for four-wheel final drive and screw
for drive flange.
Note
z Supports 1, 2 and 3 must be fitted to the unit lifting platform. VAG bolts
6. Raise front-axle carrier with unit lifting platform until it bears against the body. Position vent line at the same
time.
Note
z For details of tightening torques for running gear parts, see Group 4
(Running gear) → 40 Tightening torques for front axle.
7. Screw in bolts -arrows- on front-axle carrier.

8. Screw in bolt -arrow- connecting spring strut to trailing arm.

arm
9. Fit holders -arrow- for coolant pipes to the body.
10. Engage servo line in the three holders -arrows- on the front-axle carrier.
11. Screw servo line holders -arrow- on to air-conditioning compressor and clip in the line.
Note
Servo line holders Coolant pipe holders
Holder on air-conditioning compressor
12. Tighten fastening screw for four-wheel final drive. → Initial tightening: 67 ftlb. → Final tightening: 90 °
Note
13. Screw in drive shaft screws.
14. Connect steering column to steering gear. Screw in new screw.
Steering column mounting

15. Install cover plate on the steering.
16. Connect Servotronic plug to the steering gear.
17. Remove special tool spring compressor VW 552 from spring strut.
Installation position of spring Cover plate on steering
compressor
18. Screw in plastic nuts -arrows- on front right wheel housing liner.

19. Remove steering-wheel holder -figure- .
Note
20. Tighten bolts -arrows- on front-axle carrier.


Subsequent work - final four wheel drive
1. Install front cardan shaft → 390219 Install and remove front cardan shaft - Chapter "Installing" [9PAAE1
9PAAF1 9PAAJ1]→ 390219 Install and remove front cardan shaft - Chapter "Installing" [9PAAD1 9PAAD7
9PAAE7].
2. Remove engine support. → Support engine on the body [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]→ Support
engine on the body [9PAAD1 9PAAD7] or → Supporting engine on the body [9PAAD1 9PAAD7]
→ Supporting engine on the body [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]
3. Install right engine compartment cover → 700219 Remove and install front cover (engine compartment) -
4. Mount front wheels. → 440519 Remove and install wheel - Chapter "Installing"
5. Calibrate steering angle sensor → 456005 Initialise and calibrate steering angle sensor
6. Align front axle and adjust as required. → Suspension alignment complete
7. Install engine guard → 108019 Install and remove engine guard - Chapter "Installing".
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
39 90 35 Checking and topping up oil for transfer box - as of MY

2003
- Checking oil for transfer box
- Topping up oil for transfer box
Tools

Checking oil for transfer box
WARNING

Note
z The vehicle must stand horizontally. Inspection/drain plug
Note
The oil level can only be checked after the vehicle has been idle for 45 minutes.
Note
3. If this is not the case, top up the oil. → 399035 Inspecting and adding oil for transfer box - chapter on "Filling"
Topping up oil for transfer box
Filling oil for transfer box
WARNING

Note
The oil level can only be checked after the vehicle has been idle for 45 Inspection/drain plug
minutes.
Note
z The vehicle must stand horizontally!
Note
plug -A- . Raise filling device.
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
39 90 35 Checking and topping up oil for rear final drive - as of MY

2003
- Checking oil for rear final drive
- Topping up oil for final drive
Tools

WARNING

Note
z Vehicle must be horizontal in order to check fluid level in rear final
drive.
2. The oil level is correct if the oil reaches the lower edge of the
inspection window.
Note Control/drain plug for rear final drive

3. If this is not the case, top up the oil. → 399035 Inspecting and adding oil for rear final drive - chapter on
"Filling"
torque: 26 ftlb.
WARNING

Note
z Vehicle must be horizontal in order to fill rear final drive. Control/drain plug for rear final drive

Note
plug -A- .
torque: 26 ftlb.
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
39 90 35 Checking and topping up oil for four-wheel final drive -

as of MY 2003
- Checking oil for four-wheel final drive
- Topping up oil for four-wheel final drive
Tools

special inserts mod. AB commercially 170

available tool
accessory for the torque commercially 98-1

wrench: open ring wrench available tool
Preliminary work for oil for all-wheel final drive
Checking oil for four-wheel final drive
Checking oil for all-wheel final drive
WARNING

Note
z Vehicle must be horizontal to check oil level in all-wheel final drive. Oil inspection plug-filler screw
3. If this is not the case, top up the oil. → 399035 Checking and topping up oil for all-wheel final drive - chapter
on "Filling"
4. Screw in oil inspection plug -A- with new sealing ring. To do this, use the special tool special inserts model
AB 170 and accessory for the torque wrench: open ring wrench insert a/f 13 + adapter 98-1. →
Topping up oil for four-wheel final drive

Filling oil for all-wheel final drive
WARNING

Note
z Vehicle must be horizontal in order to fill final drive. Oil inspection plug-filler screw
Note
-A- .
3. Screw in oil inspection plug -A- with new sealing ring. To do this, use
the special tool special inserts model AB 170 and accessory for
the torque wrench: open ring wrench insert a/f 13 + adapter 98-
1. → Tightening torque: 26 ftlb.

Touch up for oil for all-wheel final drive
1. Remove engine guard. → 108019 Removing and installing engine guard - chapter on "Installing"
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
39 90 55 Changing oil for four-wheel final drive - as of MY 2003

- Changing oil for four-wheel final drive
Tools

special inserts model AB commercially 170

available tool
accessory for torque wrench: commercially 98-1

open ring wrench insert a/f 13 available tool
+ adapter
Preliminary work oil for four-wheel final drive

Changing oil for four-wheel final drive

WARNING

3. Screw in oil drain plug -B- with a new sealing ring. → Tightening
torque: 26 ftlb. Oil inspection and drain plug
4. Unscrew oil inspection plug using the special inserts model AB 170
tool.
Tool for oil inspection plug

Note
5. Using the ATF filling device for filling transmission 161, fill with oil
up to the lower edge of the oil inspection plug -A- .

6. Unscrew oil inspection plugs -A- using the special inserts model
AB tool 170 accessory for torque wrench: open ring wrench
insert a/f 13 + adapter 98-1 and screw in a new sealing ring. →
Reworking oil for four-wheel final drive

as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
39 90 55 Changing oil for rear final drive - as of MY 2003

- Changing oil for rear final drive
Tools


WARNING

2. Unscrew oil drain plug -B- and drain oil.

WARNING

Note
z Vehicle must be horizontal in order to fill rear final drive.
opening -A- . → Tightening torque: 1.25 l +0.35 l
torque: 26 ftlb.
7. Check oil for rear final drive → 399035 Checking and topping up oil
for rear final drive - chapter on "Checking"
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
39 90 55 Changing oil for transfer box - as of MY 2003

- Changing oil for transfer box
- Subsequent work for oil for transfer box
Tools


1. Slide oil collecting container under the vehicle.
WARNING


3. Screw in oil drain plug -B- with new sealing ring. → Tightening
torque: 15 ftlb.

Note
Vehicle must be horizontal in order to fill the transfer box.
Note
5. Fill with oil to the lower edge of the inspection plug opening -A- using
the ATF filling device for filling transmission 161. Raise filling Oil inspection and drain plug
device.
6. Screw in oil inspection plug -A- with a new sealing ring. →

Subsequent work for oil for transfer box
Reworking oil for transfer box

as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
39 92 19 Removing and installing sealing ring for rear transfer box

(output flange) - as of MY 2003
- Preliminary work sealing ring for transfer box
- Removing sealing ring for rear transfer box (output flange)
- Installing sealing ring for rear transfer box (output flange)
- Reworking sealing ring for transfer box
Tools

available tool .gif

hook workshop VW 681

equipment

[9PAAE1 9PAAE7 9PAAF1]→ 393519 Removing and reinstalling rear cardan shaft - chapter on "Removing"
[9PAAD1]→ 393519 21 Removing and reinstalling rear cardan shaft - chapter on "Removing" [9PAAJ1]
→ 393519 Removing and reinstalling rear cardan shaft - chapter on "Removing" [9PAAD7]
Removing sealing ring for rear transfer box (output flange)
Removing sealing ring for rear output drive (output flange)
1. Remove nut of output flange with special tool socket T10204. To do

this, secure with special tool arm bracket 3435 .
Output flange nut

3. Remove flange with shop made tool and striker vw 771/1.
ATTENTION
Leakage due to scores on the sealing face.
→
When removing the sealing ring, place the tip of the hook on the sealing ring only and not on the sealing
Removing output flange Rubber ring for rear output drive
Removing sealing ring for rear output

drive
face.
4. Remove sealing ring with special tool hook VW 681.
Installing sealing ring for rear transfer box (output flange)
Installing sealing ring at rear of transfer box (output flange)
Note
z Ensure that the round seal is
inserted.
z Fit nut using screw locking

device.
3. Screw in output flange nut

using special tool socket
T10204. To do this, counter
the flange with special tool
arm bracket 3435. → Rubber ring for rear output drive Output flange nut
Caulking nuts
Subsequent work for sealing ring for transfer box

as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
39 92 19 Removing and installing sealing ring for front transfer

box output - as of MY 2003
- Preliminary work for transfer box sealing ring
- Removing sealing ring for front transfer box output
- Installing sealing ring for front transfer box output
- Subsequent work for transfer box sealing ring
Tools

available tool .gif

arm bracket commercially 3435
available tool
socket commercially t10204

available tool

hook commercially vw 681
available tool
Preliminary work for transfer box sealing ring

[9PAAE1 9PAAF1 9PAAJ1]→ 390219 Removing and installing front cardan shaft - chapter on "Removing"
2. Support transfer box with transmission jack.
3. Support transmission with material 00000 and secure with retaining band.
4. Unscrew four exhaust system screws on the cross member -centre arrow- and unscrew screw connection
holder on body -right arrow- .
Transmission cross member Exhaust system at cross member
5. Unscrew transmission cross member on body -A- .
6. Unscrew two screws on the cross member -B- on the transfer box holder and remove transmission cross
member.
1. Unscrew collar nut of output flange with special tool socket t10204. To do this, block flange with special tool
arm bracket 3435.
3. Remove output flange with shop made tool and striker vw 771/1.
Round seal on output flange Countering flange
Note
z Fit nut using screw-locking compound, e.g. Loctite 648.
→ Driving in the sealing ring until the special tool touches the
Round seal on output flange
Note
z Fit nut using screw-locking

compound, e.g. Loctite 648.
3. Screw in new nut on output

flange using special tool
socket T10204. To do this,
counter the flange with special
tool arm bracket 3435. →
Round seal on output flange Tightening nut on output flange

Caulking nuts
Subsequent work for transfer box sealing ring

[9PAAE1 9PAAF1 9PAAJ1]→ 390219 Removing and installing front cardan shaft - chapter on "Installing"
2. Screw in new transmission cross member screws -B- on transfer box

holder. → initial tightening: 37 ftlb. → final tightening: 90 degree
of angle
3. Screw in new cross member screws on body . -A- → initial

tightening: 37 ftlb. → final tightening: 90 degree of angle

4. Fix exhaust system to transmission cross member -centre arrow- and body -outer arrow- . Observe
torques → 260119 Remove and install exhaust system

as of MY 2003
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99

WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
39 92 19 Removing and installing sealing ring for transfer box

input shaft - as of MY 2003
- Preliminary work sealing ring for input shaft transfer box
- Removing sealing ring for transfer box input shaft
- Installing sealing ring for transfer box input shaft
- Subsequent work
Tools

available tool

available tool
Preliminary work sealing ring for input shaft transfer box
ATTENTION
Damage to input shaft bearing.
→ Drive bevelled attachment in by approx. 2 mm.

→ Screw sheetmetal screw max. two turns into the sealing ring.
1. Using the bevelled attachment from the slide hammer kit 168, make
a small hole -figure- in the sealing ring.
Preparing for removal

2. Screw a suitable sheetmetal screw in by two turns.
Screwing in sheetmetal screw

3. Remove sealing ring using special tool slide hammer kit 168.

ring with grease.
Preparing the sealing ring

2. Drive new sealing ring in flush using special tool pressure piece
t10184.
Fitting sealing ring
Subsequent work

as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
39 IN Information - as of MY 2003
Two controllable locks are available in the system.
acceleration sensor) from which the corresponding lock controls are obtained. In this way the optimum power is
The locks are:
z Longitudinal lock (in the transfer box): Distributes the moment released by the gear via the cardan shafts to
the front or rear axle gear.
z Longitudinal interlock (depending on the equipment in the rear final drive): Distributes the moment to the two
The locks are:
The locks are:
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
39 Technical data - as of MY 2003

- Technical data on transfer box
- Technical data on four-wheel final drive
- Technical data on rear final drive
Technical data on transfer box
View of transfer box
z Type: Z 48.20
Model year: 2004

z Type: Z 48.00
Model year: 2003
z Type: Z 48.50
Model year: 2003
Overall view of front-axle final drive
z Type: V 48.20
Model year: 2004
z Type: V 48.00
Model year: 2003
z Type: V 48.50

Model year: 2003
Overall view of rear axle transmission
z Type: H 48.20
Model year: 2004

z Type: H 48.00
Model year: 2003
z Type: H 48.50
Model year: 2003
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
g g q g
ADVERTENCIA
40 TW Tightening torques for front axle - as of MY 2003

- Tightening torques
Tightening torques
Suspension subframe
Location Explanation Type Basic Tolerance Tolerance

value 1 2
Threaded connection, suspension Always replace screws Initial 89 ftlb.
subframe to front body, M14 x 1.5 and lock nuts after tightening
x 150 removal.
Threaded connection, suspension Always replace screws Final 180 °
subframe to front body, M14 x 1.5 and lock nuts after tightening
x 150 removal.
Threaded connection, suspension Always replace screws Initial 89 ftlb.
subframe to rear body, M14 x 1.5 and lock nuts after tightening
x 115 removal.
Threaded connection, suspension Always replace screws Final 180 °
subframe to rear body, M14 x 1.5 and lock nuts after tightening
x 115 removal.
Axle strut

value 1 2
Threaded connection, upper trailing Always replace screws Initial 37 ftlb.
arm to mounting saddle, M10 x 70 and lock nuts after tightening
removal.
Threaded connection, upper trailing Always replace screws Final 90 °
arm to mounting saddle, M10 x 70 and lock nuts after tightening
removal.
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Threaded connection securing Replace screws and Tightening 63 ftlb.

upper trailing arm to pivot bearing, lock nuts after removal. torque
M12 x 1.5
HBA screw connection with steel Tightening 3.5 ftlb.
springs, M5 x 10 torque
Level regulator screw connection Tightening 3.5 ftlb.
with air springs, M5 x 10 torque
Threaded connection securing Replace screws and Tightening 133
lower trailing arm to suspension lock nuts after removal. torque ftlb.
subframe, M14 x 1.5 x 105
lower trailing arm to pivot bearing, lock nuts after removal. torque
M14 x 1.5
Steering gear

value 1 2
Threaded connection, steering Always replace screws Initial 67 ftlb.
gear to suspension subframe, and lock nuts after tightening
M12 x 1.5 removal.
Threaded connection, steering Always replace screws Final 90 °
gear to suspension subframe, and lock nuts after tightening
M12 x 1.5 removal.
Threaded connection securing tie Replace screws and lock Tightening 67 ftlb.
rod to pivot bearing, M14 x 1.5 nuts after removal. torque
Tie rod to tie rod end screw Lock nut Tightening 52 ftlb.
connection, M14 x 1.5 torque
Heat shield screw connection, M6 Tightening 7.5 ftlb.
x 16 torque
Tie rod to steering rack screw Axial joint Initial 74 ftlb.
connection, M18 x 1.5 tightening
Tie rod to steering rack screw Axial joint Final 10 °
connection, M18 x 1.5 tightening
Pressure line to steering gear a/f - wrench size Tightening 22 ftlb. ±2 ftlb.
screw connection a/f 17 torque
Return line to steering gear screw a/f - wrench size Tightening 22 ftlb. ±2 ftlb.
connection a/f 17 torque
Steering column to mounting Tightening 17 ftlb.
bracket screw connection, M8 x torque
28
Steering column to mounting Tightening 17 ftlb.
bracket screw connection, M8 x torque
10 x 45
Expansion/return line screw Tightening 7.5 ftlb.
connection, M6 x 12 torque
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Steering wiring

value 1 2
Steering column to mounting bracket Tightening 17 ftlb.
screw connection, M8 x 10 x 45 torque
Steering column to mounting bracket Tightening 17 ftlb.
screw connection, M8 x 28 torque
Universal joint to steering gear screw Use bolt once Initial 26 ftlb.
connection, M10 x 35 only. tightening
Universal joint to steering gear screw Use bolt once Final 90 °
connection, M10 x 35 only. tightening
Steering wheel to steering column screw Use one bolt Tightening 37 ftlb. ±4.5 ftlb.
connection, M18 x 1.5 x 26 only. torque
Screw connection for attaching handle Tightening 3.5 ftlb.
to steering column, M5 x 8 torque
Fastening sealing ring/seal to firewall Tightening 3 ftlb.
torque
Wheel carrier (pivot bearing)

value 1 2
Speed sensor to wheel carrier Tightening 6 ftlb.
Brake cover plate to wheel carrier Tightening 15 ftlb.
brake calliper to wheel carrier, fastening nuts after torque
M16 x 1.5 x 48 removal.
Brake hose holder to wheel Tightening 6.5 ftlb.
carrier screw connection, M6 x 12 torque
Cable retainer to wheel carrier Tightening 22 ftlb.
Brake disc to wheel hub screw Tightening 10.5
connection, M12 x 1.5 x 16 torque ftlb.
1) Replace screws and fastening nuts whenever removed.
Spring strut

value 1 2
Spring strut to trailing arm screw Initial 111 ftlb.
connection M14 x 1.5 x 102 tightening
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Spring strut to trailing arm screw Final 90 °

connection M14 x 1.5 x 102 tightening
Spring strut bracket to piston rod screw Tightening 44 ftlb.
connection, M12 x 1.5 torque
Mounting saddle screw connection M8 Tightening 22 ftlb.
torque
Mounting saddle to body screw Initial 37 ftlb.
connection, M10 x 37 tightening
Mounting saddle to body screw Final 90 °
connection, M10 x 37 tightening
Residual pressure restraint valve screw Tightening 2 ftlb.
connection torque
Anti-roll bar/suspension/stabiliser (connecting link)

value 1 2
Threaded connection securing anti- Replace screws and Tightening 44 ftlb.
roll bar to suspension subframe, M10 lock nuts after torque
x 62 removal.
Threaded connection, anti-roll bar to Always replace screws Tightening 81 ftlb.
suspension/stabilizer (connecting and lock nuts after torque
link), M12 x 1.5 removal.
Threaded connection, Always replace screws Tightening 81 ftlb.
suspension/stabiliser (connecting link) and lock nuts after torque
to spring strut, M12 x 1.5 removal.
Off-road stabiliser (ORS)

value 1 2
Threaded connection securing Tightening 44 ftlb.
stabiliser to rear-axle suspension torque
subframe, M10 x 25
Threaded connection, anti-roll bar to Always replace Tightening 81 ftlb.
suspension/stabilizer (connecting screws and lock nuts torque
link), M12 x 1.5 after removal.
Threaded connection, See spring strut
suspension/stabiliser (connecting link)
to wheel carrier/damper strut
Union nuts to pipes screw connection Tightening 10.5 ±0.5 ftlb.
torque ftlb.
Disconnection points to pipes screw Tightening 10.5 ±0.5 ftlb.
connection torque ftlb.
Threaded connection securing line in direction of travel Tightening 30 ftlb. ±1.5 ftlb.
connections to left actuator torque
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Threaded connection securing line in direction of travel Tightening 15 ftlb. ±1.5 ftlb.
connections to right actuator torque
Threaded connection securing control Tightening 10.5 ±0.5 ftlb.
unit to lines torque ftlb.
Threaded connection securing control Tightening 33 ftlb. ±3.5 ftlb.
unit to accumulator, M14 x 1.5 torque
Pressure sensor to control unit screw Tightening 15 ftlb. ±1.5 ftlb.
connection, M10 x 1 torque
Control unit bracket screw connection Tightening 7.5 ftlb.
torque
Threaded connection securing sensor Replace screws and Tightening 2 ftlb.
to actuator lock nuts after torque
removal.
Bleeder valve screw connection Tightening 5 ftlb.
torque
Drive shaft

value 1 2
Threaded connection, drive shaft Always replace screws Initial 37 ftlb.
to front-axle transmission flange, and lock nuts after tightening
M10 x 52 x 26 removal.
Threaded connection, drive shaft Always replace screws Final 90 °
to front-axle transmission flange, and lock nuts after tightening
M10 x 52 x 26 removal.
Threaded connection securing Replace screws and lock Tightening 370 ftlb.
drive shaft to wheel hub, M24 x nuts after removal. torque
1.5
Differential

value 1 2
Threaded connection, differential Always replace screws Initial 67 ftlb.
to suspension subframe, M12 x and lock nuts after tightening
1.5 x 90 removal.
Threaded connection, differential Always replace screws Final 90 °
to suspension subframe, M12 x and lock nuts after tightening
1.5 x 90 removal.
Threaded connection securing Replace screws and lock Tightening 6 ftlb.
crash panel to differential, M6 x nuts after removal. torque
12
Wheel
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value 1 2
Threaded connection securing wheel to Do not grease Tightening 118 ftlb.
wheel hub, M14 x 1.5 x 51 screw. torque
spare wheel holder, M14 x 1.5 x 51 screw. torque
1) Do not grease screws.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
40 V0 Lifting the vehicle - as of MY 2003

- Preliminary work
Preliminary work
Raising the vehicle
DANGER
Risk of injury due to vehicles slipping or tilting off lifting platforms.
z Risk of injury due to vehicles slipping or tilting off lifting platforms may be caused by improper
on raised vehicles.

→ Check that the support plates are seated correctly by raising the vehicle slightly and performing a visual
inspection.
ATTENTION
vehicle.
underbody area.

g g
When driving into the platform lift, pay attention to work to be carried out. i.e. 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/level control, observe the following instructions.
Stop the vehicle and apply the brake.
Close vehicle doors.
Tap the right-hand rocker switch on the center console in the appropriate direction until vehicle has reached
normal level. The middle indicator light next to the rocker switch is permanently on. If a further indicator light
should come on, a different level is adjusted.
Switching off level control
To do this:
– Adjust car to normal level.
The message Control switched off appears in the variable control display of the instrument panel.
Switch on level control
To do this:
– Push → time value: 5 s +5 s forwards, or
– set off with the vehicle. Level control comes on automatically.

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Information for vehicles with Off-Road Stabiliser system (ORS)
The off-road stabiliser system can be identified by the -Button (arrow)- on

the centre console.
WARNING
The Offroad Stabilizer System (ORS) operates at an overpressure of
up to 165 bar.
z If the ORS is not depressurised, movements may occur on the
wheel carrier under certain circumstances (e.g. the off-road
stabilisers are disengaged when the vehicle is lifted, the switch
on the centre console is pressed and the wheel carrier is also
lifted). The stabilizer can close quickly. Thus there is the danger
of crushing in the area of the stabilizers and wheel carriers.
→ The ORS must be depressurised before working on it. To do this, close the Porsche System Tester and
select in the menu >> Offroad Stabi (ORS) >> Drive links >> clock valve VA or valve HA <<. The valve
clocks (audibly) until the procedure is finished.
→ Before working on the vehicle, ensure that the ORS is engaged. The indicator light on the centre console
button must be OFF . If the indicator light is on, follow the following procedure: Switch on the ignition and
engage the road driving programme >> High Range <<. The stabilizers must audibly engage. Now lift the
vehicle.
as of MY 2003
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ADVERTENCIA
40 IN Tests/notes for all-wheel drive - as of MY 2003

- Information
Information
Balancing wheels on vehicle
Electronic fine balancing (static balancing) of the wheels on the vehicle (after stationary balancing) is not required
(status July 2002).
Power test
Performance tests on roller-type test stand are not approved by Porsche!
Brake test
Brake tests may only be carried out in the road driving programme (High Range) on 1-axle roller-type test stands
with four-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!
Parking brake test
The foot-operated parking brake may only be tested on the roller brake tester with the ignition switched off and
selector lever position N selected.
Towing Tiptronic vehicles
WARNING
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No power assistance for the towed vehicle when the engine is not running.
z A lot more force has to be used when braking and steering!
→ Always tow with extreme caution, and at low speeds. Observe the Driver's Manual.
Note
z There is insufficient transmission lubrication when the engine is not running.
Select position N.
Switch ignition on (otherwise steering lock will engage and brake light and indicator light won't function).
Do not exceed top speed of 50 km/h.
Maximum towing distance 50 km.
If, owing to circumstances, vehicle has to be towed with raised axle, the cardan shaft of the axle whose wheels
are turning must be removed.
In the case of long towing distances, vehicle must be transported on a trailer.
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40 IN Overview of Cayenne running gear with steel springs - as of

MY 2003
- Information
Information
Front axle
A wide-base double control arm axle is used for the front axle of the Cayenne, with wheels suspended individually
on double control arms and spring struts with vibration dampers inside.
Steering
Rack-and-pinion steering gear with hydraulic support and - depending on the model - Servotronic for supporting
the steering auxiliary forces when travelling slowly. Steering wheel longitudinally adjustable and with height
adjustment in the corresponding model.
Rear axle
A multi-link axle is used for the rear axle of the Cayenne, with wheels suspended individually on control arms and
vibration dampers inside. The Porsche-specific vehicle handling features of driving comfort and sportiness were
important considerations during development.
Wheel rims and tires
The chart of tyres and wheels should be taken from Technical Information Group 4.
Brakes
Hydraulic dual-circuit brake system with diagonal brake circuit division. Vacuum brake booster, internally
ventilated brake discs with six-piston AI monobloc brake calipers at front axle and four-piston AI monobloc brake
calipers at rear axle.
Standard PSM with ABS, ASR (TC+MSR), ABD, lock control (lengthways)
Parking brake (foot-operated parking brake): drum brake acting mechanically on both rear wheels.
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40 IN Cayenne system overview - as of MY 2003

- Information
Information
General
The development team is expected to meet various requirements in developing the Cayenne, e.g. sporty vehicle
handling, tough off-road mission and full suitability for everyday use with maximum driving safety. Through overall
vehicle fine-tuning of the individual systems, such as axles, steering, tyres, aerodynamics and drive design, very
good vehicle handling features were implemented in both on-road and off-road operations with the following
technical specifications:
z Single-wheel suspension with steel springs using a large-base double control arm front axle and a multi-link
rear axle (standard for Cayenne S)
z Level control system with full-supporting air suspension on both axles and electronically regulated shock
absorbers (standard for Cayenne Turbo, optional for Cayenne and Cayenne S)
z Tube-type stabilizers on front and rear axle or hydraulically disengagable off-road stabilizers (optional for all
Cayenne models as part of Porsche Traction Management Plus)
z Rack-and-pinion steering gear with hydraulic assistance or speed-dependent Servotronic steering assistance
(optional)
z Extensive range of wheels and tyres, high-performance summer tyres, winter tyres, All Season tyres and All
Terrain tyres.
z Tyre pressure monitoring system - RDK (optional)
z Operating brakes customised to suit driving dynamics
z Porsche Stability Management (PSM)
z Porsche Traction Management (PTM) or optional Advanced Off-Road technical package with PTM Plus.
System Explanation
PSM (Porsche Stability Management) ABS Anti-lock Brake System
ABD Automatic Brake Differential
ASR Anti-slip control
EBD Electronic Brake Distributor
MSR Engine drag torque control
FDR Driving dynamics control
PTM (Porsche Traction Management) Permanent four-wheel drive 38/62 %
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Electronically regulated longitudinal lock

Reduction gear
PTM Plus In addition to the PTM specifications: Electronically regulated
rear axle block
Air springs with level control and vertical Full-supporting air-spring struts with integrated shock absorbers
adjustment Air supply consisting of accumulators and sensors
PASM (Porsche Active Suspension Air suspension
Management) Vibration damper with situation-dependent and continuous
shock-absorption regulation with three codes (Comfort, Normal,
Sport)
ORS (off-road Stabilizer System) Enables a greater restriction of the axles when when driving off-
road
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40 AW Safety notes and information when repairing the running

gear - as of MY 2003
Fitting vehicle parts
WARNING
Material damage. When mounting specifications are not observed, the long-term behaviour of screw-
connections is nor ensured.
z There can be limitations on the service life or function of the components.
→ All parts used on the running gear are subject to a close visual inspection.
→ Only use approved original Porsche parts.
→ Replace self-locking nuts.
→ The prescribed tightening torque must be strictly observed.
→ Observe grease specification (for example, on steering shaft).
→ Ensure that ball joint rod conical seats are clean when fitting. Clean bevel pinions with a lint-free cloth. Do not
use cleaning agent.
Spring struts/coil springs
ATTENTION
There will be alterations in handling due to installing incorrect parts.
z Prior mechanical damage to coil springs due to incorrect handling by the customer or in the workshop
can cause the coil springs to break, even at a later point in time.
→ When installing new coil springs/spring struts, make sure they are assigned correctly according to the Spare
Parts Catalogue.
→ When removing and installing coil springs, only use suitable or specified tools/spring compressors.
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→ No welding, sanding, or separating work in the area of coil springs/spring struts. Cover coil springs/spring
struts.
Wheel rims and tires
WARNING
Increased risk of accidents as a result of damage to wheels/tyres if handled improperly.
z Injuries due to the high tyre seating pressure required (max. 4 bar! this value must not be exceeded!),
cannot be ruled out.
z Welding on light-alloy wheels can cause bulges, which can cause them to break if they are used.
→ Tyres must be filled in the filling cage.

→ If the tyres do not jump over at the max. 4 bar, the tyres must be pressed off again, and lubricated with new
tyre paste and then fitted.
→ Straightening and welding work on light alloy wheels is not permissible.
Note
z Newly mounted tyres require a bedding-in period to remove the vulcanisation layer.
z Customers must be informed that the full performance of new tyres is achieved only after a distance of 100 to
200 km (60 to 120 miles) has been driven. Avoid extreme driving manoeuvres (acceleration, braking) during
this time.
Working on vehicles with PSM
DANGER
Risk of accident due to incorrect functioning of steering angle sensor if it is uncalibrated or incorrectly
calibrated.
z There is a risk of accidents causing physical damage to persons or objects in the PSM testing area.
→ After working on wheel suspension parts, when replacing the steering-angle sensor, and after changing the
wheel alignment values, calibrate the steering angle sensor with the front wheels in straight-ahead position
using the PIWIS tester.
→ Check the actual value of the steering angle sensor after a suspension alignment where no changes were
made to the wheel alignment values.
Brake system
WARNING
Increased risk of accidents and damage to the vehicle if braking effect is impaired by using non type-
specific original Porsche spare parts, if the brake pads and/or brake discs are replaced too late.
z There can be limitations on the service life or function of the components.
→
Use only the type-specific brake pads (correct brake pad quality) in the Porsche Spare Parts Catalogue.
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When installing a new expanding spring, mount a new retaining pin and new retainer (safety bracket) or
retaining pin screw on the brake calliper.
→ After repairs to the brake system, the brake pressure must be built up again by applying the brake pedal
several times.
→ Replace brake discs in good time (observe minimum brake disc thickness and surface condition).
Note
z The brake-fluid change interval using Super DOT4 brake fluid is two years.
litres = 000.043.203.67.
Handling air bag systems
WARNING
A triggering of the airbag (malfunction in the airbag system) caused by improper work on airbag
components cannot be ruled out.
z In the case of malfunction, an unsuitable steering wheel holder can cause injury or damage during
suspension alignment work.
→ Use only steering wheel holders which do not project into the area of the airbag unit during suspension
alignment work.
→ Observe safety regulations for airbag vehicles.
Steering
WARNING
Risk of accidents accompanied by danger of injury and damage to the vehicle due to incorrect handling of
Pentosin CHF 11 S.
z It is possible that the reservoir can overflow while driving if too much Pentosin CHF 11 S is added.
Overflowing onto hot components can cause fires.
z If coolant hoses come into contact with Pentosin CHF 11 S for a longer period of time, they will swell.
→ Observe the MAX. marking.

→ Multiple steering operations (manoeuvring) with the engine switched off change the fluid level in the reservoir.
The engine must be run for approx. 20 seconds immediately prior to the fluid level check.
→ If coolant hoses come into contact with Pentosin CHF 11 S, thoroughly clean them with water IMMEDIATELY
and replace if necessary.
Note
z Rack-and-pinion steering gear and servo pump must not be repaired or dismantled.
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40 06 19 Removing and installing front-axle carrier - as of MY 2003

- Preliminary work
- Tools
- Removing front-axle carrier
- Installing front-axle carrier
- Subsequent work
Tools

mounting frame commercially
available tool .gif

A
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transport eyebolt special tool 97000
press-out tool special tool T10187
spring compressor special tool VW 552

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Preliminary work
Preliminary work
In vehicles with level adjustment: Switch off level adjustment. → Lifting the vehicle
Raise the vehicle at the support points provided for this purpose. → Lifting the vehicle
Tools
Tools
-A- - Safety device 10-222 A

-B- - Spring hook or chain - for extending the threaded rods
-C- - Transport eyebolt 9700
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-A- - Mounting frame

-1- - Mount - for mounting the front-axle carrier
-3- - Mount - for mounting the front-axle carrier
-4- - Positioning guide - for positioning the mounting frame
Removing front-axle carrier
Removing front-axle carrier - V8
ATTENTION
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Increased risk of accidents when lowering in the front axle carrier.

z Material damage and injury (e.g., crushing) can occur caused by improper work.
→ Wear protective gear, e.g. gloves.

→ Position the mounting frame in the correct position on the lifting platform. Pull out front axle carrier carefully.
→ Watch out for falling parts during removal on the mounting frame.
Note
z These removal and installation instructions apply to vehicles with level adjustment and steel springs. The
points relating to level adjustment are not relevant for vehicles with steel springs.
1. Open the engine compartment lid and secure with the bonnet stay 97040.
2. Remove engine design covers.
Note
z Point 3 is not necessary for a 6-cylinder engine. There is a perforated
plate at both the front right and rear left of the engine for transporting
and raising to the safety device.
3. Remove -torque support- from the engine. Then -arrow- re-insert

fastening screw arrow.
4. Position the safety device 10-222 A correctly and fit the chain to the
fastening bracket -A- . Fit the transport eyebolt 97000 for securing
the engine -B- (the bore for the transport eyebolt is located between
cylinder 6 and 7 on the left cylinder bank).
5. Remove the front wheels. → 440519 Removing and installing wheel - section on "Removing"
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Note
z The spring struts are not removed in order to remove the front axle
carrier.
z Fix upper axle strut. The lower control arms are loosened on the front
axle carrier and remain with the spring struts in the vehicle.
7. Fix upper axle struts with spring compressor VW 552. This involves
tensioning the axle strut slightly because otherwise the top ball joint
can be damaged. When doing this, engage the -connecting piece-
into the top opening of the wheel well (double panel, under the wheel
housing cover) and into the axle strut (do not disconnect the air spring
connection!).
8. For easier removal of the outer tie rod end, swivel the relevant wheel
carrier so that the tie rod extends fully. Remove the
-outer tie-rod joints- using press-out tool T10187. When pressing
out, screw fastening nut on flush (protects the ball joint thread).
9. The screw in the steering shaft is removed from the wheel well.
Release the coolant hoses from the holders on the body. Release the
-steering column screw (arrow)- from the steering gear.
10. Remove the hydraulic lines from the steering gear (collect hydraulic
fluid in a suitable container). Remove the heat shield of the steering, if
necessary.
11. Mark the installation position of the cardan shaft and remove it from
the front-axle final drive. Make sure that the cardan shaft does not
become kinked (tie it up). → 390219 Removing and installing front
cardan shaft - section on "Removing" [9PAAE1 9PAAF1]→ 390219
Removing and installing front cardan shaft - section on "Removing"
[9PAAE7]
12. Remove drive shafts from the front-axle final drive. Make sure that the drive shafts do not become kinked (tie
them up).
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13. Remove lower control arms from the front axle carrier.
14. Remove stabiliser mount.
Note
z The mounting points for the front axle carrier (1 and 3), both right and
left, and the two positioning guides (4) that are pushed into the body
are required for removing the front axle carrier. The other mounting
points can be removed.
z The mounting points 1/11 (designation on the guide pin) are fitted into
-Position 1- . Double codes (e.g. 11, 22) are also used for mounting
the rear axle.
Mounting frame
z A second worker is required in order to avoid damaging adjacent components when lowering the front axle
carrier.
z For installation, it is a good idea to mark the installation position of the front axle carrier diagonally at 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).
15. Position the -workshop trolley- with the correctly positioned mounting frame under the front axle carrier.
17. The -arrow- show the mounting points for the mounting frame in the front axle carrier (view from below here).
18. Position the front axle carrier into the mounting points provided -(arrows)- (points 4 in the body).
19. Remove the 4 fastening screws -(arrows)- of the front axle carrier.
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20. Lower the front axle carrier with steering, final drive and stabiliser. Be careful not to damage adjacent parts
(e.g. cardan shaft, oil pan, body).
21. Remove accessories from the front axle carrier (steering, final drive, stabiliser). Get another worker to help.
Installing front-axle carrier
Installing front-axle carrier - V8

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ATTENTION
Increased risk of accidents when running in the front axle carrier.
z Material damage and injury can occur.
z Material damage and injury if the wheel carrier is raised improperly.
→ Position the mounting frame correctly on the lifting platform and carefully install the front axle carrier.
→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels). When
raising the suspension, use a suitable intermediate layer (hard rubber) .
→ Do not damage the brake cover plate.
→ Watch out for falling parts during installation on the mounting frame.
→ The steering angle sensor must be calibrated following repairs.
Note
z Before installing, give the parts a visual check.
z Note previously applied markings on the front axle carrier and on the cardan shaft.
z A second worker is required in order to avoid damaging adjacent components when fitting the front axle
carrier.
z When fitting the ball joints, ensure that the bevel pinions are clean! Remove dirt or grease on bevel pinions,
e.g. with a lint-free cloth. Do not use cleaning agent/solvent.
z Replace all fastening nuts and all expansion screws (screws which are fitted with torque angle tightening
procedure).
z The entire threaded parts of the axle must be tightened in vehicle

position. Vehicle position means: vehicle standing on the wheels, or
the wheel suspension is raised using a universal vehicle lift.
-Dimension X- , corresponds to vehicle position. → Check
dimension: 502 mm +/-10 mm
z Do not raise the wheel suspension higher than the normal vehicle
position (vehicle resting on wheels). When raising the suspension, use
a suitable -intermediate layer (hard rubber)- . Do not damage the
brake cover plate.
z Bleed power-assisted steering → Test and assembly work on power

steering.
z Observe correct tightening torques .
z Align vehicle → Suspension alignment, complete.

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z Use the -Porsche System Tester- to calibrate the steering-angle

sensor → Initialising and calibrating steering-angle sensor.
z Perform a function test.
Install in reverse order.
These removal and installation instructions apply to vehicles with level

adjustment and steel springs. The points relating to level adjustment are
not relevant for vehicles with steel springs.
1. Position the -front-axle carrier- on the mounting frame.
2. Pre-fit the accessories on the front axle carrier (steering, final drive, anti-roll bar). Get another worker to help.
3. Position the front axle carrier back in the original, marked installation position and be careful not to damage
adjacent parts.
4. Tighten the four fastening screws to the prescribed tightening torque.
5. Remove the -workshop trolley- with the mounting frame and secure
the water hose holders.
6. Fit the steering gear to the steering column and connect the hydraulic
lines.
7. Fit the cardan shaft at the points marked.→ 390219 Removing and
installing front cardan shaft - section on "Installing" [9PAAE1 9PAAF1]
→ 390219 Removing and installing front cardan shaft - section on
"Installing" [9PAAE7]
8. Install the drive shafts.
9. Fit the tie rod ends. The tightening torque for the fastening nut for Front axle carrier
attaching the tie rod end is 70 Nm (52 ftlb.).
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10. Fit the engine guard → 108019 Removing and installing the engine guard - section on "Installing" and the
front wheels → 440519 Removing and installing wheel - section on "Installing".
11. Remove the safety device 10-222 A. To do this, remove the transport eyebolt 97000 -B- and the chain -A- ,
which is used to secure the engine.
12. Fit the -torque support- .
13. Bleed power-assisted steering → Test and assembly work on power

steering.
14. Fit engine design covers and radiator tank cover.
Subsequent work
Subsequent work
Switch on level adjustment → Lifting the vehicle.
Align the vehicle → Suspension alignment, complete and calibrate it → Initialising and calibrating steering-angle
sensor.
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40 11 55 Replacing bearings for carrier - as of MY 2003

- Preliminary work
- Replacing
- Subsequent work
Tools

Counter support, 0 - 40 mm commercially NR.106
available tool

available tool
Separating device, 12 - 115 commercially NR.111

mm ø available tool
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assembly fixture VW-tool T10301
Preliminary work
Preliminary work
1. Switch off level adjustment. → 40 Lifting the vehicle
On vehicles with ORS, depressurise the system using the PIWIS Tester.
z Before working on the vehicle, ensure that the ORS is engaged. The indicator light on the centre console
button must be OFF. If the indicator light is on, follow the following procedure: Switch on the ignition and
engage the road driving programme >> High Range <<. The anti-roll bars must engage audibly.
z Before working on the ORS, always depressurise the system! To do this, close the PIWIS Tester and select
>> Offroad Stabi (ORS) >> Drive links >> Clock FA valve or RA valve <<. The valve clocks (audibly) until the
procedure is finished (approx. 20 seconds).
3. Remove underbody protection. → 50 Underbody protection
Warning notes for ORS
WARNING
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Risk of accidents! The Offroad Stabilizer System (ORS) operates at an overpressure of up to 165 bar.
Under certain conditions, motions can occur on the wheel carrier (e.g. if the Offroad stabilizers are
disengaged when lifting, the button is pressed on the centre console, and the wheel carrier is also
raised). The stabilizer can close quickly.
z Danger of crushing in the area of the stabilizers and wheel carriers. Risk of injury and material
damage due to raising the wheel carrier incorrectly.
→ Before working on the ORS, always depressurise the system! To do this, close the PIWIS Tester and select
ATTENTION
Danger of injury due to falling tools.
z Danger of crushing and deformation
→ Always use industrial footwear, goggles and protective gloves.
Tools and materials
Tools
Tool overview for suspension subframe bearings assembly fixture T10301
Tool overview for suspension subframe bearings
-A- - → Hydraulic cylinder VAS 6178 (The hydraulic cylinder is used together with the → foot pump VAS 6179
and the → pressure gauge with connecting cable VAS 6179/1 -B- .)
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-1- - Threaded rod (Inserted into the tubular piston cylinder -A- .)
-2- - Threaded nut (Screwed onto the threaded rod -1- .)
-3- - Pipe (For pressing out the suspension subframe bearings.)
-4- - Ring (For pressing out the suspension subframe bearings.)
-5- - Press-out plate (For pressing out the suspension subframe bearings.)
. -6- - Pressure piece (For pressing in the suspension subframe bearings.)
-7- - Press-in plate (For pressing in the suspension subframe bearings.)
-9- - Spacer sleeve (For pressing out the suspension subframe bearings together with pipe -3- .)
-10- - Pressure piece (For pressing in the suspension subframe bearings.)
-11- - Spacer sleeve (For pressing in the suspension subframe bearings.)
Counter support, 0 - 40 mm NR.106
Internal puller NR.108
Separating device, 12 - 115 mm ø NR.111
Replacing
Replacing bearings for carrier, front FA
Note
If a suspension subframe bearing is replaced, the other bearings must also be checked for cracks or other signs
of damage.
1. Loosen the anti-roll bar from the connecting link on both sides. (Do not loosen the anti-roll bar for the rear
front-axle bearings!)
2. Move the gear support under the engine transverse bar and lift it
slightly using a suitable base (e.g. hard rubber support). (The gear
support is not needed for the rear front-axle bearings).
Positioning the lift

3. Engage the spindle at the eyelet on the engine transverse bar at the side where you want to replace the
bearing. Guide the spindle through the lower trailing arm and tighten the spindle slightly so that the spindle is
slightly tensioned.
4. Loosen the suspension subframe bearing on both sides, carefully lower the gear support (loosen the spindle
carefully at the same time) until you get the clearance needed for using the press-out tool.
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Fitting the spindle
Tools for pressing out front-axle

bearings at the front
5. Press out suspension subframe bearing.
Note
Hold the hydraulic cylinder VAS 6178 tightly while pressing it out.
6. Attach the tools as shown in the illustration and press out the
bearing.
Note
When replacing bearings, please make sure that one arrow is pointing in
the direction of travel while the other arrow is pointing away from the
Pressing out front-axle bearing at the

front
7. Fit suspension subframe bearing and pay attention to installation position.
8. Press in suspension subframe bearing. To avoid damaging the bearing, the maximum → Pressure: 10 kN
+/-5 Sekunde must not be exceeded at the stop (10 KN = 350 bar). This conversion applies only to the
hydraulic cylinder VAS 6178. The conversion depends on the diameter of the cylinder in question.
9. Attach the tools as shown in the illustration and press in the bearing.
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Marking on suspension subframe

bearing
Tools for pressing in front-axle

bearings at the front
Note
Observe correct tightening torques.
10. Carefully lift the suspension subframe until the installation position is
reached. Fit threaded joint on suspension subframe bearing.
11. Mount anti-roll bar on the connecting link.
12. Remove the spindle.
Pressing in front-axle bearing at the

front
Replacing bearings for carrier, rear FA
Note
If a suspension subframe bearing is replaced, the other bearings must also be checked for cracks or other signs
of damage.
1. Engage the spindle at the eyelet on the engine transverse bar at the side where you want to replace the
bearing. Guide the spindle through the lower trailing arm and tighten the spindle slightly so that the spindle is
slightly tensioned.
2. Loosen the suspension subframe bearings on both sides. Loosen the spindle carefully until there is sufficient
clearance for using the press-out tool.

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Pressing out front-axle bearing at the Tools for pressing out front-axle
rear bearings at the rear
4. Attach the tools as shown in the illustration and press out the bearing.
Note
When replacing bearings, please make sure that one arrow is pointing in
the direction of travel while the other arrow is pointing away from the
Fit suspension subframe bearing and pay attention to installation position.
Marking on suspension subframe

bearing
5. Press in suspension subframe bearing. To avoid damaging the
bearing, the maximum → Pressure: 10 kN +/-5 Sekunde must not
be exceeded at the stop (10 KN = 350 bar). This conversion applies
only to the hydraulic cylinder VAS 6178. The conversion depends on
the diameter of the cylinder in question.

bearings at the rear
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6. Connect the tools together as shown in the illustration.
Note

8. Remove the spindle.

bearings at the rear
Subsequent work
Subsequent work
1. Fit underbody protection. → 50 Underbody protection
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40 15 19 Removing and installing top axle strut - Steel spring - as

of MY 2003
- Preliminary work
- Tools
- Removing upper axle strut
- Installing upper axle strut
- Subsequent work
Tools


equipment
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Preliminary work
Preliminary work
Remove the wheel. → 440519 Removing and installing wheel - chapter on "Removing"
Tools
Trailing arm tools
-A- - press-out tool T10187 - to press out the ball joint on the wheel carrier.
-B- - spring compressor VW 552 - for slightly tensioning the upper trailing arm.
Removing upper axle strut
Removing upper trailing arm
ATTENTION
Increased risk of accidents if the wheel carrier is raised improperly!
z Injuries and material damage are possible.
→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).
→ When raising the suspension, use a suitable intermediate layer (hard rubber) .
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1. Unscrew plastic nuts -arrows- on front wheel housing liner.
2. Fix upper axle strut with spring compressor VW 552. This involves
tensioning axle strut slightly because top ball joint can otherwise get
damaged. When doing this, the -Spring compressor- is pushed
through the hole in the axle strut, engaged in the upper opening of
the wheel well (double panel) and in the axle strut and tightened with
the nut. This is only necessary if the same control arm is reinstalled.
3. Unlock plug from HBA -A- and remove -arrow- .
4. Release fastening nut and press ball joint rod off with the press-out
tool T10187.
5. Remove spring strut. → 408519 Removing and installing front spring

strut (steel springs) - chapter on "Removing" [9PAAD1 9PAAD7
9PAAE1 9PAAE7]→ 408519 21 Removing and installing front spring
strut (steel springs) - chapter on "Removing" [9PAAF1 9PAAJ1]
6. Unscrew fastening screws at the sides and remove axle strut.

7. If control arm does not have to be used again, HBA sensor must be
fitted on new control arm.
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Installing upper axle strut
Installing upper trailing arm
ATTENTION
Note
the wheel suspension is being raised with a universal vehicle lift.
-Dimension X- , from → Control value: 502 mm +/-10 mm
corresponds to the vehicle position.
z Use an intermediate layer (hard rubber). Do not damage the brake

cover plate.
z Screws are Dacromet-coated and must not be greased.
z Grease the toothing of the drive shaft slightly with aluminium paste
Optimoly TA.
z Do not leave drive shafts hanging from the joint stop. Support wheel
carriers.
z Use new screws and fastening nuts.
z Make sure the bevel pinions from the ball joints are clean. Clean with a lint-free cloth as necessary. Do not
use cleaning agent.
z Observe correct tightening torques. → Tightening torques for front axle
1. Install HBA sensor and tighten at tightening torque. → 40 Tightening torques for front axle.
2. Insert upper trailing arm and fastening bolts. Fit lock nuts and tighten to specified tightening torque. →
3. Install spring strut → 408519 Removing and installing front spring strut (steel springs) - chapter on
"Installing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7]→ 408519 23 Removing and installing front spring strut
(steel springs) - chapter on "Installing" [9PAAF1 9PAAJ1].
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4. Insert wheel carrier in the ball joint, fit lock nuts, and tighten to specified tightening torque. → Tightening
5. Attach HBA connector.
6. Tighten plastic nuts -arrow- on front wheel housing liner.
Subsequent work
Subsequent work for trailing arm
Fit the wheel → 440519 Removing and installing wheel - chapter on "Installing" and tighten to specified tightening
torque. → Tightening torques for front axle
as of MY 2003
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AVERTISSEMENT
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ADVERTENCIA
40 17 19 Removing and installing bottom axle strut - as of MY

2003
- Preliminary work
- Tools
- Removing lower axle strut
- Installing lower axle strut
- Subsequent work
Tools


equipment
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Preliminary work
Preliminary work
Remove the wheel. → 440519 Removing and installing wheel - chapter on "Removing"
Tools
Trailing arm tools
-A- - press-out tool T10187 - to press out the ball joint on the wheel carrier.
-B- - spring compressor VW 552 - for slightly tensioning the upper trailing arm.
Removing lower axle strut
Removing lower trailing arm

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ATTENTION
→ Do not raise the wheel suspension higher than the normal vehicle
position (vehicle resting on wheels).
→ When raising the suspension, use a suitable intermediate layer (hard
rubber) .
2. Fix upper axle strut -Inset 1- with spring compressor VW 552. This
involves tensioning axle strut slightly because top ball joint can
otherwise get damaged. When doing this, the -Spring compressor-
is pushed through the hole in the axle strut, engaged in the upper
opening of the wheel well (double panel) and in the axle strut and
tightened with the nut.
3. Loosen the fastening nuts → see figure from the bottom ball joint and press off with the press-out tool
T10187. When doing this, leave fastening nut flush on ball journal, so as not to damage thread.
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4. Remove the lower fastening screw of the spring strut -arrow- . For this purpose, lift wheel carrier with a
suitable lift -Lift with a rubber base- (to prevent slipping) to the extent that the screw -arrow- can be
unscrewed easily.
5. Mark eccentric screws -arrow- for adjusting camber and caster on

subframe (facilitates fitting when reinstalling).
6. Then remove eccentric screws. When doing so, ensure that joint boot
is not damaged by eccentric -arrow- . Pull (press) axle strut out of
the subframe mounting points -A- .
7. Remove fastening nut -Inset 5- from ball joint. Tilt -trailing arm- down all the way and pull ball joint carefully
out of the wheel carrier.
Installing lower axle strut

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Installing lower trailing arm
ATTENTION
1. Install in reverse order.
Note
z The entire threaded parts of the axle must be tightened in vehicle position. Vehicle position means: vehicle
standing on the wheels, or the wheel suspension is being raised with a universal vehicle lift. -Dimension X- ,
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from → Control value: 502

mm +/-10 mm corresponds to
the vehicle position.
z Visually inspect all parts.
z Replace self-locking nuts.
z Replace all expansion screws

(screws which are fitted with
torque angle tightening
procedure).
z Use correct tightening torques and torque angle.
Use an intermediate layer (hard rubber). Do not damage the brake cover plate.
Screws are Dacromet-coated and must not be greased.
Subsequent work
Subsequent work for trailing arm
Following this repair work, the vehicle suspension must be aligned. → Suspension alignment, complete
as of MY 2003
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ADVERTENCIA
40 20 55 Replacing bearing for trailing arm - as of MY 2003

-
-
-
-
- Subsequent work
Tools

Pressure head - attachments special tool T10205
Assembly fixture special tool T10230
Preliminary work
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1. Raise the vehicle → 40 Lifting the vehicle and remove wheel → 440519 Removing and installing wheel -
2. Remove lower trailing arm → 401719 Removing and installing lower trailing arm.
ATTENTION
Increased risk of accidents when working with hydraulic presses - danger of crushing, deformation of
components.
z Risk of injury if the threaded rod in the tubular piston cylinder breaks because of pressure or
traction.
→ The worker must always stand away from the direction of pressure or traction on the threaded rod when
using the tubular piston cylinder.
→ Position pressure pieces correctly and ensure that they are seated properly.
→ Watch out for falling parts when working with hydraulic presses.
→ Danger of injury and material damage if the wheel carrier is raised incorrectly.
ATTENTION
Tools and materials
Lower trailing arm → Lower trailing arm with rubber-metal mounts A, B, C .
Tool set T10230 → Tool set T10230 .

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Lower trailing arm with rubber-metal

mounts A, B, C
Tool set T10230

-A- Tubular piston cylinder VAS 6178 → "See The tubular piston
Workshop cylinder is used with
Equipment the pneumatic
Manual, hydraulic pump VAS
Chapter 3.4" 6179 → "see
Workshop
Equipment Manual,
Chapter 3.4"
Assembly fixture T10230 → "See Tool set for pressing
Workshop hydraulic
Equipment mount/rubber-metal
→ Tool set Manual, mount in and out,
T10230 Chapter 2.2.3 " consisting of No. 1-
15.
-1- Threaded rod - assembly fixture T10230 → "See Used in the tubular
Workshop piston cylinder VAS
Equipment 6178 -A- .
Manual,
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Chapter 2.2.3"
-2- Nut with collar - assembly fixture T10230 → "See Screwed onto the
Workshop threaded rod -1- .
Equipment
Manual,
Chapter 2.2.3 "
-4- Pressure piece 40 - assembly fixture T10230 → "See For pressing out the
Workshop bearing -C- .
Equipment
Manual,
Chapter 2.2.3 "
-5- Pipe 56 - assembly fixture T10230 → "See For pressing out the
Workshop bearing -B, C- .
Equipment
Manual,
Chapter 2.2.3 "
-7- Adjusting washer - assembly fixture T10230 → "See Screwed into the
Workshop tubular piston
Equipment cylinder VAS 6178
Manual, -A- with two
Chapter 2.2.3 " countersunk screws.
For pressing out
bearing -A, B, C- .
For pressing in
bearing -C- .
-8- Support - assembly fixture T10230 → "See For pressing in the
Workshop bearing -C- .
Equipment
Manual,
Chapter 2.2.3 "
-9- Pipe 72 - assembly fixture T10230 → "See For pressing out the
Workshop bearing -A- .
Equipment
Manual,
Chapter 2.2.3 "
-10- Pressure piece 60 - assembly fixture T10230 → "See For pressing in the
Workshop bearing -B- .
Equipment
Manual,
Chapter 2.2.3 "
-11- Support - assembly fixture T10230 → "See For pressing in the
Workshop bearing -A- .
Equipment
Manual,
Chapter 2.2.3 "
-12- Ring - assembly fixture T10230 → "See Screwed into the
Workshop tubular piston
Equipment cylinder VAS 6178
Manual, -A- with two
Chapter 2.2.3 " countersunk screws.
For pressing in the
bearing -A, B- .
-13- Pressure piece 45 - assembly fixture T10230 → "See For pressing out the
Workshop bearing -B- .
Equipment
Manual,
Chapter 2.2.3 "
-T10205/13- Pressure head - attachments T10205 Pressure head from
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assembly fixture
T10205 (!); screwed
into the tubular
piston cylinder VAS
6178 -A- .
-14- Washer - assembly fixture T10230 Placed on the
threaded rod -1- .
-15- Nut - assembly fixture T10230 Commercially
available M14 nut.
Screwed onto the
threaded rod -1- .
Replacing
Note
If a hydraulic mount/rubber-metal mount is installed, it must be fitted in the

correct position. In other words: the "cut-outs" must be fitted horizontally,
in vehicle position (± 5°). Additional instruction in relation to the hydraulic
mount -B- : always fit the wide face of the core of the mount towards the
centre of the vehicle. Vehicle position = vehicle standing on its wheels.
Cut-outs of trailing-arm bearing in
z Position the tubular piston cylinder and pre-tension slightly to prevent installation position
the pressure pieces from slipping out of place. Check the position of
the pressure pieces again.
z Maximum assembling force must not exceed 60 KN at the stop.
z The three rubber-metal mounts -A,B,C- must be replaced once the

trailing arm is removed.
The pressure pieces and the tubular piston cylinder VAS 6178 are used
for removal. This involves screwing pressure head T10205/13 into the
tubular piston cylinder. T10230/2 is screwed on to the threaded rod and
positioned in T10205/13 for pressing bearings in and out. Nut T10230/15
and washer T10230/14 are screwed onto the opposite end of the threaded
rod .
The following pressure pieces and nuts are required for bearings -A- :
Lower trailing arm with rubber-metal

mounts A, B, C
Pressing out → Tools for pressing out hydraulic/rubber-metal mounts
z T10230/2
z T 10230/7
z T10230/9
z T10230/10
z T10230/14
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z T10230/15
Note
When using the pressure pieces, the direction arrow shows the direction
for pressing the rubber-metal mounts in or out on the trailing arm.
The pressure pieces are used as follows → Arrangement of tools for

pressing out hydraulic/rubber-metal mounts .
Tools for pressing out

hydraulic/rubber-metal mounts
Arrangement of tools for pressing out hydraulic/rubber-metal mounts
Pressing in → Tools for pressing in hydraulic/rubber-metal mounts
z T10230/2
z T10230/11
z T10230/12
z T10230/14
z T10230/15
Note
When using the pressure pieces, the direction arrow shows the direction for pressing the rubber-metal mounts in
or out on the trailing arm.
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Note
When pressing the mounts in, make sure that pressure piece 11, in
particular, is positioned correctly. Pressure piece 11 must not cover up the
bore for the bearing in the control arm!

pressing in hydraulic/rubber-metal mounts .
Tools for pressing in hydraulic/rubber-

metal mounts
Arrangement of tools for pressing in hydraulic/rubber-metal mounts
The following pressure pieces and nuts are required for bearings -B- :
Pressing out → Tools for pressing out spring-strut mounts
z T10230/2
z T10230/5
z T10230/7
z T10230/13
z T10230/14
z T10230/15
Note
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pressing out spring-strut mounts .
Tools for pressing out spring-strut

mounts
Arrangement of tools for pressing out spring-strut mounts
Pressing in → Tools for pressing in spring-strut mounts
z T10230/2
z T10230/10
z T10230/12
z T10230/14
z T10230/15
Note
The pressure pieces are used as follows → Arrangement of tools for pressing in spring-strut mounts .
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Tools for pressing in spring-strut

mounts
Arrangement of tools for pressing in spring-strut mounts
The following pressure pieces and nuts are required for bearings -C- :
Pressing out → Tools for pressing out rubber-metal mounts
z T10230/2
z T10230/4
z T10230/5
z T10230/7
z T10230/14
z T10230/15
Note
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When using the pressure pieces, the direction arrow shows the direction
for pressing the rubber-metal mounts in or out on the trailing arm.

pressing out rubber-metal mounts .
Tools for pressing out rubber-metal

mounts
Arrangement of tools for pressing out rubber-metal mounts
Pressing in → Tools for pressing in rubber-metal mounts
z T10230/2
z T10230/7
z T10230/8
z T10230/14
z T10230/15
Note
The pressure pieces are used as follows → Arrangement of tools for pressing in rubber-metal mounts .
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Tools for pressing in rubber-metal

mounts
Arrangement of tools for pressing in rubber-metal mounts
Subsequent work
Subsequent work
Note
z The entire threaded joints of the axle must be tightened in vehicle position. Vehicle position means: vehicle
standing on the wheels, or the wheel suspension is raised with a universal vehicle lift. Dimension -X- , from
→ Control value: 502 mm +/-10 mm corresponds to vehicle position.
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z Carry out a visual inspection of all parts.
z Replace all expansion screws (screws which are fitted with torque
angle tightening procedure).
z Observe correct tightening torques and torque angle → Tightening

z Make sure the bevel pinions from the ball joints are clean. Clean with
a lint-free cloth as necessary. Do not use cleaning agent.
1. Install lower trailing arm → 401719 Removing and installing lower trailing arm.
2. Fit wheel → 440519 Removing and installing wheel.
3. Carry out suspension alignment → 44 Suspension alignment, complete.
as of MY 2003
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AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
40 24 19 Removing and installing control unit for off-road

stabilizer - as of MY 2003
- Removing control unit for off-road stabilizer
- Installing control unit for off-road stabilizer
- Coding the control unit for off-road stabilizer
Removing control unit for off-road stabilizer
Removing control unit for off-road stabilizer
z The control unit for the Offroad stabilizer is located in the luggage compartment under the loadspace floor
beside the collapsible spare wheel.
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Overview of control unit for off-road stabilizer
1. Open luggage compartment lid and raise loadspace floor.
2. Release plug -1- and remove from control unit -Arrows a- .
3. Release plug -2- and remove from control unit -Arrows a- .

4. Remove control unit from the plastic mount.
Pull plug off the control unit.
Installing control unit for off-road stabilizer
Installing control unit for off-road stabilizer

1. Insert the control unit in the plastic mount.
2. Insert plug -2- into the control unit until it clicks into place.
3. Insert plug -1- into the control unit until it clicks into place.
Note
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z If a new control unit has been installed for the Offroad stabilizer,
continue with → 402419 Removing and installing control unit for
Offroad stabilizer - "Coding" section.
Insert plug into control unit
Coding the control unit for off-road stabilizer
Coding control unit for off-road stabilizer
Note
1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on ignition.
2. Select ORS control unit >> .
3. Select "Coding" >> .
4. Select Porsche version and code with the F8 key.
5. Quit the menu using << .
6. Read out fault memory.
If faults are present in the fault memory, which cannot be deleted or if the faults are displayed repeatedly, proceed
according to Rep.-Gr. 4024 Diagnosis Manual - ORS.
as of MY 2003
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ADVERTENCIA
40 25 19 Removing and installing control unit for off-road

stabiliser - as of MY 2003
- Preliminary work
- Removing control unit for off-road stabiliser
- Installing control unit for off-road stabiliser
- Subsequent work
Tools

removal tool, universal commercially NR.21
available tool
Preliminary work
Preliminary work
Lift the vehicle.
→ Lifting the vehicle [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Lifting the vehicle [9PAAJ1]
Removing control unit for off-road stabiliser

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Removing control unit for off-road stabiliser

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A - Front anti-roll bar

B - Rear anti-roll bar
C - Hydraulic unit - control unit
D - Operator control unit
E - Control unit
F - Oil dipstick
WARNING
The Offroad Stabilizer System (ORS) operates at an overpressure of up to 165 bar. If the ORS is not
depressurised, movements may occur on the wheel carrier under certain circumstances (e.g. the off-road
stabilisers are disengaged when the vehicle is lifted, the switch on the centre console is pressed and the
wheel carrier is also lifted).
z The stabilizer can close quickly. Thus there is the danger of crushing in the area of the stabilizers
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and wheel carriers. Danger of injury and material damage if the wheel carrier is raised incorrectly.
engage the road driving programme >> High Range <<. The stabilizers must audibly engage.
→ Before working on the ORS, depressurise the system. To do this, close the Porsche System Tester and
1. Connect the Porsche System Tester and depressurise the system. To do this, select the menu items >> Off-
road Stabiliser (ORS) >> Drive links >> Set front-axle or rear-axle valve <<. The valve clocks (audibly) until
the procedure is finished.
2. Open the luggage-compartment lid and remove the rear left side-panel lining → 700319 Removing and
installing rear luggage compartment side-panel lining - section on "Removing".
3. If the vehicle has a four-zone air-conditioning system, loosen the

fastening screws -4- on it.
4. Place the four-zone air-conditioning system → see figure aside

without opening the circuit → 881019 Removing and installing
auxiliary air-conditioning unit - section on "Removing".
5. Remove the cover -arrow- of the oil dipstick.

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6. Remove the 2 fastening screws -arrow- .
7. Pull the oil dipstick along with the filler tube and vent tube -arrow- out
of the expansion tank. Press the relevant plastic ring on the fluid tank
down evenly using the removal tool, universal NR.21.
8. The hydraulic lines are fed out through the luggage compartment
floor panel. Loosen the lines from outside and ensure when removing
the lines that the seals are not lost when passed through the body. If
fluid emerges, place a lint-free cloth, for example, underneath. Clean
the luggage compartment floor panel IMMEDIATELY if necessary.
9. Disconnect electric plugs.
10. Remove the three fastening screws on the control unit -arrows- and
take out the control unit.
Installing control unit for off-road stabiliser
Installing control unit for off-road stabiliser
Note
z Bleed the off-road stabiliser system (ORS).
z Observe correct tightening torques. → Lifting the vehicle [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]
→ Lifting the vehicle [9PAAJ1]
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1. Insert the control unit.
2. Guide the hydraulic lines of the control unit carefully through the body and secure into position. Fit seals.
3. Fit the control unit into the take-up points provided -arrows- .
4. Insert filler neck with filler tube and vent tube and slide in as far as
the wide section -arrow- . Insert oil dipstick.
5. Push on electric plugs.
To ensure that there are no leaks in the system, fill and bleed the off-road
stabiliser system (ORS) before installing the four-zone air-conditioning
system. Then perform a visual check for leaks on the control unit
(expansion tank, sensor connections, etc.).
6. The off-road stabiliser system is filled with Pentosin CHF 11S using
the dipstick opening → see figure → 407707 Bleeding the Off-Road
Stabiliser System (ORS).
7. Bleed the off-road stabiliser system (ORS). → 407707 07 Bleeding the Off-Road Stabiliser System (ORS) -
section on "Bleeding". The fluid level can be checked by reading the marking on the dipstick → see figure .
8. Do not top up above the max. marking → see figure . Fit the cover of the oil dipstick.
9. Insert and fit the four-zone air-conditioning system -arrow- → 881019 Removing and installing auxiliary air-
conditioning unit - section on "Installing".
Subsequent work
Subsequent work
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Fit left rear side trim panel.

→ 700319 Removing and installing
rear luggage compartment side
trim panel - section on "Installing"
as of MY 2003
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WARNUNG
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ATTENZIONE
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ADVERTENCIA
40 26 01 Off-Road Stabiliser System (ORS) - Checking fluid level -

as of MY 2003
- Procedure for checking fluid level
Procedure for checking fluid level
Off-Road Stabiliser System (ORS) - Checking fluid level

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-A- - Front stabiliser

-B- - Rear stabiliser
-C- - Hydraulic unit
-D- - Operator control unit
-E- - Control unit
-F- - Oil dipstick
Disengaging and engaging the Offroad stabilizer
Note
z Before the fluid level is checked, the Offroad stabilizer must be >> disengaged and engaged << four times.
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z To obtain a correct measured result, it is necessary to depressurise

the system. Only then will the correct fluid level be displayed.
1. To do this, switch on the ignition, and engage the off-road driving

program Low Range. Depress the brake pedal and briefly press the
rocker switch -direction arrow- forwards; the indicator light -arrow-
comes on.
2. Activate the Offroad stabilizer button four times. The indicator light
-arrow- comes on. Only initiate the next switching operation when
the off-road stabilizer has >> disengaged or engaged << audibly.
3. Switch off the off-road driving program >> Low Range << again.
Depressurising the Offroad Stabilizer System (ORS)
1. Connect the Porsche System Tester and switch on the ignition.

Switch off the off-road driving program >> Low Range <<. To do this,
use the rocker on the centre console -direction arrow- to select the
corresponding driving program. The indicator light -arrow- must be
OFF. In the menu, select >> Offroad Stabi (ORS) >> Drive links >>
Clock valve VA or valve HA <<.
2. The solenoid valve clocks (audibly) until the overpressure has been
equalized. The fluid level in the reservoir of control unit C of the
Offroad stabilizer rises.
3. The valve no longer clocks. Now the correct fluid level can be read
on the dipstick.
4. Reading and correcting the fluid level is described in the next chapter.
5. Unplug Porsche System Tester. After switching on the ignition again and engaging Low Range, the system
adjusts automatically to the correct pressure.
Reading and correcting the fluid level
The reservoir is not freely accessible. It is filled using the dipstick opening. To do this, refill the amount of fluid
necessary using suitable filling equipment. Pull out the dipstick several times and check the fluid level.
1. The dipstick is accessible below the upper cover -arrow- , rear left, in the centre of the D-pillar. Remove the
cover.
2. The dipstick -arrow- inserted in the left D-pillar. Pull out the dipstick.
3. The fluid level must be between the markings on the dipstick . Do not top up above the → see figure Max.
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mark.
4. The off-road stabiliser system is filled with Pentosin CHF 11S using
the → see figure dipstick opening .
5. After the work is completed, insert the dipstick and fit the cover.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
40 26 07 Bleeding the Off-Road Stabiliser System (ORS) - as of MY

2003

The Offroad Stabilizer System (ORS) must be bled when the system was opened (e.g., after removing the front
and/or the rear axle, or after replacing spare parts for the system). Both stabilizers are bled at the same time
when it is done.
WARNING
The Off-road Stabilizer System (ORS) operates at an overpressure of up to 165 bar. Under certain
conditions, motions can occur on the wheel carrier (e.g., if the Off-road stabilizers are disengaged when
lifting, the button is pressed on the centre console, and the wheel carrier is also raised).
and wheel carriers.
select in the menu >> Offroad Stabi (ORS) >> Drive links >> clock valve VA or valve HA
<<. The valve clocks (audibly) until the procedure is finished.
→ Wear protective gloves and goggles.
Note
z The driving programs can be selected using the rocker switch on centre console. The -arrow- on the
indicator light displays if the road driving programme >> High Range << (light OFF) or the offroad
program >> Low Range << (light ON) is engaged.
1. Connect the bleeder valves of the actuator to the front axle with a suitable transparent hose and open
approx. one turn.
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Front stabilizer, operator control unit
2. Connect the bleeder valves of the actuator to the rear axle with a suitable transparent hose and open
approx. one turn.
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3. To prevent the hoses from slipping from the bleeder valves, they
must be fastened using screw-type hose clamps/tie wraps. Because
of the high pressure occurring, they can become loose during the
bleeding process.
4. Fill with Pentosin CHF 11S in the opening of the dipstick -arrow- .
The opening is located at the left rear, in the centre of the D-pillar.
5. Pull out the dipstick and fill with Pentosin CHF 11S using suitable filling equipment.
6. Fill with Pentosin CHF 11S up to the Max. marking of the dipstick.
Note
z Connect the Porsche System Tester and switch on the hydraulic pump in the menu >> Offroad Stabi
(ORS) >> Drive links >> Switch on electrical hydraulic pump <<.
z Only allow the hydraulic pump to run for max. 10 seconds when switching it on for the first time following
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repairs.
Switch on the ignition, press the

brake pedal, and engage High
Range. Connect the Porsche
System Tester and switch on the
hydraulic pump for 10 seconds.
The Pentosin CHF 11S is pumped
through the lines.
Switch off the hydraulic pump.

Check the fluid levels on the oil
dipstick and top up to the Max.
marking.
Switch on the hydraulic pump the

2nd time for 10 seconds. The
Pentosin CHF 11S is pumped
through the lines.
Switch off the hydraulic pump.

Check the fluid levels on the oil
dipstick and top up to the Max.
marking.
Switch on the hydraulic pump the 3rd time. The Pentosin CHF 11S is pumped through the lines. Perform a visual
inspection of the front and rear axle for lack of air bubbles.
Let the hydraulic pump run until air bubbles can no longer be seen on the hoses of the actuators. Let the hydraulic
pump run for approximately an additional 1 minute. Only then it is ensured that the return line is also completely
rinsed out.
Switch off the hydraulic pump. Check the fluid levels on the oil dipstick and if necessary, top up to the Max.
marking.
Disconnect the Porsche System Tester, switch off the ignition, and close the bleeder valves of the actuators.
Remove the hoses. To protect the bleeder valves, attach the protective caps.
Checking operation
Checking operation
Note
z After pressing the button on the centre console, the hydraulic pump
starts (audibly). The stabilizers disengage or engage when a specific
overpressure has been reached in the system. A time delay between
activation until disengaging/engaging (audible) is normal.
Switch on the ignition, press the brake pedal, and engage Low Range. To
do this, briefly press the rocker switch -direction arrow- forwards. The
indicator light -arrow- comes on.
The stabilizers disengage. In other words: Press the button on the centre console. The button light -arrow- comes
on.
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In the instrument cluster (tachometer) the indicator light is on and the

stabilizers disengage audibly.
Press the button again. The button light -arrow- goes out. The stabilizers
engage again audibly and the indicator light in the instrument cluster goes
off.
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
40 26 07 Bleeding the Off-Road Stabiliser System (ORS) - as of MY

2003
- Preliminary work
Preliminary work
Raise vehicle → 40 Lifting the vehicle.

The Offroad Stabilizer System (ORS) must be bled when the system was opened (e.g., after removing the front
and/or the rear axle, or after replacing spare parts for the system). Both stabilizers are bled at the same time
when it is done.
WARNING
The Off-road Stabilizer System (ORS) operates at an overpressure of up to 165 bar. Under certain
conditions, motions can occur on the wheel carrier (e.g., if the Off-road stabilizers are disengaged when
lifting, the button is pressed on the centre console, and the wheel carrier is also raised).
and wheel carriers.
select in the menu >> Offroad Stabi (ORS) >> Drive links >> clock valve VA or valve HA
Note
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z The driving programs can be selected using the rocker switch on

centre console. The -arrow- on the indicator light displays if the road
driving programme >> High Range << (light OFF) or the
offroad program >> Low Range << (light ON) is engaged.
1. Connect the bleeder valves of the actuator to the front axle with a
suitable transparent hose and open approx. one turn.
Front stabilizer, operator control unit
2. Connect the bleeder valves of the actuator to the rear axle with a suitable transparent hose and open
approx. one turn.
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3. To prevent the hoses from slipping from the bleeder valves, they
must be fastened using screw-type hose clamps/tie wraps. Because
of the high pressure occurring, they can become loose during the
bleeding process.
4. Fill with Pentosin CHF 11S in the opening of the dipstick -arrow- .
The opening is located at the left rear, in the centre of the D-pillar.
5. Pull out the dipstick and fill with Pentosin CHF 11S using suitable
filling equipment.
6. Fill with Pentosin CHF 11S up to the Max. marking of the dipstick.
Note
z Connect the Porsche System Tester and switch on the hydraulic pump in the menu >> Offroad Stabi
(ORS) >> Drive links >> Switch on electrical hydraulic pump <<.
z Only allow the hydraulic pump to run for max. 10 seconds when switching it on for the first time following
repairs.
Switch on the ignition, press the brake pedal, and engage High Range. Connect the Porsche System Tester and
switch on the hydraulic pump for 10 seconds. The Pentosin CHF 11S is pumped through the lines.
Switch off the hydraulic pump. Check the fluid levels on the oil dipstick and top up to the Max. marking.
Switch on the hydraulic pump the 2nd time for 10 seconds. The Pentosin CHF 11S is pumped through the lines.
Switch off the hydraulic pump. Check the fluid levels on the oil dipstick and top up to the Max. marking.
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Switch on the hydraulic pump the 3rd time. The Pentosin CHF 11S is
pumped through the lines. Perform a visual inspection of the front and rear
axle for lack of air bubbles.
Let the hydraulic pump run until air bubbles can no longer be seen on the
hoses of the actuators. Let the hydraulic pump run for approximately an
additional 1 minute. Only then it is ensured that the return line is also
completely rinsed out.
Switch off the hydraulic pump. Check the fluid levels on the oil dipstick and
if necessary, top up to the Max. marking.
Disconnect the Porsche System Tester, switch off the ignition, and close
the bleeder valves of the actuators. Remove the hoses. To protect the
bleeder valves, attach the protective caps.
Checking operation
Note
z After pressing the button on the centre console, the hydraulic pump
starts (audibly). The stabilizers disengage or engage when a specific
overpressure has been reached in the system. A time delay between
activation until disengaging/engaging (audible) is normal.
Switch on the ignition, press the brake pedal, and engage Low Range. To
do this, briefly press the rocker switch -direction arrow- forwards. The
indicator light -arrow- comes on.
The stabilizers disengage. In other words: Press the button on the centre
console. The button light -arrow- comes on.
In the instrument cluster (tachometer) the indicator light is on and the

stabilizers disengage audibly.
Press the button again. The button light -arrow- goes out. The stabilizers engage again audibly and the indicator
light in the instrument cluster goes off.

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as of MY 2003
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
40 41 19 Removing and installing front drive shaft - as of MY 2003

- Preliminary work
- Tools
- Removing front drive shaft
- Installing front drive shaft
- Subsequent work
Tools

Screwdriver special tool 9546 Used to counter the ball
joints (tie rod) during
assembly and
disassembly.
Universal drive commercially NR.87-1 For pressing the drive

shaft/wheel hub available tool shaft out of the wheel
puller as of model hub.
'86
Press-out tool special tool T10187 For pressing out the

ball joint on the wheel
carrier.
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Preliminary work
Preliminary work
1. Release fastening nut for drive shaft.
2. Remove wheel. → 440519 Removing and installing wheel - section on "Removing"
Tools
Tools - Removing and installing front drive shaft

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-A- - Universal drive shaft/wheel hub puller as of model '86 NR.87-1

-B- - Protective tube - To protect the drive shaft.
-C- - Press-out tool T10187
-D- - Screwdriver 9546
Removing front drive shaft
Removing front drive shaft
ATTENTION
rubber) .
1. Push (press in) peg into the wheel hub with universal drive shaft/wheel hub extractor as of model '86
NR.87-1. → Insertion length: 20 mm +5 mm
3. Fix -upper trailing arm- with spring compressor VW 552 (vehicle in illustration with conventional
suspension). This involves tensioning axle strut slightly because top ball joint can otherwise get damaged.
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When doing this, the -spring compressor- is pushed through the hole in the axle strut, engaged in the
upper opening of the wheel well (double panel) and in the axle strut and tightened with the nut. This is only
necessary if the same control arm is reinstalled.
4. Press out tie rod on wheel carrier with press-out tool T10187.
→ see figure When pressing out, screw fastening nut on flush
(protects the ball joint thread).
5. Release lower spring strut.
6. Remove the lower connecting rod -arrow- .
7. Raise wheel carrier with a suitable lift to the extent that connecting rod and fastening pins for spring strut at
the bottom are easy to remove. Use a -lift with a rubber base- to prevent slipping.
8. Undo bolt connecting lower spring strut to axle strut -arrow- .
9. Unclip cable for wear monitor and release holder on wheel carrier.
10. Disconnect the cable on the ABS sensor.
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11. Press out wheel carrier at the top with press-out tool T10187. → see figure
12. Push the protection over the drive shaft and release the drive shaft at the transmission.
13. 1. One worker must carefully pull upper wheel carrier out and turn the steering. 2. The second worker must
carefully pull out drive shaft.
Installing front drive shaft
Installing front drive shaft
ATTENTION
Note
z The entire threaded parts of the axle must be tightened in vehicle position. Vehicle position means: vehicle
standing on the wheels, or the wheel suspension is being raised with a universal vehicle lift. -Dimension X- ,
from → Control value: 502 mm +/-10 mm corresponds to the vehicle position.
z Use an intermediate layer (hard rubber) ! Do not damage the brake cover plate.

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z Grease axle nut with a little

Optimoly TA aluminium paste
only at mounting-face ring.
z Grease the toothing of the

drive shaft slightly with
aluminium paste Optimoly TA.
z Drive shafts must not be left

hanging from the joint stop.
Tie up.
z Use new screws and fastening

nuts.
use cleaning agent.
z Use correct tightening torques and torque angle. → Tightening torques for front axle
1. Grease toothing with a little Optimoly TA aluminium paste and insert drive shaft. When doing this, press
inner joint together tightly.
2. Grease the mounting-face ring of the axle nut with a little Optimoly
TA aluminium paste. Screw on the axle nuts in order to prevent the
shaft from slipping out.
Note
z If it is not possible to push shaft in all the way, use press-out tool
T10187 to pull drive shaft in.
3. Insert upper wheel carrier and tie rod, mount using fastening nuts,
then tighten to the specified torque. → Tightening torques for front
axle Pay attention to inner joint of drive shaft.
the bottom are easy to push in.
5. Use a -lift with a rubber base- to prevent slipping.
6. Engage cable for wear monitor and mount holder on wheel carrier.
7. Connect the cable on the ABS sensor.
Subsequent work
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z Grease axle nut with a little

Optimoly TA aluminium paste
only at mounting-face ring.
z Grease the toothing of the

drive shaft slightly with
aluminium paste Optimoly TA.
z Drive shafts must not be left

hanging from the joint stop.
Tie up.
z Use new screws and fastening

nuts.
use cleaning agent.
1. Grease toothing with a little Optimoly TA aluminium paste and insert drive shaft. When doing this, press
inner joint together tightly.
TA aluminium paste. Screw on the axle nuts in order to prevent the
shaft from slipping out.
Note
z If it is not possible to push shaft in all the way, use press-out tool
T10187 to pull drive shaft in.
3. Insert upper wheel carrier and tie rod, mount using fastening nuts,
then tighten to the specified torque. → Tightening torques for front
axle Pay attention to inner joint of drive shaft.
the bottom are easy to push in.
5. Use a -lift with a rubber base- to prevent slipping.
6. Engage cable for wear monitor and mount holder on wheel carrier.
7. Connect the cable on the ABS sensor.
Subsequent work
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Subsequent work
1. Mount the drive shaft on the transmission and tighten to the specified tightening torque. → Tightening
2. Tighten lock nut for the drive shaft to the specified tightening torque. → Tightening torques for the front
axleOperate the brake whilst doing so (second fitter required).
3. Fit the wheel → 440519 Removing and installing wheel - section on "Installing" and tighten to the specified
tightening torque. → Tightening torques for front axle
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
40 41 37 Disassembling and assembling front drive shaft - as of

MY 2003
- Information
- Tools
- Disassembling drive shaft
- Assembling drive shaft
Tools

Circlip pliers commercially NR.68
available tool
Pliers for lug hose clamp commercially NR.74

available tool
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Information
Component overview
Drive shaft components

-A- Outer joint
-1- Joint pin 1 Tap joint pin out of drive Use a hammer to fit the
shaft using a hammer and joint pin as far as it will go
mandrel. on to the drive shaft.
-2- Circlip 27.5 x 2 1 Remove circlip. 1) Do not confuse circlip no. 2
with circlip no. 10 on inner
joint. The two parts are not
identical. Ensure that the
circlip is seated correctly.
-3- Hose clamp 105 x 10 1 Remove hose clamp Fit hose clamp with boot on
using a hammer and the joint pin.
chisel, for example. Do
not damage boot.
-4- Boot 1 Remove boot from the Do not confuse boot no. 4
shaft. with boot no. 7. The two
parts are not identical.
Position boot correctly.
-5- Hose clamp 35 x 10 1 Remove hose clamp For securing the boot.
using a hammer and
not damage boot.
-B- Inner joint
-6- Hose clamp 35 x 10 1 Remove hose clamp For securing the boot.
using a hammer and
not damage boot.
-7- Boot 1 Remove boot from the Do not confuse boot no. 7
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shaft. with boot no. 4. The two

parts are not identical.
Ensure correct seating.
-8- Clamp 74.5 x 10 1 Remove clamp using a Fit clamp with boot on the
hammer and chisel. joint. The clamp lug must
be positioned between two
bores on the joint.
-9- Joint 1 Press joint off the drive Fit the joint as far as it will
shaft. go on to the drive shaft
using a hammer and
mandrel. The cap (boot
holder) is part of the joint
and is not available as a
spare part.
-10- Circlip 28 x 1.5 1 Remove circlip carefully Do not confuse circlip no.
with a pliers. 1) 10 with circlip no. 2 on outer
joint. The two parts are not
identical. Ensure that the
circlip is seated correctly.
-11- Closure cap 1 Remove cap. Use two cheese-head bolts
to centre the cap. Ensure
correct seating. Seal the
sealing faces with special
sealant (refer to Spare
Parts Catalogue).
1) Danger of injury.
Tools
Tools

A Circlip pliers NR.68 See Workshop For loosening and fastening
Equipment Manual, circlips.
Chapter 2.4
B Pliers for lug hose clamp NR.74 See Workshop For securing clamps and
Equipment Manual, hose clamps.
Chapter 2.4
C Hydraulic press Commercially available
hydraulic press. To press off
the inner joint.
Disassembling drive shaft

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ATTENTION
Increased risk of accidents during disassembly work from falling parts.
z Danger of injury and damage.
→ Watch out for falling parts.

→ Get another worker to help.
The joint on the transmission side and joint pin on the wheel side of the front axle can be replaced. The entire
drive shaft must be replaced if the profile shaft is defective.
1. Remove cap from inner joint -arrow- .

2. Remove circlip using circlip pliers NR.68.
Removing cap
3. Remove clamp and hose clamp at the boot -arrows- . If you intend to
re-use the boot, make sure not to damage it.
4. Position inner joint on the ball hub (star-shaped inner ring). Do not
put it on the sheetmetal part! Press the joint off the profile shaft on a
hydraulic press.
Removing clamps
5. Release hose clamps and boots and take them off the profile shaft.
Removing boots
6. Clamp the drive shaft (use aluminium protective jaws). Position an aluminium mandrel on the ball hub (star-
shaped inner ring) -arrow- and remove the joint pin (outer joint) by hitting it several times with a hammer
-see figure- .
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Removing joint
Assembling drive shaft
ATTENTION
Increased risk of accidents during disassembly work from falling parts.
→ Watch out for falling parts.

The drive shaft is assembled in reverse order.
Check all parts to be re-used carefully.
Before fitting the joint, slide all boots, hose clamps and other clamps on to the drive shaft.
Do not confuse the boots. They are not identical parts.
Use new circlips and ensure that they are seated correctly.
1. Clamp the drive shaft (use aluminium protective jaws). Position an

aluminium mandrel on the ball hub (star-shaped inner ring) and fit the
joint -see figure- as far as it will go by hitting it several times with a
hammer.
2. Fit the joint pin as far as it will go on to the drive shaft.
Note
z Before regreasing, remove excess grease with a lint-free cloth. Do
not use cleaning agents on the joints (grease thinners!).
z Make sure that only a small amount of grease gets into the bellows.
This grease is not relevant for the actual lubrication of the joint.
Regreasing joints:
Regrease the joints with special grease (refer to Spare Parts Catalogue).
The original grease quantities for the individual joints are specified in the
following table. Fitting the joint
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Vehicle Joint, inner (gram) Joint pin, outer (gram)

V6/V8 190 120
Joint on transmission side: regrease as required, depending on the

amount of grease left in the joint. Before replacing the cap, fill in the
required amount of grease.
Greasing inner drive shaft

Joint pin on wheel side: regrease as required, depending on the amount of
grease left in the joint. The joint pin is supplied ex-works with approx. 80
grams of grease at the outside and approx. 40 grams at the inside.
Remove excess grease with a lint-free cloth. Push the required amount of
grease through the joint to the outside. Then grease the inside of the joint.
3. Fit the large hose clamps for the two boots. The hose clamp lug - on
the transmission side - must be positioned between two bores on the
joint.
Greasing outer drive shaft

4. Fit the small hose clamps for the two boots between the grooves. If
the boots are fitted correctly, the groove -A- will be visible.
Grooves in drive shaft

5. Before replacing the cap (transmission side), fill in the required amount of grease. Seal the sealing faces with
special sealant (refer to Spare Parts Catalogue). When fitting the cap, use two cheese-head bolts
-see figure- for fixing. Tap on alternate sides with a rubber hammer in order to fit the cap in the correct
position.
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Fitting cap
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
40 50 19 Removing and installing front wheel bearing housing

(wheel carrier) - as of MY 2003
- Preliminary work
- Tools
- Removing wheel bearing housing
- Installing wheel bearing housing
- Subsequent work
Tools

Universal drive commercially NR.87-1 For pressing the
shaft/wheel hub puller available tool drive shaft out of the
as of model '86 wheel hub.
Press-out tool special tool T10187 For pressing out ball

joints.
Assembly fixture special tool T10206 For pulling the drive

shafts into the wheel
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hub.
Spring compressor workshop VW 552 For tensioning the

equipment upper trailing arm.
Preliminary work
Preliminary work
1. Remove axle nuts (wheel-side drive shaft fastening). Operate the brake whilst doing so (2 workers required).
2. Raise the vehicle→ Lifting the vehicle [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Lifting the
vehicle [9PAAJ1] and remove wheel → 440519 Removing and installing wheel - section on "Removing".
Tools
Tools
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-A- - Universal drive shaft/wheel hub puller as of model '86 NR.87-1

-B- - Protective tube - To protect the drive shaft (shop-made).
-C- - Assembly fixture T10206
-A- - Press-out tool T10187

-B- - Spring compressor VW 552
Removing wheel bearing housing
Removing wheel bearing housing

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Note
z Remove the two wire retainers on the wheel bearing housing (M6 screw). Disconnect speed sensor plug.
z Push protection over input shaft.
z After removing the wheel bearing housing, place the input shaft in such a way that the inner ball joint is not
overstretched.
z Drive shafts must not be left hanging from the joint stop.
-Wheel bearing housing- with wheel hub and brake disc.
Wheel bearing housing
1. Remove the brake calliper → see figure and the two brake line
holders and pull plug off the speed sensor. Secure the brake calliper
at a suitable position in the wheel well (do not open the brake
system!).
2. Fix -upper trailing arm- with spring compressor VW 552 (vehicle in illustration with conventional
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suspension). This involves tensioning axle strut slightly because top ball joint can otherwise get damaged.
When doing this, insert tension jack into the top opening of wheel house (double panel) and in the axle strut.
3. Using the universal drive shaft/wheel hub extractor as of model

'86 NR.87-1 push (press through) peg of drive shaft by approx. 20
mm - 25 mm into the wheel hub
-Universal drive shaft/wheel hub extractor- . Make sure that the
input shaft does not become kinked between the spring strut prongs.
To do this, fasten a suitable wire in the bores of the spring strut
prongs.
4. Loosen the fastening nuts from the -bottom ball joint- and press off
with the press-out tool T10187. When doing this, leave fastening
nut flush on ball journal, so as not to damage the thread.
5. Remove fastening screw for the lower spring strut -arrow- .
6. Use a suitable -lift with rubber base- (to prevent slipping) to raise
the wheel bearing housing to a position at which the screw can be
unscrewed easily.
7. Press out the tie rod on the wheel bearing housing using the press-
out tool T10187.
8. Press out the ball joint on the control arm using the press-out tool
T10187 and secure the wheel bearing housing so that it does not fall
down (a second worker is required for this!). Pull the wheel bearing
housing out of the lower ball joint and remove it.
Installing wheel bearing housing

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Installing wheel bearing housing
ATTENTION
Note
z The entire threaded joints of the axle must be tightened in vehicle
the wheel suspension is raised with a universal vehicle lift. Dimension
-X- , from → Control value: 502 mm +/-10 mm corresponds to
vehicle position.
z Replace all expansion screws (screws which are fitted with torque angle tightening procedure).
z Observe correct tightening torques and torque angle → Tightening torques for front axle.
use cleaning agent.
-Wheel bearing housing- with wheel hub and brake disc.

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Wheel bearing housing
1. Insert the wheel bearing housing on the lower ball joint and position the input shaft (a second worker is
required). Remove the wire between the spring strut prongs. Remove drive shaft protection.
2. Mount the wheel bearing housing on the upper control arm. Fit tie rod.
TA aluminium paste. Screw on the axle nuts. If it is not possible to
push the shaft in all the way, use the assembly fixture T10206 to
pull the drive shaft in.
4. Attach the two wire retainers and the -speed sensor plug- .
5. Screw the spring strut to the lower axle strut.
6. Fit the brake calliper.
Subsequent work
Subsequent work
Mount wheel. → 440519 Removing and installing wheel - section on "Installing"
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
40 57 19 Removing and installing front wheel bearing - as of MY

2003
- Tools
- Information
- Removing front wheel bearing
- Installing front wheel bearing
- Subsequent work
Tools

puller hook special tool 92291
12 - 115 mm ø separator special tool NR.111

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attachments special tool T10205
tubular piston cylinder commercially vas

available tool 6178
Tools
Tools
Tools overview for wheel bearing

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-A- - Tubular piston cylinder VAS 6178 (The tubular piston cylinder is used together with the pneumatic
hydraulic pump.)
-1- - T10205/1 grip piece from attachments T10205 (To press the wheel hub out of the wheel bearing.)
-2- - T10205/2 bell from attachments T10205 (To press out the wheel hub. To pull off the wheel bearing inner
race from the wheel hub, use together with separator 12 - 115 mm ø No. 111.)
-3- - T10205/3 pressure piece from attachments T10205 (To press out the wheel hub.)
-4- - T10205/4 mounting from attachments T10205 (To press out the wheel bearing.)
-5- - T10205/5 pipe from attachments T10205 (To press out the wheel bearing.)
-6- - T10205/6 pressure disc from attachments T10205 (To press out the wheel bearing. And to press in the
wheel hub.)
-7- - T10205/7 pressure piece from attachments T10205 (To press in the wheel bearing.)
-8-1- - T10205/8-1 threaded rod from attachments T10205 (Used in the tubular piston cylinder -A- .)
-8-2- - T10205/8-2 threaded nut from attachments T10205 (Used on the threaded rod -8-1- .)
-10- - T10205/10 pressure piece from attachments T10205 (To press in the wheel hub.)
-13- - T10205/13 push button from attachments T10205 (Used in the tubular piston cylinder -A- .)
Information
Overview of front wheel bearing

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-1- Wheel bearing housing 1 Carry out a close visual
inspection of the seat of the
wheel bearing. There must not
be scores, grooves or
deformations.
-2- Wheel bearing 1 The wheel bearing can no Use a new wheel bearing. Do
longer be used after it is not press on the inner race.
removed. Insert the wheel bearing with
the magnetic multiple-pole ring
to the drive shaft. Check the
magnetic side (e.g., with a
paper clip). Do not use
magnets or screw drivers to
check!
-3- Snap ring 1 Use new snap ring.
-4- Wheel hub 1 Pull off the inner race of the Carry out a close visual
wheel bearing separately inspection of the seat of the
from the wheel hub. wheel hub. There must not be
scores, grooves or similar
deformations on the hub.
-5- Axle nut (fastening nut) 1 Always replace. Grease
contact surface with a little
Optimoly TA. Tightening
torque 500 Nm (8 ftlb.).
Removing front wheel bearing
Removing front wheel bearing

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ATTENTION
Increased danger of accident when handling hydraulic presses.
z Danger of crushing and material damage if the wheel carrier is raised improperly.
z Watch out for parts falling when working with the hydraulic cylinder.
→ Vehicle may not be moved if drive shafts have not been fitted and tightened.
Note
The wheel bearing is removed with the wheel bearing housing installed.
1. Remove the corresponding hub cap with puller hook 92291 and release the axle nut (fastening nut) before
lifting the vehicle. Operate the brake whilst doing so (2 fitters required).
3. Remove the axle nut (fastening nut). Perform work up to step 7 in Chapter Removing and installing front
drive shaft. → 404119 Removing and installing front drive shaft - chapter on "Removing".
4. Remove the two holders (brake hose, combination wire) on wheel bearing housing.
5. Remove the wheel speed sensor. → 451119 Removing and installing front rpm sensor - chapter on
"Removing"
6. Remove the brake disc. → 465019 Removing and installing front brake disc - chapter on "Removing"
7. Press out the wheel carrier on the top axle strut (top ball joint) with
press-out tool T10187.
8. Undo the drive shaft on the transmission. To do this, first fitter must
pull out top wheel carrier outwards carefully, so that the second fitter
can carefully pull out the drive shaft.
9. Insert the wheel bearing housing again on the top axle strut (top ball
joint) and screw on nut.
10. Remove wheel hub (tools) → see figure .
11. Secure the grip pieces (2 half shells) T10205/1 (from attachments T10205 ) with several wheel bolts behind
the wheel hub. → see figure
12. Insert the T10205/2 bell (from attachments T10205 ) into the provided groove in the correct position. → see
figure
13. Insert the tubular piston cylinder vas 6178. Position the T10205/3 pressure piece (from attachments
T10205 ) and the 8-2 nut for the threaded rod (from attachments T10205 ). Press out the wheel hub. → see
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figure
It should be ensured that the separator is not pressing on the seat of the
bearing inner race on the wheel hub → see figure .
14. If the wheel hub is used again, remove the

-Inner race of the wheel bearing- from the wheel hub. To do this,
position the 12 - 115 mm ø separator NR.111 behind the inner race.
15. Press inner race off the wheel hub. To do this, position the T10205/2 bell (from attachments T10205 )
without the grip piece. Insert the tubular piston cylinder vas 6178. Position the T10205/3 pressure piece
(from attachments T10205 ) and the 8-2 nut for the threaded rod (from attachments T10205 ). → see figure
16. Remove the -Snap ring- . → see figure

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17. Remove the wheel bearing (tools) → see figure .
18. Press out the wheel bearing. To do this, position the T10205/5 and
T10205/4 (from attachments T10205 ) in correct position on the
wheel bearing housing. Insert the tubular piston cylinder vas 6178.
Position the T10205/6 (from attachments T10205 ) and the 8-2 nut
for the threaded rod (from attachments T10205 ). → see figure
Installing front wheel bearing
Installing front wheel bearing
ATTENTION
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Note
z The wheel bearing must not come into contact with magnetic objects (e.g., magnetic screwdriver, magnet).

-Dimension X- , from → Control value: 502 mm +/-10 mm
corresponds to the vehicle position.
use cleaning agent.
1. Fit the wheel bearing (tools). → see figure
Check that the bearing seat -arrow- (in rear axle figure) is clean and the
surface is in good order. There must not be scores, grooves or
deformations.
Insert the wheel bearing with the magnetic multiple-pole ring to the drive
shaft. Check the magnetic side (e.g., with a paper clip). Do not use
magnets or screw drivers to check!
2. Position the -wheel bearing in the wheel bearing housing- in the correct position. Position the T10205/7
pressure piece (from attachments T10205 ) in the correct position on the wheel bearing. Insert the tubular
piston cylinder vas 6178. Position the T10205/9 pressure piece (from attachments T10205 ) and the 8-2
nut for threaded rod (from attachments T10205 ) in the correct position. Mount wheel bearing. Shortly
before the stop, the applied force will be between 35 kN and 60 kN. Do not exceed the maximum assembling
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force at the stop. → assembling force: 90 KN
3. Position the -snap ring- with the opening facing downward. When
the Seger ring is fitted correctly, -dimension X- is at least 15 mm. →
minimum dimension: 15 mm If this dimension is not reached, the
Seger ring must be fitted again. If necessary, carefully press the
wheel bearing again.
4. Fit wheel hub (tools) → see figure .
Carry out a close visual inspection of the seat of the wheel hub. There
must not be scores, grooves or similar deformations on the hub.
5. Position the -wheel hub- in the correct position. Position the T10205/10 pressure piece (from attachments
T10205 ) in the correct position on the wheel hub. Insert the tubular piston cylinder vas 6178. Position the
T10205/6 pressure piece (from attachments T10205 ) and the 8-2 nut for threaded rod (from attachments
T10205 ) in the correct position. Pull in the wheel hub. Shortly before the stop, the applied force will be
between 9 kN and 35 kN. Do not exceed the maximum assembling force at the stop. → assembling force:
40 KN
6. Fit drive shaft. → 404119 Removing and installing front drive shaft - section on "Installing"
7. Press out the wheel carrier on the top axle strut (top ball joint).
8. Fit the brake disc. → 465019 Removing and installing front brake disc - section on "Installing"
9. Fit the wheel speed sensor. → 451119 Removing and installing front rpm sensor - section on "Installing"
10. Fit the two holders (brake hose, combination wire) on wheel bearing housing.
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Subsequent work
Subsequent work
Fit wheel.→ 440519 Removing and installing wheel - section on "Installing"
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
40 77 19 Removing and installing front stabilizer - as of MY 2003

- Preliminary work
- Removing stabilizer
- Installing stabilizer
- Subsequent work
Preliminary work
Preliminary work
Raise the vehicle.→ Lifting the vehicle [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Lifting the
vehicle [9PAAJ1]
Remove engine guard. → 108019 Removing and installing engine guard - section on "Removing"
Removing stabilizer
Removing anti-roll bar

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-1- - Stabiliser
-2- - Stabiliser bearing
-3- - Clamp
-4- - Fastening screws
-5- - Connecting rod
-6- - Fastening screw
-8- - Fastening nut
ATTENTION
Danger of injury and material damage if the wheel carrier is raised incorrectly.
z Crushing and other injuries can occur due to slipping parts.
1. Release connecting rod right and left. When doing this, raise wheel carrier to the extent that connecting rod
fastening pin can be taken out easily. Use a -lift with rubber base- in order to prevent slipping.
2. Undo the 4 fastening screws and remove the clamps.
3. Mark the installation position -arrow- of the -halves of the stabiliser bearing- for the stabiliser with a paint
marker.
4. Carefully pull out the anti-roll bar.
Installing stabilizer
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Installing anti-roll bar
-1- - Stabiliser
-2- - Stabiliser bearing
-3- - Clamp
-4- - Fastening screws
-5- - Connecting rod
-8- - Fastening nut
ATTENTION
Danger of injury and material damage if the wheel carrier is raised incorrectly.
z Crushing and other injuries can occur due to slipping parts.
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Note
-X- , from → Control value: 502 mm +/-10 mm corresponds to
vehicle position.
z Observe correct tightening torques and torque angle → Tightening torques for front axle.
use cleaning agent.
1. Mount the -halves of the stabiliser- on the previously applied marking on the stabiliser. The larger outer
diameter of the halves of stabiliser bearing is on the wheel side.
2. Engage at the prescribed take-up points -arrow- .
3. Position anti-roll bar and fit clamps using the four fastening screws.
4. Fit connecting rod.
Subsequent work
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Subsequent work
Attach engine guard. → 108019 Removing and installing engine guard - section on "Installing"
Lower the vehicle.→ Lifting the vehicle [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Lifting the
vehicle [9PAAJ1]
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
40 77 19 Removing and installing off-road stabiliser - as of MY

2003
- Preliminary work
- Removing off-road stabiliser
- Installing off-road stabiliser
- Subsequent work
Preliminary work
Preliminary work
1. Connect the Porsche System Tester → see figure and in the menu
select >> Offroad Stabi (ORS) >> Drive links >> Clock valve VA or
valve HA <<.
Removing off-road stabiliser
Removing off-road stabiliser - V8
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Front stabiliser
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Front stabiliser (switchable)

-E- - Control unit
-F- - Oil dipstick
WARNING
Danger of accident. The Offroad Stabilizer System (ORS) operates at an overpressure of up to 165 bar. If
the ORS is not depressurised, movements may occur on the wheel carrier under certain circumstances
(e.g. the off-road stabilisers are disengaged when the vehicle is lifted, the switch on the centre console is
pressed and the wheel carrier is also lifted).
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1. Release connecting rod right and left. When doing this, raise wheel
carrier to the extent that connecting rod fastening pin can be taken
out easily. Use a suitable lift with rubber base → see figure in order
to prevent slipping.
2. Loosen the 2 lines (centre in Figure) → see figure and counter with
an open-ended wrench. Seal the lines with suitable plugs. Remove
the plug (left arrow) → see figure .
4. Mark the installation position (arrow) → see figure of the halves of

stabiliser bearing for the stabiliser with a paint marker.
Removing off-road stabiliser - V6
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Front stabiliser
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-E- - Control unit
-F- - Oil dipstick
WARNING
Danger of accident. The Offroad Stabilizer System (ORS) operates at an overpressure of up to 165 bar. If
the ORS is not depressurised, movements may occur on the wheel carrier under certain circumstances
(e.g. the off-road stabilisers are disengaged when the vehicle is lifted, the switch on the centre console is
pressed and the wheel carrier is also lifted).
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1. Release connecting rod right and left. When doing this, raise wheel
carrier to the extent that connecting rod fastening pin can be taken
out easily. Use a suitable lift with rubber base → see figure in order
to prevent slipping.
2. Loosen the 2 lines (centre in Figure) → see figure and counter with
an open-ended wrench. Seal the lines with suitable plugs. Remove
the plug (left arrow) → see figure .
4. Mark the installation position (arrow) → see figure of the halves of

stabiliser bearing for the stabiliser with a paint marker.
5. Carefully pull out the stabiliser.
Installing off-road stabiliser
Installing off-road stabiliser - V8

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Front stabiliser
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-E- - Control unit
-F- - Oil dipstick
ATTENTION
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Note

Dimension -X- , from lower edge of wing to middle of axle 502 mm
±10 mm corresponds to vehicle position.
z Use an intermediate layer (hard rubber) ! Do not damage the brake

cover plate.
z Observe correct tightening torques → Tightening torques for front

axle.
1. Mount the halves of the stabiliser bearing → see figure in the correct
position on the stabiliser. In the correct position means: The larger
outer diameter is on the wheel side.
2. Engage at the prescribed take-up points -arrow- .

3. Position stabiliser and mount clamps with the 4 fastening screws.
4. Fit the 2 lines (centre in Figure) → see figure and counter with an open-ended wrench. Plug in the plug (left
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arrow) → see figure .
5. Mount connecting rod.
Subsequent work
Bleed the Offroad Stabilizer System . → 407707 07 Bleeding the Offroad Stabilizer System (ORS)
Fit the engine guard. → 108019 Removing and installing engine guard - chapter on "installing"
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
40 85 19 Removing and installing front spring strut (steel springs)

- as of MY 2003
- Preliminary work
- Removing front spring strut
- Installing front spring strut
- Subsequent work
Tools

protective tube commercially 44
available tool
screwdriver special tool 9546

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Preliminary work
Remove wheel. → 440519 Removing and installing wheel - chapter on "removing"
Removing front spring strut
Note
z The steel springs do not apply for the Cayenne Turbo.
z Standard Cayenne Turbo equipment: Air springs with level control and vertical adjustment.
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ATTENTION
rubber) .
1. Lift wheel carrier carefully to facilitate removal. Use a suitable lift with rubber base → see figure in order to
prevent slipping.
3. Fix upper axle strut with spring compressor VW 552. This involves tensioning the axle strut slightly
because otherwise the top ball joint can be damaged. When doing this, the spring compressor VW 552
→ see figure is engaged in the upper opening of the wheel housing (double panel) and in the axle strut and
pre-tensioned with the nut. This is only necessary if the same control arm is reinstalled.
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4. Release connecting rods at stabiliser. → see figure
5. Undo bolt connecting lower spring strut to axle strut -arrow- .
6. Push protective tube 44 -A- over drive shaft. Release drive shaft at
transmission flange and lay down carefully. Use suitable base.
7. Release holder for brake line/combination wire at the top on the wheel carrier.
8. Press out ball joint of wheel carrier tie rod with press-out tool T10187 -B- . Counter with screwdriver 9546
-C- .
9. Press out ball joint of top axle strut of wheel carrier with press-out tool T10187 -B- . Counter with
screwdriver 9546 -C- .
10. Remove spring compressor VW 552 -D- , release the 4 M8 fastening nuts from mounting saddle and
carefully remove spring strut.
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Installing front spring strut
Note
z The steel springs do not apply for the Cayenne Turbo.
z Standard Cayenne Turbo equipment: Air springs with level control and vertical adjustment.
ATTENTION
Note
z The entire threaded joints of the axle must be tightened in vehicle position. Vehicle position means: vehicle
standing on the wheels, or the wheel suspension is raised with a universal vehicle lift. Dimension -X- , from
→ Control value: 502 mm +/-10 mm corresponds to vehicle position.

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z Observe correct tightening torques and torque angle → Tightening

z Make sure the bevel pinions from the ball joints are clean. Clean with
a lint-free cloth as necessary. Do not use cleaning agent.
1. Carefully insert the spring strut and tighten to mounting saddle (four
M8 fastening nuts) with the prescribed tightening torque.
2. Fix upper axle strut with spring compressor VW 552. This involves
tensioning the axle strut slightly because otherwise the top ball joint
can be damaged. When doing this, the spring compressor VW 552
→ see figure is engaged in the upper opening of the wheel housing
(double panel) and in the axle strut and pre-tensioned with the nut.
3. For easy fitting, slightly raise wheel carrier with a suitable lift so that
upper ball pin can be inserted. Use a suitable lift with rubber base
→ see figure in order to prevent slipping.
4. Mount securing pin for lower spring strut.
5. Mount connecting rod at stabiliser.
6. Mount the mount for brake line/combination wire at the top on wheel
carrier.
7. Mount drive shaft at transmission flange. Remove spring

compressor, protective tube and base.
8. Mount ball joint of tie rod on wheel carrier.
9. Tighten plastic nuts on front wheel housing liner.
Subsequent work
Mount wheel . → 440519 Removing and installing wheel - chapter on "installing"
as of MY 2003
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
40 85 37 Disassembling and assembling front spring strut (steel

springs) - as of MY 2003
- Information
- Preparations for assembly
- Assembly
Tools

socket wrench special tool 3353 For loosening lock nuts on
insert the shock absorber.
arm bracket special tool 9630 For countering the shock

absorber piston rods.
spring clamp for commercially NR.121 Standard clamping range

spring struts available tool of spring holder up to 150
mm spring diameter (size
1A).
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double-arm commercially NR.93 Commercially available

torque wrench 15 available tool torque wrench for
- 65 Nm (48 ftlb.) tightening torques of 60
Nm (44 ftlb.) ± 5 Nm (3.5
ftlb.).
Information
Component overview
The steel springs do not apply for the Cayenne Turbo.
Standard Cayenne Turbo equipment: Air springs with level regulation and vertical adjustment.
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Steel spring strut, complete
Steel spring strut, exploded drawing

-1- Hexagon nut 1 Before loosening the lock Use new lock nut. Tighten
M12 x 1.5 nut, tension coil spring to 60 Nm (44 ftlb.) ± 5 Nm
using spring clamp for (3.5 ftlb.). First position
spring struts. When concave support 3.
loosening the nut, counter
it at the piston rod using an
arm bracket 9630.
-2- Supporting mount 1 Remove complete
assembly (supporting
mount no. 2, with concave
support no. 3 and top
support no. 4).
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-3- Concave support 1 Position concave support

correctly.
-4- Top support 1 Place in correct position
with concave support no. 3.
-5- Protective sleeve 1 This is clipped into concave
support no. 3.
-6- Rubber stop 1 This is pushed into
protective sleeve no. 5.
-7- Cap 1 This is pushed into
protective sleeve no. 5 and
fitted to shock absorber.
-8- Coil spring 1 Observe allocation as per
Spare Parts Catalogue.
-9- Concave washer, bottom 1
-10- Bottom support 1 Observe colour allocation.
Only coil springs and the
bottom shim should be
installed together with
colour coding (depending
on tolerance class of
springs). Fit in correct
position with concave
washer no. 9.
-11- Vibration damper 1 Observe allocation as per
Dampers for the right and
left sides are not identical.
Mounting instructions
ATTENTION
Increased risk of accidents due to spring tensioning.
z Danger of injury and damage from springs jumping out.
→ Never use an impact bolter to loosen or tighten the fastening nut.

→ Use a commercially available changeover ratchet.
Note
z Observe the correct allocation (engine variant) when installing new coil springs and/or shock absorbers.
z Observe allocation of the bottom spring plate according to the coil spring tolerance group.
z We recommend that you replace the coil springs only in pairs.
1. Clamp the spring strut at a suitable place in the vice (use jaw liners).
2. Tension the coil springs -see figure- using spring clamp for spring struts NR.121 until the piston rod is
relieved.
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3. Loosen the connection (piston

rod to supporting mount) at
the piston rod using a
commercially available
changeover ratchet and a
socket wrench insert 3353.
Counter with an arm bracket
9630.
4. Remove all components from

the piston rod.
Removing/fitting spring-strut mount
Spring clamp
Allocation of coil spring and bottom support
The bottom support (spring plate) is allocated according to the coil spring tolerance group.
The colour coding -arrow- of the coil spring is located at the middle of the
coil spring and is indicated by coloured dots → Distinguishing feature and
allocation of coil springs and shock absorbers.
The bottom supports come in various thicknesses, differentiated by colour.

The supports used are coloured differently as required.
Marking of steel springs

Coil spring colour coding Colour of bottom support to be used
No colour coding Black
Blue Blue
Beige Beige
Distinguishing feature and allocation of coil springs and shock absorbers
The coil springs are allocated using coloured dots -arrow- . Yellow is used for the Cayenne and gold for the
Cayenne S → Allocation of coil spring and bottom support. Refer to the Parts Catalogue for the allocation.
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Model Coil spring colour coding

Cayenne Yellow (1 or 2 dots)
Cayenne S Gold (1 or 2 dots)
The shock absorbers are allocated using the spare part numbers and the
model specification. At present, two different shock absorbers, right and
left, are used on the front axle of the Cayenne and Cayenne S. Refer to
the Parts Catalogue for the allocation.
Preparations for assembly
1. Place the cap -1- , rubber stop -2- and protective sleeve -3- together
as follows before pushing them on to the piston rod:
– Push the rubber stop -2- up fully into the protective sleeve -3- .
Assembling cap 1, rubber stop 2 and

protective sleeve 3
– Slide the cap into the protective sleeve -see figure- and pull the lip carefully over the cap.
2. Place the bottom concave washer (grey) -see figure- together with the bottom support -see figure- at the
correct position (not twisted).
At the correct position means that the two individual parts are fitted precisely together.
3. Place the top concave support -see figure- together with the top support -see figure- at the correct position
(not twisted).
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Fitting bottom concave washer into Fitting cap into protective sleeve
bottom support
At the correct position means that the two individual parts are fitted
precisely together.
Marking and fitting top concave

support with top support at correct
position
Assembly
Assembly
ATTENTION

1. Position the bottom support and bottom concave washer assembly at the correct position on the shock
absorber.
At the correct position means that the two individual parts are fitted precisely together.
2. Position the pre-tensioned coil spring precisely at the stop in the bottom concave washer -arrow- .
3. Slide the protective sleeve/stop buffer/cap assembly loosely onto the piston rod.
4. Position the top concave support assembly with the top support.
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– For the left spring strut, the

marking -see figure- must be
pointing away from the
direction of travel when
installing the top concave
support.
– For the right spring strut, the

marking must be pointing in
the direction of travel when
installing the top concave
support.
Marking and fitting top concave Coil spring stop in bottom concave
support with top support at correct washer
position
– Position the top spring plate -arrow- precisely at the coil spring stop.
Top spring plate stop at coil spring

5. Once the concave support is positioned and aligned, the centre lines
-A- and -B- must be parallel. No. 1 -1- shows the connection of the
connecting rod from the stabiliser to the spring strut.
6. Once the mount is positioned, fit the new lock nut. Screw the lock nut
onto the piston rod until approx. 1 to 2 threads are visible above the
lock nut. Then tighten with double-arm torque wrench 15 - 65 Nm
(48 ftlb.) NR.93.
Concave support assembly

7. Complete the following steps to ensure that the protective sleeve (rear-axle spring strut in figure)
-see figure- is seated correctly:
– Push the protective sleeve -arrow- up fully and clip it into the concave support.
– Push the protective sleeve -arrow- down fully and clip it to the shock absorber with the cap (audible click).
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9PAAE7
as of MY 2003
Country C00, C02, C05, C07, C08,
C09, C10, C11, C12, C13, C14,
C15, C16, C18, C19, C20, C21,
C22, C23, C24, C25, C26, C27,
C28, C32, C33, C34, C35, C36,
C37, C38, C39, C45, C46, C98,
C99
Fitting protective sleeve in bottom Fitting protective sleeve in top spring

spring strut strut
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WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
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ADVERTENCIA
40 IN Component arrangement - Off-Road Stabiliser System (ORS)

- as of MY 2003
- Component arrangement - Offroad Stabiliser System (ORS)
Component arrangement - Offroad Stabiliser System (ORS)
Component arrangement - Offroad Stabiliser System (ORS)
As an option, the running gear of the Cayenne can be equipped with an Offroad Stabiliser System (ORS).
The ORS enables optimum traction on the front and rear axle in off-road operation. The stabiliser rate is lowered
to a minimum. The main part of the ORS is centrally arranged, hydraulically activated actuators. There are claw
clutches in the actuators which enable the separation of the stabiliser arm with a swivel range of approx. ±30°.
A coil spring in the actuators is used as an additional mechanism for locking the clutches. This means that if there
is pressure loss or if there are electrical defects, the clutches of the stabilisers close automatically.
When the vehicle is started, the ORS system is automatically in Onroad mode. The system can only be switched
on and off in the offroad programme >> Low Range << using the >> Release for the stabiliser (button) << in the
selector switch on the centre console. The system status is shown on the display in the instrument cluster.
If the car is driven on a steep incline or if a speed of 50 Km/h is exceeded, the stabilisers are switched to Onroad
mode, independent of the switching commands of the driver.
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Component arrangement - ORS
No. Description of component Number Location

-A- Front offroad stabiliser. 1 On the front axle
carrier.
-B- Rear offroad stabiliser. 1 On rear axle
housing.
-C- Control unit for Offroad stabiliser. 1 Behind the left
cover in the
luggage
compartment
(behind that for
auxiliary air
conditioning
system!).
-D- Release for stabiliser. 1 On the centre
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console.
-E- Control module. 1 On the rear wall
in the spare
wheel well.
-F- Dipstick. 1 Behind the
cover in the D-
pillar.
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
42 05 19 Removing and installing rear axle housing - as of MY

2003
- Preliminary work
- Removing rear axle carrier
- Installing rear axle carrier
- Subsequent work
Preliminary work
Preliminary work
1. For vehicles with level adjustment: Switch off level adjustment → Lifting the vehicle [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ Lifting the vehicle [9PAAJ1].
2. To bleed the level adjustment system (compressed air must be

released from the system), use the Porsche System Tester. To do
this, select the Bleed level adjustment menu item in the Level
adjustment system.
3. Raise the vehicle at the jacking points provided → 40 Lifting the

vehicle.
4. Remove the rear wheels → 440519 Removing and installing wheel -

5. Remove the tailpipe → 260119 Removing and installing exhaust
system - chapter on "removing".
Tools and materials
Tools
-A- - Mounting frame (See Workshop Equipment Manual, Chapter 3.0)
-11- - Take-up point for rear axle housing
-22- - Take-up point for rear axle housing
Removing rear axle carrier
Removing rear axle carrier
These removal and installation instructions apply to vehicles with level adjustment and steel springs. The points
relating to level adjustment are not relevant for vehicles with steel springs.
ATTENTION
Increased risk of accident when working on the exhaust system, the
rear axle and the vibration dampers.
z Possible danger of injury or damage.
→ Wear protective gear, e.g. gloves.

→ Position the mounting frame correctly on the lifting platform and
carefully remove the rear axle housing.
→ Watch out for falling parts during removal on the mounting frame.
1. Remove the combination wires at the joint (brake wear, CDC sensor) -1- and then unclip the rubber sleeves
-2- from the sheetmetal holders.
2. Undo the brake caliper and hang it in a suitable place in the wheel housing.
Note
z Always wear safety goggles and gloves when working on vehicles
with level adjustment.
z Mark the installation position (e.g. with a felt-tip pen) when removing
the cardan shaft.
z Mark the installation position (e.g. with a felt-tip pen) when removing
the rear axle housing.
z The take-up points 11 and 22 are required for removing the rear axle. Remove the remaining take-up points.
3. In vehicles with level adjustment, disconnect the air connection to the spring struts -arrow- (front axle
connection shown here).
4. Remove the bleeder line from the rear axle transmission.
5. Unclip both brake cables from the Quickfit attachment and remove them from the cable guides → 467919
21 Removing and installing (rear) brake cable for foot-operated parking brake - chapter on "removing". Hang
the cables in a suitable place to prevent damage.
6. Mark the installation position of the cardan shaft -arrow- .
7. Make sure that the cardan shaft does not become kinked (tie it up, -arrow- ).
8. Disconnect the plug connections for the level adjustment and
headlight levelling systems ( -arrow- ). On vehicles with differential
lock, disconnect the plug connection on the rear axle transmission.
9. For installation, it is a good idea to mark the installation position of

the rear axle housing diagonally in at least two places on the body.
To do this, place the marks vertically with respect to the floor of the
body using a → see figure felt-tip pen (e.g. mark along the rear axle
housing mount with the pen).
10. Position the mounting frame correctly on the → see figure lifting
platform.
11. Position the lifting platform with the → see figure mounting frame under the rear axle housing.
12. Push into the take-up points -arrows- provided. The -arrows- show
the take-up points for the mounting frame in the rear axle housing
(view from below here).
13. Remove the → see figure attachments on the damper housing.
14. Loosen the rear axle housing ( -arrows- ) . Lower the rear axle while
taking care not to damage adjacent components.
Subsequent work can be carried out on the mounting frame.
15. Remove the stabilizer on the vibration dampers and on the rear axle
housing.
16. Detach the half-shafts at the rear axle transmission.
Note
z Get a second worker to help to remove the wheel carrier with
accessories and the rear axle transmission.
17. Remove the damper housing.
18. Loosen the triangular control arms, control arms and tie rods on the rear axle housing. Remove the wheel
carriers with triangular control arms, control arms, tie rods and half-shafts.
19. Remove the rear axle transmission by unscrewing the screws on the rear axle housing and lifting out the
transmission.
Installing rear axle carrier
Installing rear axle carrier
ATTENTION
Increased risk of accident when working on the exhaust system, the rear axle and the vibration dampers.
When filling the air spring struts, the vehicle lifts. Damage due to raising the wheel carrier incorrectly.
z Possible danger of injury or damage (crushing, cuts).
→ Wear protective gear, e.g. gloves and safety goggles.

→ The steering angle sensor must be calibrated following removal → 456005 Initialising and calibrating
steering angle sensor.
→ Watch out for falling parts during installation on the mounting frame.
Note
z Before installing, give the parts a visual check.
z Position the rear axle housing with respect to the body at the markings made previously.
z Position the cardan shaft at the markings made previously.
z Replace all fastening nuts and all expansion screws (screws which are fitted with torque angle tightening
procedure).

the wheel suspension is being raised using a universal vehicle lift.
Dimension -X- , from lower edge of wing to middle of axle 506 mm ±
10 mm corresponds to vehicle position.
z Do not raise the wheel suspension higher than the normal vehicle
position (vehicle resting on wheels). When raising the suspension,
use a suitable intermediate layer (hard rubber).
z The vehicle suspension must be aligned following repair work →

Suspension alignment, complete.
z Calibrate the steering angle sensor with the Porsche System Tester → 456005 Initialising and calibrating
steering angle sensor.
z Calibrate level adjustment with the Porsche System Tester →

Calibration.
1. Position the rear axle housing on the mounting frame.
2. Pre-fit the accessories on the rear axle housing. Get another worker
to help. A final tightening of the screw connections must be
performed when the vehicle is in normal vehicle position.
3. Position the rear axle housing and damper housing back in the
original, marked installation position and tighten; be careful not to
damage adjacent parts -arrows- .
4. Fit the half-shafts, stabilizer, plug connections and the bleeding line
on the rear axle transmission.
5. Fit the cardan shaft, brake cables, brake calipers and combination
connectors. Follow correct cable routing.
6. On vehicles with level adjustment, attach the air connection to the
spring struts.
Subsequent work
Subsequent work
1. Fit rear muffler → 260119 Removing and installing exhaust system - chapter on "installing".
2. Fit wheels → 440519 Removing and installing wheels - chapter on "installing" .
3. To fill the level adjustment system, use the Porsche System Tester. To do this, select the Fill air suspension
menu item in the Level adjustment system. Switch on level adjustment → Lifting the vehicle [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Lifting the vehicle [9PAAJ1].
4. Perform suspension alignment → Suspension alignment, complete and calibrate → 456005 Initialising and
calibrating steering angle sensor.
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
42 08 55 Bearings for rear axle - as of MY 2003

- Preliminary work
- Replacing
- Subsequent work
Tools

Counter support, 0 - 40 mm commercially NR.106
available tool

available tool
Separating device, 12 - 115 commercially NR.111

mm ø available tool
assembly fixture VW-tool T10301
Preliminary work
Preliminary work
1. Switch off level adjustment. → 40 Lifting the vehicle
On vehicles with ORS, depressurise the system using the PIWIS Tester.
z Before working on the vehicle, ensure that the ORS is engaged. The indicator light on the centre console
z Before working on the ORS, always depressurise the system! To do this, close the PIWIS Tester and select
3. For front rear-axle suspension subframe bearings: Remove stone guard.
4. Remove rear silencer. → 260119 Removing and installing exhaust system
Tools and materials
Tools
Tool overview for suspension subframe bearings assembly fixture T10301
Tool overview for suspension subframe bearings
-A- - → Hydraulic cylinder VAS 6178 (The hydraulic cylinder is used together with the → foot pump VAS 6179
and the → pressure gauge with connecting cable VAS 6179/1 -B- .)
-1- - Threaded rod (Inserted into the tubular piston cylinder -A- .)
-2- - Threaded nut (Screwed onto the threaded rod -1- .)
-3- - Pipe (For pressing out the suspension subframe bearings.)
-5- - Press-out plate (For pressing out the suspension subframe bearings.)
. -6- - Pressure piece (For pressing in the suspension subframe bearings.)
-7- - Press-in plate (For pressing in the suspension subframe bearings.)
-9- - Spacer sleeve (For pressing out the suspension subframe bearings together with pipe -3- .)
-10- - Pressure piece (For pressing in the suspension subframe bearings.)
-11- - Spacer sleeve (For pressing in the suspension subframe bearings.)
Counter support, 0 - 40 mm NR.106
Internal puller NR.108
Separating device, 12 - 115 mm ø NR.111
Replacing
Replacing rear-axle bearings
WARNING
Under certain conditions, motions can occur on the wheel carrier (e.g. if the Offroad stabilizers are
z Danger of crushing in the area of the stabilizers and wheel carriers. Risk of injury and material
damage due to raising the wheel carrier incorrectly.
→ Before working on the ORS, always depressurise the system! To do this, close the PIWIS Tester and select
1. Move the gear support → Supporting suspension subframe under the

centre of the suspension subframe and lift it carefully using a suitable
base (e.g. hard rubber support).
2. For vehicles with Offroad Stabilizer system (ORS): Unclip the lines
from the supports at the body so that there is sufficient clearance at
the lines for lowering the suspension subframe.
Supporting suspension subframe
Note
Front rear-axle bearings: The cardan shaft must not touch the mounting
face when lowering the suspension subframe! -Arrow-
3. Loosen the threaded joint at the bearing and carefully lower the gear
support until there is sufficient clearance for using the tool.
Clearance for cardan shaft
ATTENTION
Danger of injury due to falling tools.
z Danger of crushing and deformation
→ Always use industrial footwear, goggles and protective gloves.
4. Remove washer. Attach separating device -3- between suspension

subframe bearing and washer. Insert internal puller -2- into the
suspension subframe bearing. Attach counter support -1- and pull off
the washer. Important: Please note that the washer is pressed with Removing washer
the bearing. The washer becomes loose suddenly!
Note
Hold the hydraulic cylinder VAS 6178 tightly while pressing it out.
Tools for pressing out rear-axle

bearings
6. Attach the tools as shown in the illustration and press out the
bearing.
Note
When inserting the bearing, make sure that the two bores are pointing in
an imaginary line in the direction of travel.
Pressing out rear-axle bearing

7. Insert suspension subframe bearing and pay attention to installation
position.
Installation position for rear-axle

suspension subframe bearing
8. Press in suspension subframe bearing. To avoid damaging the bearing, the maximum → Pressure: 10 kN
+/-5 kN must not be exceeded at the stop (10 KN = 350 bar). This conversion applies only to the hydraulic
Tools for pressing in rear-axle
bearings
cylinder VAS 6178. The conversion depends on the diameter of the cylinder in question.
9. Attach the tools as shown in the illustration and press in the bearing.
Note
11. For vehicles with Offroad Stabilizer system (ORS): Clip the lines into
the holder on the body.
Pressing in rear-axle bearing
Subsequent work
Subsequent work
1. Fit rear silencer. → 260119 Removing and installing exhaust system
2. For front rear-axle suspension subframe bearings: Remove stone guard.
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
42 09 19 Removing and installing rear tie rod (toe control arm) - as

of MY 2003
- Preliminary work
- Removing rear tie rod
- Installing rear tie rod
- Subsequent work
Preliminary work
Remove wheel → 440519 Removing and installing wheel - chapter on "Removing"
Removing rear tie rod

Tie rod (toe control arm)
1. Mark the position of the toe eccentric for re-installation.
2. Release tie rod at suspension subframe (eccentric screw) and at wheel carrier. Pull out tie rod.
To make removal easier, raise wheel carrier slightly with universal jack!
→ see figure Use rubber base to prevent wheel carrier from slipping!
Installing rear tie rod
Note
z The left-hand and right-hand tie rods are identical. Ensure correct installation position. The tapered end must
be secured on the wheel carrier in the direction of travel.
z When raising wheel carrier, use a suitable intermediate layer (hard

rubber). Do not damage the brake cover plate.
z Check vehicle setting values after repair and adjust if necessary.

→ 44 Complete suspension alignment
z Observe correct tightening torques. → 42 Tightening torques for rear

axle
1. Replace lock nuts. Observe correct tightening torques → 42

Tightening torques for rear axle.
Subsequent work
Perform a suspension alignment after installation → 44 Complete suspension alignment.
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
42 11 19 Removing and installing bottom axle strut - as of MY

2003
- Preliminary work
- Removing lower axle strut
- Installing lower axle strut
- Subsequent work
Preliminary work
Remove wheel . → 440519 Removing and installing wheel - chapter on "Removing"
Removing lower axle strut

1. Remove trailing arm at wheel carrier.
Mark eccentric screws before removal!
2. Remove eccentric screw and fastening screw from trailing arm to suspension subframe.
3. Remove trailing arm carefully in downward direction and underneath drive shaft.
Installing lower axle strut
ATTENTION
z Danger of injury and risk of damage to property.
Note
z Check vehicle setting values after repair and adjust if necessary. → 44 Complete suspension alignment

position! Vehicle position means: vehicle standing on the wheels, or

cover plate.
z Observe correct tightening torques. → 42 Tightening torques for rear

axle
1. Place trailing arm in suspension subframe mounting point and install

fastening screw. Install eccentric screw, turn to previously marked
position and tighten in vehicle position.
2. Position trailing arm in wheel carrier and secure against falling with
fastening screw and nut.
3. Tighten fastening nut from trailing arm to wheel carrier with specified tightening torque.
Subsequent work
Fit wheel → 440519 Removing and installing wheel - chapter on "Installing".
Check vehicle setting values and adjust if necessary → 44 Complete suspension alignment.
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
42 17 55 Replacing bearing for trailing arm - as of MY 2003

- Information
-
-
-
-
- Subsequent work
Tools

Assembly fixture special tool T10230

Information
General
The bearing for the trailing arm must be pressed in separately when replacing the wheel bearing housing. The
wheel bearing housing is not supplied with the bearing as a spare part.
Tools

-A- Tubular piston cylinder VAS 6178 See Workshop The tubular piston cylinder
Equipment is used together with the
Manual, Chapter pneumatic hydraulic pump
3.4 VAS 6179.
→ see figure Tool set Assembly fixture T10230 See Workshop Tool set for pressing
T10230 Equipment hydraulic mount/rubber-
Manual, Chapter metal mount in and out,
2.2.3 consisting of No. 1-15.
-1- Threaded rod - assembly fixture T10230 See Workshop Used in the tubular piston
Equipment cylinder VAS 6178 -A- .
Manual, Chapter
2.2.3
-2- Nut with collar - assembly fixture T10230 See Workshop Screwed onto the threaded
Equipment rod -1- .
Manual, Chapter
2.2.3
-3- Spacer sleeve 180 - assembly fixture See Workshop For pressing the bearing
T10230 Equipment out and in.
Manual, Chapter
2.2.3
-4- Pressure piece 40 - assembly fixture See Workshop For pressing out the
T10230 Equipment bearing.
Manual, Chapter
2.2.3
-5- Pipe 56 - assembly fixture T10230 See Workshop For pressing out the
Equipment bearing.
Manual, Chapter
2.2.3
-6- Pressure disc - assembly fixture T10230 See Workshop For pressing the bearing
Equipment out and in.
Manual, Chapter
2.2.3
-7- Adjusting washer - assembly fixture See Workshop Screwed into the tubular
T10230 Equipment piston cylinder VAS 6178
Manual, Chapter -A- with two countersunk
2.2.3 screws.
-8- Support 55 - assembly fixture T10230 See Workshop For pressing in the bearing.
Equipment
Manual, Chapter
2.2.3
-13- Pressure head - assembly fixture T10230 See Workshop Pressure head from
Equipment assembly fixture T10205
Manual, Chapter (!); screwed into the tubular
2.2.3 piston cylinder VAS 6178
-A- .
-14- Washer Placed on the threaded rod
-1- .
-15- Nut Commercially available
M14 nut. Screwed onto the
threaded rod -1- .
Preliminary work
1. Raise the vehicle → 40 Lifting the vehicle.
2. Remove the wheel. → 440519 Removing and installing wheel - chapter on "Removing".
Removing bearing for trailing arm
ATTENTION
components.
z Risk of injury if the threaded rod in the tubular piston cylinder breaks because of pressure or
traction.
→ The worker must always stand away from the direction of pressure or traction on the threaded rod when
using the tubular piston cylinder.
→ Position pressure pieces correctly and ensure that they are seated properly.
→ Danger of injury and material damage if the wheel carrier is raised incorrectly.
Note
z The bearing is replaced using the assembly fixture T10230.
z Pressure head no. 13 is used from the selection of attachments T10205.
1. Release brake caliper and hang at a suitable position in the wheel

well → 474119 Removing and installing rear brake caliper. Do not
open the brake system.
2. Loosen the lower trailing arm at the mount -arrows- .
3. Insert tyre mounting lever between the wheel bearing housing and the trailing arm -see figure- . Press the
trailing arm down until the bearing is freely accessible. Do not damage the brake cover plate.
4. Press the lower trailing arm down further until a suitable spacer -see figure- (e.g. wooden block) can be
inserted (makes removal easier).
5. The pressure pieces and the tubular piston cylinder VAS 6178 are used for removal. No. 13 is screwed into
the tubular piston cylinder. No. 2 is screwed on to the threaded rod and positioned in No. 13 for pressing out
the bearing.
z T10230/2
z T10230/3
z T10230/4
z T10230/5
z T10230/6
z T10230/7
z T10230/13
z T10230/14
z T10230/15
The pressure pieces -see figure- are used as follows:
Get a second worker to help when working on the wheel bearing housing.
6. Position the tubular piston cylinder -see figure- and pre-tension
slightly to prevent the pressure pieces from slipping out of place.
Check the position of the pressure pieces again.
7. The pressure piece must be positioned correctly on the contact

surfaces of the wheel bearing housing. The cut-out in the pressure
piece -arrow- should be used as a viewing window. Now press the
bearing out carefully. When doing so, stand to the side of the tubular
piston cylinder and make sure that the tubular piston cylinder cannot
fall down.
Removing bearing for trailing arm
ATTENTION
components.
z Risk of injury if the threaded rod in the tubular piston cylinder
breaks because of pressure or traction.
→ The worker must always stand away from the direction of pressure
or traction on the threaded rod when using the tubular piston
cylinder.
→ Position pressure pieces correctly and ensure that they are seated
properly.
→ Danger of injury and material damage if the wheel carrier is raised
incorrectly.
rubber) .
Note
Dimension -X- from lower edge of wing to middle of axle 506 mm ±10
mm corresponds to vehicle position.

cover plate.
z Screws and nuts are Dacromet-coated and must not be greased.
z Use new screws and lock nuts.
z Observe tightening torques → 42 Tightening torques for rear axle.
1. To fit the new bearing use the -pressure pieces- and tubular
cylinder VAS 6178. No. 13 is screwed into the tubular piston cylinder.
No. 2 is screwed onto the threaded rod and positioned in No. 13 for
pressing in the bearing.
z T10230/2
z T10230/3
z T10230/6
z T10230/7
z T10230/8
z T10230/13
z T10230/14
z T10230/15
The -pressure pieces- are used as follows:

Get a second worker to help when working on the wheel bearing housing.
2. Position the -tubular piston cylinder- and pre-tension slightly to

prevent the pressure pieces from slipping out of place. Check the
position of the pressure pieces again.
3. The pressure piece must be positioned correctly on the sealing

surfaces of the wheel bearing housing. Now press the bearing in
carefully. When doing so, stand to the side of the tubular piston
cylinder and make sure that the tubular piston cylinder cannot fall
down. Maximum assembling force must not exceed 30 KN at the
stop.
Press the bearing in until it is enclosed evenly by the rubber lip.
4. If the bearing for the axle strut is fitted cleanly, install the wheel
bearing housing in the bottom axle strut.
Subsequent work
Subsequent work
1. Fit brake caliper.→ 474119 Removing and installing rear brake caliper - chapter on "Installing".
2. Fit wheel → 440519 Removing and installing wheel - chapter on "Installing" .
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
42 21 19 Removing and installing rear drive shaft - as of MY 2003

- Preliminary work
- Removing rear drive shaft
- Installing rear drive shaft
- Subsequent work
Tools

protective tube (shop-made) commercially 00000
available tool
universal drive shaft/wheel hub commercially NR.87-1

puller as of model '86 available tool
assembly fixture special tool T10206

Preliminary work
1. Release axle nut (vehicle on ground) whilst operating the brake (2 fitters required).
2. Remove wheel → 440519 Removing and installing wheel - chapter on "removing".
3. Remove rear muffler → 260119 Removing and installing exhaust system - chapter on "Removing".
Note
z To prevent damage to the drive shaft, rear axle support side member or transmission flange, a protective
tube (shop-made) 00000 must be pushed over the drive shaft or the drive shaft must be secured.
z During removal of the drive shaft, the wheel bearing housing remains in the vehicle and is swivelled outwards
at the top side.
1. Fit protective tube (shop made) 00000 for drive shaft. Release drive
shafts on inside at transmission (both sides) and -arrow- tie up, e.g.
with a tie-wrap. This will prevent damage to the drive shaft,
suspension subframe and transmission flange.
2. Removal of rear final drive. → 390119 Removing and installing rear

final drive - chapter on "Removing"
3. Release connecting link at top on the side from which drive shaft is to
be removed.
4. Using universal drive shaft/wheel hub puller as of model '86 NR.87-1, press out peg from the drive shaft.
5. Remove previously fitted tie-wrap. Carefully pull out the drive shaft to be replaced.
Installing rear drive shaft
Installing rear drive shaft
Note
z Grease the thread of the axle nut with Optimoly HT.
z Grease the toothing of the drive shaft lightly with Optimoly HT.
z To prevent damage to the drive shaft, wheel bearing housing or transmission flange, slide a protective tube
(shop-made) 00000 over the drive shaft.
z Observe correct tightening torques. After tightening, loosen the connecting rod for the stabiliser 90 degrees,
and tighten again (settling behaviour of the ball joint!). → 420000 Tightening torques for rear axle
z The parking brake is self-adjusting. If the basic setting of the parking brake is correct, further adjustment
operations on the parking brake lever or on the turnbuckle are not necessary.
z Always check the bellows for damage and if necessary, replace them, if continuing to use the drive shaft.
1. Insert drive shaft and grease mounting-face ring of axle nut with a little
Optimoly TA aluminium paste. Screw on axle nut to prevent shaft from
slipping out. If the shaft cannot be pushed right in, use assembly
fixture T10206 to pull the drive shaft in. Protect the drive shaft. Tie up
drive shaft with a tie-wrap. This will prevent damage to the drive shaft,
suspension subframe and transmission flange.
Subsequent work
1. Push in rear final drive. Connect vent hose → 390119 Removing and installing rear final drive - chapter on
"Installing".
2. Fit rear muffler → 260119 Removing and installing exhaust system - chapter on "Installing" .
3. Mount wheel and tighten axle nut (vehicle on ground, also operate the brake - second fitter required).
9PAAD1, 9PAAD7
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
42 21 37 Disassembling and assembling rear drive shaft - as of

MY 2003
- Information
Tools

Circlip pliers commercially NR.68
available tool

available tool
Information
Component overview
Drive shaft components
No. Designation Qty. Removal Installation

A Outer joint
1 Hose clamp 69 x 10 1 Remove hose clamp Fit hose clamp with
using a hammer and boot on the joint pin.
chisel for example.
Do not damage boot.
2 Boot 1 Remove boot from
the shaft.
3 Hose clamp 35 x 10 1 Remove hose clamp Fit hose clamp on to
using a hammer and the boot.
chisel, for example.
Do not damage boot.
B Inner joint
4 Hose clamp 35 x 10 1 Remove hose clamp Fit hose clamp on to
using a hammer and the boot.
chisel, for example.
Do not damage boot.
5 Boot 1 Remove boot from
the shaft.
6 Clamp 69 x 10 1 Remove clamp using Fit clamp with boot on
a hammer and chisel the cap. The clamp
for example. Do not lug must be
damage boot. positioned between
two bores on the joint.
7 Cap 1 Seal the sealing faces
with special sealant
(refer to Spare Parts
Catalogue). Make
sure the bores are
aligned during
positioning.
8 Joint 1 Press joint off the Fit the joint as far as it
drive shaft. will go on to the drive
shaft using a hammer
and mandrel. Make
sure the bores are
aligned with the bores
on the cap.
9 Circlip 28 x 1.5 1 Remove circlip Ensure that the circlip
carefully with a is seated correctly.
pliers. 1)
10 Closure cap 1 Remove cap. Use two cheese-head
bolts to centre the
cap. Ensure correct
seating. Seal the
sealing faces with
special sealant (refer
to Spare Parts
Catalogue).
1)
Tools and materials
Tools

A Circlip pliers NR.68 For loosening and fastening circlips.
→ " siehe Handbuch Werkstatt

Ausrüstung Kapitel 2.4"
B Pliers for lug hose For securing clamps and hose clamps.
clamp NR.74
→ " siehe Handbuch Werkstatt
Ausrüstung Kapitel 2.4"
C Hydraulic press Commercially available hydraulic press. To
press off the inner joint.
ATTENTION
Watch out for falling parts during disassembly work.
→ Wear protective gear (e.g. safety shoes, gloves).

Only the joint on the transmission side can be replaced on the rear axle. Otherwise the entire drive shaft must be
replaced.
1. Remove cap from joint -arrow- .

2. Remove circlip using circlip pliers NR.68.
Removing cap
3. Remove clamp and hose clamp at the boot -arrow- .
4. Position inner joint on the ball hub (star-shaped inner ring). Do not
put it on the sheetmetal part! Press the joint off the profile shaft on a
hydraulic press.
Removing clamps
Removing boots

ATTENTION
Watch out for falling parts during disassembly work.
→ Wear protective gear (e.g. safety shoes, gloves).

1. Clamp the drive shaft (use aluminium protective jaws). Position an

aluminium mandrel on the ball hub (star-shaped inner ring) and fit the
joint -figure- as far as it will go by hitting it several times with a
hammer.
Note
z Before regreasing, remove excess grease with a lint-free cloth. Do
not use cleaning agents on the joints (grease thinners!).
Regreasing joints:
following table.
Removing joint

V6 100 100
V8 135 135
Vehicles with differential lock 135 135

Joint pin on wheel side: regrease Greasing inner drive shaft
as required, depending on the
amount of grease left in the joint.
Remove excess grease with a lint-
free cloth. Push the required
amount of grease through the joint
to the outside. Then grease the
inside of the joint.
2. Fit the large hose clamps for

the two boots. The hose
clamp lug - on the
transmission side - must be
positioned between two bores Greasing outer drive shaft
on the joint.
3. Fit the small hose clamps for the two boots. If the boots are fitted
correctly, the groove -A- will be visible.
Grooves in drive shaft

4. Before replacing the cap (transmission side), fill in the required
amount of grease. Seal the sealing faces with special sealant (refer
to Spare Parts Catalogue). When fitting the cap -figure- , use two
cheese-head bolts for fixing. Tap on alternate sides with a rubber
hammer in order to fit the cap in the correct position.
Fitting cap
as of MY 2003
WARNUNG
WARNING
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ATTENZIONE
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ADVERTENCIA
42 21 37 Disassembling and assembling rear drive shaft - as of

MY 2003
- Tools
Tools

Circlip pliers commercially 68
available tool
Pliers for lug-type hose clamp commercially 74

available tool
A Outer joint
1 Hose clamp 69 x 10 1 Remove hose clamp using a Fit hose clamp with boot on
hammer and chisel, for the joint pin.
example. Do not damage
boot.
2 Boot 1 Remove boot from the shaft.
3 Hose clamp 35 x 10 1 Remove hose clamp using a Fit hose clamp on to the boot.
hammer and chisel, for
boot.
B Inner joint
4 Hose clamp 35 x 10 1 Remove hose clamp using a Fit hose clamp on to the boot.
hammer and chisel, for
boot.
5 Boot 1 Remove boot from the shaft.
6 Clamp 69 x 10 1 Remove clamp using a Fit clamp with boot on the
hammer and chisel for cap. The clamp lug must be
example. Do not damage positioned between two bores
boot. on the joint.
7 Cap 1 Seal the sealing faces with
special sealant (refer to Spare
Parts Catalogue). Make sure
the bores are aligned during
positioning.
8 Joint 1 Press joint off the drive Using a hammer and mandrel,
shaft. drive the joint as far as it will
go onto the drive shaft. Make
sure that the holes line up
with those in the cap.
9 Circlip 28 x 1.5 1 Remove circlip carefully with Ensure that the circlip is
a pliers. 1) seated correctly.
10 Closure cap 1 Remove cap. Use two cheese-head bolts to
centre the cap. Ensure correct
seating. Seal the sealing
faces with special sealant
(refer to Spare Parts
Catalogue).
1) Danger of injury.
Tools

A Circlip pliers 68 → "See Workshop For loosening and fastening circlips.
Equipment Manual,
Chapter 2.4 "
B Pliers for lug-type hose clamp → "See Workshop For securing clamps and hose clamps.
74 Equipment Manual,
Chapter 2.4 "
C Hydraulic press Commercially available hydraulic
press. To press off the inner joint.
ATTENTION
Danger of injury. Look out for falling parts during disassembly work. Get another worker to help.
At the rear axle, only the joint on the transmission side can be replace. Otherwise the entire drive shaft must be
replaced.
1. Remove -cap from joint (direction arrow)- .
2. Remove circlip using circlip pliers 68.
3. Remove -clamp and hose clamp at the boot (arrows)- .

4. Position inner joint on the ball hub (star-shaped inner ring). Do not put it on the sheetmetal part! Press the
joint off the profile shaft on a hydraulic press.
ATTENTION
Danger of injury. Look out for falling parts during disassembly work. Get another worker to help.
1. Clamp the drive shaft (use aluminium protective jaws). Position an aluminium mandrel on the ball hub (star-
shaped inner ring) and use forceful hammer blows to drive the -joint- up to the stop.
Note
z Before regreasing, remove excess grease with a lint-free cloth. Do not use cleaning agents on the joints
(grease thinners!).
Regreasing joints:
following table.

V6 100 100
V8 135 135
Vehicles with 135 135
differential lock

Joint pin on wheel side: regrease as required, depending on the amount of

grease left in the joint. Remove excess grease with a lint-free cloth. Push
the required amount of grease through the joint to the outside. Then
grease the inside of the joint.
2. Fit the large hose clamps for the two boots. The hose clamp lug - on
the transmission side - must be positioned between two bores on the
joint.
3. Fit the small hose clamps for the two boots. If the boots are fitted correctly, the groove -A- will be visible.
4. Fill in the appropriate quantity of grease before fitting the cap (on the transmission side). Seal the sealing
surfaces with special sealant (see Spare Parts Catalogue). When fitting the cap, secure it in place with
-two pan-head screws- . Using a rubber hammer, alternate between striking one side of the cap and then
the other in order to fit it in the correct position.
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
42 52 19 Removing and installing rear wheel bearing housing

(wheel carrier) - as of MY 2003
- Preliminary work
- Removing rear wheel bearing housing (wheel carrier)
- Installing rear wheel bearing housing (wheel carrier)
- Subsequent work
Tools

protective tube (shop made) commercially 00000
available tool


Preliminary work
Preliminary work
ATTENTION
1. Loosen axle nuts (wheel-side drive shaft fastening). (Do not remove them!) This prevents the drive shaft
from slipping out when removing the wheel bearing housing. Actuate the brake while doing this.
2. Raise the vehicle→ Raising the vehicle [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Raising the
vehicle [9PAAJ1] and remove wheel → 440519 Removing and installing wheel - chapter on "Removing".
Removing rear wheel bearing housing (wheel carrier)
Removing rear wheel bearing housing (wheel carrier)
Wheel bearing housing with wheel hub and brake disc

Wheel bearing housing with wheel hub and brake disc
Note
z Before raising the vehicle, undo the drive shaft fastening at the wheel
side. Operate the brake whilst doing so (2 workers required).
z In order to prevent damage to the drive shaft, suspension subframe

or transmission flange, a protective tube (shop made) 00000 should
be pulled over the drive shaft or the drive shaft should be secured.
z The brake discs do not need to be removed to disengage the brake

cable → 467919 Removing and installing (rear) brake cable for foot-
operated parking brake.
1. Using universal drive shaft/wheel hub puller as of model '86 NR.87-1, push (press in) peg of drive shaft
approx. 20 mm - 25 mm into the wheel hub. When doing this, observe drive shaft clearance on the halfshaft
flange.
2. Loosen the drive shaft on the halfshaft flange.
3. Open the plug connections on the wheel bearing housing and pull off the plugs.
4. Remove the brake calliper from the wheel bearing housing and suspend it at a suitable position in the wheel
arch (do not open brake hydraulics!).
5. Attach the foot-operated parking brake to the actuating mechanism using an auxiliary pin → see figure . To
do this, press the adjustment device -arrow- and relieve with a max. 3.5 mm drill (or similar) → 466019
Removing and installing actuator for foot-operated parking brake.
6. Unclip the brake cable from the Quickfit in the wheel bearing housing → 467919 Removing and installing
the (rear) brake cable for foot-operated parking brake. Remove screw plug -arrow- . The screw plug hides
the view of the Quickfit. The Quickfit is positioned at approx. 3 o'clock to the right and approx. 9 o'clock to the
left.
Note
z The spring strut screws are
under tension. Carefully lever
out the lower spring strut
connection. Use a suitable lift
with a rubber base.
7. Remove the spring strut at the

wheel bearing housing.
8. Remove the two top control

arms.
9. Remove the tie rod (toe control arm) at the wheel bearing housing.
10. Loosen the lower control arm -2- at the mount -1- and take out the
wheel bearing housing with the drive shaft (a second worker is
required for this).
11. Remove the axle nuts and take out the drive shaft.
Installing rear wheel bearing housing (wheel carrier)
Installing rear wheel bearing housing (wheel carrier)
ATTENTION
Note

cover plate.
Optimoly TA.
z Grease axle nut with a little Optimoly TA aluminium paste only at

mounting-face ring.
z Drive shafts must not be left hanging from the joint stop. Support
wheel carriers.
z Use new screws and fastening nuts.
z Use a new circlip on the Quickfit.
use cleaning agent.
1. Insert the drive shaft into the wheel hub. If the shaft cannot be pushed right in, use → see figure assembly
fixture T10206 to pull the drive shaft in. Screw on the axle nuts in order to prevent the shaft from slipping
out.
2. Insert the wheel bearing housing (second worker required).
3. Fit the control arms, the spring strut and the brake calliper.
4. Fit the drive shaft on the halfshaft flange.
5. Mount the Quickfit. Make sure that the circlip is sealed and seated well and that the end of the cable
engages audibly.
6. Plug in the plug connections. Ensure correct routing.
Subsequent work
Subsequent work
1. Fit the axle nuts and the wheel → 440519 Removing and installing the wheel - chapter on "Installing".
2. Remove the auxiliary pin from the pedal module of the foot-operated parking brake.
3. Perform suspension alignment → Suspension alignment, complete.
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
42 58 19 Removing and installing rear-wheel bearing - as of MY

2003
- Preliminary work
- Removing
- Installing
- Subsequent work
Tools

separating device 12 - 115 mm commercially NR.111

ø available tool

tubular piston cylinder commercially VAS
available tool 6178
Preliminary work
Preliminary work
ATTENTION
The wheel bearing is removed with the wheel bearing housing installed.
1. Remove the corresponding hub cap with puller hook 92291 and release the axle nut (lock nut) before lifting
the vehicle. Operate the brake whilst doing so (second fitter required).
2. Raise the vehicle→ 40 Raising the vehicle and remove the relevant rear wheel → 440519 Removing and
installing wheel - chapter on "Removing".
3. Remove axle nut (lock nut) and the drive shaft → 422119 Removing and installing drive shaft - chapter on
"Removing" [9PAAE1 9PAAE7 9PAAF1]→ 422119 Removing and installing drive shaft - chapter on
"Removing" [9PAAD1 9PAAD7]→ 422119 Removing and installing drive shaft - chapter on "Removing"
[9PAAJ1]. To remove and install the drive shaft, the rear final drive must be removed → 390119 Removing
and installing rear final drive - chapter on ""Removing" [9PAAD1 9PAAD7]→ 390119 Removing and
installing rear final drive - chapter on ""Removing" [9PAAE1 9PAAE7 9PAAF1 9PAAJ1].
Tools and materials
Tools
-A- - Tubular piston cylinder VAS 6178 (The tubular piston cylinder is used together with the pneumatic
hydraulic pump.)
-1- - T10205/1 grip piece from attachments T10205 (To press the wheel hub out of the wheel bearing.)
-2- - T10205/2 bell from attachments T10205 (To press out the wheel hub. To pull off the wheel bearing inner
race from the wheel hub, use together with separator 12 - 115 mm ø No. 111.)
-3- - T10205/3 pressure piece from attachments T10205 (To press out the wheel hub.)
-4- - T10205/4 mounting from attachments T10205 (To press out the wheel bearing.)
-5- - T10205/5 pipe from attachments T10205 (To press out the wheel bearing.)
-6- - T10205/6 pressure disc from attachments T10205 (To press out the wheel bearing. And to press in the
wheel hub.)
-8-1- - T10205/8-1 threaded rod from attachments T10205 (Used in the tubular piston cylinder -A- .)
-8-2- - T10205/8-2 threaded nut from attachments T10205 (Used on the threaded rod -8-1- .)
-10- - T10205/10 pressure piece from attachments T10205 (To press in the wheel hub.)
-13- - T10205/13 push button from attachments T10205 (Used in the tubular piston cylinder -A- .)
Removing
Removing rear wheel bearing
Component overview of wheel bearing
Component overview of wheel bearing
-1- - Wheel bearing housing (Carry out a close visual inspection of the seat of the wheel bearing. There must be
no scores, grooves or similar deformations.)
-2- - Wheel bearing (The wheel bearing can no longer be used once it is removed. Use a new wheel bearing. Do
not press on the inner race. Insert the wheel bearing with the magnetic multiple-pole ring towards the drive
shaft. Check the magnetic side (e.g., with a paper clip). Do not use magnets or screw drivers for the check!
-3- - Circlip (Use new circlip.)
-4- - Wheel hub (Pull off the inner race separately from the wheel bearing. Carry out a close visual inspection of
the seat of the wheel hub. There must be no scores, grooves or similar deformations on the hub.)
-5- - Axle nut (Lock nut - always replace. Grease contact surface with a little Optimoly TA. Tightening torque 370
ftlb.
1. Release brake caliper and hang at a suitable place in the wheel housing.
2. Remove brake disc → 465319 Removing and installing rear brake

disc - chapter on "Removing"
3. Disengage the cable of the foot-operated parking brake and remove
the brake shoes.
4. Remove wheel speed sensor -see illustration- → 451119 Removing and installing front speed sensor -
5. Remove wheel hub (tools).
6. Secure the grip pieces (two half shells) (from attachments T10205 )
with several wheel bolts behind the wheel hub.
7. Insert the T10205/2 bell (from attachments T10205 ) in the correct

position in the groove provided.
8. Insert the tubular piston cylinder VAS 6178. Position the T10205/3 pressure piece (from attachments
T10205 ) and the T10205/8-2 threaded nut (from attachments T10205 ). Press out the wheel hub.
Ensure that the separating device does not press on the seat of the
bearing inner race on the wheel hub.
9. If the wheel hub is used again, remove the → see figure inner race of
the wheel bearing from the wheel hub. To do this, position the
separating device 12 - 115 mm ø NR.111 behind the inner race.
10. Press inner race off the wheel hub. To do this, position the T10205/2
bell (from attachments T10205 ) without the grip piece. Insert the
tubular piston cylinder VAS 6178. Position the T10205/3 pressure
piece (from attachments T10205 ) and the T10205/8-2 threaded nut
(from attachments T10205 ).
11. Remove the circlip -arrow- .
12. Remove the wheel bearing (tools).
13. Press out the wheel bearing. To do this, position the T10205/4 mounting (from attachments T10205 ) and
the T10205/5 pipe (from attachments T10205 ) in the correct position on wheel bearing housing. Insert the
tubular piston cylinder VAS 6178. Position the T10205/6 pressure disc (from attachments T10205 ) and
the T10205/8-2 threaded nut (from attachments T10205 ).
Installing
Installing rear wheel bearing
Note
z The wheel bearing must not come into contact with magnetic objects (e.g., magnetic screwdriver, magnet).


cover plate.
z Screws and nuts are Dacromet-coated and must not be greased.
z Grease axle nut with a little Optimoly TA aluminium paste only at

mounting-face ring.
Optimoly TA.
z Drive shafts must not be left hanging from the joint stop! Tie up.

z The wheel bearing seat must be free of grease.
z Observe correct tightening torques. → 42 Tightening torques for rear axle
1. Fit the wheel bearing (tools).
Check that the bearing seat -arrow- is clean and the surface is in good
order. There must be no scores, grooves or deformations.
Insert the wheel bearing with the magnetic multiple-pole ring to the drive
shaft. Check the magnetic side (e.g., with a paper clip). Do not use
magnets or screw drivers to check!
2. Position the → see figure wheel bearing in the wheel bearing housing
in the correct position. Position the T10205/7 pressure piece (from
attachments T10205 ) in the correct position on the wheel bearing.
Insert the tubular piston cylinder VAS 6178. Position the T10205/9
pressure piece (from attachments T10205 ) and the T10205/8-2
threaded nut (from attachments T10205 ) in the correct position.
Mount the wheel bearing. Shortly before the stop, the applied force
will be between 26 ftlb. and 44ftlb. The maximum assembling force
must not exceed 67 ftlb. at the stop.
3. Position the → see figure circlip with the opening facing downward.
When the Seger ring is fitted correctly, the dimension -X- is at least
15 mm. If this dimension is not reached, the Seger ring must be fitted
again. If necessary, carefully press the wheel bearing again.
4. Fit the wheel hub (tools).

Carry out a close visual inspection of the seat of the wheel hub. There
must not be scores, grooves or similar deformations on the hub.
5. Position the → see figure wheel hub in the correct position. Position
the T10205/10 pressure piece (from attachments T10205 ) in the
correct position on the wheel hub. Insert the tubular piston cylinder
VAS 6178. Position the T10205/6 pressure disc (from attachments
T10205 ) and the T10205/8-2 threaded nut (from attachments
T10205 ) in the correct position. Pull in the wheel hub. Shortly before
the stop, the applied force will be between 6.5 ftlb. and 26 ftlb. The
maximum assembling force must not exceed 30 ftlb. at the stop.
6. → see figure Fit wheel speed sensor → 451119 Removing and

installing front speed sensor - chapter on "Installing".
Subsequent work
Subsequent work
1. Fit the drive shaft, brake shoes, brake disc, and brake caliper in reverse order. Engage the cable of the foot-
operated parking brake and adjust the brake shoes → 468316 Adjusting foot-operated parking brake -
chapter on "Adjusting".
2. Fit wheel → 440519 Removing and installing wheels - chapter on "installing" .

as of MY 2003
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42 71 19 Removing and installing rear spring strut (steel springs) -

as of MY 2003
- Preliminary work
- Removing rear spring strut (steel springs)
- Installing rear spring strut (steel springs)
- Subsequent work
Preliminary work
Preliminary work
ATTENTION
Remove wheel → 440519 Removing and installing wheel - section on "Removing".
Removing rear spring strut (steel springs)
Removing rear spring strut (steel springs)

Rear-axle spring strut (steel springs, complete)
Note
z Spring strut screws are under tension. Use a suitable lift with rubber
base.
1. Remove spring strut at wheel carrier. Let connecting rod hang to the
side.
2. Release spring strut at top (four screws at the damper housing)

-arrows- . To do this, use a 3/8 inch changeover ratchet with
extension and universal joint.
3. Carefully remove the spring strut assembly with damper housing
from the vehicle.
Installing rear spring strut (steel springs)
Installing rear spring strut (steel springs)
Note
z Tighten all four screws for spring strut attachment at top (damper housing top) to the specified tightening
torque! To do this, use an extension and a universal joint for the inner fastening screws!

-X- , from lower edge of wing to middle of axle 506 mm ± 10 mm
corresponds to vehicle position.
z Carry out a visual inspection of all parts!
z Replace self-locking nuts!
angle tightening procedure)!
z Observe correct tightening torques and torque angle → 42 Tightening torques for rear axle!
1. Insert spring strut into vehicle. When doing this, tighten the rear inner fastening screws (from the damper
housing at top) with an extension and universal joint. Tighten all four screws to 60 Nm (44 ftlb.)!
2. Install lower spring strut attachment with connecting rod. While doing
so, use the transmission jack to install the fastening screw. Tighten
fastening screw to the correct tightening torque and torque angle! Do
not damage the brake cover plate.
Subsequent work
Subsequent work
Fit wheel → 440519 Removing and installing wheel - section on "Installing".
as of MY 2003
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42 71 37 Disassembling and assembling rear spring strut (steel

springs) - as of MY 2003
- Information
- Preparations for assembly
- Assembly
Tools

socket wrench special tool 3353 For loosening lock nuts on
insert the shock absorber.
arm bracket special tool 9630 For countering the shock

absorber piston rods.
spring clamp for commercially NR.121 Standard clamping range

spring struts available tool of spring holder up to 150
mm spring diameter (size
1A).
double-arm commercially NR.93 Commercially available
torque wrench 15 available tool torque wrench for
- 65 Nm (48 ftlb.) tightening torques of 60
Nm (44 ftlb.) ± 5 Nm (3.5
ftlb.).
Information
Component overview
The steel springs do not apply for the Cayenne Turbo.
Standard Cayenne Turbo equipment: Air springs with level regulation and vertical adjustment.
Steel spring strut, complete
Steel spring strut, exploded drawing

-1- Hexagon nut 1 Before loosening the lock Use new lock nut. Tighten
M12 x 1.5 nut, tension coil spring to 60 Nm (44 ftlb.) ± 5 Nm
using spring clamp for (3.5 ftlb.). First position
spring struts. When spring-strut mount 2.
loosening the nut, counter
it at the piston rod using
an arm bracket 9630.
-2- Supporting mount 1 Remove complete
assembly (mount no. 2.,
with mount plate no. 3,
top support no. 4 and top
concave washer no. 5).
-3- Concave support 1
-4- Top support 1 Place in correct position
with spring retainer no. 5.
-5- Concave washer, top 1
-6- Protective sleeve 1
-7- Rubber stop 1
-8- Cap 1 Fit to shock absorber.
-9- Coil spring 1 Observe allocation as per
-10- Concave washer, bottom 1
-11- Bottom support 1 Observe colour allocation.
Only coil springs and the
bottom shim should be
installed together with
colour coding (depending
on tolerance class of
springs). Fit in correct
position with spring plate
no. 10.
-12- Vibration damper 1 Observe allocation as per
The vibration dampers for
the right and left sides are
identical parts.
Mounting instructions
ATTENTION

Note
z Observe the correct allocation (engine variant) when installing new coil springs and/or shock absorbers.
z We recommend that you replace the coil springs only in pairs.
z Observe allocation of the bottom spring plate according to the coil spring tolerance group.
1. Clamp spring strut on eye of vibration damper in the vice (use jaw liners).
2. Tension the coil springs -see Figure- using spring clamp for spring struts NR.121 until the piston rod is
relieved.
Spring clamp
3. Loosen the connection (piston rod to spring-strut supporting mount) at the piston rod using a commercially
available changeover ratchet and a socket wrench insert 3353. Counter with an arm bracket 9630.
4. Remove all components from the piston rod.
Allocation of coil spring and bottom support
The bottom support (spring plate) is allocated according to the coil spring tolerance group.
The colour coding -arrow- of the coil spring is located at the middle of the
coil spring and is indicated by coloured dots → Distinguishing feature and
allocation of coil springs and shock absorbers.
The bottom supports come in various thicknesses, differentiated by colour.

The supports used are coloured differently as required.

Coil spring colour coding Colour of bottom support to be used
No colour coding Black
Blue Blue
Beige Beige
Distinguishing feature and allocation of coil springs and shock absorbers

The coil springs are allocated using coloured dots -arrow- . Grey is used
for the Cayenne and white for the Cayenne S → Allocation of coil spring
and bottom support. Refer to the Parts Catalogue for the allocation.

Model Coil spring colour coding
Cayenne Grey (1 - 3 dots)
Cayenne S White (1 - 3 dots)
The shock absorbers are allocated using the spare part numbers and the model specification. At present, three
different shock absorbers are used on the rear axle of the Cayenne and Cayenne S. Refer to the Parts Catalogue
for the allocation.
1. Place the cap -1- , rubber stop -2- and protective sleeve -3- together
as follows before pushing them on to the piston rod:
– Push the rubber stop -2- up fully into the protective sleeve -3- .
Assembling cap 1, rubber stop 2 and

protective sleeve 3
Fitting cap into protective sleeve
– Insert the cap into the protective sleeve -see figure- and pull the lip carefully over the cap.
2. Place the bottom concave washer -see figure- together with the
bottom support -see figure- at the correct position (not twisted).
precisely together.
Fitting bottom concave washer into

bottom support
3. Place the top concave washer -1- together with the top support -2- at
the correct position (not twisted).
precisely together.
Fitting top concave washer with top

support
Assembly
ATTENTION
→ Never use an impact bolter to loosen or tighten the lock nut.

1. Position the bottom support and bottom spring retainer assembly at the correct position on the shock
absorber.
2. Position the pre-tensioned coil spring precisely at the stop in the

bottom concave washer -arrow- .
3. Slide the protective sleeve/stop buffer/cap assembly loosely onto the
piston rod.
Coil spring stop in bottom concave

washer
4. Position the top mount plate assembly -1- with the top support -2- .
Fitting top concave washer with top

support
– Position the top spring plate -arrow- precisely at the coil spring stop.
Top spring plate stop at coil spring

5. Once the concave support is positioned and aligned, the centre lines -A- and -B- must be parallel.
6. Once the mount is positioned, fit the new lock nut. Screw the lock nut onto the piston rod until approx. 1 to 2
threads are visible above the lock nut. Then tighten with double-arm torque wrench 15 - 65 Nm (48 ftlb.)
NR.93.
7. Complete the following steps to ensure that the protective sleeve -see figure- is seated correctly:
– Push the protective sleeve -arrow- up fully and clip it into the concave support.
Fitting protective sleeve in top spring Concave support assembly
strut
– Push the protective sleeve -arrow- down fully and clip it to the shock
absorber with the cap (audible click).
Fitting protective sleeve in bottom

spring strut
as of MY 2003
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42 90 19 Removing and installing stabiliser - as of MY 2003

- Preliminary work
- Removing stabiliser
- Installing stabiliser
- Subsequent work
Preliminary work
ATTENTION
2. Remove exhaust system → 260119 Removing and installing exhaust system - section on "Removing".
Removing stabiliser
Component overview - anti-roll bar → Component overview - anti-roll bar
Component overview - anti-roll bar
1- Anti-roll bar
2- Anti-roll-bar mount
3- Clamp
4- Fastening screws
5- Connecting rod
6- Fastening nut
7- Fastening screw
1. Release connecting rod at anti-roll bar on left and right. To do this,

use a suitable lift to raise the wheel carrier so far that the pin of the
connecting rod can be pulled easily out of the anti-roll bar. Use a
suitable lift with rubber base -see figure- to prevent slipping.
2. Undo the four fastening screws and remove the clamps.
3. Mark the installation position -arrow- of the anti-roll-bar mount halves with respect to the anti-roll bar with a
paint marker.
4. Carefully pull out the anti-roll bar.
Installing stabiliser
ATTENTION
Increased risk of accidents if the
wheel carrier is raised
improperly!
z Danger of injury and risk of
damage to property.
→ Do not raise the wheel

suspension higher than the
normal vehicle position
(vehicle resting on wheels).
→ When raising the suspension,
use a suitable intermediate
layer (hard rubber) .
→ Do not damage the brake
cover plate.
Note
-X- , from lower edge of wing to middle of axle 506 mm ±10 mm
corresponds to vehicle position.
z Use correct tightening torques and torque angle. → 42 Tightening torques for rear axle
1. Fit the → see figure anti-roll-bar halves at the previously applied marking on the anti-roll bar. The larger outer
diameter of the halves of the anti-roll-bar mount is on the wheel side.
2. Engage anti-roll-bar mount halves at the take-up points provided -arrow- .
3. Position anti-roll bar and fit clamps with the four fastening screws. Fit connecting rods to anti-roll bar.
4. Tighten the four anti-roll bar fastening screws.
Subsequent work
1. Fit exhaust system → 260119 Removing and installing exhaust system - section on "Installing" .
2. Lower the vehicle → 40 Lifting the vehicle.

as of MY 2003
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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42 90 19 Removing and installing off-road stabiliser - as of MY

2003
- Preliminary work
- Removing off-road stabiliser
- Installing off-road stabiliser
- Subsequent work
Preliminary work
1. Connect the Porsche System Tester and in the menu select >> Offroad Stabi (ORS) >> Drive links >> Clock
valve VA or valve HA <<.
2. Raise vehicle at the jacking points provided → 40 Lifting the vehicle.
3. Remove the rear muffler → 260119 Removing and installing exhaust system - chapter on "removing".
Removing off-road stabiliser

A - Front stabilizer
B - Rear stabilizer
C - Hydraulic unit
D - Control unit
E - Control unit
F - Dipstick
WARNING
Under certain conditions, motions can occur on the wheel carrier (e.g., if the Offroad stabilizers are
z Danger of crushing in the area of the stabilizers and wheel
carriers. Injury and material damage due to raising the wheel
carrier incorrectly.
→ Before working on the vehicle, ensure that the ORS is engaged. The
indicator light on the centre console button must be OFF . If the
indicator light is on, follow the following procedure: Switch on the
ignition and engage the road driving programme >> High Range <<.
The stabilizers must audibly engage.
→ Before working on the ORS, depressurise the system!. To do this,
connect the Porsche System Tester and in the menu select >>
Offroad Stabi (ORS) >> Drive links >> Clock valve VA or valve HA
use a suitable intermediate layer (hard rubber) .
1. Release connecting link at stabilizer on left and right. To do this, use a suitable lift to raise the wheel carrier
sufficiently for the pin of the connecting link to be pulled easily out of the stabilizer. Use a suitable lift with
→ see figure rubber base in order to prevent slipping.
2. Loosen the lines -arrows- and counter with an open-ended wrench.

Seal the lines with suitable plugs. Release the connector.
3. Undo the four fastening screws and remove the clamps.
4. Mark the installation position -arrow- of the stabilizer bearing halves

with respect to the stabilizer with a paint marker.
5. Carefully pull out the stabilizer.
Installing off-road stabiliser
ATTENTION
z Injury and material damage possible.
Note
z Observe tightening torques → 42 Tightening torques for rear axle.
1. Mount → see figure stabilizer bearing halves in the correct position

on the stabilizer. In the correct position means: The larger outer
diameter is on the wheel side.
2. Engage stabilizer bearing halves at the take-up points provided

-arrow- .
3. Insert stabilizer and fit clamps with the four fastening screws. Mount
connecting links at stabilizer.
4. Fit the four stabilizer fastening screws in vehicle position.
5. Fit the lines -arrows- and the connector. Fit the lines -arrows- and counter with an open-ended wrench.
Connect the connector.
Subsequent work
1. Fit the rear muffler → 260119 Removing and installing exhaust system - chapter on "installing".
2. Bleed the Offroad Stabilizer System → 402607 Bleeding the Offroad Stabilisator System (ORS) - chapter on
"bleeding".
9PAAD1, 9PAAD7
as of MY 2003
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42 TW Tightening torques for rear axle - as of MY 2003

- Technical values
Technical values
Suspension subframe

value 1 2
Threaded connection securing Replace screws and Tightening 89 ftlb. +180
suspension subframe to front fastening nuts after torque degrees
body, M14 x 1.5 x 135 removal.
Axle strut

value 1 2
Threaded connection securing front Replace screws and Tightening 67 ftlb. +90
upper trailing arm to suspension fastening nuts after torque degrees
subframe, M12 x 1.5 x 70 removal.
Threaded connection securing front Replace screws and Tightening 111 +90
upper trailing arm to wheel carrier, fastening nuts after torque ftlb. degrees
Threaded connection securing ABS Tightening 6 ftlb.
cable holder M6 torque
Threaded connection securing top Tightening 6 ftlb.
front Z-level regulator M6 torque
Threaded connection securing top Tightening 6 ftlb.
front Z-HBA on vehicle with steel torque
springs M6
Threaded connection securing holder Tightening 3.25
to suspension subframe (Z-HBA on torque ftlb.
vehicle with steel springs), M5 x 10
Threaded connection securing holder Tightening 3.25
to suspension subframe (Z-level torque ftlb.
regulator), M5 x 10
Threaded connection securing rear Replace screws and Tightening 67 ftlb. +90
upper trailing arm to suspension fastening nuts after torque degrees
Threaded connection securing rear Replace screws and Tightening 111 +90
upper trailing arm to wheel carrier, fastening nuts after torque ftlb. degrees
Threaded connection securing lower Replace screws and Tightening 111 +90
trailing arm to front suspension fastening nuts after torque ftlb. degrees
Threaded connection securing lower Replace screws and Tightening 133
trailing arm to rear suspension fastening nuts after torque ftlb.
subframe, M14 x 1.5 removal.
Threaded connection securing lower Replace screws and Tightening 111 +90
trailing arm to wheel carrier, M14 x 1.5 fastening nuts after torque ftlb. degrees
x 100 removal.
Threaded connection securing lower Replace screws and Tightening 67 ftlb. +90
trailing arm to rear wheel carrier fastening nuts after torque degrees
(spring strut + connecting rod), M12 x removal.
1.5 x 120
Tie rod

value 1 2
Threaded connection securing tie Replace screws and Tightening 133 ftlb.
rod to suspension subframe, M14 fastening nuts after torque
x 1.5 x 82 removal.
Threaded connection securing tie Replace screws and Tightening 111 ftlb. +90
rod to wheel carrier, M16 x 1.5 x fastening nuts after torque degrees
125 removal.

Tie rod to:
Suspension subframe M14 x 1.5 x 82 2) 180 (133)
Wheel carrier M16 x 1.5 x 125 1) 150 (111) + 90°
1) Always replace screws and fastening nuts, which have to be tightened with torque angle, after being tightened.
2) Replace screws and fastening nuts whenever removed.
Spring strut

value 1 2
Threaded connection securing spring Tightening 22 ftlb.
strut to damper housing, M8 torque
suspension/stabiliser to wheel fastening nuts after torque degrees
carrier/shock absorber strut, M12 x 1.5 removal.
x 120
Damper housing

value 1 2
spring damper to damper housing torque
M8
Threaded connection securing Z- Tightening 44 ftlb.
damper housing (clip) to G-damper torque
housing, M10 x 25
Threaded connection securing G- Replace screws and Tightening 67 ftlb. +90
damper housing to body, M12 x fastening nuts after torque degrees
1.5 x 80 removal.
Anti-roll bar/suspension/stabiliser

value 1 2
Threaded connection securing anti-roll Tightening 37 ftlb.
bar to rear-axle suspension subframe, torque
M10 x 25
Threaded connection securing anti-roll Replace screws and Tightening 74 ftlb.
bar to suspension/stabilizer, M12 x 1.5 fastening nuts after torque
removal.
carrier/shock absorber strut, M12 x 1.5 x removal.
120
Off-road stabiliser (ORS)

value 1 2
Threaded connection securing stabiliser Tightening 37 ftlb.
to rear-axle suspension subframe, M10 torque
x 25
Threaded connection for Replace screws and Tightening 74 ftlb.
suspension/stabiliser, M12 x 1.5 fastening nuts after torque
removal.
carrier/shock absorber strut, M12 x 1.5 x removal.
120
Threaded connection for union nut Tightening 10.5 +0.5 ftlb. -0.5 ftlb.
torque ftlb.
Threaded connection for disconnection Tightening 10.5 +0.5 ftlb. -0.5 ftlb.
points torque ftlb.
Threaded connection securing line Tightening 30 ftlb. +1.5 ftlb. -1.5 ftlb.
connections to left actuator (in direction torque
of travel)
Threaded connection securing line Tightening 15 ftlb. +1.5 ftlb. -1.5 ftlb.
connections to right actuator (in torque
direction of travel)
Threaded connection securing sensor to Replace screws and Tightening 2 ftlb.
actuator fastening nuts after torque
removal.
Bleeder valve screw connection Tightening 5 ftlb.
torque
Drive shaft

value 1 2
drive shaft to transmission flange, fastening nuts after torque degrees
M10 x 52 removal.
drive shaft to wheel hub, M24 x fastening nuts after torque
1.5 removal.
Wheel carrier

value 1 2
ABS sensor to wheel carrier, M6 torque
x 16
calliper carrier to wheel carrier, torque
M8 x 16
calliper carrier to wheel carrier, torque
M6 x 12
Threaded connection securing Tightening 10.5
brake disc to wheel hub, M12 x torque ftlb.
1.5
Threaded connection for screw Tightening 10.5
plug, M12 x 1.5 x 5.5 torque ftlb.
brake calliper to wheel carrier, fastening nuts after torque
brake calliper to wheel carrier, torque
M6 x 12
brake calliper to wheel carrier, torque
M6 x 16
Differential

value 1 2
differential to suspension fastening nuts after torque degrees
Wheel

value 1 2
wheel hub, M14 x 1.5 x 51 bolts. torque
spare wheel mount, M14 x 1.5 x 51 bolts. torque
as of MY 2003
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43 30 Disassembling and assembling front spring strut - as of MY

2003
- Information
- Information
- Disassembling and assembling
Tools

Socket wrench insert VW-tool 3353
Arm bracket special tool P 9630

Information
Notes on repairing air-spring struts
Note
As of a mileage of 200,000 Km it is recommended that the air springs be replaced per axle if there is damage to
one air spring.
If the shock absorbers leak, the complete air spring strut is to be replaced. The oil of the shock absorber can
damage the roller.
When depressurised, the air spring must not be twisted. There is the danger that the roller in the inside of the air
spring will be damaged by bending or folding and thus significantly reduce the running time.
Air-spring strut
1. Before loosening the air lines in the installed state, check if the rolling
boot is still filled with the residual pressure of approx. 3 bar. To do
this, press on the rolling boot of the air spring with your thumb. The
rolling boot must give perceptible resistance. If no significant
resistance can be felt, the air spring is depressurised and must be
replaced along with the residual pressure retaining valve.
The greatest possible care and cleanliness, as well as perfect tools are
important requirements for carrying out perfect repairs on air-spring struts.
The general and basic rules of safety apply. These are specifically listed
here again for repairing air-spring struts.
– Thoroughly clean the connection points and their surroundings

before loosening them. Checking the air bellows
– Do not use fibre-shedding cloths.
– Do not take spare parts out of the packaging until right before installation.
– Only use lubricants that have part numbers.
– Carefully cover open components or close them if the repair work will not be carried out immediately.
– Do not use an impact bolter.
– Observe correct tightening torques. → 43 Tightening torques
Residual pressure retaining valve
ATTENTION
Lowering of the vehicle when loosening the air line. The residual pressure retaining valve can become
loose when loosening the air line.
z The vehicle lowers on the side on which the line/the residual pressure retaining valve is loosened.
Risk of squashing.
→ When loosening the residual pressure retaining valve, lift the vehicle on a platform lift.
→ Only leave the vehicle on the platform lift until a new residual pressure retaining valve is installed and the
air-spring strut is filled.
The residual pressure retaining valve may only be replaced if:
1 - Residual pressure retaining valve

2 - Socket insert
Removing/fitting residual pressure

retaining valve
– it was damaged during removal and installation,
– it was damaged while disassembling and assembling the air-spring strut,
– the sealing ring is faulty,
– it does not allow any more air to come out (valve jammed).
If the residual pressure retaining valve is jammed, the vehicle must be lifted for replacement on the platform lift
and the wheels must be allowed to turn freely. It must not be compressed with an empty rolling boot.
Gaskets, sealing rings and bellows
Always replace sealing rings and bellows.
After removing gaskets, examine the contact surfaces on housings for burrs and damage.
Always loosen and tighten screws or nuts in diagonally opposite sequence for mounting covers and housing.
Tools and materials
Tools for repairing air-spring struts
Torque wrench 2-10 Nm (1.5-7.5 ftlb.)
Torque wrench 60-100 Nm (44-74 ftlb.)
Socket wrench insert 3353
Arm bracket P 9630
Information
Overview of front air-spring strut

Note
The components of the air spring -7- (figure shows component arrangement of front air-spring strut), Items
-2, 3, 4, 5- (figure shows front air-spring strut), cannot be disassembled.
z Always replace the complete air spring -7- (figure shows component arrangement of front air-spring strut)!
Front air-spring strut
1 - Sealing ring
2 - Lid
3 - Outer guide
4 - Rolling boot
5 - Rolling piston
6 - Bellows
7 - Shock absorber
8 - Sealing ring
Component arrangement of front air-spring strut
2- Mounting saddle
3- Hexagon nut
4- Spring-strut mount
5- Sealing ring
6- Residual pressure retaining valve
7- Air spring
8- Rubber stop
9- Shock absorber
10 - Sealing ring
11 - Boot/bellows
12 - Clamp
Disassembling and assembling
Disassembling spring strut
ATTENTION
The air-spring strut is pressurised with approx. 3 bar residual pressure. Never us an impact bolter to
loosen the fastening screws. Do not bend over the mounting saddle during disassembly.
z Risk of injury from the pressurised air-spring strut when loosening the screws.
→ Always unscrew the screws on the mounting saddle by one turn only, on alternating sides. During
disassembly, allow the air to escape by tilting the mounting saddle slightly.
1. Clamp the air-spring strut on the lower mounting point (use

aluminium protective jaws -A- !).
2. Loosen the fastening screws on the mounting saddle and carefully

remove the mounting saddle.
Lower mounting point for air-spring

strut
3. Remove spring-strut mount with socket wrench insert 3353 and arm
bracket P 9630.

4. Remove clamp.
Note
When replacing the air spring, always replace the boot/bellows.
If the rolling piston slips out of the outer guide during disassembly, it must
be correctly positioned again when assembling.
z When sliding in the rolling piston, the roller must lie evenly between
the outer guide and rolling piston (roll fold).
Air-spring strut clamp

5. Push bellows downward and secure in this position (2nd worker
required!). Grasp rolling piston -1- and remove it upward from the
shock absorber by turning slightly to the left/right.
Air-spring strut rolling piston

6. When replacing the air spring, push the rubber stop -1- out of the
centring device.
7. Remove boot/bellows.
Rubber stop
8. When replacing the shock absorber, remove the wheel acceleration
sensor -1- and fit it on the new shock absorber.
Wheel acceleration sensor

Assembling spring strut
Note
If the rolling piston slips out of the outer guide during disassembly, it must be correctly positioned again.
z When sliding in the rolling piston, the roller must lie evenly between the outer guide and rolling piston (roll
fold).
If the shock absorber is not replaced, the sealing ring must be replaced.
z Make sure that everything remains absolutely clean. The smallest impurities can cause leakages.
z Clean the contact surfaces of the sealing rings with a lint-free cloth.
z Lightly grease sealing rings with Syntheso Glep 1 (ET No. 000.043.204.68).
1. Replace sealing ring on shock absorber -Arrow- (figure shows rear

shock absorber).
2. Pull boot/bellows completely over the collar of the shock absorber, so

that it engages (small diameter downward, 2nd worker required).
3. Fit rubber stop (small diameter downward).
Shock absorber sealing ring

4. Position the air spring on the shock absorber. Grasp the rolling piston
and push it downward by turning it slightly to the left and right. If the
rolling piston has slipped out of the outer guide, it must be pushed
back in again while forming a circumferential uniform roll fold on the
rolling boot -Arrows- .
Roll fold
5. Clean the surfaces -2- on the mounting saddle and on the air spring with a lint-free cloth. Replace sealing
ring -1- on the air spring.
Note
To align the air spring, carefully
turn the rolling piston in order to
not damage the roller.
6. Fit and align the air spring.

While doing so, the residual
pressure retaining valve -1-
must be located exactly at the
imaginary axis of symmetry
-Arrow- of the air-spring strut.
Sealing ring
The residual pressure
retaining valve must be facing
in the opposite direction to the
CDC valve.
7. Fit bellows at the top.

8. Fit spring-strut mount using socket wrench insert 3353 and arm
bracket P9630.

9. Fit mounting saddle -Screws A- and align it so that the upper arm of
the bearing -B- points to the residual pressure retaining valve.
Fitting mounting saddle

10. Align the air spring again so that the residual pressure retaining valve is located exactly at the axis of
symmetry -Arrow- of the air-spring strut.
11. Fill the air-spring strut. → 4301 Filling specification for air-spring strut
Checking the air-spring strut
Checking for leaks
1. Dip the filled air-spring strut completely into a water bath.

Note
Before fitting the air-spring strut in the vehicle, carefully blow out and dry
all electrical connections and the residual pressure retaining valve with
compressed air.
2. There must be no air bubbles rising in the water bath. If no air

bubbles can be seen, the air-spring strut can be fitted in the vehicle.
3. If air bubbles appear in the water bath, the air-spring strut must be
disassembled again. Replace all sealing rings again. Check the
residual pressure retaining valve again visually.
4. Repeat the leak test in the water bath.
Aligning the mounting saddle
as of MY 2003
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43 25 Disassembling and assembling rear spring strut - as of MY

2003
- Information
- Information
- Disassembling and assembling
Tools

Socket wrench insert VW-tool 3353
Arm bracket special tool P 9630

Information
Notes on repairing air-spring struts
Note
As of a mileage of 200,000 Km it is recommended that the air springs be replaced per axle if there is damage to
one air spring.
If the shock absorbers leak, the complete air spring strut is to be replaced. The oil of the shock absorber can
damage the roller.
When depressurised, the air spring must not be twisted. There is the danger that the roller in the inside of the air
spring will be damaged by bending or folding and thus significantly reduce the running time.
Air-spring strut
1. Before loosening the air lines in the installed state, check if the rolling
boot is still filled with the residual pressure of approx. 3 bar. To do
this, press on the rolling boot of the air spring with your thumb. The
rolling boot must give perceptible resistance. If no significant
resistance can be felt, the air spring is depressurised and must be
replaced along with the residual pressure retaining valve.
The greatest possible care and cleanliness, as well as perfect tools are
important requirements for carrying out perfect repairs on air-spring struts.
The general and basic rules of safety apply. These are specifically listed
here again for repairing air-spring struts.
– Thoroughly clean the connection points and their surroundings

before loosening them. Checking the air bellows
– Do not use fibre-shedding cloths.
– Do not take spare parts out of the packaging until right before installation.
– Only use lubricants that have part numbers.
– Carefully cover open components or close them if the repair work will not be carried out immediately.
– Do not use an impact bolter.
– Observe correct tightening torques. → 43 Tightening torques
Gaskets, sealing rings and bellows
Always replace sealing rings and bellows.
After removing gaskets, examine the contact surfaces on housings for burrs and damage.
Always loosen and tighten screws or nuts crosswise for mounting covers and housing.

ATTENTION
Lowering of the vehicle when loosening the air line. The residual pressure retaining valve can become
loose when loosening the air line.
z The vehicle lowers on the side on which the line/the residual pressure retaining valve is loosened.
Risk of squashing.
→ When loosening the residual pressure retaining valve, lift the vehicle on a platform lift.
→ Only leave the vehicle on the platform lift until a new residual pressure retaining valve is installed and the
air-spring strut is filled.
The residual pressure retaining valve may only be replaced if:
1 - Residual pressure retaining valve

2 - Socket insert
Removing/fitting residual pressure

retaining valve
– it was damaged during removal and installation,
– it was damaged while disassembling and assembling the air-spring strut,
– the sealing ring is faulty,
– it does not allow any more air to come out (valve jammed).
If the residual pressure retaining valve is jammed, the vehicle must be lifted for replacement on the platform lift
and the wheels must be allowed to turn freely. It must not be compressed with an empty rolling boot.
Tools and materials
Tools for repairing air-spring struts
Torque wrench 2-10 Nm (1.5-7.5 ftlb.)
Torque wrench 60-100 Nm (44-74 ftlb.)
Socket wrench insert 3353
Arm bracket P 9630
Information
Overview of rear air-spring strut
Note
The components of the air spring -7- (figure shows component arrangement of rear air-spring strut), Items
-2; 3; 4; 5- (figure shows rear air-spring strut), cannot be disassembled.
z Always replace the complete air spring -7- (figure shows component arrangement of rear air-spring strut)!
Rear air-spring strut
1 - Sealing ring
2 - Lid
3 - Outer guide
4 - Rolling boot
5 - Rolling piston
6 - Bellows
7 - Shock absorber
8 - Sealing ring
Component arrangement of rear air-spring strut
2- Mounting saddle
3- Hexagon nut
4- Spring-strut mount
5- Sealing ring
6- Residual pressure retaining valve
7- Air spring
8- Rubber stop
9- Hexagon nut
10 - Protective cap
11 - Shock absorber
12 - Sealing ring
13 - Boot/bellows
14 - Clamp
Disassembling and assembling
Disassembling spring strut
ATTENTION
The air-spring strut is pressurised with approx. 3 bar residual pressure. Never us an impact bolter to
loosen the fastening screws. Do not bend over the mounting saddle during disassembly.
z Risk of injury from the pressurised air-spring strut when loosening the screws.
→ Always unscrew the screws on the mounting saddle by one turn only, on alternating sides. During
disassembly, allow the air to escape by tilting the mounting saddle slightly.
1. Clamp the air-spring strut on the lower mounting point (use

aluminium protective jaws -A- !).
2. Loosen the fastening screws on the mounting saddle.
Lower mounting point

3. Carefully remove the mounting saddle over the residual pressure
retaining valve in direction of arrow.
4. Remove spring-strut mount Air-spring strut mounting saddle
with socket wrench insert
3353 and arm bracket P9630.

5. Remove clamp.
Note
If the rolling piston slips out of the outer guide during disassembly, it must
be correctly positioned again when assembling.
z When sliding in the rolling piston, the roller must lie evenly between
the outer guide and rolling piston (roll fold).
Air-spring strut clamp

6. Push bellows downward and secure in this position (2nd worker
required!). Grasp the rolling piston and remove it upward from the
shock absorber by slightly turning to the left/right.
Air-spring strut rolling piston

7. When replacing the air spring, push the rubber stop -1- out of the
centring device.
8. Remove boot/bellows.
9. When replacing the shock absorber, remove the cap and fit it on the
new shock absorber.
Rubber stop
Assembling spring strut
Note
If the rolling piston slips out of the outer guide during disassembly, it must be correctly positioned again.
z When sliding in the rolling piston, the roller must lie evenly between the outer guide and rolling piston (roll
fold).
If the shock absorber is not replaced, the sealing ring must be replaced.
z Make sure that everything remains absolutely clean. The smallest impurities can cause leakages.
z Clean the contact surfaces of the sealing rings with a lint-free cloth.
z Lightly grease sealing rings with Syntheso Glep 1 (ET No. 000.043.204.68).
1. Replace sealing ring on shock absorber -Arrow- .
2. Pull boot/bellows completely over the collar of the shock absorber so

that it engages (small diameter downward, 2nd worker required).
3. Fit rubber stop (small diameter downward).
Shock absorber sealing ring

4. Position the air spring on the shock absorber. Grasp the rolling piston
and push downward by turning it slightly to the left and right. If the
rolling piston has slipped out of the outer guide, it must be pushed
back in again while forming a circumferential uniform roll fold on the
rolling boot -Arrows- .
Roll fold
5. Clean the surfaces -2- on the mounting saddle and on the air spring with a lint-free cloth. Replace sealing
ring -1- on the air spring.
6. Align the air spring so that the residual pressure retaining valve is located close to the imaginary axis of
Sealing ring
Aligning the air spring
symmetry (approx. 10° off-centre) of the air-spring strut.

7. Fit bellows (large diameter up).
8. Fit spring-strut mount with socket wrench insert 3353 and arm
bracket P9630.

9. Fit mounting saddle and while doing so align it so that the upper arm
of the bearing points to the residual pressure retaining valve.
10. Fill the air-spring strut. → 4301 Filling specification for air-spring
strut
Aligning the mounting saddle

Checking the air-spring strut
Checking for leaks
1. Dip the filled air-spring strut completely into a water bath.

Note
Before fitting the air-spring strut in the vehicle, carefully blow out and dry all electrical connections and the
residual pressure retaining valve with compressed air.
2. There must be no air bubbles rising in the water bath. If no air bubbles can be seen, the air-spring strut can
be fitted in the vehicle.
3. If air bubbles appear in the water bath, the air-spring strut must be disassembled again. Replace all sealing
rings again. Check the residual pressure retaining valve again visually.
4. Repeat the leak test in the water bath.
as of MY 2003
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43 01 IN Filling specification for air-spring strut - as of MY 2003

- Filling specification for air-spring strut
Tools

Compressed gas bottle with commercially 00000
pressure gauge unit available tool
adapter special tool T10157/1
Filling specification for air-spring strut
Overview of air-spring strut

- - Top part of air-spring strut with residual pressure retaining valve without plug connection (a/f 12). (The
1- adapter T10157/1 is fitted to the residual pressure retaining valve before the air-spring strut is filled.)
- - Compressed gas bottle with pressure gauge unit 00000 (The required pressure is set on the
2- compressed gas bottle using the commercially available pressure gauge unit. The compressed gas bottle is
filled with Argon or Corgon!)
- - Air-spring filling unit VAS 6231 00000 (The air-spring strut can be filled with individual pressure shots
3- using the air-spring filling unit.)
- - Adapter T10157/1 (The adapter T10157/1 is fitted to the residual pressure retaining valve before the air-
4- spring strut is filled.)
General information on air-spring strut
The air-spring struts are pre-filled to approx. 3 bar overpressure ex-works. If a new air-spring strut is installed, air
can diffuse (escape) from the bellows of the air-spring strut as a result of storage times of varying duration. If the
air-spring strut is removed from the transport packaging and installed without being filled, the bellows can fall into
folds, thereby damaging the air-spring strut. For this reason, all air-spring struts must be re-filled prior to use! The
procedure is described in detail in the course of the repair instructions.
Filling the air-spring strut
ATTENTION
Increased risk of accident due to compressed gas bottles under high pressure (up to 200 bar).
→ Observe the relevant operating regulations for handling compressed air and gas filling units.
→ Observe accident prevention regulations.
Note
z Do not remove air-spring strut from transport packaging until it has been filled. This will prevent damage to
the inner bellows.
z The air-spring strut must be screwed securely in the transport packaging during filling.
z During assembly work, make sure that there are no pressure marks on the protective boot of the air-spring
strut.
z After installation, first set the high level, then go to normal level. Repeat this procedure once more. This
procedure replaces most of the gas with the cleaned air from the air supply unit.
1. Remove transport packaging lid..
2. Pull off protective cap on residual pressure retaining valve. Carefully remove any left-over packaging.
3. Pull off plug connection on residual pressure retaining valve (a/f 12)
and screw on the filling unit adapter T10157/1 at the correct position
on the residual pressure retaining valve.
Note
z The air-spring strut must only be filled with the approved gasses,
dual-process gasses Argon and Corgon.
z In isolated cases, up to 11 bar overpressure (upper tolerance, spring

strut depressurised) is required to open the residual pressure
retaining valve.
z Fill the air-spring strut using several individual pressure shots. Filling
the air with individual pressure shots will prevent the air-spring strut
from being filled with too much overpressure.
z Do not fill the air-spring strut with overpressure of more than 4.5 bar.
z The residual pressure retaining valve automatically reduces excessive overpressure to the minimum
overpressure of approx. 3 bar.
4. Fit the → see figure filling unit to the pressure gauge unit of the compressed air bottle.
5. Set the → see figure pressure gauge unit (flow limiter) to approx. 20 l/min -arrow- .
6. Overcome the counter-pressure of the residual pressure retaining valve with several individual pressure
shots and fill the air-spring strut. When sufficient air has been filled, between 2.5 and 4.5 bar -arrows- , pull
off the connection from the residual pressure retaining valve. Do not exceed the maximum value of 4.5 bar.
7. Once the air-spring strut has been filled correctly, it can be removed from the transport packaging and fitted.
as of MY 2003
Country C00, C02, C05, C07, C08,
C09, C10, C11, C12, C13, C14,
C15, C16, C18, C19, C20, C21,
C22, C23, C24, C25, C26, C27,
C28, C32, C33, C34, C35, C36,
C37, C38, C39, C45, C46, C98,
C99
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43 15 19 Removing and installing compressor for the level control

system - as of MY 2003
- Preliminary work
- Removing the compressor
- Installing the compressor
- Subsequent work
Preliminary work
1. Raise vehicle at the jacking points provided → 40 Lifting the vehicle.

2. Remove right cover → 519319 Removing and installing centre cover
- chapter on "removing" .
Removing the compressor

The compressor -3- is only installed for the level adjustment system and is attached as a compact air supply unit
with valve block -4- on a vibration-insulated support to the right underbody.
-1- - Air-spring strut, front axle
-2- - Air-spring strut, rear axle
-3- - Compressor
-4- - Valve block
ATTENTION
Residual air can escape when removing the air lines.
→ Wear protective goggles.

Note
z Place the take-up plates of the platform lift at the jacking points so
that the fastening points of the underbody panel are accessible → 40
Lifting the vehicle (see Switching off level adjustment).
z To bleed the level adjustment system (compressed air must be

this, in the system >> Level adjustment >> select the menu item
>>Bleed << and bleed the accumulator, and front and rear axles.
z Clean the screw connection of the lines from the valve block before
removing.
z Protect the screw connection of the lines from dirt with suitable plugs.
1. Unclip the suction line and the plug connections -arrows- .
2. Remove the → see figure air lines (colour-coded) from the valve unit
and the brown air line (running under the valve unit).
3. Release the mounting points on the body -A, B & C- and remove the
compressor unit (compressor, valve block).
Disconnect compressor from the valve unit:
z Release the tie-wrap and attachment at the support

z Unclip the air line and remove
z Remove the compressor from the support.
Installing the compressor
Note
z Install in reverse order.
z The air lines are coloured and designated with letters.
z Pay attention to cleanliness, if necessary clean the screw connections of the air lines with a lint-free cloth.
z Replace locking screws and nuts.
z Pay attention to tightening torques → 43 TW Tightening torques - see chapter on "Technical values".
z To fill the level adjustment system, use the Porsche System Tester. To do this, in the system >> Level
adjustment >> select the menu item >> Fill <<; then fill the front and rear axles and the accumulator. Switch
on level adjustment → 40 Lifting the vehicle(see Switching on level adjustment).
1. Fit compressor on the support, clip in the line, and fasten the cable.
2. Insert compressor unit and mount on the body -(A, B & C)- .
3. Fit the → Air lines for valve block air lines to the valve block.
-1- - black
-2- - lilac
-3- - blue
-4- - green
-5- - red
-6- - yellow
-7- - brown
Air lines for valve block

4. Fit the suction lines and the plug connections.
5. Fill the pneumatic system using the Porsche System Tester.
Subsequent work
Fit right cover → 519319 Removing and installing centre cover - chapter on "installing" .
as of MY 2003
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43 16 19 Removing and installing level control module - as of MY

2003
- Removing level control module
- Installing the level control module
- Coding level control module
- Calibrating the level control module
Tools

PIWIS Tester special tool 9718
Removing level control module
Removing level control module
WARNING
Risk of damage to electronic control modules.
z If care is not taken, electrical and electronic components may be destroyed.
→ Before removing the control module, switch off the ignition and remove the ignition key.
Note
z The control module is located behind the right rear side section trim.
Overview of level control module
1. Remove the cover of the right rear side section trim.
2. Remove warning triangle and emergency kit.
3. Pull up the clip of the control module holder and tilt the control module out of the holder.
4. Pull the latch of the upper electrical plug upwards -a- and remove plug.
Pull plug off at the bottom of the level
control module.
Pull plug off at the top of the level

control module.
5. Pull out control module and pull the latch on the electrical plug -a- and remove plug.
Installing the level control module
Installing the level control module
1. First place the smaller plug on the control module and slide in the
latch -a- .
Push plug on at the bottom of the level

control module.
2. Position the control module in the installation position and insert the second plug on the control module and
lock it -a- .
3. Code level control module. → 431619 Removing and installing level control system control module -
"Coding" chapter
4. Calibrate the level control module → 431619 Removing and installing level control system control module -
"Calibrating" chapter
5. Insert the control module into the holder and position with the clip.
6. Store the emergency kit and warning triangle and place on the cover of the right rear side section trim.
Push plug on at the top of the level
control module.
Coding level control module
Coding level control module
Note
z During coding, it is essential to guarantee the power supply for the PIWIS Tester 9718. It is essential to
z The PIWIS Tester 9718 instructions take precedence and in the event of a discrepancy these are the
the PIWIS tester 9718.
1. Connect the PIWIS tester 9718 to the vehicle and start it. Switch on the ignition. >> Continue.
3. Using the >> key, move from the vehicle type to the list of control modules.
4. Select Level control and press the >> .
5. Select Coding and press the >> .
6. Select Select country and code with the F8 .
Select country
Cayenne RoW
Cayenne Thailand
7. Read out fault memory and erase if required.
Calibrating the level control module
Calibrating the level control module
Note
z During coding, it is essential to guarantee the power supply for the PIWIS Tester 9718. It is essential to
z The PIWIS Tester 9718 instructions take precedence and in the event of a discrepancy these are the
the PIWIS tester 9718.
Information, measuring points, procedure, and conditions for calibration: → 43 Calibration
1. Connect the PIWIS tester 9718 to the vehicle and start it. Switch on the ignition. >> Continue.
3. Using the >> key, move from the vehicle type to the list of control modules.
4. Select Level control and press the >> .
5. Select Actual values and press the >> .
6. Select the Actual values menu and display the safety code. Then read out the safety code and make note
of it.
7. Select the menu Calibration, enter the safety code and carry out the Calibration function. Follow the
instructions on the PIWIS tester .
8. Read out fault memory and erase if required.
as of MY 2003
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43 18 55 Replacing front level sensor - as of MY 2003

- Removing front level sensor
- Installing front level sensor
Removing front level sensor
Note
z In running gear with level adjustment, a self-levelling sensor is installed on each spring strut.
z Removal and installation is described for the right spring strut.
z The self-levelling sensor is screwed to the bearing block and upper control arm.
Turn steering until access to the self-levelling sensor is achieved..
1. Counter with an open-ended wrench on the two flats -1- and unscrew
the fastening nuts -2- .
2. Unscrew both fastening screws -3- .
3. Disengage lever from self-levelling sensor, swivel it forwards and remove the sensor.
4. Press the electric connector together -a- and pull it off.
Installing front level sensor

Note
z In running gear with level
adjustment, a self-levelling
sensor is installed on each
spring strut.
z Removal and installation is

described for the right spring
strut.
z The self-levelling sensor is

screwed to the bearing block and upper control arm.
1. Press the electric connector onto the self-levelling sensor until it clicks into place..
2. Tighten fastening screws -3- → 43 TW Tightening torques - see

chapter on "Technical values".
3. Engage lever of self-levelling sensor and position the sensor.

4. Position the fastening nut -2- , counter with an open-ended wrench
on the two flats -1- and tighten the nut→ 43 TW Tightening torques -
see chapter on "Technical values".
If a new self-levelling sensor is installed, then the control unit for level
adjustment must be calibrated.
Calibrating control unit for level adjustment
Information, measuring points, procedure, and conditions for calibration: → 43 K2 Calibrating - chapter on
"calibrating"
3. Select "Level adjustment" using the cursor keys.
4. Select the menu "Teach" and perform the calibration function.
5. Read out fault memory. If fault is present, proceed in accordance with Rep - Gr. 4316 Level adjustment
diagnosis.
as of MY 2003
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43 19 55 Replacing rear level sensor - as of MY 2003

- Removing rear level sensor
- Installing rear level sensor
Removing rear level sensor
Note
z In running gear with level adjustment, a self-levelling sensor is
installed on each spring strut.
z The self-levelling sensor is screwed to the suspension subframe and

upper control arm.
1. Counter with an open-ended wrench on the two flats -1- and unscrew
the fastening nuts.
2. Unscrew both fastening screws -2- .
3. Press the electric connector together -a- and pull it off.
Installing rear level sensor

Note
z In running gear with level adjustment, a self-levelling sensor is
installed on each spring strut.
z The self-levelling sensor is screwed to the suspension subframe and

upper control arm.
1. Press the electric connector onto the self-levelling sensor until it

clicks into place..
2. Tighten fastening screws -3- → 43 TW Tightening torques - see

3. Engage lever of self-levelling sensor and position the sensor.
4. Position the fastening nut -2- , counter with an open-ended wrench

on the two flats -1- and tighten the nut→ 43 TW Tightening torques -
see chapter on "Technical values".
If a new self-levelling sensor is installed, then the control unit for level
adjustment must be calibrated.
Calibrating control unit for level adjustment
Information, measuring points, procedure, and conditions for calibration: → 43 K2 Calibrating - chapter on
"calibrating"
3. Select "Level adjustment" using the cursor keys.
4. Select the menu "Teach" and perform the calibration function.
5. Read out fault memory. If fault is present, proceed in accordance with Rep - Gr. 4316 Level adjustment
diagnosis.
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43 25 19 Removing and installing rear spring strut (air springs) -

as of MY 2003
- Preliminary work
- Removing rear spring strut
- Installing rear spring strut
- Subsequent work
Tools

insert part VW-tool T10212
Preliminary work
Preliminary work
ATTENTION
Increased risk of accidents due to raising the wheel carrier incorrectly.
The relevant wheel must be removed when carrying out repairs to avoid damaging the drive shaft.
1. Remove wheel → 440519 Removing and installing wheel - chapter on "Removing".
Removing rear spring strut
Removing rear spring strut
Air-spring strut at rear

adjustment system.
2. Fit protective tube on drive shaft (shop-made to protect the drive
shaft).
3. Loosen pressure line on residual pressure retaining valve -arrow- using insert part T10212 (front spring
strut connection in figure). Then, unclip the pressure line from the holders and set it aside.
4. Remove stone guard for CDC sensor -arrow- .
5. Disconnect CDC sensor plug connection -arrow- , remove the cable from the holder, and set the cable
aside.
6. Remove the fastening screw for the connecting link/spring strut on

the wheel carrier. To do this, use a suitable → see figure lift with
rubber base in order to prevent slipping. Lay the connecting link
aside.
7. Remove the four fastening screws (top) -arrows- .
8. Carefully remove spring strut → see figure downwards -arrow- .

Installing rear spring strut
Installing rear spring strut
ATTENTION
Increased risk of accident due to raising the wheel carrier
incorrectly. When filling the air spring struts, the vehicle lifts.
Note
z Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels). When
raising the suspension, use a suitable intermediate layer (hard rubber).
z Do not damage the brake cover plate.

the wheel suspension is being raised with a universal vehicle lift!
10 mm corresponds to vehicle position!
z Carry out a visual inspection of all parts!
z Replace self-locking nuts!
z If a new spring strut is fitted, it must be pre-filled to 3 bar in its original

packaging → Filling specification for air-spring strut.
z Replace all expansion screws (screws which are fitted with torque angle tightening procedure)!
z Use correct tightening torques and torque angle! → Tightening torques for rear axle
1. Insert spring strut into vehicle.

2. Fit the four fastening screws -arrows- .
3. Carefully raise the air spring strut using a suitable -figure- lift with
rubber base. Then, pull the wheel carrier downwards in order to fit
4. Attach the fastening screw for the connecting link/spring strut -arrow-
to the wheel carrier.
5. Connect the CDC sensor plug connection to the lower part of the
spring strut -(arrow)- . Insert cable into the holders.
6. Fit stone guard for CDC sensor -arrow- .
7. Fit pressure pipe to residual-pressure retaining valve using insert part T10212 → Tightening
torques [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Tightening torques [9PAAJ1]. Then clip the
pressure line into the retaining devices.
8. Remove protective tube from drive shaft.
Subsequent work
Subsequent work
1. Fit wheel → 440519 Removing and installing wheels - section on "Installing" .
2. To fill the air suspension (the system must be filled with compressed
air), use the -Porsche System Tester- . To do this, select the menu
item Fill air suspension in the Air suspension system.
3. Switch on level adjustment → Lifting the vehicle [9PAAD1 9PAAD7

9PAAE1 9PAAE7 9PAAF1]→ Lifting the vehicle [9PAAJ1].
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43 30 19 Removing and installing front spring strut (air springs) -

as of MY 2003
- Preliminary work
- Removing front spring strut
- Installing front spring strut
- Subsequent work
Tools

protective tube (shop made) commercially 00000
available tool

insert part VW-tool T10212

Preliminary work
Preliminary work
1. Remove cowl panel → 664419 Removing and installing cowl panel - section on "Removing".
2. Remove the relevant engine compartment side cover → 700219 Removing and installing front cover (engine
compartment) - section on "Removing".
3. Remove hub cap using puller hook 9229 and undo drive shaft fastening at the side of the wheel before
raising the vehicle. Operate the brake whilst doing so (second fitter required).
4. Remove wheel → 440519 Removing and installing wheel - section on "Removing".
The air springs are installed as standard in the Cayenne Turbo and are optional in the Cayenne S. The steel
springs are not applicable for the Cayenne Turbo.
ATTENTION
Increased risk of accident due to raising the wheel carrier incorrectly.
When fitting/removing the air spring strut, the drive shaft is removed and installed.

adjustment system.
2. Lift wheel carrier carefully to facilitate removal. Use a suitable → see figure lift with rubber base in order to
prevent slipping.
3. Loosen pressure line at the residual pressure retaining valve -arrow- using insert part T10212.
4. Separate compact connector (in wheel housing on side member) -arrow- and the plug connections for the
wheel acceleration sensor and self-levelling sensor.
5. Remove lower connecting link -arrow- using the lift to support the wheel carrier (assembly aid).
6. Unscrew plastic nuts -arrows-
on wheel housing liner.
7. Fix upper trailing arm using spring compressor VW 552. This

involves tensioning the trailing arm slightly because otherwise the top
ball joint can be damaged. Insert the -figure- spring compressor into
the top opening of the wheel housing (double panel under the wheel
housing cover) and attach it to the trailing arm. This is only necessary
if the same control arm is reinstalled.
8. Remove lower spring strut and undo brake calliper.
9. Slide protective tube (shop made) 00000 over drive shaft. Release
drive shaft at transmission flange and lay down carefully. Use a
suitable base for the front axle carrier.
10. Using universal drive shaft/wheel hub puller as of model '86

NR.87-1, push (press through) peg of drive shaft by approx. 20 mm -
25 mm into the wheel hub.
11. Remove the two holders (brake hose, combination line) on wheel
carrier and let them hang.
12. Disconnect ABS sensor plug connection.
13. Remove the relevant outer -figure- tie rod joint using the press-out
tool T10187. When pressing out, screw fastening nut on flush (this
protects the ball joint thread).
14. Press out → see figure ball joint of upper trailing arm from wheel carrier using press-out tool T10187.
15. Remove the spring compressor VW 552.
16. Remove brake calliper fastening screws and hang -figure- brake calliper in a suitable place in the wheel
housing.
17. Remove drive shaft. To do this, the first fitter must carefully pull the top of the wheel carrier outwards and the
second fitter must carefully guide out the drive shaft.
18. Remove the three mounts for the spring strut in the engine compartment (two mounting points in front of
plenum panel and one inside the plenum panel). The three mounting points -(arrow)- are shown here from
inside the wheel housing (wheel carrier installed).
19. Carefully guide out the spring
strut.
ATTENTION
Increased risk of accident due to raising the wheel carrier
incorrectly. When filling the air spring struts, the vehicle lifts.
Note
z If a new spring strut is fitted, it must be pre-filled to 3 bar in its original packaging → Filling specification for
air-spring strut.

position. Vehicle position means: vehicle standing on the wheels or
the wheel suspension being raised using a universal vehicle lift.
z Use an intermediate layer → see figure (hard rubber). Do not damage

the brake cover plate.
z When fitting the ball joints, ensure that the bevel pinions are clean!
Remove dirt or grease on bevel pinions, e.g. with a lint-free cloth. Do
not use cleaning agent/solvent.
z Observe correct tightening torques. → Tightening torques for front

axle
1. Carefully guide in spring strut -arrow- , position with the auxiliary pins
and tighten at the mounting saddle with the specified tightening
torque → Tightening torques for front axle.
2. Fit drive shaft. To do this, first fitter must carefully pull the top of the wheel carrier outwards and the second
fitter must carefully guide in the drive shaft.
3. Fit brake calliper on wheel carrier (do not tighten brake calliper fastening screws yet).
4. Mount wheel carrier on upper trailing arm. When doing this, observe
drive shaft clearance (use suitable base). To facilitate assembly and
avoid the upper ball pin falling into the stop, raise the wheel carrier
slightly with a suitable lift so that the upper ball pin can be inserted.
Use a → see figure lift with rubber base in order to prevent slipping.
5. Insert spring compressor VW 552 and slightly tension upper trailing
arm.
6. Fit fastening bolt for lower spring strut. Remove spring compressor
VW 552 tension jack.
7. Grease mounting-face ring of axle nut with a little Optimoly TA

aluminium paste. Screw on axle nut to prevent the shaft from slipping
out. If the shaft cannot be pushed right in, use assembly fixture
T10206 to pull the drive shaft in. Remove protective tube (shop
made) 00000 and base.
8. Fit drive shaft to the transmission flange and tighten brake calliper
fastening screw → Tightening torques for front axle.
9. Mount connecting link.
10. Connect compact connector in wheel housing -arrow- . Mount

support for brake hose/combination line on top of wheel carrier.
Connect sensor connectors.
Note
z Observe torque on residual pressure retaining valve.
11. Fit pressure line at residual pressure retaining valve -(arrow)- using
insert part T10212. Note tightening torque. → Tightening torques for
front axle
12. Mount ball joint of tie rod on wheel carrier. → see figure Tighten lock
nut to specified tightening torque → Tightening torques for front axle.
13. Screw in plastic nuts -arrows- on wheel housing liner.
Subsequent work
Subsequent work
1. Fit wheel → 440519 Removing and installing wheels - section on "Installing" .
2. Tighten axle nuts → Tightening torques for front axle. Operate the brake whilst doing so (second fitter
required).
3. Fit the relevant engine compartment side cover → 700219 Removing and installing front cover (engine
compartment) - section on "Removing".
4. Fit cowl panel → 664419 Removing and installing cowl panel - section on "Removing".
5. To fill the level adjustment system, use the Porsche System Tester. To do this, select the Fill level
adjustment menu item in the Level adjustment system. Switch on level adjustment → Lifting the
vehicle [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Lifting the vehicle [9PAAJ1].
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43 34 19 Removing and installing sensor for body - as of MY 2003

- Preliminary work
- Removal
- Installing
- Subsequent work
Preliminary work
Preliminary work
Note
These instructions for removal and installation describe all the sensors for the body (two sensors at the front, one
sensor at the rear).
Installation position at front: Position 8, under the left and right wings.
Installation position at rear: Position 8, under the boot floor plate on the right (sensor can be accessed from the
interior!).
Front sensor
2. Remove wheel housing liner. → 505619 Removing and installing front wheel housing liner
Rear sensor
Note
For removing and installing the rear sensor, it is not necessary to lift the vehicle.
The rear sensor can be accessed from the interior.
1. Remove boot floor plate (centre part) and remove only the right side cover. → 700619 Installing and
removing luggage compartment trim (loadspace cover)
Removal
Removing
Front sensor
1. First push together the sensor connector -arrow- firmly (makes

removal easier!). Lift connector lock and then remove connector!
2. Loosen screw of holder and remove sensor.
Rear sensor
Sensor for body at front

1. First push together the sensor connector -arrow- firmly (makes
removal easier!). Lift connector lock and then remove connector!
2. Loosen nut of holder and remove sensor.
Sensor for body at rear
Installing
Installing
Front sensor
1. Insert sensor with holder in the correct position -arrow- and tighten the fastening screw.
2. Plug in connector. Pay attention to correct line routing.
Rear sensor
1. Insert sensor with holder in the correct position -arrow- and tighten the fastening nut.
2. Plug in connector. Pay attention to correct line routing.

Sensor for body at rear
Sensor for body at front
Subsequent work
Subsequent work
Front sensor
1. Install wheel housing liner. → 505619 Removing and installing front wheel housing liner
Rear sensor
2. Fit right side cover and install the boot floor plate (centre part). → 700619 Installing and removing luggage
compartment trim (loadspace cover)
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43 85 41 Repairing pressure hose - as of MY 2003

- Repairing pressure hose
Tools

Cutters VAS 6228 commercially 00000
available tool
Repairing pressure hose
Cutters VAS 6228 00000 for cutting through pressure hose.
Cutters VAS 6228

Notes on replacing pressure hoses
Note
z Faulty pressure hoses can be replaced in sections.
z Using a plug connection (see Spare Parts Catalogue), individual sections of pressure hoses can be safely
joined again.
z The pressure hoses are correctly fitted when the first colour marking
(self applied) is no longer visible and the second colour marking is
still visible.
z To check that the pressure hose is fitted correctly, pull it slightly

against the insertion direction. If it is fitted correctly, it cannot be
pulled out or only pulls out when great force is applied.
The following points must be observed when choosing the repair point:
– The repair point must lie in an area protected from water spray
– The push-on connector must be fastened with tie-wraps to the

structure or a cable guide
– Straight pipe sections should be chosen for the repair
– Position the pressure hose back in its original fastenings
– Insert the ends of the pressure hoses firmly into the push-on connector.
Repair
Note
When filling the air suspension, the vehicle lifts.
2. To bleed the air suspension (air pressure must be allowed to escape

out of system - if this has not already happened due to the faulty
line), use the Porsche System Tester. To do this, select the menu
item Bleed air suspension in the Air suspension system.
3. When repairing the pressure hose, cut off the damaged section squarely using the cutters cutters VAS 6228
00000.
4. Mark the pressure hose to be replaced in colour (e.g. with a waterproof marker). Measured from the cut-off
end of the hose, make two coloured marks at 16 mm and 22 mm respectively -(arrows)- .
5. Insert the pipe until the range between the two colour markings min. 16 mm up to max. 22 mm -(arrows)-
has been reached.
To fill the air system, use the Porsche System Tester. To do this, select the menu item Fill air suspension in the
Air suspension system. Switch on level adjustment → 40 Lifting the vehicle.
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43 IN Position of air suspension components - as of MY 2003

- Position of air suspension components
Position of air suspension components

The Cayenne Turbo and the optional Cayenne and Cayenne S are equipped with a level adjustment system with
full-supporting air suspension on both axles and the electronically regulated damping of Porsche Active
Suspension Management (PASM) .
The air suspension with level adjustment makes it possible to actively adapt the ground clearance of the Cayenne
to the situation in which the vehicle is being used or to its load. More ground clearance off-road by manual
adjustment to off-road level or automatic lowering at high speed.
Depending on the load, by increasing or decreasing the air volume it is possible to achieve various vehicle heights
with different suspension characteristics. 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 compressor, a solenoid block and two
accumulators.
Wheel acceleration sensors -9- are no longer fitted as of January 2004. Precise data and scopes can be found in
the spares catalogue. If the air-spring struts have to be replaced, the wheel acceleration sensors (for vehicles
before January 2004) will need to be installed on the new air-spring struts.
No. Description of component Number Location
-1- Air spring strut, front axle 2 Wheel
housing/lower
control arm
-2- Air-spring strut, rear axle 2 Damper housing
(cross
member)/wheel
bearing housing
-3- Compressor 1 Underbody right
-4- Valve block 1 Underbody right
-5- Front accumulator, 5.21 litres 1 Underbody left
-6- Rear accumulator 4.87 litres 1 Boot floor plate
-7- Air suspension control unit 1 Luggage
compartment
right
-8- Body acceleration sensors ( 2x front and 1x rear) 3 Front wheel
housing
(right/left), boot
floor plate right
-9- Wheel acceleration sensors 2 Spring strut front
-10- Self-levelling sensors, front axle 2 Control arm
upper
-11- Self-levelling sensors, rear axle 2 Control arm
upper
-12- Compressed air connection 1 Under seat
frame front right
-13- Suction line for compressor 1 Connection to
air cleaner
housing
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43 K2 Calibration - as of MY 2003
- Calibration
Calibration
Calibration must be carried out if control unit and/or self-levelling sensors are replaced. When doing this, the self-
levelling sensors are calibrated by determining a correction value (corresponding to the actual height of vehicle)
and permanently storing it in the control unit.
Notes on calibration
Note
z Prior to calibration, the normal level must be adjusted! → 43 Calibration (Conditions for carrying out
calibration)
z Ensure that tyre pressures have been adjusted to the respective tyre specifications. → 43 Calibration
(Wheels and tyres)
z During calibration, the vehicle is raised and lowered!
z When engine is running, switch air extraction system on.
z The security code is displayed in the Porsche System Tester under menu >> Level adjustment >> Actual
values.
The nominal values for the nominal heights of the level sensors are stored in the control unit. The actual values of
the respective axle heights, front left, front right, rear left, rear right, have to be measured manually and then
entered with the Porsche System Tester. The actual values are to be measured on the two axle supports (front
axle, rear axle), both on the right and left. → 43 Calibration (conditions for carrying out calibration)
Measuring point for rear axle
The distance (middle of wheel) between the road (wheel contact area on measuring platform) and the measuring
point -A- on the axle support is measured.
Measuring point for front axle

The distance (middle of wheel) between the road (wheel contact area on
measuring platform) and the measuring point -A- on the axle support is
measured.
Conditions for carrying out calibration
Calibration can only be carried out while vehicle is stationary.
The vehicle must be on the measuring platform.
The foot-operated parking brake is to be operated.
The car is to be adjusted to normal level. → 43 Calibration (Adjusting car to normal level)
Connect the Porsche System Tester. Select the test step Calibration in the Air suspension/level adjustment
system.
When calibrating, the vehicle moves down first and then moves up to normal level.
After normal level has been reached, determine the actual values of axle heights at measuring points.
If an implausible value is entered (actual value is not accepted), measure height again and enter value.
Stop the vehicle and apply the brake.
Close vehicle doors.
Tap the right-hand rocker switch on the centre console in the appropriate direction until vehicle has reached
normal level. The middle indicator light next to the rocker switch is permanently on. If a further indicator light
should come on, a different level is set.
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43 TW Tightening torques - as of MY 2003

Tightening torques

value 1 2
Mount for compressor M8 x 50 Tightening 17 ftlb.
torque
Mount for compressor M8 x 70 Tightening 17 ftlb.
torque
Mount for valve block M6 Tightening 7.5 ftlb.
torque
Mount for pressure accumulator front Tightening 17 ftlb.
M8 x 16 torque
Mount for pressure accumulator rear Tightening 7.5 ftlb.
M6 x 15 torque
Mount for pressure accumulator rear Tightening 17 ftlb.
M8 x 16 torque
Pressure line to spring strut Tightening 2 ftlb.
torque
Pressure line to valve block Tightening 3 ftlb.
torque
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45 11 19 Removing and installing speed sensor - as of MY 2003

- Preliminary work
- Removing speed sensor
- Installing speed sensor
- Subsequent work
Preliminary work
Raise vehicle → 40 Lifting the vehicle.
Removing speed sensor
1. At the front, turn the steering so far that the speed sensor is made more easily accessible. The wheel in the
rear does not need to be removed.
2. Disconnect speed sensor connector.
3. Unscrew fastening screws and remove speed sensor.
Installing speed sensor
Note
z The speed sensor must be inserted using Optitemp (Optitemp LG2, 25-ml spray can available under Part No.
000.043.204.21).
z The bore for mounting the speed sensor must be free of dirt.

1. Position speed sensor in the installation position and screw down.
2. Plug in connector.
Subsequent work
Lower vehicle → 40 Lifting the vehicle.
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45 30 19 Removing and installing hydraulic unit - as of MY 2003

- Preliminary work
- Removing hydraulic unit
- Installing hydraulic unit
Tools

Preliminary work
1. Remove plenum panel cover. → 664419 Removing and reinstalling cowl panel cover - chapter on
"Removing"
2. Using the bonnet stay 97040 the bonnet can be opened wider for better accessibility of the plenum panel.
To do this, remove the front gas spring and mount the bonnet stay. → 553119 Removing and reinstalling
front gas spring - chapter on "Removing"
3. Remove the DME control module -arrows- . → 247019 Removing and reinstalling DME control module-
reinstalling DME control module- chapter on "Removing" [9PAAJ1]
Removing hydraulic unit

Note
z When fitting the hydraulic connections, the electric plug connections
on the control units must remain connected as long as possible. This
prevents the plug connections on the hydraulic unit or in the
connectors inside from being splashed with brake fluid or water.
z Any damp connector must be wiped dry before being disconnected

from the connector on the hydraulic unit. If necessary, provide the
connector with a suitable protector.
z Brake fluid on electrical contacts (even thinned brake fluid) leads to

corrosion and may cause faults in the system.
z The brake lines must not be bent in the area of the hydraulic unit.
z Clean the interfacing points of the brake lines, but not with cleaning agents.
z Rinse off any brake fluid emerging thoroughly with water.
The → see figure hydraulic unit is installed in the plenum panel on the front right, under the DME control unit.
Note
z When fitting the hydraulic connections, the electric plug connections
on the control units must remain connected as long as possible. This
prevents the plug connections on the hydraulic unit or in the
connectors inside from being splashed with brake fluid or water.
z Any damp connector must be wiped dry before being disconnected

from the connector on the hydraulic unit. If necessary, provide the
connector with a suitable protector.

1. Release the ground cable -arrow- , unclip the wiring harness and set it aside.
2. Remove the support for the DME control unit -arrow- .
3. Remove the housing of the intake air duct. To do so, loosen the two
external fastening nuts and the two retaining clips in the inside of the
air duct.
4. Provide a suitable protector for the control unit connector.
5. Activate the brake pedal by hand using the brake pedal loader, (do
not clamp it yet!). Plug the vent hose of the vent bottle onto the front
left and rear left bleeder screw of the brake calliper (2nd fitter
required). Open the bleeder screws until the brake pedal is
completely pressed down. Tighten the brake pedal loader and close
the bleeder screws. This will close the central valves of the tandem
brake master cylinder so that only a little brake fluid can flow out of
the opened brake system.
6. A sufficient number of cloths should be put under the hydraulic unit to absorb any brake fluid emerging. If
some runs into the plenum panel nonetheless, immediately rinse thoroughly with water.
7. Mark the → see figure lines on the hydraulic unit (colour marking,
etc.) and remove. Seal the loosened lines with suitable plugs.
8. Pull off the control unit connector from the control unit.
9. Remove the hydraulic unit (a/f 8) and take out of the bracket,
upwards.
Installing hydraulic unit
DANGER
Porsche Stability Management does not work without values for the current brake pressure.
z Danger of personal injury and material damage when the hydraulic unit is not calibrated.
→ After assembling the hydraulic unit, a static test and a swap test must be carried out with the Porsche
System Tester.
→ After assembly of the brake master cylinder or the hydraulic unit, the pressure sensor must be calibrated
with the Porsche System Tester.
Note
z When fitting the hydraulic connections, the electric plug connections on the control units must remain
connected as long as possible. This prevents the plug connections on the hydraulic unit or in the connectors
inside from being splashed with brake fluid or water.
z Any damp connector must be wiped dry before being disconnected from the connector on the hydraulic unit.
If necessary, provide the connector with a suitable protector.
z Brake fluid on electrical contacts (even thinned brake fluid) leads to corrosion and may cause faults in the
system.
Note
z Remove the plugs on the new hydraulic unit after the respective brake line is fitted.
z Pay attention to tightening torques → 47 TW Tightening torques for brake hydraulic system - see chapter on
"Technical values".
1. Bleed the brake system . To ensure the full function of the brake system, drain approx. 250 ccm brake fluid
from each wheel → 470107 Bleeding the brake system - see section on "Bleeding".
2. Calibrate the pressure sensor with the → Porsche System Tester .

To do this, select menu >> PSM >> Calibration >> Pressure sensor
<<. The security code is displayed in the Porsche System Tester
under menu >> PSM >> Actual values <<.
3. The combination sensor (which contains the longitudinal and

transverse acceleration sensor) and the steering-angle sensor must
then be calibrated. The procedure for this is described in Step 2.
4. Perform a swap test with the Porsche System Tester. To do this,

select menu >> PSM > > Function selection >> Drive links <<.
Note Porsche System Tester

When replacing the hydraulic unit, the connected control mechanism must be coded with the Porsche System
Tester (running gear and country coding).
z To do this, select menu >> PSM >> Function selection >> Coding << and the relevant country. Observe the
country coding!
5. Code hydraulic unit.
6. Perform a function test. During the test drive, perform at least one ABS control operation, taking the road
conditions into consideration. Read out fault memory. There must not be any stored faults.
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45 60 05 Initialising and calibrating steering angle sensor - as of

MY 2003
- Checking steering angle sensor
- Adjusting steering angle sensor
Checking steering angle sensor
Initialise steering-angle sensor
ATTENTION
Increased risk of accident whever power supply is interrupted. PSM does not function.
→ The steering-angle sensor must be initialised (taught) whenever the battery is disconnected.
Note
z The steering-angle sensor is integrated into the steering column switch and records the movements of the
steering wheel (steering wheel angle) using light switches. The data is transmitted to the PSM control unit via
the CAN bus.
z During initialisation, the steering-angle sensor learns its current position (straight-ahead position).
z The steering-angle sensor must always be initialised if terminal 30 was interrupted (for example, battery
replacement, undervoltage, steering column switch disconnected, relevant fuse removed)!
z Calibration must be performed when working on or carrying out subsequent work on the chassis. This is
described in detail in the next chapter → 456000 15 Initialising and calibrating steering-angle sensor - section
on "Calibrating".
z The calibration results in zero point balancing (exactly straight ahead).
z The steering angle sensor is calibrated when first fitted and when any work has been carried out on steering
and chassis. Examples of this would be opening the steering wiring and alterations to toe and camber.
z Calibration includes initialisation.
1. Turn wheels to straight-ahead position.
2. Start engine.
3. From the straight-ahead position, turn steering wheel approx. 20° to the left and 20° to the right (past straight-
ahead position).
4. Drive the vehicle straight ahead for at least one second at a speed of over 4 km/h (2.5 mph).
Following successful initialisation, the stored fault code is set to "Not present". The PSM indicator light in the
instrument cluster goes out.
ATTENTION
Increased risk of accident if the battery is disconnected after initialising and/or the relevant fuse is
removed. There must be no undervoltage during the process.
→ Every time the battery is disconnected, the relevant fuse removed or an undervoltage is present, the steering-
angle sensor must be initialised (taught).
Adjusting steering angle sensor
Calibrating steering-angle sensor
Note
z The steering-angle sensor must be recalibrated on the measuring platform following repairs to or work on the
chassis/steering or if the steering-angle sensor/steering column switch/hydraulic unit is replaced.
z In order to be able to calibrate the steering angle sensor correctly, the vehicle must be on the measuring
platform, the wheel alignment values correct and the steering in the straight-ahead position.
z The security code is displayed in thePIWIS tester under Menu >> PSM >> Actual values.
The steering angle sensor must be calibrated using the menu with the Porsche System Tester under the specified
test conditions:
1. Switch on ignition.
2. Running gear set according to Porsche specifications.
3. Wheels in straight-ahead position and steering wheel horizontal.
4. In the straight-ahead position, the steering wheel must deviate by no more than ± 2.0° from the horizontal
position (steering centre position).
5. After successful calibration, the stored fault code is erased from the fault memory. The PSM indicator light in
the instrument cluster goes out.
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45 60 19 Removing and installing steering-angle sensor - as of MY

2003
- General information
- Replacing the steering-angle sensor
General information
The steering-angle sensor is integrated into the → see figure steering column switch.
The steering angle is recorded in the contact unit for airbags (spiral spring) -C- . The sensed data is sent from the
electronic unit -E- via the drive CAN bus to various systems (e.g., PSM, corner-sensitive headlight) for further
processing. Replacement of the steering angle sensor requires the steering column switch to be removed.
If faults have been diagnosed on the steering-angle sensor, the steering column switch must be disassembled
into the components -A, B, C, D, E- .
It is only permissible to replace the steering-angle sensor as the combination of the components contact unit for
airbag -C- (spiral spring) and electronic unit -E- .
A- Direction indicator switch
B- GRA switch
C- Contact unit for airbag (spiral spring)
D- Switch for wiper and washer system
E- Electronic unit
Replacing the steering-angle sensor
A - Direction indicator switch

B - GRA switch
C - Contact unit for airbag (spiral spring)
D - Switch for wiper and washer system
E - Electronic unit
1. In order to replace the steering angle sensor, the components contact unit for airbag -C- and the electronic
unit -E- must be replaced → 945019 Removing and installing steering column switch (Removing and
installing steering column switch includes disassembling and assembling).
2. Once installed, the steering angle sensor must be calibrated with the Porsche System Tester PSM
→ 456015 Initialising and calibrating steering-angle sensor.
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45 61 55 Replacing combination sensor - as of MY 2003

- Preliminary work
- Replacing combination sensor
- Subsequent work
Preliminary work
Preliminary work
The combination sensor is located under the centre console.
The functions listed below are integrated into the combination sensor:
z Rate-of-turn sensor
z Lateral acceleration sensor
z Axial acceleration sensor
Overview of combination sensor
1. Disconnect battery. → 90 Work instructions after disconnecting the

battery
2. Remove centre console cover and cup holder. → 681919 Removing

and installing cover for centre console [9PAAD1 9PAAE1 9PAAF1
9PAAJ1]→ 681919 Removing and installing cover for centre
console [9PAAD7 9PAAE7]
3. Remove triggering unit for airbag → 695319 Removing and installing
triggering unit for airbag
Combination sensor under the centre

console (cup holder)
Warning notes
ATTENTION
Increased risk of accident if combination sensor is uncalibrated or incorrectly calibrated.
→ After installation or replacement of combination sensor, calibrate vehicle with the Piwis tester.
→ Calibration must only be performed with the vehicle >> standing horizontally with the brakes off <<.
Replacing combination sensor
Replacing combination sensor
Separate the cross bar of the carpet -arrow - . Underneath is the

combination sensor.
Separating carpet at combination

sensor
First push on the combination sensor connector firmly (makes removal
easier!). -arrow- . Lift connector lock and then remove connector!
Replace combination sensor. → Tightening torque: 8 (6 ftlb.) Nm +/-1

(0.5 ftlb.) Nm
Pulling off plug of combination sensor
Subsequent work
Subsequent work
1. Install triggering unit for airbag. → 695319 Removing and installing triggering unit for airbag
2. Install centre console cover. → 681919 Removing and installing cover for centre console [9PAAD1 9PAAE1
9PAAF1 9PAAJ1]→ 681919 Removing and installing cover for centre console [9PAAD7 9PAAE7]
Note
After installation or replacement of combination sensor, calibrate vehicle.
z Calibration must only be performed with the vehicle >> standing horizontally with the brakes off <<.
4. Calibrate combination sensor. To do this connect the Piwis tester: Select >> Vehicle Cayenne >> System
PSM >> Actual values menu >> Security code << (at end of list). Note the security code. Quit >> Actual
values menu << .
5. Select >> Calibration menu << . Enter security code. Calibrate >> Lateral acceleration sensor << and >>
Axial acceleration sensor << in sequence using the menu.
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45 IN Information on PSM - as of MY 2003

- Information on PSM
Information on PSM
PSM is an active control system to stabilise the vehicle at the limit of driving dynamics. Sensors continuously
determine:
z Vehicle speed
z Direction of travel (steering angle)
z Transverse acceleration
z Longitudinal acceleration
z Rate of turn
Note
z The PSM (Porsche Stability Management) is automatically ready/switched on after each engine start.
Off-road PSM
When the Low Range/Off-road programme is switched on, an off-road PSM specially adapted for off-road terrain
to improve traction is automatically activated. At speeds below 35 km/h, the off-road PSM reacts later in the case
of under or oversteering and improves the steering control.
Switching off PSM
Press the PSM switch. The PSM switches off after a short delay.
When the PSM is off, the PSM OFF warning light in the instrument panel and the indicator light in the switch are
lit.
z When braking, the vehicle is also stabilised when the PSM is switched off!
z One-sided wheel spin is also prevented when the PSM is switched off!
z On Tiptronic vehicles, the slip upshift function is switched off when PSM is switched off → 45 IN Information
on PSM - chapter on "Information"! Characteristic features of Tiptronic vehicles (slip upshift).
The 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 difficult terrain (if one or more wheels have little or no road grip - engine performance is
reduced)
Switching PSM back on
Press the PSM switch. The PSM switches on after a short delay.
Characteristic features of Tiptronic vehicles (slip upshift)
z When a maximum permissible speed difference between front and rear axle is exceeded, the integrated slip
monitoring shifts into the next highest gear. This increases the driving stability on slippery roads.
z When PSM is switched off, the slip monitoring (slip upshift function) is also switched off. In this way, the
Tiptronic enables an active sporty driving style even when the friction coefficient is low as is the case with
manual transmission vehicles.
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46 05 19 Removing and installing brake pedal - as of MY 2003

- Preliminary work
- Removing brake pedal
- Installing brake pedal
- Subsequent work
Tools

unlocking tool special tool T10189
Preliminary work
1. Move the driver's seat back.
2. Remove the lower cover. → 702219 Removing and installing cover under dashboard - chapter on
"removing" . At the diagnostic socket just unclip the connector from the rear.
Removing brake pedal
Note
z For better accessibility, remove the lower cover under the steering column.
1. Remove the lower cover. → 702219 Removing and installing cover

under dashboard - chapter on "removing" .At the diagnosostic socket
-arrow- just unclip the connector from the rear.
2. Remove the lower cover (in knee area) and the deformation
element→ 701919 Removing and installing trim under dashboard -
chapter on "removing" .
3. Remove the holder for the stop light switch and unclip the connector
-arrow- → 943619 Removing and installing stop light switch - chapter
on "removing".
Clip for stop light switch

4. Remove the holder -arrow- of the lower cover for the dashboard.
5. Remove relay carrier -arrows- → 979019 Removing and installing relay carrier, plenum panel E-box - chapter
on "removing".
6. Remove both control units -arrow- , on the right side under the dashboard → 966619 Removing and installing
Kessy/immobilizer control unit - chapter on "removing", → 971019 Removing and installing vehicle electrical
system control unit - chapter on "removing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 971019
21 Removing and installing vehicle electrical system control unit - chapter on "removing" [9PAAJ1].
7. Release the support (relay carrier/Kessy control unit/immobilizer/vehicle electrical system control unit) (left
side and front engaged, right side screwed) and let them hang. In this way, the brake pedal shaft can be
pushed out toward the centre of the vehicle (cardan tunnel).
8. Disengage the brake pushrod from the brake pedal mounting using
the unlocking tool T10189 . Observe the following procedure for this
purpose:
-1- - unlocking tool T10189 for brake pedal.
– Position the unlocking tool T10189 -1- so that the fork sits in correct position in the brake pedal mounting (in
the inset, the fork in contact, view against the direction of travel).
– Position the unlocking tool T10189 so that it is located in the right

mould of the support and is perpendicular to the vehicle floor. Like
this, the force deflection point (bending in the unlocking tool T10189)
is precisely next to the screw head -arrow- .
– When pressing forward on the lever (unlocking tool) (in direction of travel!), the brake pedal mounting is
pressed apart and the ball of the pushrod is released. At the same time, pull the brake pedal to the rear
(against the direction of travel!) and release the brake pedal from the pushrod.
9. Counter the brake pedal shaft (pin) -arrows- on the right side and slightly loosen to the left -(arrows)- . The
nut remains on the brake pedal shaft to protect the thread.
10. Loosen the two upward running struts of the articulated strut and let them hang. To do this, remove the
retainer on each retaining pin, remove the retaining pins, and let the struts hang down.
11. Using a hammer, force out the brake pedal shaft a few millimetres with short, heavy blows from left to right.
Brake pedal released from the
pushrod
Releasing pushrod from brake pedal
12. Place a screwdriver under the head of the brake pedal shaft (right side). Remove the nut, and lever out the
brake pedal shaft carefully toward the centre of the vehicle (cardan tunnel).
13. Carefully press out the brake pedal shaft so that the brake pedal can be removed.
Installing brake pedal

Note
z Do not grease or spray the brake pedal shaft (pin).
z For vehicles with automatic transmission a spacer tube is used instead of the clutch pedal.
z Use new lock nuts.
z Observe correct tightening torques → 46 TW Tightening torques for brake mechanics - chapter on "Technical
values".
z Tightening torque for brake pedal shaft (pin): 15 ± 2 ftlb.
Subsequent work
Remove the lower cover → 702219 Removing and installing cover under dashboard - chapter on "installing".
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46 TW Technical data/brake wear limits - as of MY 2003

- Technical values
Technical values
Technical data for Cayenne 17" brake system (3.2-litre)

value 1 2
Operating brake (foot Hydraulic dual-circuit brake system with
brake) with grey cast iron diagonal brake-circuit division. Vacuum
brake discs (standard brake booster, internally ventilated brake
brake) with PSM (Porsche discs with six-piston aluminium monobloc
Stability Management) as fixed-caliper brake at front axle and four-
standard piston aluminium monobloc fixed-caliper
brake at rear axle.
PSM Porsche Stability Management (PSM) as
standard with functions ABS, ASR
(Traction Control TC, engine drag torque
control MSR, ABD, lock control
(longitudinal). Optional: level adjustment,
infinite shock absorber adjustment, rear
axle block.
Tandem-brake booster Ø 9/10
(vacuum) inch
Boost ratio 7
Brake master cylinder Ø 26.99
mm
Brake-circuit division 18/18
mm
Brake master cylinder Ø 330
front mm
Brake discs Ø rear 330
mm
Brake disc thickness front 32
mm
Brake disc thickness rear 28
mm
Thickness tolerance of 0.01
brake disc max. mm
Effective brake disc Ø front 265.6
mm
Effective brake disc Ø rear 280.4
mm
Piston Ø in brake caliper 2 x 34 mm + 2 x 36 mm + 2 x 38 mm
front
Piston Ø in brake caliper 2 x 28 mm +2 x 30 mm
rear
Brake pad area front 384
cm²
Brake pad area rear 188
cm²
Total brake pad area 572
cm²
Technical data for 18" brake system (4.5-litre and 4.5-litre twin-turbo)

value 1 2
Operating brake (foot Hydraulic dual-circuit brake system with
brake at rear axle.
axle block.
(vacuum) inch
Boost ratio 7
mm
mm
front mm
mm
mm
mm
brake disc max. mm
Effective brake disc Ø front 284.6
mm
Effective brake disc Ø rear 280.4
mm
front
rear
cm²
cm²
cm²
Technical data for 19" brake system (4.5-litre twin-turbo) KIT

value 1 2
Operating brake (foot Hydraulic dual-cicuit brake system with
brake at rear axle.
axle block.
(vacuum) inch
Boost ratio 7
mm
mm
front mm
mm
mm
mm
brake disc max. mm
Effective brake disc Ø front 304
mm
Effective brake disc Ø rear 306
mm
front
rear
cm²
cm²
cm²
Technical data, wear limits for Cayenne 17" brake system (3.2-litre)

value 1 2
Pad thickness front Wear limit 2 mm approx.
10.5 mm
Pad thickness rear Wear limit 2 mm approx.
11.5 mm
Brake disc thickness front new 32 mm
Brake disc thickness rear new 28 mm
Brake disc minimum Only as new brake discs may be 31.6 mm
thickness after machining, reworked! Only rework the brake disc
front symmetrically, evenly from both sides!
Brake disc wear 30 mm
dimension front
dimension rear
Peak-to-valley surface 0.006 mm
roughness of brake disc
after machining max.
Thickness tolerance of 0.01 mm
brake discs after
machining max.
Lateral runout of brake 0.03 mm
disc max.
Lateral runout of wheel 0.02 mm
hub max.
disc when installed max.
Pushrod play not adjustable
Parking brake (foot- Drum brake acting mechanically on
operated parking brake) both rear wheels
Parking-brake drum Ø Wear limit 211 mm 210 mm
Brake shoe width 30 mm
Brake pad thickness Wear limit 1 mm 3 mm
Technical data on wear limits for 18" brake system (4.5-litre and 4.5-litre twin-turbo)

value 1 2
10.5 mm
11.5 mm
dimension front
dimension rear
brake discs after
machining max.
disc max.
hub max.
Technical data on wear limits for 19" brake system (4.5-litre twin-turbo) KIT

value 1 2
11.25 mm
12.2 mm
dimension front
dimension rear
brake disc after
machining max.
disc max.
hub max.
9PAAD1, 9PAAD7, 9PAAJ1
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46 11 15 Adjusting the brake pushrod - as of MY 2003

- Adjusting
Tools

Adjusting
Adjusting the brake pushrod
Note
z The brake pushrod play is strictly specified.
z The play cannot be adjusted.
The brake pushrod can be removed from the brake pedal with the unlocking tool T10189 .

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46 TW Tightening torques for brake mechanics - as of MY 2003

- Tightening torques for brake mechanics
Tightening torques for brake mechanics

value 1 2
Brake caliper to wheel carrier Thread M16 x 1.5 (Replace Tightening 200
front screws and lock nuts after torque ftlb.
each removal.)
Brake caliper to wheel carrier Thread M14 x 1.5 (Replace Tightening 133
rear screws and lock nuts after torque ftlb.
each removal.)
Fastening screw, brake Thread M12 x 1.5 (Replace Tightening 10.5
caliper to wheel hub (front screws and lock nuts after torque ftlb.
and rear axle) each removal.)
Plug, brake disc rear Thread M12 x 1.5 x 5.5 Tightening 10.5
torque ftlb.
Brake cover plate to front Thread M8 x 12 Tightening 15 ftlb.
axle torque
Caliper carrier to wheel Thread M8 x 16 Tightening 15 ftlb.
carrier rear torque
Caliper carrier to wheel Thread M6 x 12 Tightening 6 ftlb.
carrier rear torque
Retaining pin for front brake Thread M8 x 15 (always Tightening 22 ftlb. +/-1.5 ftlb.
pads replace retaining pin) torque
Speed sensor to front and Thread M6 x 16 Tightening 6 ftlb.
rear axles torque
Brake hose holder to wheel Thread M6 x 12 Tightening 6.5 ftlb.
carrier front axle torque
Cable holder to wheel carrier Thread M8 x 14 Tightening 22 ftlb.
front axle torque
Brake booster Thread M8 Tightening 19 ftlb. +/-2 ftlb.
torque
Mount for hydraulic unit Thread M6 x 10 Tightening 7.5 ftlb.
support torque
Mount for intermediate piece Thread M6 x 14 Tightening 7.5 ftlb.
torque
Foot-operated parking brake Thread M8 x 40 Tightening 17 ftlb.
pedal to mounting bracket torque
Foot-operated parking brake Thread M8 x 16 Tightening 17 ftlb.
pedal to mounting bracket torque
Deflector to body (tunnel) Thread M8 x 20 Tightening 17 ftlb.
torque
Pedals (pedal bearing block) Thread M8 x 20 Tightening 17 ftlb. +/-2 ftlb.
to firewall torque
Clutch slave cylinder to pedal Thread M6 x 25 Tightening 7.5 ftlb. +/-1.0 ftlb.
bearing block torque
Screws for articulated strut to Tightening 7.5 ftlb. +/-1.0 ftlb.
pedal bearing block torque
Brake lever shaft bolt Thread M8 Tightening 15 ftlb. +/-2 ftlb.
(inserted from right to left) torque
Clip (holder) stop light switch Tightening 6 ftlb. +/-0.5 ftlb.
torque
Wheel to wheel hub Thread M14 x 1.5 Tightening 118
torque ftlb.
ABS cable holder to wheel Thread M6 x 16 Tightening 6 ftlb.
carrier rear axle torque
Brake line holder to brake Thread M6 x 12 Tightening 6 ftlb.
caliper rear axle torque
Cable holder for speed Thread M6 Tightening 6 ftlb.
sensor/ABS to control arm torque
rear (upper front)
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46 01 Checking the thickness of the disc brake pads - as of MY

2003
- Checking
Checking
Checking thickness of the disc brake pads
WARNING
Risk of accident if brake pads and brake discs are not replaced in time.
z Injury and material damage due to impaired braking effect.
→ Brake discs must be replaced on reaching the wear limits.
Note
z If brake pad wear is indicated by the warning light, the warning contact (sensor including line and plug
connection) must also be replaced.
z 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- .
z Warning contacts must be replaced if the core of the line is worn.
z However, if only the plastic part of the warning contact is worn, there is no need to replace it.
ATTENTION
Increased risk of accident or damage to brake discs when mounting/removing wheels.
z Material damage to the brake discs.
→ Use assembly aids (assembly pins) to exclude any possibility of

heavy contact of the wheel with the brake disc. The assembly aids
(assembly pins) are located in the luggage compartment.
1. To check the brake pads, remove the wheels. Before

removal/installation of wheel, screw the assembly aids (assembly
pins) -see illustration- , instead of two wheel bolts, into the wheel
hub. During removal, first remove the three remaining wheel bolts
and remove the wheel carefully without touching the brake discs.
2. Visually inspect the brake pads for wear.
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46 IN Component arrangement - foot-operated parking brake - as

of MY 2003
- Component arrangement
Component arrangement
A foot-operated parking brake is used in the Porsche Cayenne.
Special demands for a sporty, multi-purpose vehicle have been taken into account when designing the foot-
operated parking brake. To achieve the required capabilities, it was designed as a foot-activated parking brake
with an intermediate transmission ratio. The Cayenne can be parked reliably with a full load on gradients of 55 %.
A cable is routed from the foot-operated lever to a deflection lever under the centre console which transmits
traction to a turnbuckle with a transmission ration of 3.1. Two cables are routed from the turnbuckle to the parking
brakes on the rear axle.
The foot-operated parking brake is designed as a duo-servo drum brake and is integrated into the rear brake
discs.
A - Parking brake release. Location: lower dashboard trim panel.
B - Parking brake pedal. Location: left side of driver's footwell.
C - Parking brake cable. Location: under carpet in driver's footwell.
D - Deflector. Location: under centre console.
E - Brake cable, rear. Location: Each fitted from the console/deflector to a rear wheel brake.
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46 IN Component arrangement - foot-operated parking brake - as

of MY 2003
- Information
Information
Component arrangement - foot-operated parking brake
A foot-operated parking brake is used in the Porsche Cayenne.
Special demands for a sporty, multi-purpose vehicle have been taken into account when designing the foot-
operated parking brake. To achieve the required capabilities, it was designed as a foot-activated parking brake
with an intermediate transmission ratio. The Cayenne can be parked reliably with a full load on gradients of 55 %.
A cable is routed from the foot-operated lever to a deflection lever under the centre console which transmits
traction to a turnbuckle with a transmission ration of 3.1. Two cables are routed from the turnbuckle to the parking
brakes on the rear axle.
The foot-operated parking brake is designed as a duo-servo drum brake and is integrated into the rear brake
discs.
-A- - Parking brake release. Arrangement: In the trim for lower dashboard.
-B- - Parking brake pedal. Arrangement: In left of driver's footwell.
-C- - Parking brake cable. Arrangement: Under carpet in driver's footwell.
-D- - Deflector. Arrangement: Under centre console.
-E- - Brake cable, rear. Arrangement: Fitted from the console/deflector to a rear wheel brake.
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46 36 19 Removing and installing the front disc brake pads - as of

MY 2003
- Preliminary work
- Removing
- Installing
- Subsequent work
- Information
Tools

Preliminary work
Preliminary work
Remove wheel → 440519 Removing and installing wheel - chapter on "removing".
Removing
Removing front brake pads

The core of the warning contact line must not be left exposed! Worn insulation is not significant!
If necessary, remove a little brake fluid from the expansion tank by suction to prevent overflow when the disc
brake pad is pushed back!
1. Remove fastening screw at retainer pin. Then screw in auxiliary

screw M8. Hold down expanding springs with a screwdriver
-see illustration- and remove retainer pin.
2. Remove warning contact line from brake caliper and expanding
spring. Remove warning contacts from the brake disc pads.
3. Place piston resetting fixture (replaces P83) NR.144, see

Workshop Equipment Manual, Chapter 2.4, on brake caliper between
the disc brake pads and push the pads back evenly -arrows- .
4. Remove disc brake pads.
Installing
Installing front disc brake pads
WARNING
Danger of accident if old parts are fitted on brake caliper.
z Fit new expanding spring, new retaining pin and new retaining pin screw on the brake caliper.
→
WARNING
Danger of accident if brake pads of the wrong quality are installed.
z Use only the type-specific brake pads in the Porsche Spare
Parts Catalogue.
Do not grease the back of the disc brake pad!
The new disc brakes must be clean and free of grease!
Check disc brakes for wear; for wear limits see → 46 Technical
data/brake wear limits!
Use a new repair kit!
Observe tightening torques → 46 Tightening torques for brake mechanics.
1. If necessary, push brake piston back into its original position using the piston resetting fixture (replaces
P83) NR.144, see Workshop Equipment Manual, Chapter 2.4.
2. Fit new disc brake pads.
Note
z Make sure that the retaining pin is inserted in the correct position! The flat side surfaces prevent the retaining
pin from twisting in the brake caliper.
3. Install expanding spring. Centre the retaining pin in the bore with the
M8 auxiliary screw. To do so, press retaining pin back with auxiliary
screw and push retaining pin through. Remove auxiliary screw and fit
fastening screw at retaining pin with specified tightening torque → 46
Tightening torques for brake mechanics!
4. Install warning contact line at disc brake pads and expanding spring -arrows- . The cable guide in the
expanding spring must be at the bottom!
6. Check brake fluid level and correct if necessary. The brake fluid level
must lie within the -MAX-MIN marking- .
Subsequent work
Subsequent work
1. Fit wheel → 440519 Removing and installing wheel - chapter on "installing" .
Information
Bedding in the brake pads
New brake pads require a bedding-in period of approx. 200 km! 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!
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46 36 20 Removing and installing front brake pads - as of MY 2003

- Preliminary work
- Removing front brake pads
- Installing front brake pads
- Subsequent work
Tools

Preliminary work
Preliminary work
1. Remove wheel. → 440519 Removing and installing wheel
WARNING
z This can result in longer braking distances and more wear.
→ Use only the type-specific brake pads in the Porsche Spare Parts Catalogue.
1. Remove fastening screw at retainer pin. Next screw the M8 auxiliary

screw into the retaining pin. Hold down expanding springs with a
→ see figure screwdriver and remove retaining pin.

the disc brake pads and push the pads back evenly
-direction arrows- .
Installing front brake pads
WARNING
z This can cause malfunctions.
→ Fit new expanding spring, new retaining pin and new retaining pin
screw on the brake caliper.
Do not grease the back of the disc brake pad !
Check disc brakes for wear. For wear limits see Technical Data → 46
TW Technical data/brake wear limits - chapter on "Technical values"!
The core of the warning contact line must not be left exposed! Worn
insulation is not significant!
Observe correct tightening torques → 46 TW Tightening torques for brake

mechanics - chapter on "Technical values"!
Removing brake pad
Note
z Make sure that the retaining pin is inserted in the correct position.
The flat side surfaces prevent the retaining pin from twisting in the
brake caliper.
M8 auxiliary screw. To do so, push retaining pin back with auxiliary
TW Tightening torques for brake mechanics - chapter on "Technical
values"!
6. Check brake fluid level and correct if necessary. The brake fluid level must lie within the → see figure MAX -
MIN marking.
emergencies!
Subsequent work
Mount wheel. → 440519 Removing and installing wheel
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46 38 19 Removing and installing the rear disc brake pads - as of

MY 2003
- Preliminary work
- Removing
- Installing
- Subsequent work
- Information
Tools

Preliminary work
Preliminary work
Removing
Removing rear disc brake pads

1. Remove lock (securing clip) -top arrow- from retaining pin and
remove retaining pin -direction arrow- inwards.

3. Remove expanding spring.

Installing
Installing rear disc brake pads
WARNING
z Fit new expanding spring, new retaining pin and new safety bracket on the brake calliper.
→
WARNING
z Use only the type-specific brake pads in the Porsche Spare Parts Catalogue.
Note
z The back of the pad backing plates must not be greased.
z Check disc brakes for wear; for wear limits see → 46 Technical data/brake wear limits.
z Disc brakes must be clean and free of grease.
z The core of the warning contact wire must not be left exposed! Worn insulation is not significant.
z If necessary, remove a little brake fluid from the expansion tank by suction to prevent spilling when the disc
brake pad is pushed back.
z Use new repair kit.
z Observe tightening torques → 46 Tightening torques for brake mechanics.
2. Fit disc brake pads.
3. Fit expanding spring, retaining pin -direction arrow- and lock (safety
bracket) -top arrow- at top of retaining pin.
4. Fit warning contact line at bottom of brake caliper -bottom arrow-

and warning contacts at disc brake pads.
5. Press the brake pedal several times while the car is stationary to
position the pads on the brake disc.
6. Check brake fluid level and correct if necessary. The brake fluid level must lie within the
-MAX-MIN marking- .
Subsequent work
Subsequent work
Information
emergencies!
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46 38 20 Removing and installing rear brake pads - as of MY 2003

- Preliminary work
- Removing rear disc brake pads
- Installing rear disc brake pads
- Subsequent work
Tools

Preliminary work
Preliminary work
WARNING
The core of the warning contact line must not be left exposed! Worn insulation is not significant !
1. Remove lock (securing clip) -arrow- at top from retaining pin and
remove retaining pin -direction arrow- inwards


WARNING
→ Fit new expanding spring, new retaining pin and new retaining pin screw on the brake caliper.
The back of the pad backing plates must not be greased !
Check disc brakes for wear. For wear limits see Technical Data → 46 TW Technical data/brake wear limits -
chapter on "Technical values"!
New disc brakes must be clean and free of grease!
Observe correct tightening torques → 46 TW Tightening torques for brake mechanics - chapter on "Technical
values"!
3. Install expanding spring, retaining pin -direction arrow- and lock

(safety bracket) -arrow- at top of retaining pin.
4. Install warning contact line at bottom of brake caliper -arrow- and

warning contacts at disc brake pads.
must lie within the → see figure MAX - MIN marking.
emergencies!
Subsequent work
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46 50 02 Checking front brake discs (wear assessment) - as of MY

2003
- Information
- Checking
Tools

dial gauge set with ball joint commercially NR.147-
arm available tool 1
adapter plate special tool P

9510/1
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 arise through 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.
The 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.
The maximum crack length limit is calculated as follows:
0.5 x a ( -a- = width of friction surface in mm).
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.
Width of friction surface a

Bedding in the brake pads and brake discs
New brake pads require a bedding-in period of approx. 200 km! Not until then do they achieve 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.
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. -steel rule-
Note
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.
As a precaution, brake discs must
be replaced when:
z the → Maximum crack

length: 0.5 x a mm (a =
friction surface width in mm) is
exceeded!
width: 1 mm is exceeded!
depth: 1.5 mm is exceeded!
Brake discs Width of friction surface a

Checking front brake discs (minimum thickness)
Note
Normally, brake discs are used until the maximum wear dimension is reached. → 46 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 (see Workshop Equipment Manual, Chapter 3.4).
z Only as new brake discs may be reworked!
z 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.
Wear areas A and B

The central wear area -B- is the area with the highest degree of wear.
– Measure the brake discs with a suitable micrometer at a minimum of three different places ( -A, B, C- ),
offset by 120°.
Checking lateral runout (brake disc/wheel hub) and thickness tolerance
Note
Fasten dial gauge set with ball joint arm to wheel bearing housing.
For checking lateral runout two
adapters are used. The brake disc
and wheel hub can be measured
with these.
Brake disc lateral runout
Measurement points for brake disc Wear area B

thickness
1. Remove the wheel → 440519 Removing and installing wheel and fit
the adapter plate P 9510/1 with tightening torque 160 Nm (118 ftlb.).
Adapter plate on wheel hub

2. Fit the adapter dial gauge set with ball joint arm NR.147-1 at a
suitable position on the wheel bearing housing.
3. 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
Note
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 Dial gauge on brake disc
hub. You should always measure the external and internal diameters
of the wheel bolt area.
1. Remove the brake disc. → 465019 Removing and installing the front brake disc
2. Fit the adapter dial gauge set with ball joint arm NR.147-1 at a suitable position on the wheel bearing
housing. Fit the dial gauge with some preload.
Brake disc thickness tolerance
– Brake disc thickness tolerance max. 0.01 mm

.
– Measure the thickness tolerance with a suitable micrometer screw within the braking surface at approx. eight
points.
Dial gauge on wheel hub
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46 50 19 Removing and installing front brake disc - as of MY 2003

- Preliminary work
- Removing front brake disc
- Installing front brake disc
- Subsequent work
Tools

Preliminary work
Preliminary work
Removing front brake disc
Note
z In order to gain better access for removal of the brake calliper, it is beneficial to turn the wheels fully either to
the right or the left.
1. Release retainer for plug of wear indicator on wheel carrier.
2. Disconnect the speed sensor on the ABS sensor.
3. Push brake pad back slightly and evenly with piston resetting
fixture (replaces P83) NR.144, see Workshop Equipment Manual,
Chapter 2.4 -direction arrow- . Make sure that no brake fluid runs
out of the supply tank - if necessary, remove by suction.
4. Undo brake caliper on wheel carrier and hang it in a suitable place in
the wheel well (do not open the brake hydraulics!).
5. Remove brake disc after unscrewing the fastening screw. If

necessary, remove the brake disc by tapping it gently with a rubber
hammer.
Installing front brake disc

Do not confuse right and left brake discs during assembly!
Distinguishing characteristic: Part No.! The flat surface of the brake discs is marked with R = right or L = left.
1. Check that all parts are in perfect condition and replace them if necessary.
2. Clean the levelling and centring surfaces on the brake disc and wheel hub. Then apply a very thin coat of
Optimoly TA to the centring surface on the wheel hub.
3. Fit the brake disc. Observe correct tightening torque → 46 TW Tightening torques for brake mechanics -
4. Fit the brake caliper. Replace the brake caliper fastening screws after each removal. Observe correct
tightening torque → 46 TW Tightening torques for brake mechanics - chapter on "Technical values".
5. Install retainer for plug of wear indicator on wheel carrier.
6. Connect the speed sensor on the ABS sensor.

Subsequent work
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46 53 02 Checking rear brake discs (wear assessment) - as of MY

2003
- Information
- Checking
Tools


9510/1
Information
brake discs.

Checking
Checking rear brake discs (evaluating cracks)
limits.
Note
be replaced when:

exceeded!

Checking rear brake discs (minimum thickness)
Note
-A- Outer and inner wear areas.
Wear areas A and B

offset by 120°.
Note
with these.

thickness

suitable position on the wheel bearing housing (schematic
representation of front axle).
Note
Dial gauge on brake disc
– Measure the wheel hub lateral runout at the front face of the wheel
1. Remove the brake disc. → 465319 Removing and installing rear brake disc
housing (schematic representation of front axle). Fit the dial gauge with some preload.

.
– Measure the thickness tolerance with a suitable micrometer screw within the braking surface at approx. 8
points.
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46 53 19 Removing and installing rear brake disc - as of MY 2003

- Preliminary work
- Removing rear brake disc
- Installing rear brake disc
- Subsequent work
Tools

Preliminary work
Preliminary work
1. Remove wheel → 440519 Removing and installing wheel.
2. Remove brake caliper → 474119 Removing and installing rear brake caliper - chapter on "Installing".
Removing rear brake disc

1. Disconnect plug connection for brake pad wear indicator on wheel carrier.
2. Remove screw plug -arrow- . The adjustment device can be turned through this bore.
3. Turn the brake disc in such a way that the adjustment device
becomes visible. With a → see figure screwdriver through the bore,
turn the adjustment device towards "release".
Chapter 2.4 -direction arrow- .

the wheel well (do not open the brake hydraulics). But first pull out
the electrical lines from the holder on the brake caliper and the brake
pad wear line from the holder on the wheel carrier.
hammer.
Installing rear brake disc

3. Fit the brake disc. Observe tightening torque. → 46 TW Tightening
torques for brake mechanics - chapter on "Technical values".
4. Adjust the brake shoes of the foot-operated parking brake with a

→ see figure screwdriver . → 468316 Adjusting foot-operated parking
brake - chapter on "adjusting"
5. Fit the brake caliper. Replace the brake caliper fastening screws after
each removal. Observe tightening torque. → 46 TW Tightening
torques for brake mechanics - chapter on "Technical values".
Subsequent work
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46 58 19 Removing and installing front brake cable for foot-

operated parking brake - as of MY 2003
- Preliminary work
- Removing front brake cable
- Installing front brake cable
- Subsequent work
Preliminary work
1. Move control pedal to zero position (pull release). Parking brake is released.
2. Remove trim panel in the sill area → 680519 Removing and installing inner door sill trim - chapter on
"removing" .
3. Remove lower A-pillar trim panel panel → 705719 Removing and installing A-pillar trim panel panel - chapter
on "removing".
4. Remove centre console → 681719 Removing and installing centre console - chapter on "removing" .
5. Remove cover in the driver's footwell → 702219 Removing and installing cover under dashboard - chapter
on "removing".
Removing front brake cable
Front brake cable -C-
Note
z Front brake cable means: From the release for the foot-operated parking brake to the deflector under the
centre console.
z The actuating pedal for the foot-operated parking brake does not have to be removed to do this.
1. Fix the adjustment device using an → see figure auxiliary pin (max. 3.5 mm Ø) . In other words: press the
adjustment device together -arrow- until the assembly bores are covered and the auxiliary pin can be
inserted → 466019 Removing and installing actuator for foot-operated parking brake - chapter on
"removing". Only remove the ball head of the brake cable -1- when the brake cable has been removed from
the deflector (centre console) .
2. Lift the front carpet (do not bend) and push the rear carpet aside.
3. Remove securing clip on the deflector -arrow- .
4. Unclip securing clip using a → see figure screwdriver and remove it.
5. Remove the ball head from the latch on the deflector. To do this
→ see figure place an open-ended wrench (a/f 22) on the deflector
hexagon and turn it until the end of the cable can be removed
(arrow).
6. To remove the brake cable, press the retaining lugs on the securing clip -arrows- ) together and pull it out of
the bracket.
7. Remove the cover of the actuating module.
Note
z The cable retainer on the actuating pedal for the front brake cable
cannot be removed and is not available as an individual part. During
removal, carefully press the → see figure cable retainer back using a
small screwdriver.
8. Remove the brake cable at the actuating pedal. To do this, press the
retaining lugs on the securing clip -arrows- together and pull the
brake cable out of the bracket. Push the ball head out of the latch.
Carefully press the securing lug back using a small screwdriver and
remove the brake cable .
9. Remove the brake cable under the wiring harness and under the air guide.
Installing front brake cable
1. Lay the brake cable under the wiring harness -arrow- and under the air guide -arrow- .
2. Fit the ball head to the latch on the actuating pedal. Make sure that the securing lug is not damaged.
3. Push the ball head into the latch on the deflector. To do this → see figure use an open-ended wrench (a/f 22)
on the deflector hexagon and turn it until the end of the cable can be inserted.
4. Engage the → see figure securing clip into the bracket on the
deflector and make sure it is fitted correctly. Observe the following
note for this purpose:
Note
z Damaged securing clips must be replaced. The brake cable can
become detached if the securing clip is defective.
z Pass securing clip behind brake cable.
z Clip in securing clip -direction arrow- .
z → see figure Securing clip in end position.
5. Install cover of driver's footwell → 702219 Removing and installing cover under dashboard - chapter on
"Installing" and lay the carpet .
6. Perform a function test.

Subsequent work
1. Fit centre console → 681719 Removing and installing centre console - section on "Installing" .
2. Install lower A-pillar trim panel panel → 705719 Removing and installing A-pillar trim panel panel - chapter
on "Installing" and fit the trim panel in the sill area → 680519 Removing and installing inner door sill trim -
3. Remove → see figure auxiliary pin from the actuator of the foot-
operated parking brake and install cover on actuating module.
4. Install driver's seat → 720119 Removing and installing driver's seat -

chapter on "Installing" .
5. Carry out a function test on the foot-operated parking brake.
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46 60 19 Removing and installing pedal for foot-operated parking

brake - as of MY 2003
- Preliminary work
- Removing pedal for foot-operated parking brake
- Installing pedal for foot-operated parking brake
- Subsequent work
Preliminary work
1. Remove lower trim panel in footwell (with diagnostic socket and footwell lighting) and the trim panel support
on the bulkhead (only inserted) → 702219 Removing and installing cover under dashboard - chapter on
"removing" .
2. Remove lower dashboard trim panel → 701919 Removing and installing trim panel under dashboard -
3. Remove side cover of dashboard (fuse box) and the lower A-pillar
trim panel → 702419 Removing and installing trim panel for front side
section - chapter on "removing". To remove the A-pillar trim panel,
only partial removal of the >> trim panel for front side section << is
required!
Removing pedal for foot-operated parking brake
Pedal for foot-operated parking brake (FPB)
The foot-operated parking brake is abbreviated to FPB in the table below.

-A- Mounting points for FPB 2 Replace micro-encapsulated
pedal screw. M8 tightening torque
= 17 ftlb.
-B- Cable receiver for bowden 1 Take off side cover Pay attention to routing of
cable for releasing the (dashboard) to facilitate bowden cable.
FPB removal.
-C- Cable receiver for front 1 Take care not to damage The cable retainer engages
brake cable cable retainer during automatically during
removal. Not available as installation.
individual part.
-D- Contact switch 1 Check function of contact
switch following installation
(signal light in instrument
cluster).
-E- Adjustment device 1 Automatically set when
(automatic cable actuated for first time.
adjustment)
-F- Assembly bore 1 Only for installation (makes
brake cable assembly
easier).
Removing pedal for foot-operated parking brake (FPB)
1. Loosen bowden cable for releasing the FPB at the dashboard (at the side). Pull the release lever slightly.
Then, slide the bowden cable in the direction of travel and take the bowden cable sleeve out of the bracket.
2. Remove protective cover (two screws) over the foot-operated parking brake pedal.
3. Remove cover (protective grille) of foot-operated parking brake pedal.
4. Remove FPB switch.

Note
z Fix cables using tie-wraps to prevent damage while removing and
inserting the FPB pedal.
z The → see figure cable retainer for the front brake cable cannot be
removed and is not available as an individual part. Push the cable
retainer back carefully during removal (Point 8).
5. Lay the carpet aside. Remove fastening screws of FPB pedal (two
M8 screws). Next remove the FPB pedal. The pedal must not be
actuated (removal aid).
6. Disengage front cable. To do this → see figure carefully press back

the retaining lug using a small screwdriver.
Installing pedal for foot-operated parking brake
Note
z Replace micro-encapsulated screws.
z If the bowden cable or front brake cable are damaged, replace them.
z Automatic cable adjustment means that the foot-operated parking

brake does not need to be set (basic setting).
1. Fix the adjustment device using an auxiliary pin (max. 3.5 mm Ø )

-arrow- (this makes assembly easier). In other words: press the
adjustment device together until the assembly bores are covered and
the auxiliary pin can be inserted. Engage front brake cable. The
retainer engages automatically. Remove the auxiliary pin again.
2. Insert the FPB pedal.
3. Tighten the fastening screws to 23 Nm (17 ftlb.). Take off the additional tie-wraps used during removal.
4. Remove FPB switch. Route cables neatly.
5. Engage the bowden cable for releasing the FPB in the lever.
6. Engage bowden cable in the release lever.
7. Lay carpet. Fit cover (protective grille) of foot-operated parking brake pedal and protective cover (two
screws) over the pedal.
Subsequent work
1. Fit lower A-pillar trim panel and side cover of dashboard→ 702419 Removing and installing trim panel for
front side section - chapter on "installing".
Remove lower dashboard trim panel → 701919 Removing and installing trim panel under dashboard - chapter on
"installing".
2. Remove lower trim panel in footwell (with diagnostic socket and footwell lighting) and the trim panel support
on the bulkhead (only inserted) → 702219 Removing and installing cover under dashboard - chapter on
"installing" .
3. Check operation of foot-operated parking brake.
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46 79 55 Replacing rear brake cable for foot-operated parking

brake - as of MY 2003
- Preliminary work
- Removing and installing rear brake cable
- Releasing brake cable at wheel bearing housing
- Subsequent work
Preliminary work
1. Move control pedal of the foot-operated parking brake to the zero position. To do this, pull the release lever on
the dashboard.
2. Remove cover in the footwell → 702219 Removing and installing cover under dashboard - chapter on
"removing".
Removing and installing rear brake cable
Removing rear brake cable
Rear brake cable -E- means: From the deflector under the centre console -D- to the Quickfit lock in the brake drum
on the rear wheel.
Note
z When performing various tasks on the rear axle, e.g. removing and installing the wheel bearing housing, the
brake cable only needs to be detached without removing the entire brake cable. The description at the end of
the installation chapter, → 467955 Replacing rear brake cable for foot-operated parking brake - chapter on
"detaching", can be used for this purpose.
1. Fix the adjustment device using an → see figure auxiliary pin (max. 3.5 mm Ø ) . In other words, press the
adjustment device together -arrow- until the assembly bores coincide and the auxiliary pin can be inserted
→ 466019 Removing and installing pedal for foot-operated parking brake - chapter on "Removing". The cover
of the pedal need not be removed. The auxiliary pin can be inserted through the cover .
2. Remove centre console → 681719 Removing and installing centre console - chapter on "Removing" .

4. Remove the relevant rear wheel → 440519 Removing and installing wheel - chapter on "Removing".
5. Pull the balancing clip of the deflector completely back, against the
direction of travel, and loosen the → see figure small fastening screw.
6. To remove and disengage the ball head(s) of the cables, the nut on
the threaded rod -arrow- can be loosened by a few turns. (Note the
number of turns! Mark the nut, if necessary)
7. Push the ball head out of the balancing clip of the deflector in -direction of arrow- and remove it sideways.
Press the sleeve of the cable in the interior (two plastic lugs) gently together and push through to the rear,
against the direction of travel.
8. Remove the → see figure sheetmetal clips of the hand brake cables at the fuel tank (underbody) with a
screwdriver.
9. Pull the relevant cable out to the rear.

Note
z The screw plug -arrow- of the brake disc obscures the view of the
Quickfit. The Quickfit is positioned at approx. 3 o'clock to the right and
approx. 9 o'clock to the left.
z The brake discs do not have to be removed to disengage the brake

cables.
10. Remove the screw plug -arrow- on the brake disc.
11. Remove the brake cable. Do not loosen the circlip! To do this, insert a
screwdriver between the sleeve of the brake cable and the wheel
bearing housing .
12. Pull the sleeve of the cable -arrow- as far as possible out of the wheel
bearing housing.
13. Push the cable gently into the brake drum. Use a small screwdriver inserted through the brake disc opening to
press the retaining spring and hexagon on the expander lever upwards and at the same time pull the brake
cable out of the brake drum.
Installing rear brake cable

Note
z On vehicles whose cables are
still good but stretched, the -3-
ring grooves of the circlip can
be used as compensation.
z In this case, loosen the → see figure circlip carefully (do not remove
from brake cable!) and move by one ring groove. The circlip and cable
are only available as an assembly. The settings should be the same
on both sides.
z If the circlip has been damaged during removal/fitting (e.g. bent out of
shape, circlip bent up), the entire cable must be replaced.
z Use new sheetmetal clips. Pay attention to the installation position.
1. Insert the end of the cable with the hexagon into the Quickfit on the
wheel bearing housing. Push the cable at the other end (ball head)
towards the wheel bearing housing until the hexagon engages audibly
in the Quickfit. Ensure a good seal.
2. Look through the brake disc opening with a small lamp to check that the end of the cable (hexagon) is seated
correctly in the Quickfit.
3. Make sure that the circlip is seated correctly -arrow- . (Shown here on
the removed cable.)
4. Push the end of the cable with the ball head through the underbody
and clip in the two plastic tabs. Mount the ball head in balancing clip in
the passenger compartment. Fit the nut on the threaded rod using the
number of turns noted previously. Ensure correct cable routing.
5. Remove the → see figure auxiliary pin from the FPB pedal.
6. Perform a function test. If necessary set the brake shoes to the basic setting → 468316 Adjusting foot-
operated parking brake - chapter on "adjusting".
Note
z Tolerances in the cables (different length right to left) can cause the balancing clip to be out of line when the
foot-operated parking brake (FPB) is actuated. Press the FPB pedal gently until the cables are tensioned.
Only then should you tighten the small screw (Torx T15) on the balancing clip by hand .
7. Install centre console → 681719 Removing and installing centre console - chapter on "installing" .
8. Install cover in the footwell → 702219 Removing and installing cover under dashboard - chapter on
"installing".
9. Fit the screw plug on the brake disc.
Releasing brake cable at wheel bearing housing
Removing brake cable
1. Fix the adjustment device using an → see figure auxiliary pin (max. 3.5 mm Ø ) . In other words: press the
adjustment device together -arrow- until the assembly bores are covered and the auxiliary pin can be inserted
→ 466019 Removing and installing pedal for foot-operated parking brake - chapter on "removing".
3. Remove the relevant rear wheel → 440519 Removing and installing wheel - chapter on "removing".
4. Remove the brake cable from the guide of the rear axle housing and loosen it by moving it to and fro.
Note
z The screw plug -arrow- of the brake disc obscures the view of the Quickfit. The Quickfit is positioned at
approx. 3 o'clock to the right and approx. 9 o'clock to the left.
z The brake discs do not have to
be removed to disengage the
brake cables.
5. Remove the screw plug

-arrow- on the brake disc .
6. Remove the brake cable. Do not loosen the circlip! To do this, insert a
screwdriver between the sleeve of the brake cable and the wheel
bearing housing .
7. Pull the sleeve of the cable as far as possible out of the wheel bearing
housing.
8. Push the cable gently into the brake drum. Use a small screwdriver
inserted through the brake disc opening to press the retaining spring
and hexagon on the expander lever upwards and at the same time
pull the brake cable out of the brake drum.
Installing brake cable

1. Insert the → see figure end of the cable with the hexagon into the
Quickfit on the wheel bearing housing. The hexagon in the Quickfit
must engage audibly. Ensure a goodl seal.
2. Look through the brake disc opening with a small lamp to check that
the end of the cable (hexagon) is seated correctly in the Quickfit.
3. Fit the screw plug on the brake disc.
4. To fit the brake cable correctly into the guides on the underbody and
on the rear axle carrier, the brake cable must be taut. To do this, tug
on the brake cable, against the direction of travel, in the cable sleeve
area (thickening) on the rear axle carrier. This gives clearance
between the brake cable and the cardan shaft.
5. Perform a function test.

6. Install cover in the footwell → 702219 Removing and installing cover under dashboard - chapter on
"installing".
Subsequent work
Mount the wheel → 440519 Removing and installing wheels - chapter on "installing" and tighten to the specified
tightening torque.
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46 83 15 Adjusting the foot-operated parking brake - as of MY 2003

- Checking
- Adjusting
Tools

piston resetting fixture (replaces commercially NR.144
P83) available tool
Checking
Foot-operated parking brake: Checking free play
The foot-operated parking brake, hereafter referred to as the FPB, is equipped with asbestos-free brake pads. The
FPB pedal module is located on the left in the driver's footwell.
Note
z Adjustments must only be carried out at the two rear wheel adjustment devices. No adjustment may be made
on the pedal module or on the Z deflector on the centre console.
Check free play at the pedal module:
To do this, measure from the left seat rail up to the lower edge of the pedal plate of the FPB!
2. Depress pedal 40 mm (+ 5 mm). When this dimension is reached, the wheels must be able to turn without
grinding the brake pads.
3. Depress pedal 75 mm (+ 5 mm). When this dimension is reached, the wheels must be fixed. If the wheels can
still turn, the FPB must be adjusted!
Adjusting
The rear wheels must be removed to gain access to the adjustment device → 440519 Removing and installing
wheel - chapter on "removing".
(evenly) pressed back a little with the piston resetting fixture (replaces
P83) NR.144, see Workshop Equipment Manual, Chapter 2.4
-direction arrow- !
freely.
2. Remove rear wheels → 440519 Removing and installing wheel -

3. Adjust brake shoes (on both wheels). To do this, unscrew the plug
-arrow- and turn the brake disc with the opening towards the
adjustment device position. Using a screwdriver, adjust the adjustment
device until the wheel can no longer be turned. Then unscrew by 6
teeth (wheels must be free to turn).

6. Fit rear wheels → 440519 Removing and installing wheel - chapter on
"installing" .
as of MY 2003
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46 83 16 Adjusting the foot-operated parking brake - as of MY 2003

- Preliminary work
- Foot-operated parking brake: checking free play
- Subsequent work
Tools

piston resetting fixture (replaces commercially NR.144
P83) available tool
Preliminary work
Raise vehicle → 40 V0 Lifting the vehicle - chapter on "preliminary work".
Foot-operated parking brake: checking free play

The foot-operated parking brake, hereafter referred to as the FPB, is equipped with asbestos-free brake pads. The
FPB pedal module is located on the left in the driver's footwell.
Note
z Adjustments must only be carried out at the two rear wheel adjustment devices. No adjustment may be made
on the pedal module or on the Z deflector on the centre console.
Check free play on the pedal module:
To do this, measure from the left seat rail up to the lower edge of the pedal plate of the FPB!
1. Depress → Adjustment value: 40 mm +5 mm . If this dimension is reached, the wheels must be able to turn
without grinding the brake pads.
2. Depress → Adjustment value: 75 mm +5 mm . If this dimension is reached, the wheels must be fixed. If the
wheels can still turn, the FPB must be adjusted!
The rear wheels must be removed so that the adjustment device can be accessed! → 440519 Removing and
installing wheel
pressed back slightly and evenly with the piston resetting fixture
(replaces P83) NR.144, see Workshop Equipment Manual, Chapter 2.4
-direction arrow- !
freely.
2. Remove rear wheels. → 440519 Removing and installing wheel
3. Adjust brake shoes (on both wheels). To do this, unscrew the plug
-arrow- and turn the brake disc with the opening towards the
adjustment device position. Using a screwdriver, modify the
adjustment device until the wheel can no longer be turned. Then
unscrew 6 teeth (wheels must be free to turn).

Subsequent work
Mount rear wheels. → 440519 Removing and installing wheel
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46 83 56 Replacing brake shoes - as of MY 2003

-
- Replacing
Preliminary work
2. Remove brake calliper and brake disc → 465319 Removing and installing rear brake disc.
Replacing
Removing
Note
The cover (grille) on the actuating mechanism of the foot-operated parking brake (FPB) does not need to be
removed. The auxiliary pin can be inserted through the cover (grille).
Wear protective gloves.
z Watch out for sharp edges in the area of the actuating mechanism for the foot-operated parking brake (FPB).
Loosen and secure operating cable.
1. Remove cover over actuating mechanism for foot-operated parking brake (FPB).
2. Move pedal of foot-operated parking brake (FPB) into zero position. To do this, pull the release lever on the
dashboard.
3. Fix the adjustment device using an -auxiliary pin with diameter of max. 3.5 mm- . In other words: press
the adjustment device together -Arrow- until the assembly bores are covered and the auxiliary pin can be
inserted → 467955 Replacing rear brake cable for foot-operated parking brake.
Adjustment device for foot-operated
parking brake
4. Remove some of the brake cable. Do not loosen the circlip! To do this, insert a -screwdriver- between the
sleeve of the brake cable and the wheel bearing housing.
5. Pull the -sleeve of the cable- as far as possible out of the wheel
bearing housing.
6. Then push the cable gently into the expanding-lock. Use a small
screwdriver to press the retaining spring and hexagon down at the
expander lever and at the same time pull the brake cable out of the
expanding-lock.
7. Loosen the adjustment device -C- with a screwdriver.
8. Remove pressure pieces with tensioning springs -F- .
ATTENTION
Risk of injury (e.g. crushing) when removing and installing springs.
z Springs can pop out.
z The edges of springs may be sharp.

→ Be very careful when working on the brake system.
9. Disengage the two tension springs -D and E- .
10. Remove brake shoes with adjustment device and expanding-lock

-A, B and C- . Component overview for parking brake
Installing
ATTENTION
Risk of injury (e.g. crushing) when removing and installing springs.
z Springs can pop out.
z The edges of springs may be sharp.

→ Be very careful when working on the brake system.
Installation is performed in reverse order.
Align the entire unit in the middle.
Component overview for parking brake

Subsequent work
1. Install brake disc and brake calliper → 465319 Removing and installing rear brake disc.
2. Pull the auxiliary pin out of the adjustment device.
3. Adjust the foot-operated parking brake → 468316 Adjusting the foot-

operated parking brake.
4. Fit wheel → 440519 Removing and installing wheel.
5. Install trim under instrument panel on driver's side → 701919

Removing and installing trim under instrument panel.
6. Install cover in the footwell → 702219 Removing and installing cover
under instrument panel.
Adjustment device for foot-operated

parking brake
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46 Brake disc measurement sheet - as of MY 2003

- Information
Information
Brake disc measurement sheet
Note
Notes on checking and measurement points can be found in:
z → 46 Technical data/brake wear limits
z → 465002 Checking front brake discs (wear assessment)
z → 465302 Checking rear brake discs (wear assessment)
To document the measured result, a copy or print of the data card illustrated can be used. The data cards cannot
be ordered.
1. Make a copy or print of the data card shown.
Note
z Actual values that are identical in all versions are already entered!
z In the course of further development these values may change. If necessary, carry out a check and insert the
new values accordingly. → 46 Technical data/brake wear limits
2. Before measurement (Test 1 through Test 3), enter the general data, vehicle type and the missing nominal
values (new brake disc thickness / brake disc wear limit) into the data card.
3. Carry out measurements (actual status) and enter the values in the alignment 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 labour operation numbers.
– Measuring brake discs: 80 time units per axle.
Brake disc measurement

Customer: Rep. Order No.:
Street: Vehicle Ident No.:
Place: Reg. number:
Telephone: Date of first registration:
Vehicle type: Odometer reading [km/miles]
Checker Date/Signature
Nominal values
Test 1 = brake disc thickness
- Brake disc thickness, new [mm]: Front: Rear:
- Wear limit [mm]: Front: Rear:
Test 2 = lateral runout
- Brake disc installed [mm] max.: 0.06
- Wheel hub max.:
- Brake disc removed [mm] max.: 0.03
Test 3 = Thickness tolerance of brake disc
Thickness tolerance of brake disc [mm] max.:
Measured values front left front right rear left rear right
(actual values) [mm]
Test 1 = Brake disc thickness (measured at 3 points, each offset by 120°)
Measurement point A
Measurement point B
Measurement point C
Test 2 = lateral runout
- Brake disc installed
- Wheel hub
- Brake disc removed
(difference wheel
hub/brake disc
installed)
Test 3 = Thickness tolerance of brake disc
Thickness tolerance
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46 05 19 Removing and installing brake pedal - as of MY 2003

- Preliminary work
- Removing brake pedal
- Installing brake pedal
- Subsequent work
Tools

Preliminary work
1. Move the driver's seat back.
2. Remove the lower cover. → 702219 Removing and installing cover under dashboard - chapter on
"removing" . At the diagnostic socket just unclip the connector from the rear.
Removing brake pedal
Note
z For better accessibility, remove the lower cover under the steering column.
1. Remove the lower cover. → 702219 Removing and installing cover

under dashboard - chapter on "removing" .At the diagnosostic socket
-arrow- just unclip the connector from the rear.
2. Remove the lower cover (in knee area) and the deformation
element→ 701919 Removing and installing trim under dashboard -
chapter on "removing" .
3. Remove the holder for the stop light switch and unclip the connector
-arrow- → 943619 Removing and installing stop light switch - chapter
on "removing".

4. Remove the holder -arrow- of the lower cover for the dashboard.
5. Remove relay carrier -arrows- → 979019 Removing and installing relay carrier, plenum panel E-box - chapter
on "removing".
6. Remove both control units -arrow- , on the right side under the dashboard → 966619 Removing and installing
Kessy/immobilizer control unit - chapter on "removing", → 971019 Removing and installing vehicle electrical
system control unit - chapter on "removing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 971019
21 Removing and installing vehicle electrical system control unit - chapter on "removing" [9PAAJ1].
7. Release the support (relay carrier/Kessy control unit/immobilizer/vehicle electrical system control unit) (left
side and front engaged, right side screwed) and let them hang. In this way, the brake pedal shaft can be
pushed out toward the centre of the vehicle (cardan tunnel).
8. Disengage the brake pushrod from the brake pedal mounting using
the unlocking tool T10189 . Observe the following procedure for this
purpose:
-1- - unlocking tool T10189 for brake pedal.
– Position the unlocking tool T10189 -1- so that the fork sits in correct position in the brake pedal mounting (in
the inset, the fork in contact, view against the direction of travel).
– Position the unlocking tool T10189 so that it is located in the right

mould of the support and is perpendicular to the vehicle floor. Like
this, the force deflection point (bending in the unlocking tool T10189)
is precisely next to the screw head -arrow- .
– When pressing forward on the lever (unlocking tool) (in direction of travel!), the brake pedal mounting is
pressed apart and the ball of the pushrod is released. At the same time, pull the brake pedal to the rear
(against the direction of travel!) and release the brake pedal from the pushrod.
9. Counter the brake pedal shaft (pin) -arrows- on the right side and slightly loosen to the left -(arrows)- . The
nut remains on the brake pedal shaft to protect the thread.
10. Loosen the two upward running struts of the articulated strut and let them hang. To do this, remove the
retainer on each retaining pin, remove the retaining pins, and let the struts hang down.
11. Using a hammer, force out the brake pedal shaft a few millimetres with short, heavy blows from left to right.
Brake pedal released from the
pushrod
Releasing pushrod from brake pedal
12. Place a screwdriver under the head of the brake pedal shaft (right side). Remove the nut, and lever out the
brake pedal shaft carefully toward the centre of the vehicle (cardan tunnel).
13. Carefully press out the brake pedal shaft so that the brake pedal can be removed.
Installing brake pedal

Note
z Do not grease or spray the brake pedal shaft (pin).
z For vehicles with automatic transmission a spacer tube is used instead of the clutch pedal.
z Use new lock nuts.
z Observe correct tightening torques → 46 TW Tightening torques for brake mechanics - chapter on "Technical
values".
z Tightening torque for brake pedal shaft (pin): 15 ± 2 ftlb.
Subsequent work
Remove the lower cover → 702219 Removing and installing cover under dashboard - chapter on "installing".
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46 11 15 Adjusting the brake pushrod - as of MY 2003

- Adjusting
Tools

Adjusting
Adjusting the brake pushrod
Note
z The brake pushrod play is strictly specified.
z The play cannot be adjusted.
The brake pushrod can be removed from the brake pedal with the unlocking tool T10189 .

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46 36 19 Removing and installing the front disc brake pads - as of

MY 2003
- Preliminary work
- Removing
- Installing
- Subsequent work
- Information
Tools

Preliminary work
Preliminary work
Removing

1. Remove fastening screw at retainer pin. Then screw in auxiliary

screw M8. Hold down expanding springs with a screwdriver
-see illustration- and remove retainer pin.

the disc brake pads and push the pads back evenly -arrows- .
Installing
Installing front disc brake pads
WARNING
z Fit new expanding spring, new retaining pin and new retaining pin screw on the brake caliper.
→
WARNING
z Use only the type-specific brake pads in the Porsche Spare
Parts Catalogue.
Do not grease the back of the disc brake pad!
Check disc brakes for wear; for wear limits see → 46 Technical
data/brake wear limits!
Observe tightening torques → 46 Tightening torques for brake mechanics.
Note
z Make sure that the retaining pin is inserted in the correct position! The flat side surfaces prevent the retaining
pin from twisting in the brake caliper.
M8 auxiliary screw. To do so, press retaining pin back with auxiliary
Tightening torques for brake mechanics!
must lie within the -MAX-MIN marking- .
Subsequent work
Subsequent work
1. Fit wheel → 440519 Removing and installing wheel - chapter on "installing" .
Information
emergencies!
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46 36 20 Removing and installing front brake pads - as of MY 2003

- Preliminary work
- Removing front brake pads
- Installing front brake pads
- Subsequent work
Tools

Preliminary work
Preliminary work
WARNING
1. Remove fastening screw at retainer pin. Next screw the M8 auxiliary

screw into the retaining pin. Hold down expanding springs with a
→ see figure screwdriver and remove retaining pin.

Installing front brake pads
WARNING
→ Fit new expanding spring, new retaining pin and new retaining pin
screw on the brake caliper.
Do not grease the back of the disc brake pad !
Check disc brakes for wear. For wear limits see Technical Data → 46
TW Technical data/brake wear limits - chapter on "Technical values"!
The core of the warning contact line must not be left exposed! Worn
insulation is not significant!
Observe correct tightening torques → 46 TW Tightening torques for brake

mechanics - chapter on "Technical values"!
Removing brake pad
Note
z Make sure that the retaining pin is inserted in the correct position.
The flat side surfaces prevent the retaining pin from twisting in the
brake caliper.
M8 auxiliary screw. To do so, push retaining pin back with auxiliary
TW Tightening torques for brake mechanics - chapter on "Technical
values"!
6. Check brake fluid level and correct if necessary. The brake fluid level must lie within the → see figure MAX -
MIN marking.
emergencies!
Subsequent work
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46 38 19 Removing and installing the rear disc brake pads - as of

MY 2003
- Preliminary work
- Removing
- Installing
- Subsequent work
- Information
Tools

Preliminary work
Preliminary work
Removing

1. Remove lock (securing clip) -top arrow- from retaining pin and
remove retaining pin -direction arrow- inwards.


Installing
WARNING
z Fit new expanding spring, new retaining pin and new safety bracket on the brake calliper.
→
WARNING
z Use only the type-specific brake pads in the Porsche Spare Parts Catalogue.
Note
z The back of the pad backing plates must not be greased.
z Check disc brakes for wear; for wear limits see → 46 Technical data/brake wear limits.
z Disc brakes must be clean and free of grease.
z The core of the warning contact wire must not be left exposed! Worn insulation is not significant.
z If necessary, remove a little brake fluid from the expansion tank by suction to prevent spilling when the disc
brake pad is pushed back.
z Use new repair kit.
z Observe tightening torques → 46 Tightening torques for brake mechanics.
3. Fit expanding spring, retaining pin -direction arrow- and lock (safety
bracket) -top arrow- at top of retaining pin.
4. Fit warning contact line at bottom of brake caliper -bottom arrow-

and warning contacts at disc brake pads.
6. Check brake fluid level and correct if necessary. The brake fluid level must lie within the
-MAX-MIN marking- .
Subsequent work
Subsequent work
Information
emergencies!
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46 38 20 Removing and installing rear brake pads - as of MY 2003

- Preliminary work
- Removing rear disc brake pads
- Installing rear disc brake pads
- Subsequent work
Tools

Preliminary work
Preliminary work
WARNING
The core of the warning contact line must not be left exposed! Worn insulation is not significant !
1. Remove lock (securing clip) -arrow- at top from retaining pin and
remove retaining pin -direction arrow- inwards


WARNING
→ Fit new expanding spring, new retaining pin and new retaining pin screw on the brake caliper.
The back of the pad backing plates must not be greased !
Check disc brakes for wear. For wear limits see Technical Data → 46 TW Technical data/brake wear limits -
chapter on "Technical values"!
New disc brakes must be clean and free of grease!
Observe correct tightening torques → 46 TW Tightening torques for brake mechanics - chapter on "Technical
values"!
3. Install expanding spring, retaining pin -direction arrow- and lock

(safety bracket) -arrow- at top of retaining pin.
4. Install warning contact line at bottom of brake caliper -arrow- and

warning contacts at disc brake pads.
emergencies!
Subsequent work
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46 50 02 Checking front brake discs (wear assessment) - as of MY

2003
- Information
- Checking
Tools


9510/1
Information
brake discs.

Checking
Checking front brake discs (evaluating cracks)
limits.
Note
be replaced when:

exceeded!

Checking front brake discs (minimum thickness)
Note
-A- Outer and inner wear area.
Wear areas A and B

offset by 120°.
Note
with these.

thickness

suitable position on the wheel bearing housing.
Note
– Measure the wheel hub lateral runout at the front face of the wheel Dial gauge on brake disc
1. Remove the brake disc. → 465019 Removing and installing the front brake disc
housing. Fit the dial gauge with some preload.

.
– Measure the thickness tolerance with a suitable micrometer screw within the braking surface at approx. eight
points.
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46 50 19 Removing and installing front brake disc - as of MY 2003

- Preliminary work
- Removing front brake disc
- Installing front brake disc
- Subsequent work
Tools

Preliminary work
Preliminary work
Removing front brake disc
Note
z In order to gain better access for removal of the brake calliper, it is beneficial to turn the wheels fully either to
the right or the left.
1. Release retainer for plug of wear indicator on wheel carrier.
2. Disconnect the speed sensor on the ABS sensor.
Chapter 2.4 -direction arrow- . Make sure that no brake fluid runs
out of the supply tank - if necessary, remove by suction.
the wheel well (do not open the brake hydraulics!).

hammer.
Installing front brake disc

3. Fit the brake disc. Observe correct tightening torque → 46 TW Tightening torques for brake mechanics -
4. Fit the brake caliper. Replace the brake caliper fastening screws after each removal. Observe correct
tightening torque → 46 TW Tightening torques for brake mechanics - chapter on "Technical values".
5. Install retainer for plug of wear indicator on wheel carrier.
6. Connect the speed sensor on the ABS sensor.

Subsequent work
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47 TW Tightening torques for brake hydraulics - as of MY 2003

Tightening torques

value 1 2
Brake pressure line to brake Thread M10/M12 Tightening 10.5 +/-0.5 ftlb.
master cylinder, brake hose, torque ftlb.
distributor, brake caliper and
hydraulic unit
Mount for hydraulic unit support Thread M6 x 10 Tightening 7.5 ftlb.
torque
Mount for intermediate piece Thread M6 x 14 Tightening 7.5 ftlb.
torque
Brake caliper to wheel carrier Thread M16 x 1.5 x 48 x 33 Tightening 200
front axle (Replace screws and lock torque ftlb.
nuts after each removal.)
Brake caliper to wheel carrier Thread M14 x 1.5 x 40 Tightening 133
rear axle (Replace screws and lock torque ftlb.
nuts after each removal.)
Connecting line to brake caliper Thread M10 x 1 Tightening 9.5 ftlb. +/-0.5 ftlb.
torque
Bleeder screw on brake caliper Thread M10 x 1 Tightening 10.5 +/-1.5 ftlb.
torque ftlb.
Brake pressure line to brake Thread M10 x 1 Tightening 10.5 +/-0.5 ftlb.
caliper torque ftlb.
Cap screws for brake lines Thread M10 x 1 Tightening 10.5 +/-0.5 ftlb.
torque ftlb.
Brake booster Thread M8 Tightening 19 ftlb. +/-2 ftlb.
torque
Brake booster to brake master M8 thread Tightening 19 ftlb. +/-3 ftlb.
cylinder torque
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47 01 07 Bleeding the brake system - as of MY 2003

- Bleeding the brake system
Bleeding the brake system
DANGER
→ After assembling the hydraulic unit, a static test and a swap test must be carried out with the Porsche System
Tester.
→ After assembly of the brake master cylinder or the hydraulic unit, the pressure sensor must be calibrated with
Note
z The brake fluid change interval is two years, using Super DOT 4 brake fluid.
litres = 000.043.203.67.
1. Open reservoir.
2. Connect a bleeding device to the brake fluid reservoir. Switch on the bleeding device. Bleeding pressure is
approx. 2.0 bar.
Note
z Always bleed both bleeder valves on the brake caliper.

3. Continue the bleeding procedure at the brake calipers. Do so in the following sequence: rear right/rear
left/front right/front left.
4. Use a transparent hose and a collecting bottle to check the escaping brake fluid is clean and free of air
bubbles and to determine the amount of brake fluid used.
5. Open each bleeder valve until clear, bubble-free brake fluid emerges.
6. Tighten the bleeder valves to the specified tightening torque and remove the bleeder hoses.
7. Remove bleeding device from brake fluid reservoir and screw cap on.
The brake fluid level in the brake fluid reservoir must be between the
MIN and MAX markings once the vehicle has been filled and bled.
Adjust the brake fluid level if necessary.
8. Generate vacuum in brake booster by starting engine. Check brake-

pedal travel and pedal feel.
Checking after bleeding
Note
z If the pedal travel is too long or the pedal feels too soft when applied, carry out the following procedure.
z Two workers are required for this.
z Also carry out this procedure if the brake hydraulic system was largely empty.
Connect a bleeding device to the brake fluid reservoir. Switch on the bleeding device. Bleeding pressure is approx.
2.0 bar.
1. Open bleeder valve at rear on right-hand side, then push the brake pedal all the way down about 5 times and
tap the brake caliper gently several times with a rubber hammer during the bleeding process.
2. Hold for 2 - 3 seconds after each depression, then release pedal slowly. After applying pedal for the fifth time,
hold pedal down and close bleeder valve.
3. Repeat this procedure in the sequence rear left/front right/front left.

4. Tighten the bleeder valves to the specified tightening torque and remove the bleeder hoses.
5. Remove bleeding device from brake fluid reservoir; correct brake fluid level is necessary.
6. Generate vacuum in brake booster by starting engine. Check brake-pedal travel and pedal feel.
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47 08 55 Changing the brake fluid - as of MY 2003

- Checking brake fluid level
- Changing the brake fluid
Visually inspect brake fluid level. The brake fluid level must be between
the MAX and MIN markings. The brake fluid reservoir is located under the
left plenum panel cover -arrow- .
Note
z The brake fluid level must not exceed the MAX mark.

Quantity supplied: 1 litre = 000.043.203.66; 30 litres =
000.043.203.67.
Note
z The brake fluid change interval is two years using Super DOT 4 brake
fluid.

Quantity supplied: 1 litre = 000.043.203.66; 30 litres =
000.043.203.67.
z Drain brake fluid from every brake caliper at both bleeder valves.
1. Open threaded cover of brake fluid reservoir -arrow- .
2. Connect a bleeding device to the brake fluid reservoir.
3. Switch on the bleeding device. Bleeding pressure is approx. 2.0 bar.
4. Continue changing the brake fluid at the brake calipers. Do so in the following sequence: rear right/rear
left/front right/front left.
5. Open every bleeder valve until clear, bubble-free brake fluid emerges and until the corresponding change
quantity per brake caliper is reached (approx. 250 cm3).
freedom from air bubbles and to determine the brake fluid used.
7. Tighten the bleeder valves to the specified tightening torque → 47 TW Tightening torques for brake hydraulic
system - chapter on "Technical values" and remove the bleeder hoses.
8. Switch off bleeding device and remove the adapter on the brake fluid
reservoir. The brake fluid level in the brake fluid reservoir must be
between the MIN and MAX markings once the vehicle has been filled
and bled. Adjust the brake fluid level if necessary.
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47 15 19 Removing and installing brake master cylinder (HBZ) - as

of MY 2003
- Preliminary work
- Removing the brake master cylinder
- Installing the brake master cylinder
- Subsequent work
Preliminary work
1. Remove both wiper arms → 922519 Removing and installing wiper arm - chapter on "removing".
2. Remove cover in engine compartment → 700219 Removing and installing front cover (engine compartment)
- chapter on "removing".
Removing the brake master cylinder
Note
z Before disconnecting the connector from the brake master cylinder
(pressure sensor) first wipe off any moisture with a lint-free cloth.
z Brake lines are to be sealed with suitable plugs.
z In order to catch escaping brake fluid, place a cloth under the brake
booster.
Note
z In the case of assembly work on the hydraulic connections, the electrical plug connections on the brake
master cylinder must always be connected. This prevents the plug connections on the brake master cylinder
and the inside of the plugs being splashed with brake fluid or water.
z Clean any plug connections that have become dirty or damp during removal or fitting with a lint-free cloth.
z Brake fluid on electrical contacts (even thinned brake fluid) leads to corrosion and may cause faults in the
system.
z Remove any escaping brake fluid immediately; if necessary, rinse with water and dry.
The brake master cylinder is located on the left in the engine compartment, under the cowl panel cover -arrow- on
the brake booster .
1. Push both connectors -arrows- on the plenum panel (oxygen sensor cable) from the bracket.
2. Open the cable clip on the plenum panel and loosen the cable.
4. Disconnect the connector on the cover of the brake fluid reservoir and remove the cover -arrow- .
5. Remove the brake fluid from the brake fluid reservoir by suction. To do this, use a double-acting hand pump.
6. Bend both → see figure lugs on the brake fluid reservoir carefully
outward and pull off the container upwards.
7. Loosen the brake lines from the brake master cylinder.
8. Unclip the brake line on the brake master cylinder to the left front
wheel and remove the fastening clip -arrow- .
9. Remove the brake master cylinder from the brake booster.
10. Remove the connector of the pressure sensor at the underside of the
brake master cylinder.
Installing the brake master cylinder
DANGER
→ After assembly of the brake master cylinder or hydraulic unit, the pressure sensor must be calibrated with
→ To do this, calibrate the pressure sensor in the menu >> PSM >> Calibration >> Pressure sensor <<.
→ The security code is stored under menu >> PSM >> Actual values >> Security code <<. The code is entered
in the last four positions.
Note
z Cleanliness is essential when installing the brake master cylinder so that dirt does not enter the system. This
can cause faults in the system.
z Replace worn sealing rings.
z Pay attention to tightening torques → 47 TW Tightening torques for brake hydraulic system - chapter on
"Technical values".
Install in reverse order .
1. Connect the connector of the pressure sensor to the underside of the brake master cylinder.
2. Fit the brake master cylinder loosely on the brake booster. Ensure sealing ring is seated properly between
the brake master cylinder and the brake booster. Insert pushrod in the correct position in the brake master
cylinder.
3. Loosely fit brake lines of brake master cylinder.
4. Fit the brake master cylinder on the brake booster and fit the brake lines. Fit the brake line of the left front
wheel with the clip to the brake master cylinder.
5. Attach the brake fluid reservoir (observe sealing rings) and check for
correct seating of the lugs.
6. First insert the seal of the plenum panel and then slide the plenum
panel in from above. Fit the fastening screws.
7. Lay the cable and fit into clip on plenum panel.
8. Push the two large connectors into the bracket on the plenum panel.
9. Connect the connector to the cover of the brake fluid reservoir.
Subsequent work
1. Fit the right and the rear covers → 700219 Removing and installing front cover (engine compartment) -
chapter on "installing" and the cowl panel → 664419 Removing and installing cowl panel - chapter on
"installing".
2. Install both wiper arms → 922519 Removing and installing wiper arm - chapter on "installing".
3. Bleed the vehicle → 470107 Bleeding the brake system - chapter on "bleeding". After the bleeding operation,
do not top up the brake fluid level above -MAX- .
4. Calibrate the pressure sensor with the Porsche System Tester.

as of MY 2003
C16, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32,
C33, C34, C35, C36, C37, C38, C39, C45, C46, C98, C99
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47 39 19 Removing and installing front brake calliper - as of MY

2003
- Preliminary work
- Removing front brake calliper
- Installing front brake calliper
- Subsequent work
Tools

Preliminary work
1. Raise vehicle → 40 V0 Lifting the vehicle - chapter on "preliminary work".
Removing front brake calliper
Note
z To gain better access for removal of the brake caliper, it helps to turn
the steering fully either to the right or the left.
2. Release and unclip the plug from the wear indicator -arrow- . Loosen
the brake line on the brake caliper -arrow- and collect brake fluid in a
suitable container. Close off the line with suitable plugs.
Note
z Never use an impact bolter to loosen and tighten the brake calliper on
the wheel carrier.
3. Remove brake calliper from wheel carrier -arrows- .
Installing front brake calliper

Note
z Replace screws and lock nuts.
z Never use an impact bolter to loosen and tighten the brake calliper on the wheel carrier.
z Observe correct tightening torques → 40 TW Tightening torques for front axle - chapter on "Technical
values".
The brake caliper is installed in reverse order .
1. Fit the brake caliper.
2. Fit the brake line to the brake caliper.
3. Clip in the wear indicator connector.
Subsequent work
1. Bleed the brake system → 470107 Bleeding the brake system - chapter on "bleeding".
2. Mount the wheel → 440519 Removing and installing wheel.
as of MY 2003
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47 41 19 Removing and installing rear brake calliper - as of MY

2003
- Preliminary work
- Removing rear brake calliper
- Installing rear brake calliper
- Subsequent work
Tools

socket-wrench insert, multiple commercially NR.33

tooth with pin guide available tool
Preliminary work
1. Raise vehicle → 40 V0 Lifting the vehicle - chapter on "preliminary work".
Removing rear brake calliper
Brake caliper
2. Release and unclip the connector from the wear indicator -arrow- .
3. Remove cable holder for the brake line and wear indicator -arrow- .
Note
z Never use an impact bolter to
loosen and tighten the brake
calliper on the wheel carrier.
4. Loosen the brake line on the

brake calliper -arrow- and
collect brake fluid in a suitable
container. Close off the line
with a suitable plug. Remove
the brake calliper from the
wheel carrier using a socket-
wrench insert, multiple
tooth with pin guide NR.33
-arrows- .
Installing rear brake calliper
Note
z Replace screws and lock nuts.
z Never use an impact bolter to loosen and tighten the brake calliper on the wheel carrier.
z Pay attention to tightening torques → 42 TW Tightening torques for rear axle - chapter on "Technical values".
The brake caliper is installed in reverse order.
1. Fit the brake caliper.
2. Fit the brake line and cable holder.
3. Clip in the wear indicator connector.
Subsequent work
1. Bleed the brake system → 470107 Bleeding the brake system - chapter on "bleeding".
2. Mount the wheel → 440519 Removing and installing wheel.
as of MY 2003
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47 70 19 Removing and installing brake booster - as of MY 2003

- Preliminary work
- Removing brake booster
- Installing brake booster
- Subsequent work
Tools

Preliminary work
1. Switch off the ignition.
2. Remove both wiper arms → 922519 Removing and installing wiper arm - chapter on "removing".
3. Remove cover in engine compartment → 700219 Removing and installing front cover (engine compartment)
- chapter on "removing".
4. Remove cowl panel → 664419 Removing and installing cowl panel - chapter on "removing".
Removing brake booster

Note
z During assembly work on hydraulic connections, the electrical plug
connections on the hydraulic unit must always be connected. This
prevents the plug connections on the hydraulic unit and the inside of
the connectors being splashed with brake fluid or water.
z Damp connectors must be wiped dry before disconnection.

The brake master cylinder is located on the left in the engine compartment, under the cowl panel cover -arrow- ,
together with the brake booster.
Note
z Brake lines are to be sealed with suitable plugs.
z To catch escaping brake fluid, place a cloth under the brake booster.
1. Push both connectors -arrows- on the plenum panel (oxygen sensor

cable) from the bracket.
2. Open the cable clip on the plenum panel and loosen the cable.
4. Partly remove the brake master cylinder (brake fluid reservoir) → 471519 Removing and installing brake
master cylinder - chapter on "removing".
5. Disconnect the vacuum line on the brake booster.
6. Disconnect the connector from distance sensor of the brake booster

-arrow- .
7. Unclip the cable over the brake booster from the holders -arrows-
and pull upwards.
8. Unclip the brake line to left front wheel out of the bracket underneath
the relay carrier.
9. Remove the brake master cylinder → 471519 Removing and

installing brake master cylinder - chapter on "removing".
10. Loosen two M6 screws on the lower closing panel -arrows- (upper
screw head covered) (shown here when fitting the brake booster,
relay carrier removed).
Note
z If the rubber bushes stick to the holders in the plenum panel when
removing the relay carrier, these must be fitted in the openings
provided before being inserted again.
11. Release the relay carrier in the plenum panel and hinge it to one
side. To do this, unclip the six plugs in the rear section of the relay
carrier ( -arrow- and right marking).
12. Remove the cover under the dashboard on the driver's side in the
passenger compartment → 700219 Removing and installing front
cover (engine compartment) - chapter on "removing".
13. Pull off connector of stop light switch -arrow- and remove the complete holder → 943619 Removing and
installing stop light switch - chapter on "removing".
Note
z When loosening the pushrod of the brake booster with the unlocking
tool T10189 from the pushrod of the pedal, the tool must first be
inserted and then the brake pedal pulled out into the passenger
compartment.
14. Release brake pedal from pushrod -arrow- of brake booster with
unlocking tool → 460519 Removing and installing brake pedal -
15. To do this, insert the unlocking tool T10189 from below into the
bush on the brake pedal -arrow- .
16. Remove the four M8 lock nuts on the brake booster in the passenger
compartment.
17. Remove front left wheel housing liner.
18. Disconnect the brake line in the wheel housing on the intermediate
piece -arrow- and seal with suitable plugs.
19. Remove both clips for the air-conditioning lines in the plenum panel.
20. Pull the brake lines to the brake master cylinder and left front wheel carefully forward and press the air-
conditioning lines down. Make sure that the boot on the brake booster -arrow- does not get stuck in the duct
to the passenger compartment.
21. Carefully pull out the brake booster -direction arrow- to the front.
Installing brake booster
DANGER
→ After assembly of the brake master cylinder or hydraulic unit, the pressure sensor must be calibrated with
→ To do this, calibrate the pressure sensor in the menu >> PSM >> Calibration >> Pressure sensor <<.
→ The security code is stored under menu >> PSM >> Actual values >> Security code <<. The code is entered
in the last four positions.
Note
z Absolute cleanliness is necessary when installing the brake booster as well as the adjacent brake master
cylinder. Dirt can cause faults in the system.
z Calibrate the vehicle with the Porsche System Tester.
z Bleed the vehicle according to the plan to ensure full operation of the brake system.
z When inserting the brake booster, make sure the brake pushrod and boot are guided correctly.
z Pay attention to tightening torques → 47 TW Tightening torques for brake hydraulic system - see chapter on
"Technical values".
1. Carefully pull the brake lines of the brake master cylinder and left front wheel forward and press the air-
conditioning lines downward.
2. Carefully insert the brake booster -direction arrow- .
3. Guide the → see figure pushrod of the brake booster through the opening in the passenger compartment.
Ensure the boot is seated correctly.
4. Fit the brake booster with four M8 fastening nuts.
5. Press the brake pedal forward until the ball socket engages in the mounting point.
6. Fit the holder for the stop light switch and connect the connector
-arrow- → 943619 Removing and installing stop light switch -
7. Fit the cover on the driver's side → 700219 Removing and installing
front cover (engine compartment) - chapter on "installing".
8. Fit the clamps of the air-conditioning lines.
Note
z If the rubber bushes stick to the holders in the plenum panel when
removing the relay carrier, these must be fitted in the openings
provided before being inserted again.
9. Install relay carrier in the plenum panel. To do this, fit the six
connectors in the rear section of the relay carrier ( -arrow- and right
marking).
10. Join the closing panel using the two M6 screws -arrows- (shown
here when fitting the brake booster - relay carrier removed).
11. Join the brake line in the front left wheel housing (remove sealing plugs).
12. Install front left wheel housing liner.
13. Clip the brake line to left front wheel in the bracket underneath the
relay carrier in the plenum panel.
14. Connect the plug on the distance sensor of the brake booster.
15. Connect vacuum pipe to the brake booster.
16. Fit brake master cylinder → 471519 Removing and installing brake
master cylinder - chapter on "installing" .
17. Fit left plenum panel partition.
Subsequent work
1. Fit the right and the rear covers → 700219 Removing and installing front cover (engine compartment) -
chapter on "installing" and the cowl panel → 664419 Removing and installing cowl panel - chapter on
"installing".
2. Install both wiper arms → 922519 Removing and installing wiper arm - chapter on "installing".
3. Bleed the vehicle → 470107 Bleeding the brake system - chapter on "bleeding".
4. Calibrate the pressure sensor with the Porsche System Tester.
as of MY 2003
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48 TW Tightening torques for steering - as of MY 2003

Tightening torques
Location Explanation Type Basic Tolerance 1 Tolerance

value 2
Steering gear to M12 x 1.5 thread (replace Tightening 90 (67 +90 °
suspension subframe screws and fastening nuts torque ftlb.) Nm
after removal)
Tie rod to pivot bearing M14 x 1.5 thread (replace Tightening 90 (67
screws and fastening nuts torque ftlb.) Nm
after removal)
Axial joint to steering rack M18 x 1.5 thread Tightening 100 (74 +10 °
torque ftlb.) Nm
Tie rods to tie-rod ball M14 x 1.5 thread Tightening 70 (52
(lock nut) torque ftlb.) Nm
Heat shield for steering M6 x 16 thread Tightening 10 (7.5
gear torque ftlb.) Nm
Steering column to M8 x 28 thread Tightening 23 (17
mounting bracket torque ftlb.) Nm
Steering column to M8 x 10 x 45 thread Tightening 23 (17
mounting bracket torque ftlb.) Nm
Multiple-tooth fit bolt, M8 Tightening 20 (15
x 10 x 45 torque ftlb.) Nm
Universal joint to steering M10 x 35 thread (replace Tightening 35 (26 +90 °
gear screws and fastening nuts torque ftlb.) Nm
after removal)
Steering wheel to M18 x 1.5 x 26 thread Tightening 50 (37 +/-6 (4.5
steering column torque ftlb.) Nm ftlb.) Nm
Pressure line to steering a/f 17 thread (a/f = wrench Tightening 30 (22 +/-3 (2 ftlb.)
gear size 17) torque ftlb.) Nm Nm
Return line to steering a/f 17 thread (a/f = wrench Tightening 30 (22 +/-3 (2 ftlb.)
gear size 17) torque ftlb.) Nm Nm
Expansion/return hose to M6 x 12 thread Tightening 10 (7.5
steering gear torque ftlb.) Nm
Sealing sleeve to M6 thread Tightening 4 (3 ftlb.)
assembly plate torque Nm
(bulkhead)
Handle for attachment to M5 x 8 thread Tightening 4.5 (3.5
steering column torque ftlb.) Nm
Hydraulic pump to engine M8 x 35 thread Tightening 23 (17
torque ftlb.) Nm
Pulley to hydraulic pump M8 x 16 thread Tightening 23 (17
torque ftlb.) Nm
Intake pipe to hydraulic M6 x 12 thread Tightening 10 (7.5
pump torque ftlb.) Nm
Expansion hose to a/f 16 thread Tightening 30 (22 +/-3 (2 ftlb.)
hydraulic pump torque ftlb.) Nm Nm
as of MY 2003
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48 IN Assessment of steering column after accident damage - as

of MY 2003
- Information
Information
Overview of steering column
Fundamentals
Various kinds of damage can be caused to steering columns in the event of accidents or driving conditions similar
to accidents. In cases where the steering column shows no external damage it can be difficult to detect damage.
This damage represents an unacceptable risk for the vehicle, since it could lead to failure of the steering system.
To decide whether the steering column of a vehicle involved in an accident must be replaced or may continue to
be used, the following guidelines are helpful.
Assessment of the steering column of a vehicle involved in an accident
The steering column may remain in the vehicle if all the following conditions are met:
No visible damage (breakage, cracks, deformation) to such front-axle parts as steering arms, steering gear,
steering column mountings, steering wheel and airbag unit, wheel rims, wheel bearing housing (wheel carriers),
tie rods, steering shaft or to the points on the body where wheel suspension parts are bolted on.
No impermissible rise in torque and no jamming or catching when the steering gear is turned from stop to stop.
When the steering is turned, the front wheels must be free (front axle raised) and, in addition, the engine must be
switched off (pump of power steering undriven).
The steering column does not catch/jam when turned separately without steering gear.
No axial play in the steering column.
The steering column must be replaced by a new or exchange unit if one of the following points applies:
Impact is felt by occupants.
Airbag has been triggered.
The carriage-to-console gap dimension is greater than 0.5 mm → 48 Assessment of steering column after
accident damage section on "Checking the steering column of a vehicle involved in an accident".
Visible or perceptible damage to the steering column.
Play in steering shaft line.
Fire damage.
Additionally, for vehicles with electrically adjustable steering columns, if the adjustment does not function perfectly
(the axial and/or vertical adjustment time from stop to stop is too long, unusual noises are heard in this area).
The steering intermediate shaft and/or a universal joint is touching another component or has clearance of less
than 5 mm with it.
The steering wheel is more than 10° out of line when the marking for steering centre position overlaps → 44
Suspension alignment, complete section on "Adjust toe".
If permanent deformation, breakage, cracks or play have been detected in:
steering gear,
steering column mountings,
tie rods,
steering arms,
spring struts,
wheel carriers,
control arms,
front axle carrier (suspension subframe)
then the steering column must be checked according to the criteria listed above.
Checking the steering column of a vehicle involved in an accident
The gap dimension on the steering column can still be used. The → Gap
dimension: 0.5 mm -X- . If the gap is larger, the steering column must be
replaced. In this case, the driver has been forced against the steering
wheel in an accident and has pushed the carriage in the steering module
in the direction of travel. The gap dimension X can be checked using a
feeler gauge.
If the listed criteria are insufficient for a decision, we recommend that the
steering column be replaced by a new or exchange unit.
as of MY 2003
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48 IN Assessment of steering gear after accident damage - as of

MY 2003
- Information
Information
Fundamentals
Various kinds of damage can occur to the steering gear in the event of accidents or driving conditions similar to
accidents. In cases where the steering gear shows no external damage it can sometimes be difficult and costly to
detect damage. Nevertheless, this damage represents an unacceptable risk for the vehicle, since it could lead to
failure of the steering system.
A comprehensive check on all individual parts of the steering gear is not usually feasible due to the relatively high
cost and is not possible using ordinary workshop resources. Instead, consideration must be given to the condition
of other components that are easier to check.
To decide whether the steering gear of a vehicle involved in an accident must be replaced or may continue to be
used, the following guidelines are helpful.
Assessment of the steering of a vehicle involved in an accident
The steering gear may remain in the vehicle if all the following conditions are met:
No visible damage to such front-axle parts as wheel rims, spring struts, wheel carriers, control arms, steering
arms, tie rods, suspension subframe, the steering shaft or to the points on the body where wheel suspension
parts are bolted on.
No impermissible rise in torque and no jamming or catching when the steering gear is turned from stop to stop.
When the steering is turned, the front wheels must be free (front axle raised) and, in addition, the engine must be
switched off (pump of power steering undriven).
The permissible tolerances for wheel alignment must not be exceeded.
The steering gear must be replaced by a new or exchange unit if one of the following points applies:
Visible or perceptible damage to the steering gear.
Fire damage (e.g. steering bellows burnt).

Permanent deformation or breakage of:
Steering-gear mountings
Tie rods
Steering arms
Spring struts
Wheel carriers
Control arms
Suspension subframe
If the listed criteria are insufficient for a decision, we recommend that the steering gear be replaced with a new or
exchange unit.
Exceptional regulation/order handling
If a workshop's intended exchange of steering gear is refused by a customer or insurer for reasons of costs, an
expert or - if this is impossible abroad, the importer - should be called in at the cost of the refusing party. If the
decision contradicts the guideline, we recommend that a memorandum be drawn up on the point and that it be
countersigned by the expert.
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48 IN Test and assembly work on power steering - as of MY 2003

- Information
- Checking
- Bleeding
Information
General
Note
z Rack-and-pinion steering gear and servo pump must not be repaired or dismantled!
Damage to the power steering is caused by a shortage of oil in the hydraulic system. Even small leaks can cause
the fluid to escape and damage the servo pump as a result of the high oil pressure in the hydraulic circuit.
Grunt-like noises on turning the steering to full lock or foam formation in the reservoir indicate a shortage of oil
and/or the absorption of air. Before filling the reservoir, any existing leaks must be eliminated . In this case the oil
level in the reservoir 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, then there is air in the hydraulic system.
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 MAX/MIN marking is mounted on the reservoir cap

→ see figure . The marks are for a fluid level with a cold engine (approx.
20 °C)!
Checking
Checking fluid level for power-assisted steering
ATTENTION
Note
z The reservoir is located at the front left of the engine compartment.
z A dipstick with MAX-MIN marks is mounted on the cap of the

reservoir. They are for a fluid level with a cold engine (approx. 20°C).
z The MAX mark can easily be exceeded at higher temperatures.
Check the fluid level (Pentosin CHF 11 S) when the engine is stopped and
cold (approx. 20°C).
Pentosin tank in the engine
compartment
The fluid level must be between the MAX and MIN marks → see figure .
1. Start engine and run it at idle speed for approx. 20 seconds. Switch
off engine.
2. Open engine cover and 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.
Bleeding
Bleeding the steering system

1. After installation is complete, raise the vehicle so that the wheels are no longer touching the ground.
2. Open engine cover, lid and reservoir.

3. Fill reservoir up to the MAX mark, until the level no longer drops.
4. Then turn the steering to the left and to the right. Hold the steering on
full lock for approx. 30 seconds on each side until the level no longer
drops. Continually check the fluid level and fill to the MAX mark again
if necessary.
5. Lower vehicle onto the wheels. Briefly start the engine, let it run for
approx. 1 second and add Pentosin again. This procedure causes
the fluid level in the reservoir to fall rapidly, so constantly add
Pentosin CHF 11 S. The reservoir must not be sucked dry.
6. If the fluid level in the reservoir does not fall any further when the
engine is briefly turned over, start the engine and let it run at idling
speed.
7. Turn steering on full lock several times to left and right at idling speed and observe the fluid level during this
procedure (second worker required). If it continues to fall, add fluid until the level in the reservoir remains
constant and no more air bubbles circulate in the reservoir when the steering wheel is turned.
8. Switch engine off and set the correct fluid level. This must be between the MAX and MIN markings.
When the correct level has been reached, no air bubbles must be circulating in the reservoir and the fluid level
must no longer drop.
as of MY 2003
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48 10 19 Removing and installing steering wheel - as of MY 2003

- Preliminary work
- Removing steering wheel
- Installing steering wheel
- Subsequent work
Preliminary work
2. Remove steering wheel airbag unit. → 695819 Removing and installing driver's airbag unit - chapter on
"removing"
Removing steering wheel
ATTENTION
Increased risk when handling airbag modules.
z Injury and material damage may occur if airbag units are not
handled correctly → 69 AW Safety regulations for vehicles with
airbag and belt tensioner - chapter on "General warning notes".
→ Observe safety regulations for handling airbag modules.
1. Turn wheels to straight-ahead position. Before removing steering

wheel, make a coloured mark on steering wheel and steering column
(centring of airbag spiral spring).
Note
z Disconnect steering wheel heating if fitted on vehicle.
2. Remove steering wheel by releasing multiple-tooth screw.

Installing steering wheel
Note
z The steering wheel is made of magnesium alloy! The tightening torques must be strictly observed!
z Wheels straight ahead and observe previously applied markings!
z Airbag unit must lock with an audible click! Check by pulling at airbag unit!
z Always replace the multiple-tooth screw!
z Observe tightening torque. → 48 TW Tightening torques for steering - chapter on "Technical values".
Installation of the steering wheel takes place in reverse order.
Subsequent work
1. Install steering wheel airbag unit. → 695819 Removing and installing driver's airbag unit - chapter on
"installing"
2. Connect battery. → 90 Work instructions after disconnecting the battery
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48 13 19 Removing and installing steering column trim - as of MY

2003
- Removing steering column trim
- Installing steering column trim
Removing steering column trim

1. Adjust the steering column downward and to the rear.
2. Angle the steering wheel 90° to the left, press the left → see figure
locking lug forward with a screwdriver and unclip it.
3. Angle the steering wheel 90° to the right, press the right locking lug
forward with a screwdriver and unclip it.
4. Pull the top steering column trim back -arrow- and tip it up slightly so
that the steering column trim can be removed from the front guide.
5. Use a small screwdriver to unclip the retaining strip for the gap cover (leather) -arrows- . Remove the top
steering column trim.
6. Remove the steering column adjusting lever.
7. Remove the two fastening
screws -arrow- from the lower
steering column trim at the left
and right next to the steering
column.
Note
z On vehicles with an electrically adjustable steering column, unlock
and pull off the connector of the steering column actuator -arrow- .
8. Remove the trim carefully downwards.
Installing steering column trim
Note
z After installation, check the gap and seating of the steering column
trim and adjust as required.
1. Fit lower trim panel. If necessary, clip in the connector for the electric
steering column actuator. Fit the lower trim in the correct position
using the fastening screws.
2. Clip in the retaining strip for the gap cover, starting from one side.
3. Fit the upper cover at the instrument cluster and make sure that the locking lugs clip in correctly on the
steering wheel side.
4. Install the steering column adjusting lever.
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48 15 19 Removing and installing steering column - as of MY 2003

- Preliminary work
- Removing the steering column
- Installing the steering column
- Subsequent work
Preliminary work
Note
z The fore-and-aft adjustment must be brought to the fully extended position for the electrically adjustable
steering column. The vertical adjustment must be moved to the centre position. This will improve access to
the fastening screws on the mounting bracket.
1. Disconnect the battery. → 9000IN Work instructions after disconnecting the battery - section on
"Disconnecting"
Removing the steering column
Steering column detached
ATTENTION
Increase risk when handling airbag modules.
z Injury and material damage may occur if airbag units are not
handled correctly → 6900AW Safety regulations for handling
airbag and belt tensioner units - section on "General warning
notes".
→ Observe safety regulations for handling airbag modules.
Removing airbag module

Note
z The fore-and-aft adjustment must be brought to the fully extended position for the electrically adjustable
steering column. The vertical adjustment must be moved to the centre position. This will improve access to
the fastening screws on the mounting bracket.
1. Remove driver's airbag unit. To do this, turn the steering wheel 90° from the centre position. Press on
retaining clips with a screwdriver. Turn the steering wheel another 180° and repeat the procedure. Unclip
airbag unit → 695819 Removing and installing driver's airbag unit - chapter on "removing".
2. Turn the steering wheel to the straight-ahead position and remove → 481019 Removing and installing
steering wheel - chapter on "removing".
3. Remove cover from steering column switch and remove steering column switch → 945019 Removing and
installing steering column switch - chapter on "removing".
4. Release universal joint on steering gear -arrow- .
5. Remove lock nuts for mounting sealing bellows on bulkhead -arrows- (one lock nut hidden).
Mounting sealing bellows
6. Remove the two fastening screws of the holder for the stop light switch -arrows- .
7. Disconnect electric plug connections.
8. Remove fastening screw on mounting bracket (mount of upper

universal joint) -arrow- .
9. Remove fastening screws -1-4- on the mounting bracket and pull out complete steering column.
Installing the steering column
Note
z Observe the tightening sequence of steering column at mounting bracket.
z Once the battery is disconnected, perform the work required for full restoration of normal driving → 90 Work
z Calibrate steering-angle sensor → 456015 Initialising and calibrating
steering-angle sensor.
z The electronic steering column lock (ELV) must be taught using the
Porsche System Tester by selecting the menu items >> Kessy >>
Learning functions >> Teach ELV <<. You can get the necessary
immobiliser code from IPAS or from your importer by specifying the
vehicle identification number.
z The electrically adjustable steering column must be adapted in the

vehicle → 729319 Removing and installing control unit for memory
seat adjustment.
z Always replace the fastening screw for the universal joint of the
steering column.
z Replace locking screws and nuts.
z Observe correct tightening torques → 48 TW Tightening torques for

steering - chapter on "Technical values".
The steering column must only be replaced as a complete unit. Individual

components cannot be disassembled and replaced.
1. Insert the steering column and the fastening screws in the order
indicated -1, 2, 3, 4- on the assembly cross member.
2. Fit fastening screw to mounting bracket -arrow- (mount of upper universal joint), cardanic, free of warping
(movable in every direction).
3. Slide the steering shaft (universal joint) to correct position, steering gear in centre position, as far as it will go.
When fitted correctly and tension-free, the universal joint must be at a maximum distance -arrows- of 4 mm
from the outermost edge of steering gear dust boot.
Max.distance of universal joint from Mount of upper universal joint
steering
4. Fit steering-column switch → 945019 Removing and installing steering-column switch - chapter on
"installing".
5. Fit steering wheel → 481019 Removing and installing steering wheel - chapter on "installing".
6. Install airbag unit → 695819 Removing and installing driver's airbag unit - chapter on "installing".
Subsequent work
1. Fit the stop light switch support and the linings → 701919 Removing and installing lower dashboard cover -
2. Connect battery. → 90 Work instructions after disconnecting the battery
9PAAD1, 9PAAD7
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48 29 19 Removing and installing switch for height and fore-and-

aft adjustment - as of MY 2003
- Removing switch for height and fore-and-aft adjustment
- Installing switch for height and fore-and-aft adjustment
Removing switch for height and fore-and-aft adjustment
Removing switch for height and fore-and-aft adjustment
Remove trim panel for steering column → 481319 Removing and installing trim panel for steering column -
1. Unscrew the fastening screw -1- .

2. Turn switch inwards -Arrow A- and remove it from the holder.
Installing switch for height and fore-and-aft adjustment
Installing switch for height and fore-and-aft adjustment
1. Insert switch into the holder -Arrow A- and turn to the fastening
position -Arrow B- .
2. Secure the switch with the fastening screw -1- .
Install trim panel for steering column → 481319 Removing and installing
trim panel for steering column - chapter on "Installing"
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48 55 19 Removing and installing sealing bellows of the steering

column (steering column removed) - as of MY 2003
- Removing sealing bellows of the steering column
- Installing sealing bellows of the steering column
Removing sealing bellows of the steering column

Overview of steering column - sealing bellows → Overview of steering column
Note
z To remove and install the sealing bellows, the steering column must be removed.
z To do this, the catalytic converter on the side of the steering column must be removed. → 267319 Removing
and installing (main) catalytic converter - section on "Removing" [9PAAD1 9PAAD7]→ 267319 Removing
and installing (main) catalytic converter - section on "Removing" [9PAAE1 9PAAE7 9PAAF1 9PAAJ1]
z When the intermediate steering shaft has been separated, make sure that everything remains extremely
clean. The grease on the individual parts must not be wiped off. If these individual parts are stored for a long
period of time, they must be protected from dust and dirt.
1. Remove steering column. → 481519 Removing and installing steering column - section on
"Removing" [9PAAJ1]→ 481519 Removing and installing steering column - section on "Removing" [9PAAD1
9PAAD7]→ 481519 Removing and installing steering column - section on "Removing" [9PAAE1 9PAAE7
9PAAF1]
2. Both parts of the intermediate steering shaft must be marked for

assembly -colour dots- . This ensures that both sections will not be
installed offset.
3. Disconnect the steering column at the intermediate steering shaft

→ see figure . The lower steering shaft can be pulled from the upper
steering shaft with a brief jerk at the pressure point.
4. Remove the sealing bellows of the steering column.
Installing sealing bellows of the steering column
Note
z The steering columns must only be replaced as a complete unit. Individual components cannot be
disassembled and replaced.
z Make sure that everything remains absolutely clean.
z Use the prescribed lubricant on the sliding part (see Parts Catalogue in Main Group 40305). This lubricant is
available under the following part numbers: Container quantity: one 10-gram tube = 000.043.205.44!
z Use the prescribed lubricant at the sleeve contact point with the friction ring of the sealing sleeve (see Parts
Catalogue in Main Group 40305). This lubricant is available under the following part number: Container
quantity: one 30-gram tin = 999.917.557.00!
z Fit together both parts of the steering column that were previously marked with -colour markings- .
z The lower steering shaft must slide on the upper steering shaft
smoothly and without catching.
1. Fit the sealing bellows of the steering column in the correct position.
2. Slide the lower steering shaft onto the upper steering shaft → see
figure . Overcome the pressure point with a strong jerk.
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48 69 19 Removing and installing Servotronic control module - as

of MY 2003
- Removing Servotronic control module
- Installing Servotronic control module
Removing Servotronic control module
Removing Servotronic control unit

Remove trim panel under dashboard → 701919 Removing and installing trim panel under dashboard - chapter on
"Removing".
Remove holder for stop light switch → 481519 Removing and installing steering column - chapter on
"Removing" [9PAAJ1]→ 481519 Removing and installing steering column - chapter on "Removing" [9PAAD1
9PAAD7]→ 481519 Removing and installing steering column - chapter on "Removing" [9PAAE1 9PAAE7
9PAAF1].
1. Release the left relay carrier -Arrows A- and pull it down and out -Arrow B- .
2. Remove the control unit from the relay carrier -arrow- .
Installing Servotronic control module

Installing Servotronic control unit
1. Place control unit on the relay carrier -arrow- .
2. Press the relay carrier into the holder -Arrow A- until the locking tabs
engage audibly.
Install holder for stop light switch → 481519 Removing and installing
steering column - chapter on "Installing" [9PAAJ1]→ 481519 Removing
and installing steering column - chapter on "Installing" [9PAAD1 9PAAD7]
→ 481519 Removing and installing steering column - chapter on
"Installing" [9PAAE1 9PAAE7 9PAAF1].
Install trim panel under dashboard → 701919 Removing and installing trim
panel under dashboard - chapter on "Installing".
as of MY 2003
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48 79 19 Removing and installing tie rod - as of MY 2003

- Tools
- Removing tie rod
- Installing tie rod
Tools

Screwdriver special tool 9546
assembly tool for spring-band commercially NR.72

clamps available tool

available tool
Torque wrench, signal- commercially NR.90
transmitting with changeover available tool
ratchet
Accessory for torque wrench: commercially NR.95-1

Open-jawed wrench insert, a/f available tool
24
Open-jawed wrench insert a/f commercially NR.95-2

38 available tool
Press-out tool special tool T10187

Tools
Tools

-A- Press-out tool T10187 See Workshop To press out the ball joint on
Equipment Manual, the wheel carrier.
Chapter 2.2.3
-B- Screwdriver 9546 See Workshop To counter the ball joints (track
Equipment Manual, rod) during assembly and
Chapter 2.2.2 disassembly.
-C- Accessory for torque wrench: See Workshop To fit tie rod (lock nut).
Open-jawed wrench insert, a/f Equipment Manual,
24 NR.95-1 Chapter 2.4
-D- Open-jawed wrench insert a/f See Workshop To fasten tie rod to steering
38 NR.95-2 Equipment Manual, gear (steering rack).
Chapter 2.4
-E- Pliers for lug hose clamp See Workshop To fasten joint boot to steering
NR.74 Equipment Manual, housing.
Chapter 2.4
-F- Torque wrench, signal- See Workshop To adjust the tightening torque.
transmitting with changeover Equipment Manual,
ratchet NR.90 Chapter 2.4
Removing tie rod
Removing tie rod

1. Remove wheel → 440519 Removing and installing wheel - chapter on "removing".
2. For easier removal of the outer tie rod end, swivel the relevant wheel
carrier so that the tie rod extends fully. Remove the outer tie rod
joints with the press-out tool T10187. When pressing off, screw lock
nut on flush (protects the ball joint thread).
3. Right tie rod: Remove heat shield near joint boot of right tie rod.
4. Remove small clamp -arrow- of joint boot using assembly tool for
spring-band clamps NR.72.
5. Cut open and remove large clamp -arrow- of joint boot using a pair of side cutters.
6. Carefully pull the joint boot -see figure- outwards until the axial joint is accessible.
7. Disassemble axial joint -arrow- from the steering rack using open-jawed wrench insert a/f 38 NR.95-2 for
torque wrench and remove the complete tie rod.
Installing tie rod
Installing tie rod
Note
z The tie rods are delivered preset as an assembly (tie rod/tie rod joint).
z If the joint boot is to be used again, before installing inspect for wear (cracks, slits) and check that sealing
surfaces are clean.
z Identify position of tie rod joint on the (pre-) set tie rod and, in order to fit the joint boots and the small clamp,
remove/fit lock nut and tie rod joint.
z During installation, insert new sealing rings -arrow- on the steering gear. Take care not to damage the
sealing ring when fitting the joint boot.
z Carry out a close visual inspection of all parts.
z When fitting the ball joints, ensure that the bevel pinions are clean!
Remove dirt or grease on bevel pinions, e.g. with a lint-free cloth. Do
not use cleaning agent/solvent.
z Observe correct tightening torques → 48 Tightening torques for

steering.
z Calibrate steering angle sensor . → 456005 Initialising and calibrating

steering-angle sensor - chapter on "Calibrating".
Ensure that no damage (scoring or similar damage) is caused to the

steering rack.
Fit joint boot (not twisted) and secure with new clamps -see figure- .
The arrow denotes the clamp lug .
When fitting the large clamps, it is essential to observe the following

installation position (right/left). The clamps must be fitted in the correct
position. Place the pliers for lug hose clamp NR.74 on the clamping
washer lug and lightly clamp. It should still be possible to easily turn the
clamps. Check the position of the clamp once more, correcting if
necessary, and then compress the clamp lug fully.
The clamp of the left joint boot must be clamped on the steering gear so
that the clamp lug -arrow- is in line with the steering shaft! Failure to
observe this can lead to constrictions in the area of the supply and return
lines.
The clamp of the right joint boot must be clamped on the steering gear so
that the clamp lug -arrow- points horizontally with the front axle carrier
(suspension subframe) in the direction of travel. Failure to observe this
can lead to constrictions in the area of the heat shield.
Check vehicle toe and adjust → 44 complete suspension alignment if

necessary .
Observe correct tightening torques → 48 Tightening torques for steering.

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48 90 19 Removing and installing steering gear - as of MY 2003

- Preliminary work
- Removing steering gear
- Installing steering gear
- Information
Tools

pliers for hose clamp commercially NR.74
available tool
Preliminary work
Preliminary work
Note
wheel in centre position with steering wheel holder). If this is not done, the airbag contact unit will have to be
put in the centre position after installation of the steering gear → 945019 Removing and installing steering
column switch.
z Before the feed and return lines are loosened, place a suitable container underneath to collect steering fluid.
z Wear protective goggles and gloves.
1. Remove wheel → 440519 Removing and installing wheel - section on "Removing".
2. Remove engine guard → 108019 Removing and installing engine guard - section on "Removing"
3. Remove wheel-housing liner → 505619 Removing and installing front wheel-housing liner - section on
"Removing" .
Removing steering gear
Removing steering gear

Note
wheel in centre position with steering wheel holder). If this is not done, the airbag contact unit will have to be
put in the centre position after installation of the steering gear → 945019 Removing and installing steering
column switch.
z Before the feed and return lines are loosened, place a suitable container underneath to collect steering fluid.
z Wear protective goggles and gloves.
1. Remove the outer tie rod joints with the press-out tool T10187. When pressing off, screw lock nut on flush
(protects the ball joint thread).
2. Remove fastening screws -arrows- from heat shield (steering

gear/steering shaft). If vehicle is a Cayenne with Servotronic, pull off
connector.
3. Remove fastening screw from universal joint of steering shaft -arrow-

(push universal joint slightly upwards).
4. Release rear mount of front-axle drive (right-hand side of vehicle). Lift front axle drive with a suitable jack
-see figure- (use wooden block or rubber base to prevent slipping. Remove fastening screw and lift front-
axle final drive just enough to access the bearing eye above the bolting point of the front axle carrier (do not
press the cardan shaft into the stop).
5. Re-insert fastening screw -arrow- (better access). The drive remains
in the raised position and the jack can be removed.
6. Release supply and return lines -arrows- (collect steering fluid in a

suitable container). Close the lines and any open threaded bores with
suitable plugs.
7. Remove the fastening screws of steering gear -arrows- .
8. For easier removal of the steering gear, loosen the fastening nut on the coolant hoses. Then unclip coolant
hoses from brackets and lay them upwards -see figure- (cut-away view of steering gear shown here).
9. Remove heat shield and push steering gear -see figure- to the right, out of the subframe mounting points,
and turn to the rear.
10. Turn steering gear -arrow- to the rear by approx. 90-100 degrees.
11. Unclip the coolant hoses in the wheel housing from the retaining clip. Then carefully guide out steering gear
-see figure- through the left wheel housing.
Installing steering gear
Installing steering gear
WARNING
Risk of accident due to malfunction in PSM control range if steering-angle sensor is not calibrated or is
incorrectly calibrated.
z Possibility of serious injury or material damage.
→ Calibrate steering-angle sensor with wheels in straight-ahead position using the Porsche System Tester
→ 456005 Initialising and calibrating steering-angle sensor.
→ If steering wheel has been removed, ensure that airbag spiral spring is in centre position → 945019
Removing and installing steering-column switch.
Note
z When topping up or filling in Pentosin, make sure that it does not come into contact with the coolant hoses.
To avoid overflow caused by overfilling, observe the instructions → 48 Test and assembly work on power
steering.
z If coolant hoses come into contact with Pentosin, clean them thoroughly with water IMMEDIATELY!
z Replace visibly swollen coolant hoses.

After fitting the pressure lines, fill steering hydraulics with Pentosin CHF 11 S and bleed steering system → 48
Test and assembly work on power steering.
Replace all elastic bolts and lock nuts.
Tighten all threaded connections with the specified tightening torque values → 48 Tightening torques for steering.
Check and/or adjust toe-in → 44 Suspension alignment, complete.
Calibrate steering-angle sensor → 456019 Installing and removing steering-angle sensor.
Information
Installation instructions
Replace fastening screw of steering shaft whenever it has been removed. Ensure it is fitted correctly. Insert
fastening screw (in correct position, not from the threaded side).
Push on universal joint (steering shaft) in correct position, with steering

gear and steering wheel or airbag contact unit (spiral spring) in centre
position. When doing this, only place steering transmission screws in
position (to facilitate assembly when pushing universal joint on). After the
fastening screws of steering have been tightened, push universal joint on
as far as it will go. When fitted correctly and tension-free, the universal
joint is allowed to be at a maximum distance -arrows- of 4 mm from the
outermost edge of steering gear dust boot.
Replace steering gear fastening screws.
Screw threads must be clean and free of grease.
Ensure that no damage (scoring or similar damage) is caused to the

steering rack.
If the tie rods are to be reused, detach them from removed steering gear
and fit them on new steering gear. Insert new sealing rings -arrow- on
steering gear.
Note
z The left clamp of the joint boot must be clamped so that the clamp lug
-arrow- is in line with the steering pinion.
z The right clamp of the joint boot must be clamped so that the clamp
lug -arrow- points horizontally with the front axle carrier (suspension
subframe) in the direction of travel.
z Failure to do this can lead to constrictions on the left-hand side in the

vicinity of the feed and return lines and on the right-hand side in the
vicinity of the heat shield.
Fit joint boot (not twisted) and secure with new clamps -arrow- (use pliers for hose clamp NR.74, Workshop
Equipment Manual, commercially available tools).
Check the joint boot is not worn (cracks, slots) and that sealing surfaces are clean.
When fitting the ball joints, ensure that the conical seats are clean. Remove dirt or grease on conical seats, e.g.
with a lint-free cloth. Do not use cleaning agent/solvent.
Observe airbag safety instructions → 69 Safety instructions when working on vehicles with airbag and belt
tensioners .
Install airbag unit for driver → 695819 Removing and installing driver's airbag unit - chapter on "Installing"
Observe notes on steering-gear centre position in the section on front track adjustment in Repair Group 44 → 44
Suspension alignment, complete.
Calibrate steering-angle sensor → 456005 Initialising and calibrating steering-angle sensor.
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48 92 19 Removing and installing radiator for power steering - as

of MY 2003
- Preliminary work
- Removing radiator for power steering
- Installing radiator for power steering
- Subsequent work
Preliminary work
Preliminary work
1. Raise the vehicle → Lifting the vehicle [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Lifting the
vehicle [9PAAJ1].
2. Remove engine guard → 108019 Removing and installing engine guard - section on "Removing"
3. Remove front apron → 631519 Removing and installing front apron - section on "Removing"
Removing radiator for power steering
Removing radiator for power steering
The -cooler for power steering system- is located at the

-radiator module (radiator, condenser, ATF cooler, cooler for power steering system)- , behind the front
apron.
Servo oil cooler
ATTENTION
Increased risk of accident from Pentosin CHF 11 S getting onto the
surrounding area (e.g. onto the coolant hoses) when the oil coolant
hoses are loosened (opened).
→ Collect any emerging Pentosin.

→ Wear protective goggles when carrying out overhead work on lines
with Pentosin.
→ If coolant hoses come into contact with Pentosin, thoroughly clean
them with water IMMEDIATELY.
1. Remove lateral air guides and the air guide at the top -arrows- .
Note
z For the Cayenne Turbo, the centre piece of the air guide is a single-
part.
2. The bottom air guide -arrows- does not have to be removed.

Remove retaining bracket (front apron engine guard) and move the
lock carrier into the service position → 503809 Loosening and
fastening lock carrier (service position) - section on "Loosening".
3.
4. Use an appropriate collecting container for any Pentosin which runs

out. Release hoses from radiator for power steering and close with
suitable plugs. Remove the mount of the radiator for power steering
-arrow- , only screwed on the left-hand side.
Mount for the servo oil cooler
5. Unclip the radiator for power steering from the mount -arrow- .
6. Bracket
7. Pull the
-retaining frame for radiator-
carefully to the front.
8. Carefully push the radiator module back. Pull the

-cooler for power steering system- out between the radiator
module and the retaining frame for the radiator.
Installing radiator for power steering
Installing radiator for power steering

1. Push the -cooler for power steering system- in between the
radiator module and the retaining frame for the radiator.
2. Retract the radiator for power steering into the mount -arrow- .
3. Clip the radiator for power steering into the bracket -arrow- . Ensure correct seating.
4.
5. Fit fastening screw -arrow- , connect hoses for power steering radiator and fit securing clamps. The hoses
must not be twisted in the process.
6. Together with bottom air guide, move bumper out of service position and into normal position → 503819
Removing and installing lock carrier and fit retaining bracket (front apron engine guard).
7. Install top air guide -arrows- and lateral air guides.
Subsequent work
Subsequent work
1. Fit front apron → 631519 Removing and installing front apron - section on "Installing" .
2. Mount engine guard → 108019 Removing and installing engine guard - section on "Installing"
3. Fill Pentosin and bleed steering → Test and assembly work on power steering.
4. Lower the vehicle → Lifting the vehicle [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ Lifting the
vehicle [9PAAJ1].
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48 98 19 Removing and installing hydraulic pump (Cayenne V6) -

as of MY 2004
- General
- Preliminary work
- Removing hydraulic pump (Cayenne V6)
- Installing hydraulic pump (Cayenne V6)
- Subsequent work
Tools

hose clamp special tool 3094
General
Position of hydraulic pump on engine
Damage to the power steering will occur if there is a shortage of oil in the hydraulic system. Even small leaks can
cause the hydraulic fluid to escape and damage the servo pump as a result of high oil pressure occurring in the
hydraulic circuit.
Grunt-like noises that can be heard when the steering is locked, or foam formation in the reservoir indicate a
shortage of oil and/or that air has also been sucked in. Before filling the reservoir, any existing leaks must be
eliminated on the suction side. Alternatively, the defective part on the pressure side should be replaced.
ATTENTION
Preliminary work
Preliminary work
Note
z The engine does not have to be removed in order to remove and install the hydraulic pump.
z The hydraulic pump in the V6 engine is accessible from beneath.

Note
z Before removing the cover of the air cleaner box , the intake manifold must be disengaged from the air
cleaner housing.
z Loosen the pulley of the hydraulic pump before removing the drive belt.
Hydraulic pump (pulley removed)
1. Remove the left engine compartment cover. → 700219 Removing and installing front cover (engine
Note
z Before removing the cover of the air cleaner box , the intake manifold
must be disengaged from the air cleaner housing.
z Loosen the pulley of the hydraulic pump before removing the drive
belt.
2. Disconnect intake manifold at the air cleaner cover. To do this, turn

the -pins 180°- and pull them out. Then set the intake manifold
aside ..
3. Remove air cleaner → 242455 Replacing air-cleaner element - chapter on "Replacing".
Removing hydraulic pump (Cayenne V6)
Removing hydraulic pump (Cayenne V6)

Note
z The engine does not have to be removed in order to remove and install the hydraulic pump.
z The hydraulic pump in the V6 engine is accessible from beneath.
1. Loosen pulley of hydraulic pump, but do not remove it.
2. Slacken drive belt and remove from the pulley. → 137819 Removing and installing drive belt - chapter on
"Removing"
4. Remove engine guard. → 108019 Removing and installing engine

guard - chapter on "Removing".
5. Remove pulley.
6. Clamp both lines to the hydraulic pump (suction line, pressure pipe)
with a hose clamp 3094 as close as possible to the hydraulic pump
as possible.
7. Remove both lines to the hydraulic pump (suction line, pressure

pipe). Close the open connections with suitable plugs. Collect
emerging hydraulic fluid in a suitable container.
8. Remove hydraulic pump.
Installing hydraulic pump (Cayenne V6)
Installing hydraulic pump (Cayenne V6)
Note
z In vehicles without Servotronic, the hydraulic system must be flushd with approx. two litres of Pentosin CHF
11 S .
z The hydraulic system must be bled after repair → 48 Test and assembly work on power steering. The
vehicle must be lowered onto the wheels for this.
z Only use Pentosin CHF 11 S to fill the hydraulic system.

z Pay attention to the hydraulic fluid level.
z Replace sealing rings.
z When replacing the hydraulic pump observe the instructions in the Technical Information, Replacing servo
pump: Group 4, No. 5/03.
z Observe correct tightening torques → 48 Tightening torques for steering.
1. Fit the hydraulic pump. → Tightening torque: 17 ftlb.
2. Fit pulley on the hydraulic pump and screw in the screws.
3. Fit drive belt in correct position and tension → 137801 Check drive belt - chapter on "Checking".
4. Tighten the pulley on hydraulic pump. → Tightening torque: 17 ftlb.
5. Fit both hydraulic lines. → Tightening torque: 22 ftlb. +/-2.0 ftlb. → Tightening torque: 7.5 ftlb. Remove
hose clamp 3094.
Subsequent work
Subsequent work
1. Fit air cleaner. → 242455 Replacing air-cleaner element - chapter on "Replacing"
2. Fit intake manifold on cover for air cleaner housing.
3. Disconnect pressure pipe on the servo oil cooler (line leading to the hydraulic fluid tank). Have a suitable
plug ready and close the line (emerging hydraulic fluid!). Collect emerging hydraulic fluid in a suitable
container.
4. Fill the hydraulic fluid tank. Use a suitable auxiliary hose (approx. 10 - 15 cm, shop-made) to carry hydraulic
fluid that emerges during flushing into a suitable container (approx. 1.5 litres).
5. Flush the hydraulic system with the engine running by turning the steering several times to the right or left
stop, and adjust the hydraulic fluid level several times as required. The vehicle must be lowered onto the
wheels for this. The tank must not run empty while the engine is running (two workers required).
6. Fit the pressure pipe on the servo oil cooler.
7. Bleed the hydraulic system with the engine running by turning the steering several times to the right or left
stop and adjust the hydraulic fluid level several times as required → 48 Testing and assembly work on
power steering.
8. Fit engine guard → 108019 Removing and installing engine guard - chapter on "installing".
9PAAD1, 9PAAD7
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48 98 55 Replacing hydraulic pump (Cayenne V6) - as of MY 2004,

until MY 2005
- Replacing
Replacing
Replacing hydraulic pump
Hydraulic pump V6 (conversion)
A - Suction connection as of model year 2006

B - Suction connection until model year 2005
The hydraulic pump that was installed in vehicles up to model year 2005 will no longer be available as a spare
part. Only the new hydraulic pump will be offered as of model year 2006.
With the introduction of the new hydraulic pump from model year 2006, a modified suction connection will be used
for the suction pipe to the hydraulic reservoir, together with modified hose routing.
Spare parts for vehicles as of model year 2006:
z New hydraulic pump, including the new suction connection for the suction pipe to the hydraulic reservoir.
Vehicles up to model year 2005 must have the new hydraulic pump installed. To do this, the suction connection
on the hydraulic pump for the suction pipe to the hydraulic reservoir must be refitted.
Spare parts for vehicles up to model year 2005:
z New hydraulic pump

z Old suction connection (will be offered as a spare part)
z O-ring
z Hexagon-head bolt
Reason for the modified suction pipe to the hydraulic reservoir is the introduction of a new alternator as of model
year 2006. Should this require a conversion, you can find further information in the repair instructions → 272255
Replacing generator.
1. Refit hydraulic pump suction connection (if necessary up to model year 2005). Use new O-ring and hexagon-
headed bolt.
2. Refit pulley of old hydraulic pump on the new hydraulic pump.
9PAAD1, 9PAAD7

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50 IN Work sequence for determining scope of damage to

vehicles involved in an accident - as of MY 2003
Notes
Note
z A body is constructed so that it has deformable zones in the front and rear areas. These deformable zones
enable absorption of impact energy through their special design. The bearing structure in these areas is
adapted by a specific cross section reduction to provide optimum energy reduction in the event of an impact.
z Due to the vehicle dimensions in the side area of the body, deformable zones cannot be provided for
absorbing energy. The impact energy can only be absorbed to a lesser extent here through the deformation
of doors and pillars. This is also the case for the roof area where only the roof skin can absorb impact energy
to a very small extent. In these areas, passenger protection is guaranteed by a rigid design of the passenger
cell.
z The aim of this design is to absorb the impact energy in defined areas to keep the passenger cell as free of
damage as possible in the event of an accident. If the passenger cell has been deformed in the event of an
accident, extremely large reshaping forces can be expected. Repair work is often only possible in this case
by replacing body parts.
z In general, an impact occurs diagonally or offset to the vehicle axle so that mixed forms are usually the result
of a front and side impact or a rear and side impact. The deformation is not always restricted to the impact
area. Due to inertia forces of masses, such as running gear, drive line, occupants of the vehicle and load or
the body itself, deformation can also occur in the opposite areas.
z The following work sequence should provide assistance to correctly determine the scope of damage of
vehicles damaged in an accident.
Work sequence for determining scope of damage to vehicles involved in an accident

1. Identify impact points on the outer shell or the wheels
2. Remove accessories which limit view of the impact area
3. Check unit mounts, running gear parts and steering parts for deformation and cracks
4. Determine scope of damage on the body

→ Identifiable deformations on the body structure
→ No identifiable deformations on the body structure
Identifiable deformations on the body structure

1. Visual inspection of the structural parts for creasing and bending, starting from the point of impact toward the
centre of the vehicle
2. Visual inspection of the structural parts at the joints for gaping panel connections (e.g. entry area at the side
member under the rubber seal of the door)
3. Drive vehicle onto a lifting platform and raise. Measure the measuring points or reference points specified in
the repair check dimensions table diagonally, horizontally and vertically using a beam compass or an
electronic measuring system and compare with the specified values
→ Check dimensions for body repair
4. Decide whether vehicle is technically repairable
5. Decide whether vehicle is economically repairable
Repair vehicle, if necessary.
No identifiable deformations on the body structure

1. Check seam joining line on the add-on parts
→ Diagram - body gap dimensions
2. Check accessories for paint abrasion (accessories which have been in contact during the impact)
3. Drive vehicle onto a lifting platform and raise. Measure the measuring points or reference points specified in
the repair check dimensions table diagonally, horizontally and vertically using a beam compass or an
electronic measuring system and compare with the specified values
→ Check dimensions for body repair
4. Determine scope of any existing damage to vehicle parts

If necessary, measure running gear electronically
→ Assessment of steering gear after accident damage
→ Assessment of steering column after accident damage
→ Suspension alignment, complete
5. Decide whether vehicle has to be repaired
Repair vehicle, if necessary.
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50 IN Work sequence for accident repair - as of MY 2003

- Information
Information
Procedure for accident repairs.

1. Determine scope of damage
2. Expose the area to be repaired
3. Make an economic or technical decision: Should parts be repaired or replaced?
4. Determine the scope of replacement parts and order the parts

See below: "Repairs"→ 50 Work sequence for accident repairs
See below: "Replacing parts"→ 50 Work sequence for accident repairs
5. If necessary, primer and seal the seam areas
6. If necessary, renew the stone impact protection
7. Paint the repaired area
8. If necessary, touch up the undersealing
9. Seal cavities
10. Fit accessories
Repair
1. Cover undamaged areas of the vehicle
2. Reshape damaged areas
3. Fill or soak reshaped areas
4. Apply fine filler on repair areas

Replacement
1. Cover undamaged areas of the vehicle so that they are protected against fire
2. Disconnect battery
3. Pre-paint new parts from the inside
4. Reshape damaged area by straightening so that adjacent contours or gap dimensions correspond to the
standard condition
5. Roughly cut out damaged areas
6. Cut out remaining pieces
7. Fit new parts in, then check the gap dimensions with the accessories fitted
8. Protect spot-welded flanges against corrosion
9. Observe safety and quality instructions on welding
10. Weld in new parts
11. Grind visible weld seams flat; if necessary apply body solder or filler
as of MY 2003
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50 AW Safety notes - as of MY 2003

- Safety instructions for raising vehicles
- Safety instructions for adhesive bonding
- Safety instructions for installation work
- Safety instructions for corrosion protection
Safety instructions for raising vehicles
Danger of injury when raising vehicles
DANGER
Risk of fatal injury! Vehicle can slip or topple off the lifting platform!
z Risk of (fatal) injury due to vehicles slipping or tilting off lifting platforms may be caused by improper
on raised vehicles!

→ Check the correct seating of the support plates by raising the vehicle slightly and conducting a visual
inspection.
Damage when raising vehicles
ATTENTION
vehicle.
underbody area.
Danger of injury when welding
DANGER
Risk of fatal injury from high voltage during electric welding!
z Danger of explosion and fire when welding in the area of highly inflammable materials.
z Irritation to respiratory tracts from toxic zinc oxide emitted when welding galvanised steel!
z Danger of injury from unintentional triggering of pyrotechnical safety components!
z Danger of injury from weld spatters and UV light when welding!
→ Do not perform welding work in a damp environment or on wet ground; there is a risk of fatal injury from the
voltage being conducted through the human body. Persons with heart pacemakers should not perform
welding work. Use insulating underlays.
→ Remove highly flammable materials from the work area; if necessary, remove units with fuel-carrying parts
and protect work areas in the vehicle that are at risk of catching fire using fire-proof covers.
→ Ventilate the work area well.
→ Remove smoke gases with a suitable extraction system (refer to Workshop Equipment Manual).
→ Wear suitable protective equipment, such as protective clothing, gloves, a welding shield and, if necessary,
a protective mask.
→ For welding work, always disconnect both terminals on the battery. In the case of welding work in the
immediate vicinity of the control modules for pyrotechnical safety systems, remove the control modules
before beginning work.
→ In addition, the guidelines of the welding equipment manufacturer and the legal accident prevention
regulations and those of the mutual indemnity association (BGV D1) must be observed.
Safety instructions for flying sparks during grinding and welding work
ATTENTION
Danger of explosion and fire from flying sparks during grinding and welding work!
z Danger of injury and danger of damage to vehicle parts and other vehicles due to flying sparks
→ Cover vehicle parts such as battery, fuel system, paintwork, glass and passenger compartment parts with
fire-proof covers and, if necessary, remove batteries and fuel-carrying components.
→ No other vehicles may be left unprotected in areas used for body repair!
Safety instructions for fuel tank

ATTENTION
Danger of fire due to fuel tank or fuel-carrying parts heating up during grinding and welding work!
→ When carrying out grinding and welding work near the fuel tank or fuel-carrying parts, make sure that these
parts do not heat up!
→ It is recommended to remove endangered parts!
→ Cover the welding area generously with fire-proof covers!
Safety instructions for air conditioning
ATTENTION
Danger of injury! Bursting of the filled air-conditioning system during welding and brazing work!
z Danger of injury due to the filled air-conditioning system bursting during welding and brazing work.
→ No welding, brazing or hot-air heating may be performed on parts of the filled air-conditioning system!
→ While drying after painting work, the temperature burden on the vehicle must not exceed two hours at a
maximum temperature of 80 °C!
→ Make sure that parts of the air-conditioning system do not heat up during welding or brazing work on the
vehicle!
→ In the case of extreme heating of filled air-conditioning systems, a very strong overpressure may be caused
in the system which may lead to an explosion.
Safety instructions for adhesive bonding
Danger of poisoning and injury when adhesive bonding
ATTENTION
Danger of poisoning and injury when handling adhesive!
z Danger of poisoning from breathing in vapours or from swallowing adhesive.
z Risk of injury due to contact with skin or eyes.

→ Do not eat, drink, or smoke while carrying out work.
→ Avoid direct contact with eyes and skin. Wear suitable protective equipment, such as protective clothing,
gloves, and if necessary, a protective mask.
→ If clothing is soiled with adhesive, change clothing immediately and only use again after they have been
cleaned.
→ Also observe the product-specific processing and safety instructions on the packing container and packing
container imprints.
→ In case of eye contact: Rinse eyes immediately and thoroughly with lukewarm running water and consult an
eye doctor.
→ In case of skin contact: Rinse contacted skin areas immediately with lukewarm running water and soap.
→ If adhesive is swallowed: Rinse mouth and consult a doctor.
Safety instructions for Teromix-6700 two-component adhesive
ATTENTION
Material damage! Setting time of adhesive is not observed!!
z Danger of damage to side section if setting time of adhesive is not observed.
→ The new part must be welded in within 30 minutes!
Safety instructions for installation work
Safety instructions for sharp-edged body and unit parts
ATTENTION
Danger of injury! Sharp-edge burrs on body and unit parts!
z Injuries from sharp edges on body and unit parts.
→ Wear protective gloves when working in the area of sharp-edged body and unit parts!
Safety instructions for airbag system
DANGER
Danger of injury! Unintentional activation of airbag units!
z Serious injury due to unintentional activation of airbag units!
→ The ground strap of the battery must be disconnected during work on the airbag system and alignment
bench jobs when the body is being repaired!
→ After the battery is disconnected, assembly work or work on the vehicle with a hammer or similar tools must
not be started until after a waiting period of 1 minute!
Safety instructions for corrosion protection
Safety instructions for plug location plan (body)
ATTENTION
Material damage when removing plugs!
z Danger of corrosion and of uncontrolled water penetration!
→ The body apertures are sealed with plugs at the factory, and must be sealed with the plugs provided once
more following disassembly or repair work!
Safety instructions for water drains (body)
ATTENTION
Danger of material damage when cleaning the water drainage hoses!
z Water drainage hoses can be pushed out or deformed by blowing them out of the body during
cleaning!
→ When cleaning, only blow the water drainage hoses out with light compressed-air pressure!
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50 IN General information and notes on quality - as of MY 2003

- Battery trickle charge
- Information on electronic control units
- Information on maintaining long-life corrosion protection
Note
z In order to prevent the vehicle battery from discharging when visiting the workshop, a battery charging unit
with a rated current of at least 40 A must be connected as soon as the vehicle is unlocked.
Refer to → 2706 Batteryfor instructions about connecting the battery charging unit.
Information on electronic control units
Note
z If electronic components, e.g. ABS control module, have been removed for repair work and are then reused,
they must undergo a functional check after fitting in accordance with existing specifications.
Protection against overvoltage when performing welding work
To protect electronic control units from overvoltage during electric arc welding, the following work regulations must
be observed:
z When performing welding work: Remove plug connections on the engine, transmission, and airbag control
unit.
z Remove clamp from negative terminal of battery and cover battery.
z When welding work is extensive, electronic control units in the immediate vicinity of the welding point must be
removed.
z Connect the ground connection of the electric arc welding equipment as near as possible to the welding point
on the part to be welded. Ensure that there are no electrically insulated parts between the ground connection
and the welding point.
z Do not touch electronic control units or electric cables with the ground connection or the welding electrode.
Replacing control modules
The replacement of electronic control modules after an accident is necessary if at least one of the following
conditions is met:
The housing is noticeably deformed or damaged.
The supporting surface or bracket is deformed (the unit shows no external damage).
The plug connection is damaged or corroded by moisture.
Functional checks or self-diagnosis of the unit reveals the fault "Control module faulty".
Information on maintaining long-life corrosion protection
Note
z After repair work, the standard corrosion-inhibiting coating should only be restored with the corrosion-
inhibiting agents approved by the manufacturer. The following points must be observed for body repairs.
z Always apply welding primer to both sides of the welding flange when resistance spot welding.
z Prime repair areas from outside. Prime on both sides in the accessible areas.
z Seal all sheetmetal overlaps, sheetmetal edges, butt joints, weld seams etc. with body sealant.
z When replacing structurally bonded body parts, proceed according to the information in the respective repair
instructions.
z Only apply body sealant to primed sheetmetal parts.
z Apply top coat paint to the inside of the outer sheetmetal shell before welding. See "Paint build-up": → "Paint
Manual "
z Build up paint on bright sheetmetal panels according to the painting methods described in the → "Paint
manual".
z Repair or create standard undersealing by applying long-life undersealing material.
z Preserve cavities in the repair area with cavity preservative after applying a top coat paint.
z Check that the standard water drains (plugs) function correctly or clean them after the cavity preservation
material has dried.
Prerequisite for maintaining the long-life guarantee
All body repairs must be performed properly and according to the specific instructions defined by Porsche for
sheetmetal, painting and corrosion inhibition/preservation work. In order not to put the long-life guarantee at risk, a
paint condition report will be drawn up 2 years after delivering the vehicle. This condition report must be updated
every two years by every Official Porsche Centre.
as of MY 2003
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50 WM Tools and metalworking tools for body repairs - as of MY

2003
- Metalworking tools
Tools

Celette type straightening commercially we1121
system available tool
Car Bench commercially we1122

available tool
Tools and materials

Shown on Celette type
Celette type straightening system we1121
Car Bench we1122
Metalworking tools
Electrical equipment
-1- - Drill
-2- - Angle grinder, large
-3- - Angle grinder, small
-4- - Sander
-5- - Hot-air gun
Mechanical equipment
-6- - Hole punch

-7- - Edge setter
Compressed-air equipment
-8- - Air chisel

-9- - Body saw
-10- - Spotweld release
Welding equipment
-11- - Spotweld device and Multispot metalworking tool
-12- - MIG welder
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50 IN Diagram - keys to symbols for welding work - as of MY 2003

- Resistance spot-welding
- Inert-gas arc welding (MAG procedure)
- Gas welding
Resistance spot-welding
A - Spot seam, single row

B - Spot seam, double row
C - Spot seam, double row offset
Inert-gas arc welding (MAG procedure)
A - Plug weld
B - Stitch weld
C - Full weld
C - Intermittent full weld
Gas welding
A - Brazing
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50 IN Check dimensions for body repair - as of MY 2003

- Check dimensions for body repair
Tools

Telescopic measuring rod commercially NR.126
available tool
Tools and materials
Tools and materials
Telescopic measuring rod NR.126
Check dimensions for body repair

Check dimensions, front of vehicle
Messpunkte: -P1L- - RPS 1) Attachment of bumper, front left
-P1R- - RPS 1) Attachment of bumper, front right
-P2L- - Support for wing mounting point, front left
-P2R- - Support for wing mounting point, front right
-P3L- - Cross member support for wing mounting point, front left
-P3R- - Cross member support for wing mounting point, front right
-P4L- - RPS 1) Spring strut mount, left
-P4R- - RPS 1) Spring strut mount, right
-P5L- - RPS 1) Reinforcement, wing mounting point, rear left
-P5R- - RPS 1) Reinforcement, wing mounting point, rear right
Note
z All dimensions are measured on the body shell (with units removed) middle hole or middle screw connection
point. The dimensions are measured directly and, therefore, are oblique dimensions. Refer to the relevant
vehicle views for the positions of the measuring points. The measuring points are identified for the right or left
side in relation to the direction of travel (viewed from above). Dimensions which are only specified for the left
side of the vehicle also apply to the mirror image on the right side of the vehicle.
Note
z The specified dimensions are used only for an approximate estimation of possible structural damage. Repairs
to the vehicle must be done using an alignment system.
1) RPS = Relative Positioning System
Measured path Designation Dimension

P1L - P1R RPS 2) Attachment of bumper, front -P1- 936 ± 1 mm
P2L - P2R Cross member support for wing mounting -P2- 1642 ± 1 mm
point, front
P3L - P3R Support for wing mounting point, front -P3- 1082 ± 1 mm
P4L - P4R RPS 2) Spring strut mount -P4- 1420 ± 1 mm
P5L - P5R Reinforcement, wing mounting point, rear -P5- 1488 ± 1 mm
P1L - P2R Front of vehicle, diagonal dimension 1 -V1- 1357 ± 1 mm
Check dimensions, rear

Messpunkte: -P24L- - Attachment of bumper, rear left (bottom, outside)
-P24R- - Attachment of bumper, rear right (bottom, outside)
-P25L- - Attachment of bumper, rear left (top, inside)
-P25R- - Attachment of bumper, rear right (top, inside)
-P26L- - Attachment of rear lid, left (bottom, outside)
-P26R- - Attachment of rear lid, right (bottom, outside)
-P27L- - Attachment of rear lid, left (top, inside)
-P27R- - Attachment of rear lid, right (top, inside)

P24L - P24R Attachment of bumper, rear (bottom, outside) -P24- 1180 ± 1 mm
P25L - P25R Attachment of bumper, rear (top, inside) -P25- 1051 ± 1 mm
P26L - P26R Attachment of rear lid, (bottom, outside) -P26- 1074 ± 1 mm
P27L - P27R Attachment of rear lid, (top, inside) -P27- 816 ± 1 mm
P24L - P26R Rear, diagonal dimension 1 -H1- 1654 ± 1 mm
Check dimensions, roof
Messpunkte: -P28L- - Attachment of roof support system, left, front

-P28R- - Attachment of roof support system, right, front
-P29L- - Attachment of roof support system, centre, left
-P29R- - Attachment of roof support system, centre, right
-P30L- - Attachment of roof support system, left, rear
-P30R- - Attachment of roof support system, right, rear
-P31L- - Attachment of large volume roof, front, left
-P31R- - Attachment of large volume roof, front, right
-P32L- - Attachment of large volume roof, in front of centre, left
-P32R- - Attachment of large volume roof, in front of centre, right
-P33L- - Attachment of large volume roof, rear of centre, left
-P33R- - Attachment of large volume roof, rear of centre, right
-P34L- - Attachment of large volume roof, rear, left
-P34R- - Attachment of large volume roof, rear, right

P28L - P28R Attachment of roof support system, front -P28- 992 ± 1 mm
P29L - P29R Attachment of roof support system, centre -P29- 992 ± 1 mm
P30L - P30R Attachment of roof support system, rear -P30- 992 ± 1 mm
P28L - P30R Roof, diagonal dimension 1 -D1- 1523 ± 1 mm
P31L - P31R Attachment of large volume roof, front -P31- 992 ± 1 mm
P32L - P32R Attachment of large volume roof, in front of -P32- 992 ± 1 mm
centre
P33L - P33R Attachment of large volume roof, rear of -P33- 992 ± 1 mm
centre
P34L - P34R Attachment of large volume roof, rear -P34- 992 ± 1 mm
P31L - P34R Roof, diagonal dimension 2 -D2- 1724 ± 1 mm
Floorpan check dimensions
View of vehicle underside

Messpunkte: -P6L- - Attachment of front axle, front, left
-P6R- - Attachment of front axle, front, right
-P7L- - RPS 1) Side member, front, left
-P7R- - RPS 1) Side member, front, right
-P8L- - Attachment of engine carrier, left
-P8R- - Attachment of engine carrier, right
-P9L- - Attachment of front axle, rear, left
-P9R- - Attachment of front axle, rear, right
-P10L- - RPS 1) Entire vehicle, front, left
-P10R- - RPS 1) Entire vehicle, front, right
-P11L- - Side member, front floor, attachment of transmission cross member, front left
-P11R- - Side member, front floor, attachment of transmission cross member, front right
-P12L- - Floor side member, front, attachment of transmission cross member, left, rear
-P12R- - Floor side member, front, attachment of transmission cross member, right, rear
-P13L- - RPS 1) Side member, centre (front left)
-P13R- - RPS 1) Side member, centre (front right)
-P14L- - Paint drain hole, side member, centre, (front left)
-P14R- - Paint drain hole, side member, centre, (front right)
-P15L- - Attachment of transmission, rear, left
-P15R- - Attachment of transmission, rear, right
-P16L- - Paint drain hole, side member, centre (rear left)
-P16R- - Paint drain hole, side member, centre (rear right)
-P17L- - RPS 1) Entire vehicle, centre, left
-P17R- - RPS 1) Entire vehicle, centre, right
-P18L- - RPS 1) Side member, centre (rear left)
-P18R- - RPS 1) Side member, centre (rear right)
-P19L- - Attachment of rear axle, front, left
-P19R- - Attachment of rear axle, front, right
-P20L- - Attachment of cross member rear axle, front, left
-P20R- - Attachment of cross member rear axle, front, right
-P21L- - Attachment of cross member rear axle, rear, left
-P21R- - Attachment of cross member rear axle, rear, right
-P22L- - RPS 1) Entire vehicle, rear, left
-P22R- - RPS 1) Entire vehicle, rear, right
-P23L- - Attachment of rear axle, rear left (top, inside)
-P23R- - Attachment of rear axle, rear right (top, inside)

P6L - P6R Attachment of front axle, front -P6- 882± 1 mm
P7L - P7R RPS 2) Side member, front -P7- 880± 1 mm
P8L - P8R Attachment of engine carrier -P8- 860± 1 mm
P9L - P9R Attachment of front axle, rear -P9- 860± 1 mm
P10L - P10R RPS 2) Entire vehicle, front -P10- 880± 1 mm
P11L - P11R Transmission cross member, front -P11- 861 ± 1 mm
P12L - P12R Transmission cross member, rear -P12- 976 ± 1 mm
P13L - P13R RPS 2) Side member, centre (front) -P13- 1020 ± 1 mm
P14L - P14R Paint drain hole, side member, centre (front) -P14- 1105 ± 1 mm
P15L - P15R Rear transmission attachment -P15- 143 ± 1 mm
P16L - P16R Paint drain hole, side member, centre (rear) -P16- 1115 ± 1 mm
P17L - P17R RPS entire vehicle, centre -P17- 1116 ± 1 mm
P18L - P18R RPS side member, centre (rear) -P18- 1115 ± 1 mm
P19L - P19R Attachment of rear axle, front -P19- 1115 ± 1 mm
P20L - P20R Attachment of cross member rear axle, front -P20- 1115 ± 1 mm
P21L - P21R Attachment of cross member rear axle, rear -P21- 1115 ± 1 mm
P22L - P22R RPS 2) Entire vehicle, rear -P22- 1115 ± 1 mm
P23L - P23R Attachment of rear axle, rear (top, inside) -P23- 1115 ± 1 mm
P6L - P9L Floor, length dimension 1 -A- 638 ± 1 mm
P9L - P19L Floor, length dimension 2 -B- 1876 ± 1 mm
P19L - P23L Floor, length dimension 3 -C- 920 ± 1 mm
P9L - P6R Floor, diagonal dimension 1 -U1- 1079 ± 1 mm
P19L - P23L Floor, diagonal dimension 9 -U9- 1445 ± 1 mm
as of MY 2003
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50 IN Diagram - body gap dimensions - as of MY 2003

- Gap dimensions, body front
- Gap dimensions, body centre
- Gap dimensions, body rear
Tools

Star gauges for body gap special tool NR.127-
dimensions 1
Note
z Set gap dimensions on the lids, doors and covers, or accessories in accordance with the gap specifications.
z Given a clearance in the openings that is too great or too small, the movable body parts or the accessories
must be centred accordingly.
z Ensure that the gaps do not run in a wedge-shaped fashion or do not narrow at local points.
z The given values are guidelines which should be observed as far as possible.
z The guidelines apply to repair and assembly work.

Tools and materials
Item Special tool designation Explanation

1 Star gauges for body gap dimensions NR.127-1
Gap dimensions, body front
Designation Di- Note

men-
sion
Wing to front cover -a- 3.5 ±0.8 mm
Front lid to front spoiler -b- 4+1 mm
-c- 1 mm Cover only lowered (max. 1 mm)
Main headlight to front spoiler, at side -d- 5 ±0.5 mm
Main headlight to front lid -e- 3.5 ±0.8
Main headlight to wing -f- 3 ±0.5 mm
Front spoiler to wing -g- 0.5 ±0.5 mm Gap is evident
Direction indicator to front spoiler -h- 1 mm Gap is evident
Headlight washing system cover to front spoiler -j- 1 mm All the way round
Fog light to front spoiler -k- 2 mm All the way round
Main headlight to front spoiler, at bottom -l- 3 ±0.5 mm
Insignia to front spoiler -m- -- Equal, all the way around
Gap dimensions, body centre

men-
sion
Windscreen to outer roof panel -a- 4-1 mm Gap width
-b- 3 mm Installation depth:
Mirror surround to roof trim strip -c- 3 mm
Sliding roof panel to outer roof panel -d- 1 mm Sliding roof panel only lowered at
front, only raised at rear (max. 1 mm)
Outer roof panel to outer side section -e- Approx. mm The projection of the side section at
2.5 to the outer roof panel is approx. 2.5
approx. 3.5 mm at the A-pillar, increases
continuously to 3.5 mm to the C-pillar
and then returns to 2.5 mm at the D-
pillar.
Door window to trim strip or outer side section -f- 5 mm
Door to outer side section -g- 4 ±0.5 mm Door only raised (max. 1 mm)
Door cover to outer door panel -h- 1 mm
-j- 5 mm
Front door to rear door -k- 4.5 ±0.5 mm Rear door only lowered (max. 1 mm)
Mirror housing to mirror cover -l- 2 mm
Mirror glass to mirror housing -m- 3 mm
Front door to front wing -n- 4.5 ±0.5 mm Front door only recessed (max. 1
mm)
Front wing to A-pillar -o- 2 mm
Gap dimensions, body rear

men-
sion
Rear lid to tail light -a- 4.5 ±0.5 mm
Rear lid trim to outer side section -b- 4.5 ±1 mm
Rear window to outer side section -c- 4.5 ±0.5 mm
-d- 3 mm
Brake light to rear spoiler -e- 2 mm
Rear spoiler to outer roof panel -f- 6 ±0.5 mm
-g- 1 mm Only lowered
Filler flap to outer side section -h- 2 ±0.3 mm
Tail light to outer side section -j- 3 ±0.5 mm
Rear spoiler to outer side section -k- 0.5 ±0.5 mm Gap is evident
Tail light to rear spoiler -l- 3 ±0.5 mm
Trim strip to rear window -m- 4.5 mm
Trim strip to cover -n- 2 mm
Cover to rear lid -o- 2 mm
Lower rear lid to rear spoiler -p- 4.5 +1 mm
Rear spoiler cover to rear spoiler -r- 2 mm
-q- 1 mm
-t- 2 mm
-s- 1 mm
Side of rear lid to rear spoiler -u- 4.5 ±0.5 mm
as of MY 2003
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50 IN Diagram - plug plan - as of MY 2003

- Accessories
- Unpainted bodyshell
ATTENTION
Corrosion due to entry of water though leaking or missing plugs!
z Danger of material damage (corrosion) due to entry of water though leaking or missing plugs!
→ The body apertures are sealed with plugs in the factory, and must be sealed with the plugs provided once
more following disassembly or repair work!
Accessories
Rear lid
A - Rubber grommet hole Ø 20 mm
Unpainted bodyshell
Top of front of vehicle
A - Plug hole Ø 20 mm
B - Plug hole Ø 15 mm
C - Plug hole Ø 10 mm
D - Plug hole 15 x 20 mm
E - Plug hole Ø 30 mm
F - Plug hole 20 x 25 mm
Bottom of front of vehicle
Side of front of vehicle
Lower side member
G - Plug hole Ø 40 mm
Underside of floor
Top of lower side member and floor

C - Plug hole Ø 10 mm
G - Plug hole Ø 40 mm
Bottom of rear end
Top of rear end
Side of rear end
as of MY 2003
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50 IN Seam seals - as of MY 2003

- Accessories
Accessories
Accessories
Note
z In the case of repair work, accessories must be sealed before assembly (painting) according to the following
illustrations.
z The sealing material, Würth's "Klebt und Dichtet" body sealant (see Parts Catalogue, Main Group 8), can be
applied directly to the components that are coated with KTL paint.
z The seam seal can be painted over when it has reached approx. 70 % hardness (approx. 4 - 5 h at 20 °C, 50
% relative air humidity. Higher air humidity or dampening with water accelerates the hardening process).
z The hardening can be checked with a nail test. Press a finger nail gently into the hardened sealing mass; if
this causes no damage to the sealing mass surface, the seam seal can be painted.
Front lid
Front door
In the areas marked -A- , smoothen the seam sealing compound following application using a spatula.
Rear door
In the areas marked -A- , smoothen the seam sealing compound following application using a spatula.
Rear lid
Unpainted bodyshell
Note
z In the case of repair work, the unpainted body shell must be sealed before assembly (painting) according to
the following illustrations.
z The sealing material, Würth's Klebt und Dichtet body sealant (see Parts Catalogue, Main Group 8), may only
be applied to primed sheetmetal.

Lower side member
Underside of floor
Note
z The seam sealing compound may only be applied thinly in the marked areas.
Top of lower side member and floor
Note
Note
Bottom of rear end
Top of rear end
Side of rear end
Tank tray
as of MY 2003
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50 IN Undersealing - as of MY 2003
Unpainted bodyshell
A - 0.3 mm
B - 0.6 mm
C - 1.0 mm
D - 2.0 mm
Note
z In the case of repair work, the standard chipping protection / undersealing of the body structure must be
restored according to the following illustrations after painting and prior to unit assembly.
z The undersealing can only be applied to primed sheetmetal.

A - 0.3 mm
B - 0.6 mm
Lower side member
Note
z Apply the chipping protection / undersealing to the lower side member up to the top edge.
A - 0.3 mm
C - 1.0 mm
D - 2.0 mm
Underside of floor
A - 0.3 mm
B - 0.6 mm
C - 1.0 mm
Bottom of rear end
A - 0.3 mm
B - 0.6 mm
C - 1.0 mm
A - 0.3 mm
B - 0.6 mm
C - 1.0 mm
A - 0.3 mm
B - 0.6 mm
C - 1.0 mm

as of MY 2003
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50 IN Cavity preservation - as of MY 2003

- Accessories
Accessories
Note
z In the case of repair, the standard cavity preservation material must be applied to body accessories
according to the following illustrations.
z The cavity preservation must be applied after completion of the assembly work.
Front door
Rear door
Unpainted bodyshell
Note
z In the case of repair, the standard cavity preservation material must be applied to body accessories
according to the following illustrations.
z In the case of repair work, cavity preservation must also be applied to the areas of the corresponding repair
points.

Lower side member
Bottom of rear end

Top of rear end
as of MY 2003
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50 IN Vehicle identification number - as of MY 2003

- Imprinting vehicle identification number
- Encoding of the Vehicle Ident. No.
Tools

Marking punch special tool 9693
Letter/digit embossing tool 8 special tool NR.128-

mm DIN 1451, closely spaced 1
lettering
Tools and materials
z Letter/digit embossing tool 8 mm DIN 1451, closely spaced lettering NR.128-1

z Marking punch 9693
Imprinting vehicle identification number
Note
z After replacing the body or the sheetmetal parts in the area of the vehicle identification number (firewall), the
original vehicle identification number must be reimprinted onto the new body or the new sheet metal part.
z An incorrectly imprinted vehicle identification number should be permanently crossed through with an X so
that it remains legible. In such cases, the applicable vehicle identification number must be imprinted above
the crossed out number in the replacement field.
z For information on procedures for documenting a newly imprinted vehicle identification number in the vehicle
documents or in the case of questions concerning homologation, contact the importer of the respective
country involved.
z In Germany, the newly imprinted vehicle identification number must be reported in writing to the vehicle
registration office immediately. We recommend cutting out the area containing the original vehicle
identification number and submitting it to the registration office as proof.
1. Location of the vehicle identification number
1.1. The vehicle identification number must be applied at the rear right
of the floorpan.
1.2. Two fields are provided for use.
1.3. Field -A- is the standard location to apply the vehicle identification
number.
1.4. Field -B- is the spare space for a corrected vehicle identification
number.
2. Re-imprinting new vehicle identification number
Note
z When imprinting the vehicle identification number, the floorpan must be supported by a suitable tool.
2.1.
2.2. Stamp the vehicle identification number with 8-mm letter/digit embossing tool with DIN 1451 close
spaced lettering NR.128-1 and delimiter marking punch 9693 in field -A- .
2.3. Mask the imprinted vehicle identification number after priming.
2.4. Apply exterior paintwork.
2.5. Remove the mask from the vehicle identification number.
2.6. Paint repair area with clear lacquer.
Encoding of the Vehicle Ident. No.
A - Delimiters (positions 1 and 19)

B - World Manufacturer Code (positions 2 - 4)
C - Type code USA./CAN./MEX./BRAZ., Filler ZZZ for RoW (positions 5 - 7)
D - Type (positions 8 - 9, 13)
E - Test digit for USA, Filler Z for RoW (position 10)
F - Model year (position 11)
G - Production plant (position 12)
H - Serial number (positions 14-18)
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50 IN Processing structural body adhesives - as of MY 2003

- Information on the use of structural adhesives in vehicle construction
- Processing adhesives
- Handling processing devices
Tools

Teromix gun commercially
available tool .gif
Double cartridge gun commercially VAS

available tool 5237
Tools and materials
Tools and materials for structural bonding

-A- Double cartridge gun VAS 5237 → "See Workshop
Equipment Manual,
Chapter 3.5 "
-B- Teromix gun → "See Workshop
Equipment Manual,
Chapter 3.5 "
-C- Teromix 6700 adhesive set → "See Parts Catalogue in Contains set components C1 - C2
Main Group 8"
-D- Terokal 5045 adhesive set → "See Parts Catalogue in Contains set components D1 - D4
Main Group 8"
Item Designation Item Designation

-B1- Piston rod -D1- Cartridge, component A
-B2- Gun grip -D2- Cartridge, component B
-C1- Double cartridge -D3- Mixing nozzle
-C2- Processing nozzle -D4- Processing nozzle
Information on the use of structural adhesives in vehicle construction
General
Structural bonding in the body shell means that the adhesive assumes functions of stiffness, crash strength and
endurance strength, whereby the characteristics of the body shell are positively influenced in a significant way. In a
conventional steel body shell, use is made of a high-strength, heat-hardening single-component epoxy resin
adhesive that fully hardens in the cathodic immersion paint drying oven. In the case of a repair, this adhesive is
replaced by a cold-hardening two-component epoxy resin adhesive, since the hardening temperatures necessary
for the single-component epoxy resin adhesive are not conceivable on an assembled vehicle. For both series
production of bodies-in-white and repair, structural bonded joints are regularly used in combined jointing
processes.
Resistance spot-welding combined with adhesive bonding and mechanical jointing processes
In the case of spot weld bonding for repair and series production, the entire extent of adhesive surfaces and spot
welds is replaced. In this case, before actually spot weld bonding, the unhardened adhesive must be displaced
from the joint area by an appropriate squeeze time. In the case of two-component adhesives, the hardening
reaction starts immediately after mixing and application; this increases the viscosity and so there is only a certain
time window in which spot weld bonding can be performed if the process is to be reliable. For this reason, all time-
intensive preliminary work (drilling, cutting to size, fixing etc.) on the parts to be joined must be performed before
application of adhesive and jointing. This also applies to mechanical jointing processes where the adhesive has to
be displaced from the joint area.
Separating body components
In the case of 3-layer spot-welded panel joints with a hardened bonded

layer in which only the outer panel needs to be replaced, drill the outer
panel in the area of the spotwelds sufficiently well without damaging the
spotweld and bonded joint in the second component layer.
Separating body components

In the case of 3-layer spot-welded panel joints with a hardened bonded
layer on the outer panel, drill the outer panel in the area of the spotwelds
sufficiently well without damaging the spotweld in the second component
layer. After removing the loosened body part, old adhesive must be
removed and any uneven spots sanded down. The flange area must then
be pre-treated for bonding.
Separating bonded body components

Welding in body components
Note
z In areas in which bonded flanges are spot-welded in an unhardened state, suction devices must be used due
to combustion products.
z Areas that can only be accessed from one side must be joined with MAG plug-welds or MAG welded seams.
In these cases, no adhesive can be used in the vicinity of the welded
seam because this would burn and would have a negative effect on
the joint.
z The areas without adhesive must be protected using appropriate anti-

corrosion and sealing measures.
Once the spare parts have been attached, repair spotwelds must be placed
on the old spotwelds because there is no current flow possible in areas with
a hardened bonded layer. Welding procedures other than resistance spot-
welding are not permitted since the thermal effect would destroy the
bonded joint over a wide area.
Spot-welding body components
Spot-welding body components
Processing adhesives
ATTENTION

cleaned.
container imprints.
eye doctor.
Note
z In addition to this manual, observe the relevant job descriptions for body repairs!
Note
z Bonding surfaces must be free from oil, old adhesive, dirt, moisture, and layers of paint and oxide.
z Body structural adhesive must only be used on bare metal components.
z To improve adhesion, the bonding surface must be roughened with sandpaper. Remove paint layers (cathodic
immersion painting) using dry sandpaper or fibre discs with a grain of 100 to 150.
z The bare bonding surface must then be cleaned with a lint-free cloth soaked in acetone.
z Leave cleaned areas to dry for approx. 1 -2 minutes. Bonding areas must be completely dry. Dispose of the
used, acetone-soaked cleaning cloth as special-category waste.
z Ensure that clean gloves are worn when touching cleaned surfaces to avoid transferring sweat from the hands
and dirt onto the bonding area.
z The jointing operation must take place directly after application of the adhesive in order to guarantee a high
quality and reliable bond. Otherwise the adhesive bead must be removed, with pre-treatment of the surface
and application of the adhesive being repeated.
Preparing adhesive flanges
Bonding operation
Minimum ambient and material temperature during working and hardening is 18° C. The coating thickness of
approx. 3 mm should not be exceeded; if necessary, spread the mixed adhesive on the bonding surface with a
spatula. Areas not coverd by cathodic immersion painting and exposed body panels must be brushed or filled with
structural adhesive.
Jointing operation
Join, fix and resistance spot-weld parts within the working time. The jointing operation must take place directly after
application of the adhesive in order to guarantee a high quality and reliable bond. Otherwise the adhesive bead
must be removed, with pre-treatment of the surface and application of the adhesive being repeated.
Remove excess material

Remove most of the excess material with paper or cloth. Finish cleaning visible surfaces with a cloth soaked in
acetone. Hardened material can only be removed mechanically.
Hardening
The body structural adhesive used hardens at room temperature. Hardening can be accelerated by heat (e.g. with
an infra-red radiator in a painting booth). Do not load bonded parts until hardening is complete.
Teromix 6700 Terokal 5045

adhesive set adhesive set
Initial strength at (23 °C) Approx. 2 h Approx. 6 h
Hardening time at room Approx. 6 h Approx. 36 h
temperature (23 °C)
Hardening time at 80 °C Approx. 10 min Approx. 45 min
Max. hardening temperature Approx. 140 °C 1) Approx. 180 °C 2)
1) After this time assembly work is permitted

2) Quick (max. 1 h)
Further work on the vehicle

The time from joining the repaired components to handing over the vehicle to the customer must be at least 48
hours. After repairs with adhesive, allow at least ten hours before moving or carrying out further work on the vehicle
(leave standing overnight) to avoid damage to the bonded joint by premature loading.
Disposal
Small amounts remaining after mixing and complete hardening may be disposed of as domestic waste.
Handling processing devices
Teromix gun
ATTENTION
→ Observe the safety instructions of the individual adhesive set components.
Note
1. Fold out holder.

1.1. Release holder -arrow- and fold down.
Releasing holder
2. Press sliding lock upwards
2.1. Press sliding lock upwards in direction of arrow -arrow- .
Pressing sliding lock

3. Insert piston rod.
3.1. Hold sliding lock pressed and insert piston rod -B1- completely into the gun grip -B2- .
4. Insert mixing cartridge.

Inserting cartridges Inserting piston rod
4.1. Insert double cartridge -C1- into the holder from above.
5. Engage holder with double cartridge.
5.1. Swivel holder with double cartridge upwards by 90 ° -arrow- .
5.2. Engage holder on gun grip.
Engaging holder
6.
6.1. Turn screw cap 90 ° counter-clockwise and remove.
6.2. Remove closure cap.

6.3. Keep screw cap and closure cap for sealing the container later on.
Removing lid
7. Fit processing nozzle.
7.1. Position processing nozzle -C2- and turn clockwise 90°.
8. Mix adhesive components.
8.1. By activating the valve of the gun grip, allow the piston rod to move
out slowly until the adhesive is visible in the processing pipe.
Fitting processing nozzle

9. Bond the body part.
Note
z 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.
z The bonding material has an open time of → Working time: 30 min ,

within which the bonding material must be applied and the body
component joined. Any resistance welding to be carried out in the area
of the bonding must be done in this time.
Working time of structural adhesive
z Do not load bonded parts until hardening is complete!
z If the contents of the cartridge are not completely used up, the processing nozzle should be removed and the
cartridge sealed with the closure cap. In the event of later processing, a new processing nozzle must be used.
9.1.
Double cartridge gun
ATTENTION
→ Observe the safety instructions of the individual adhesive set components.
Note
1. Prepare cartridge components A and B -H5, H6- .
1.1. Pierce the membrane in the nozzle connection of components A and B (aluminium cartridge) -H5, H6- with a
screwdriver and enlarge the opening. Remove flanged cover on end of cartridge.
2. Screw on mixing nozzle -H7- .

2.1. Screw both cartridges onto the mixing nozzle.
3. Insert mixing cartridge in the double cartridge gun
3.1. Move pressure piston back fully.
3.2. Insert double cartridge -H5, H6- into the bonding gun -A- .
4. Press out bonding material.
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.
4.2. Wipe off the emerging adhesive.
5. Screw on processing nozzle -H8- .
5.1. Screw processing nozzle -H8- onto the mixing nozzle -H7- .
6. Align processing nozzle.

6.1. Turn the processing nozzle on the mixing nozzle until the illustrated position is reached.
Note
z In this position, the closed surfaces must be visible at the horizontal mixing nozzle from above and below and
the mixing blade of the mixer insert from the sides.
6.2.
7. Mix adhesive components.
7.1. By activating the valve -arrow- allow the pressure piston to move out
slowly until the adhesive is visible in the processing pipe.
8. Bond the body part.
Note
z 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.
z The bonding material has an open time of → Working time: 60 min ,

within which the bonding material must be applied and the body
component joined. Any resistance welding to be carried out in the area
of the bonding must be done in this time.
Working time of structural adhesive
z Do not load bonded parts until hardening is complete!
z If the contents of the cartridge are not completely used up, the processing nozzle should remain screwed onto
the mixing nozzle. The thoroughly mixed bonding material hardens later in the processing nozzle and seals
the adhesive components from the air. In the event of later processing, a new processing nozzle must then be
used.
8.1.
as of MY 2003
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50 14 51 Sealing front panel - as of MY 2003

- Preliminary work
- Sealing front panel
- Subsequent work
Preliminary work
Preliminary work
1. Disconnect battery. → 2706IN Work instructions after disconnecting the battery [9PAAD1 9PAAD7]
→ 2706IN Work instructions after disconnecting the battery [9PAAE1 9PAAE7 9PAAF1]→ 2706IN Work
instructions after disconnecting the battery [9PAAJ1]
3. Remove the cardan shaft. → 390219 Removing and installing front cardan shaft - chapter on
"Removing" [9PAAD1 9PAAD7 9PAAE7]
4. Remove primary catalytic converter. → 267619 Removing and installing primary catalytic converter - chapter
on "Removing" [9PAAE1 9PAAE7]→ 267619 Removing and installing primary catalytic converter - chapter
on "Removing" [9PAAD1 9PAAD7]→ 267619 Removing and installing primary catalytic converter - chapter
on "Removing" [9PAAF1 9PAAJ1]
5. Remove wiper motor. → 921519 Removing and installing wiper motor - chapter on "removing"
6. Remove DME control module. → 247019 Removing and installing DME control module - chapter on
"Removing" [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 247019 21 Removing and installing DME
control module - chapter on "Removing" [9PAAJ1]
7. Remove alarm siren. → 966519 Removing and installing alarm siren - chapter on "Removing"
Sealing front panel
Removing support for DME control module

Loosening ground straps
1. Screw down fastening nut -1- and take off ground strap with the twist lock.
2. Open the retaining clips -arrow A- and take out the DME control
module wire harness -arrow B- .
3. Unscrew the fastening screw -2- and the two fastening nuts -3- and
take out the support for the DME control module.
Removing support for DME control

module
Removing intake pipe on the heating/fresh air unit
1. Pull out wire harness retaining clips on the intake manifold -arrow A-
and unclip the wire harness on the intake manifold -arrow B- .
2. Pull out air inlet grille -arrow C- .
3. Open both retaining clips in the intake manifold -arrow D- .

4. Unscrew the two fastening nuts -1- and remove the intake manifold.
Removing intake pipe on the

Sealing front panel heating/fresh air unit
Installation position of firewall plate on front panel
1. Unclip wire harness -A- in plenum panel and lay it to one side and to the front.
2. Remove left and right heat shield (above the catalytic converters).
2.1. Unscrew fastening nuts and fastening screw -A- on the right and left heat shield.
2.2. Remove left and right heat shield.
DANGER
Left and right heat shield (above the Wire harness in plenum panel
catalytic converters)
Danger of injury!
z Wear suitable protective clothing.
→ Observe warnings on the isopropanol and body sealant containers.

Note
After cleaning with isopropanol, a ventilation period of approx. 30 minutes
must always be observed.
Sealing front panel
3. Clean surrounding edge between the firewall plate and the front
panel from the outside, in the area shown -arrows- , at the edge with
cleaning agent (isopropanol).
DANGER
Danger of injury!
z Wear suitable protective clothing.
→ Observe warnings on the isopropanol and body sealant containers.

Note
When sealing the firewall plate, ensure without fail that the water drains in the air-conditioning system are not
blocked with sealant.
4. Seal firewall plate from the outside, in the area shown -arrows- , at the edge between the firewall plate and
front panel, all the way round with → Sikaflex-529 body sealant, 000.043.206.36 .
5. Install left and right heat shield (above the catalytic converters).
5.1. Position left and right heat shield.
5.2. Screw on left and right heat shield plate using the fastening nuts and fastening screw -A- on the left and
right heat shield plate.
Wire harness in plenum panel Left and right heat shield (above the
6. Route wire harness -A- in the plenum panel and clip it in. catalytic converters)
Installing intake pipe on the heating/fresh air unit
1. Position intake manifold and secure with both fastening nuts -1- . →
Tightening torque : 4.5 ftlb.
2. Close both retaining clips in the intake manifold -arrow A- .
3. Insert air inlet grille -arrow B- .
4. Clip in wire harness to intake manifold -arrow C- and insert wire

harness retaining clips on intake manifold -arrow D- .
Installing intake pipe on the

heating/fresh air unit
Installing support for DME control module
1. Position support for DME control module and screw down both fastening nuts -3- and the fastening screw -2-
. → Tightening torque: 6 ftlb. → Tightening torque: 6 ftlb.
2. Insert DME control module in the retaining clips -arrow A- and close the retaining clips -arrow B- .
3. Mount ground straps together with the twist lock on the stud and screw down with the fastening nut -1- . →
Subsequent work
Subsequent work
1. Check connection points on main wire harness for corrosion and rework if necessary. → 970949 Reworking
main wire harness - chapter on "Reworking"
2. Install alarm siren. → 966519
Removing and installing alarm
siren - chapter on "Installing"
3. Install DME control module.

installing DME control module
- chapter on
"Installing" [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]
→ 247019 23 Removing and
installing DME control module
- chapter on
"Installing" [9PAAJ1] Fastening ground straps
4. Install wiper motor. → 921519 Removing and installing wiper motor -

5. Install primary catalytic converter. → 267619 Removing and installing

primary catalytic converter - chapter on "Installing" [9PAAE1 Installing support for DME control
9PAAE7]→ 267619 Removing and installing primary catalytic module
converter - chapter on "Installing" [9PAAD1 9PAAD7]→ 267619
Removing and installing primary catalytic converter - chapter on
6. Install cardan shaft. → 390219 Removing and installing front cardan shaft - chapter on "Installing" [9PAAE1
9PAAF1 9PAAJ1]→ 390219 Removing and installing front cardan shaft - chapter on "Installing" [9PAAD1
9PAAD7 9PAAE7]
8. Carry out work instructions after disconnecting the battery. → 2706IN Work instructions after disconnecting
the battery [9PAAD1 9PAAD7]→ 2706IN Work instructions after disconnecting the battery [9PAAE1 9PAAE7
9PAAF1]→ 2706IN Work instructions after disconnecting the battery [9PAAJ1]
as of MY 2003
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50 18 55 Replacing frame head (impact absorber mount) - as of

MY 2003
- Preliminary work
- Removing frame head (impact absorber mount)
- Preparing connection areas of the body for installing the frame head (impact absorber mount)
- Preparing frame head (impact absorber mount) for installation
- Installing frame head (impact absorber mount)
- Subsequent work
Tools

special tool 00000

dimensions 1
Spotweld drill; see Gr. 2.4; special tool NR.129
Workshop Equipment Manual
Preliminary work
Preliminary work for body repairs with alignment bench

1. Removing accessories in the repair area.
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.
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.
Note
z 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.
3.1. Position vehicle on straightening bench, align according to the reference holes and bolt firmly with the
straightening set.
4. Cover accessories adjacent to the repair area on the vehicle.
4.1. Cover all accessories remaining on the vehicle and the neighbouring areas with fire-proof, protective
covers.
5. Reshape connection area of the sheetmetal parts to be replaced.
6. Exposing welding areas.
6.1. Remove undersealing, paint, etc. from the welding areas of the body with a hot-air gun or rotary brush.
Safety instructions for body repairs

DANGER
Risk of damage and injury if the safety instructions for body repairs are not observed.
z Ignoring the safety instructions for body repairs can result in material damage and injury.
→ The following safety notes as well as all the general information and quality instructions must be observed in
the case of body repairs.
→ Danger of injury when raising vehicles → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Risk of material damage when raising vehicles → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Danger of injury during welding work → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7
→ Safety instructions relating to flying sparks during grinding and welding work → 5000AW Safety
instructions [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Danger of poisoning and injury when using adhesive → 5000AW Safety instructions [9PAAD1 9PAAD7
9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for Teromix-6700 two-component adhesive → 5000AW Safety instructions [9PAAD1
9PAAD7 9PAAE1 9PAAE7 9PAAF1]→ 5000AW Safety instructions [9PAAJ1]
→ Safety instructions for handling sharp-edged body and unit parts → 5000AW Safety instructions [9PAAD1
→ Safety instructions for handling the airbag system → 5000AW Safety instructions [9PAAD1 9PAAD7
→ Safety instructions for handling the fuel tank → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
→ Safety instructions for handling the air-conditioning system → 5000AW Safety instructions [9PAAD1
→ → 5000IN General information and notes on quality
Tools and materials
Tools and materials for body repairs
Straightening set 9PA Cayenne; see Gr. 3.5; Workshop Equipment Manual
Resistance spot welder; see Gr. 3.5; Workshop Equipment Manual
Metal inert gas (MIG) welder; see Gr. 3.5; Workshop Equipment Manual
Pneumatic body saw PS1; see Gr. 3.5; Workshop Equipment Manual
Oscillating body saw (special electric cutter); see Gr. 3.5; Workshop Equipment Manual
Rotary brush; see Gr. 3.5; Workshop Equipment Manual
Hole punch; see Gr. 3.5; Workshop Equipment Manual
Hot-air gun Leister Elektron; see Gr. 3.5; Workshop Equipment Manual
Cartridge gun VAG 1628; see Gr. 3.5; Workshop Equipment Manual
Spotweld drill; see Gr. 2.4; Workshop Equipment Manual NR.129 00000
Star gauges for body gap dimensions NR.127-1
Body sealant from Würth Klebt und Dichtet; see Parts Catalogue; Main Group 8
Removing frame head (impact absorber mount)
Removing frame head (impact absorber mount)
Note
z 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. Grind the inert gas arc welding joints between the frame head
(impact absorber mount) and top side member using the parting
grinder → see figure (areas -A- , -B- , -C- , -D- ).
2. Remove frame head (impact absorber mount).
Preparing connection areas of the body for installing the frame head (impact
absorber mount)
Preparing connection areas of body for installing frame head (impact absorber mount)
1. Clean welding and sealing areas.
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.
2. Coat spot-weld flange areas with zinc powder paint.
2.1. Coat all spot-weld flange areas with zinc powder paint.
Preparing frame head (impact absorber mount) for installation
Preparing frame head (impact absorber mount) for installation

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.
Installing frame head (impact absorber mount)
Installing frame head (impact absorber mount)

1. Fit the frame head (impact absorber mount) to the body.
1.1. Position the frame head (impact absorber mount) against the body
and fix in place with a straightening attachment.
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 figure .
2.1. Apply a full weld to the frame head (impact absorber mount) in the areas -A- , -B- , -C- and -D- using inert-
gas arc welding.
Subsequent work
Subsequent work for body repairs
1. Remove vehicle from the alignment bench.
2. Clean spot-welded joints and sheetmetal flanges with a wire brush.

3. Prime flange areas with 2K primer.
4. Restore standard seal with body sealant → 5000IN Seam sealing.
5. Restore standard undersealing with underbody sealant → 5000IN

Underbody protection.
6. Paint repair area and adjacent surfaces, if necessary.
7. Apply cavity preservation to the accessible areas of the repair.

→ 5000IN Cavity preservation.
8. Install removed accessories in the repair area.
as of MY 2003
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WARNING
AVERTISSEMENT
ATTENZIONE
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ADVERTENCIA
50 38 09 Detaching and fastening lock mount (service position) -

as of MY 2003
- Preliminary work
- Detaching lock mount
- Securing lock mount
- Disconnecting cable for front lid lock
- Connecting cable for front lid lock
- Subsequent work
Tools

Service fastening screw commercially
available tool .gif
Preliminary work
Preliminary work
1. Removing the front spoiler.
1.1. → 631519 Removing and installing front apron - section on "Removing"
2. Removing the front lid seal.
2.1. → 553319 Removing and installing front lid seal - section on "Removing" [9PAAD1 9PAAD7 9PAAE1
9PAAE7]→ 553319 21 Removing and installing front lid seal - section on "Removing" [9PAAF1 9PAAJ1]
3. Removing the front engine compartment cover.
3.1. → 700219 Removing and installing front cover (engine compartment) - section on "Removing"
4. Disconnecting cable for front lid lock.
4.1. → Disconnecting cable for front lid lock
Tools and materials
Detaching lock mount
1. Remove the rubber covers.
1.1. Pull rubber cover on the right -1- up and off.
1.2. Pull rubber cover on the left -2- up and off.
ATTENTION
Danger of injury and material damage as a result of incorrect handling of airbag sensors!
z Incorrect handling of airbag sensors can result in injury and material damage.
→ Always observe the safety regulations for handling airbag units.→ Safety regulations for handling airbag
and...
→ Remove ignition key. Disconnect battery . Route or isolate the ground strap so that all contact with a ground
carrier (e.g. body, seat frame) is avoided.→ Work instructions after disconnecting the battery.
→ Before the connector is disconnected from the sensor, always wait for 1 minute before disconnecting the
battery.
2. Remove side air guides.

Cayenne Turbo only
2.1. Unclip airbag sensor wiring harness -14- .
2.2. Slide the side air guide -15- outwards and remove.
3. Undo fastening screws -5- .

3.1. Unscrew the fastening screws on both sides of the vehicle.
4. Screw in service fastening screws -4- .
4.1. Screw in service fastening screws on both sides of the vehicle and tighten by hand.
→ Tools and Materials
5. Undo fastening screws -5- .

5.1. Unscrew fastening screws on both sides of the vehicle.
6. Undo fastening screws -6 and 7- .
6.1. Unscrew fastening screws on both sides of the vehicle.
7. Release air guides.

7.1. Release air guides at the air filter housing sections -8- .
8. Disconnect electrical plug connection.
8.1. Disconnect the electrical plug -9- on the left side of the vehicle. Release the lock and disconnect the plug.
9. Release charge air cooler

Cayenne Turbo only
9.1. Undo fastening screws -16- .
9.2. Remove spacers -17- .
10. Remove front spoiler guide rails at the sides.

10.1. → 631519 Removing and installing front spoiler
11. Pull the lock mount to the service position.
Securing lock mount
1. Slide the lock mount into its installation position.
1.1. To prevent damage to the accessories, slide the lock mount back
into the installation position on both sides evenly.
2. Screw in -5- fastening screws.
2.1. Screw in fastening screws on both sides of the vehicle and tighten slightly.
3. Unscrew the service fastening screws -4- .

3.1. Undo service fastening screws on both sides of the vehicle.
4. Screw in the fastening screws -3- and tighten slightly.
4.1. Screw in fastening screws on both sides of the vehicle and tighten slightly.
4.2. Position the lock mounts according to the existing impressions.

5. Fix the lock mount in its installation position
5.1. Screw in fastening screws -6 and 7- on both sides of the vehicle

and tighten finger-tight.
6. Adjust the lock mount.
7. Tighten the fastening screws on the lock mount.
7.1. Tighten fastening screws -3- , -5- , -6 and 7- to the specified tightening torque. → Tightening torque: 6.5
Nm +/-0.5 Nm → Tightening torque: 9 (6.5 ftlb.) Nm +/-1 (0.5 ftlb.) Nm → Tightening torque: 65 (48
ftlb.) Nm +/-10 (7.5 ftlb.) Nm
8. Install front spoiler guide rails at the sides.

8.1. → Removing and installing front spoiler
9. Connect the air guides.
9.1. Connect the air guides at

the air cleaner housings -8- .
10. Fasten charge air cooler

Cayenne Turbo only
10.1. Insert spacers -17- .

10.2. Screw in fastening screws -16- and tighten to the specified
tightening torque. → Tightening torque: 9 (6.5 ftlb.) Nm +/-1 (0.5
ftlb.) Nm
11. Install side air guides.

Cayenne Turbo only
11.1. Position the side air guide -15- and move it to the centre of the vehicle until it engages.
11.2. Position and clip in air sensor wiring harness -14- .
12. Install front lid seal.
12.1. → Removing and installing front lid seal [9PAAD1 9PAAD7 9PAAE1 9PAAE7]→ Removing and installing
front lid seal [9PAAF1 9PAAJ1]
13. Connect the electric plug connection -9- .
13.1. Connect the electric plug connection on the left side of the vehicle.
14. Install the rubber covers.
14.1. Put on the right -1- rubber cover from above and press in the
rubber tabs.
Disconnecting cable for front lid lock
Note
z On right-hand drive vehicles, the cable for the lid lock is located on the right side of the vehicle.
1. Release the connection piece from the body.
1.1. Unclip the connection piece -10- from the body.

2. Unlock the connection piece.
2.1. Release the locking tabs -11- with a commercially available
screwdriver -arrow- .
3. Open the connection piece and disengage the cable.
Connecting cable for front lid lock
1. Engage the cable and close the connection piece.
1.1. Engage the cable for the front lid lock -13- and close the lid -12- on the connection piece.
2. Attach the connection piece.
2.1. The locking tabs -11- must audibly engage in place.

3. Secure the connection piece to the vehicle body.
3.1. Clip the connection piece -10- to the body.
Subsequent work
Subsequent work
1. Connect cable for front lid lock.
1.1. → Connecting cable for front lid lock
2. Check function of lid lock.
2.1. Engage the locking hook on the lock in the catch using a screwdriver and trip by actuating the lid release in
the vehicle.
In the case of a malfunction, check the bottom lock section or lid release cable for damage; replace if
necessary.
3. Install the front spoiler.
3.1. → 631519 Removing and installing front apron - section on "Installing"
4. Install front engine cover.
4.1. → 700219 Removing and installing front cover (engine compartment) - section on "Installing"
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
50 38 19 Removing and installing lock carrier - as of MY 2003

- Preliminary work
- Removing lock carrier
- Installing lock carrier
- Subsequent work
Preliminary work
Preliminary work
1. Put lock carrier in service position → 503809 Loosening and fastening the lock carrier (service position) -
chapter on "Loosening".
Removing lock carrier
Removing lock carrier
1. Unscrewing radiator module
1.1. Remove upper fastening screws -3- on radiator module and secure radiator module -1- onto vehicle to
prevent it from tipping over or falling.
1.2. Unscrew and remove fastening clip -5- .
1.3. Remove plastic guide element -4- .
1.4. Release connector -7- ( -arrow A- ) and remove it -arrow B- .

2. Removing service fastening screws
2.1. Get a second worker to prevent lock carrier from falling.
2.2. Remove service fastening screws -6- .
3. Removing lock carrier

3.1. Remove lock carrier by pulling it towards the front.
Installing lock carrier
Installing lock carrier
1. Installing lock carrier

1.1. Position lock carrier from the front.
2. Screwing in service fastening screws
2.1. Get a second worker to prevent lock carrier from falling.
2.2. Screw in and tighten the service fastening screws -6- .
3. Securing radiator module
3.1. Push in plug -7- ( -arrow A- ) until the locking tab -arrow B- is felt
to engage.
3.2. Slide radiator module -1- into the fastening fork on the lock mount.
3.3. Install plastic guide element -4- .

3.4. Attach and hook in fastening clip -5- .
3.5. Screw in upper fastening screws -3- of radiator module and tighten to the specified tightening torque. →
Tightening torque: 6.5 (4.8 ftlb.) Nm +/-1 (0.5 ftlb.) Nm
Subsequent work
Subsequent work
1. Cayenne Turbo only: Install charge air cooler→ 214323 23 Installing charge air cooler - chapter on
"Installing".
2. Put lock carrier in assembly position → 503809 Loosening and fastening the lock carrier (service position) -
chapter on "Fastening".
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
50 39 55 Replacing spring strut mount - as of MY 2003

- Preliminary work
- Removing spring strut mount
- Preparing connection areas of body for installing spring strut mounts
- Preparing spring strut mount for installation
- Installing spring strut mount
- Installing bracket for torque support
- Subsequent work
Tools

special tool 00000

dimensions 1
Preliminary work

Note
straightening set.
covers.

DANGER
Tools and materials
Removing spring strut mount
Removing spring strut mount
Note
1. Detach the spring strut mount.

1.1. Cut the welded joint between the spring strut mount and the top
side member, firewall and side member using the spotweld cutter
(areas -A, D- , -E- , -I- , -J- , -K, L- ).
1.2. Grind the inert gas arc welding joints between the spring strut mount, top side member, firewall and side
member using the parting grinder (areas -B- , -C- , -F- and -H- ).
2. Remove the spring strut mount.
Preparing connection areas of body for installing sprin
Preparing connection areas of body for installing spring strut mount

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.
Preparing spring strut mount for installation

Preparing spring strut mount
for installation

1.1. Grind both sides of the connection flange of the new parts in the marked areas -A, B- , -D, E- , -F, G- ,
-H, I- , -J- until bare using a rotary brush.
2. Drill holes for plug welding using inert gas.

3.1. Coat all spot-weld flange areas with zinc powder paint (areas -D- ,
-G- ).
Installing spring strut mount
Installing spring strut mount

1. Fit the spring strut mount to the body.
1.1. Position the spring strut mount against the body and fix in place with a straightened bracket.
1.2. Fix the spring strut mount to the body with tensioning clamps.
2. Resistance spot-weld the spring strut mount.
2.1. Resistance spot-weld the spring strut mount in areas -D- and -G- .
3. Inert gas arc weld the spring strut mount.

4. Install torque support bracket.
- only when replacing the right
spring strut mount
4.1. → 503955 Replacing spring

strut mount - chapter on
"Installing"
Installing bracket for torque support
Installing bracket for torque support
1.1. Grind both sides of the connection flange of the new parts in the marked areas until bare using a rotary
brush.
1.2. Grind the spring strut mount close to contact surfaces to the new part until bare.
2. Fix bracket for torque support.
2.1. Fix the torque support bracket by assembling the mounting bearer
on the body, aligning it and securing it with tensioning clamps.
3. Inert gas arc weld the torque support bracket.

3.1. Inert gas arc weld the torque support bracket in the areas -M, N-
with a full weld.
4. Inert gas arc weld the torque support bracket.
4.1. Remove the mounting bearer.
4.2. Inert gas arc weld the torque support bracket in area -O- with a full weld.
Subsequent work
Subsequent work for body
repairs
1. Remove vehicle from the

alignment bench.
2. Clean spot-welded joints and

sheetmetal flanges with a wire
brush.
3. Prime flange areas with 2K

primer.
4. Restore standard seal with

body sealant → 5000IN Seam
sealing.
5. Restore standard undersealing with underbody sealant → 5000IN Underbody protection.
7. Apply cavity preservation to the accessible areas of the repair. → 5000IN Cavity preservation.
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
50 56 19 Removing and installing front wheel housing liner - as of

MY 2003
- Removing front wheel housing liner
- Installing front wheel housing liner
Removing front wheel housing liner
Removing front wheel-housing liner
1. Loosen wheel-housing liner.
1.1. Unscrew fastening screws -2- .

1.2. Turn retaining nuts -3- on the studs.
2. Open plastic clips.
2.1. Open the three plastic clips -4- in the area where the wheel housing
meets the wing.
3. Remove connecting piece.
3.1. Turn fastening screws -5- between wheel-housing liner and

connecting piece and between connecting piece and front spoiler
-6- .
3.2. Pull out connecting piece -7- .
4. Loosen servo valve line at the left wheel-housing liner.
4.1. Pull servo valve wire harness off the left wheel-housing liner at the
retaining clips -Arrows- .
5. Release wheel-housing liner from the rear notches.
5.1. Disengage the wheel-housing liner in the area beside the side
direction indicators and in the area where the wheel housing meets
the wing.
Loosening servo valve line at the left

wheel-housing liner
6. Remove wheel-housing liner.
6.1. Pull wheel-housing liner -1- down and out.
Installing front wheel housing liner
Installing front wheel-housing liner
1. Install connecting piece.
1.1. Insert connecting piece -7- .
1.2. Screw in fastening screws -6- between connecting piece and front
apron and tighten to specified tightening torque. → Tightening
torque: 2.5 (2.0 ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm .
2. Position wheel-housing liner -1- .
2.1. Insert wheel-housing liner.

2.2. Screw retaining nuts -3- onto studs and tighten slightly.
3. Secure servo valve line at the left wheel-housing liner.
3.1. Route servo valve wire harness and push it onto the left wheel-
housing liner using the retaining clips -Arrows- .
Securing servo valve line at the left

wheel-housing liner
4. Tighten connecting piece.
4.1. Screw in rear fastening screws -5- between connecting piece and
wheel-housing liner and tighten slightly.
5. Position plastic straps.
5.1. In the transition area beside the wing, close the three plastic straps
-4- , screw in the corresponding fastening screws -2- and tighten
slightly.
6. Align and install wheel-housing liner.
6.1. Screw in the remaining fastening screws -2- and tighten slightly.
6.2. Check wheel-housing liner
-1- in the area of the side
direction indicator and along
the wheel housing to make
sure that it is correctly
seated.
6.3. Tighten all fastening points
-2- , -3- and -5- to specified
tightening torque →
Tightening torque: 1.5 (1.0
ftlb.) Nm +/-0.5 (0.5 ftlb.)
Nm → Tightening torque:
1.5 (1.0 ftlb.) Nm +/-0.5 (0.5
ftlb.) Nm → Tightening
torque: 2.5 (2.0 ftlb.) Nm
+/-0.5 (0.5 ftlb.) Nm .
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
50 72 55 Replacing side member for wheel housing upper section

- as of MY 2003
- Preliminary work
- Removing side member for wheel housing upper section
- Preparing connection areas of body for installing side member for wheel housing upper section
- Preparing side member for installing wheel housing upper section
- Fitting side member for wheel housing upper section
- Installing side member for wheel housing upper section
- Subsequent work
Tools

special tool 00000

dimensions 1
Preliminary work

Note
straightening set.
covers.
DANGER
Tools and materials

Removing side member for wheel housing upper section
Removing side member for wheel housing upper section
1. Separating the side member for the wheel housing upper section
from the wing mounting point support
1.1. Cut the welded joint between the wing mounting point support and side member bracket using the spotweld
cutter (areas -A- ).
1.2. Grind the inert gas arc welded joint between the wing mounting
point support and front side member and side member bracket with
a parting grinder (areas -B- , -C- ).
1.3. Cut out the laser welded joint on the side member for the wheel housing upper section in the area of the
cut offset -X- using the parting grinder (area -D- ).
1.4. Cut the side member for the wheel housing upper section in the areas -E- and -F- using the oscillating body
saw. The dimension -X- (or -X- ) → Cut dimension, old part: 80 mm must be maintained. Do not damage
the internal components.
2. Removing side member for wheel housing upper section
Preparing connection areas of body for installing side member for wheel housing
upper section
Preparing connection areas of body for installing wheel housing upper section side member

brush. Grind the connection flanges until bare.
Preparing side member for installing wheel housing upper section
Preparing wheel housing upper section side member for installation
1. Produce repair parts.

1.1. Cut the connection area to the A-pillar on the new parts, side
members for wheel housing upper section, inner and outer. Ensure
that the repair parts in the area of the cut overlap by -W- (or -W- )
→ Overlap: 50 mm .

3.1. Drill 7 mm holes or use a hole punch (areas -I- , -J- ) on the inside and outside of the wheel housing
fastening flange of the side member. Maintain a distance of approx. 20 mm between the holes.
4.1. Coat all spot-weld flange areas (areas -A- , -D- or -D- ) with zinc powder paint.
Fitting side member for wheel housing upper section
Fitting side member for wheel housing upper section
1. Fit the side member for the wheel housing upper section to the body.
1.1. Fix the wing mounting point support to the body with the attachment set.
1.2. Place the side member for the wheel housing upper section (inner part) on the body and fix in place with
the straightening bracket. Fix the side member for the wheel housing upper section (inner part) to the
remaining piece on the body using tensioning clamps.
1.3. In the area of the overlap of the side member for the wheel housing
upper section (inner part) and body, cut the two sheetmetal plates
with a cut -W- (or -W- ) using the oscillating body saw. Do not
damage the internal components.
1.4. Place the side member for the wheel housing upper section (outer
part) on the body and fix in place with the straightening bracket. Fix
the side member for the wheel housing upper section (outer part) to
the remaining piece on the body using tensioning clamps.
1.5. In the area of the overlap of the side member for the wheel housing
upper section (outer part) and body, cut the two sheetmetal plates
with a cut -W- (or -W- ) using the oscillating body saw. Do not
damage the internal components.
2. Prepare joints of side member for installing wheel housing upper

section.
2.1. Remove side member for wheel arch.
2.2. Remove remaining pieces.
2.3. Grind both sides of the welding areas in the area of the cuts on the
body and new parts until bare using a rotary brush.
3. Coating spot-weld flange areas with zinc powder paint
3.1. Touch up the spot-weld flange areas of the overlap with zinc
powder paint.
Installing side member for wheel housing upper section
Installing side member for wheel housing upper section
1. Fix the side member for the wheel housing upper section to the body.
1.1. Place the side member for the wheel housing upper section (inner and outer part) on the body and fix in
place with the straightening bracket. Fix the side member for the wheel housing upper section to the
remaining piece on the body using tensioning clamps.
2. Resistance spot-weld the support for the wing mounting point and
side member for wheel housing upper section.
2.1. Resistance spot-weld the support for the wing mounting point and
side member for wheel housing upper section in the areas -A- , -D-
and -G- .
3. Weld support for the wing mounting point and side member for wheel
housing upper section under shielding gas.
3.1. MIG weld the side member for wheel housing upper section in the
areas -E- , -F- and -C- with a full weld. Plug-weld the support for the
wing mounting point in the area -I- , -J- under shielding gas. MIG
weld the support for the wing mounting point in the area -B- , -H-
with an intermittent weld.
Subsequent work
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
50 79 55 Replacing front side member - as of MY 2003

- Preliminary work
- Removing front side members
- Preparing connection areas of body for installing front side member
- Preparing front side member for installation
- Installing front side members
- Subsequent work
Tools

special tool 00000

dimensions 1

Preliminary work

Note
straightening set.
covers.

DANGER
Tools and materials
Removing front side members
Note
1. Cut off side member for wheel housing upper inner section.
Cutting off top inner side member

2. Cut off side member for wheel housing upper outer section.
2.1. Cut out the laser welded joint on the side member for the wheel
housing upper section in the area of the cut offset -X2- using the
parting grinder (area -A1- ).
Cutting off top outer side member

3. Separate welded joints at the upper spring strut mount.
3.1. Mill off the welded joints in area -A, D- using a spotweld cutter.
Separating welded joints at the spring

strut mount
4. Separate welded joints at the reinforcement for the spring strut
mount.
Separating welded joints at the

reinforcement for the spring strut
mount
5. Separate welded joints at the firewall.
Separating welded joints at the firewall

6. Separate welded joints at the firewall lower section.

lower section
7. Separate welded joints at the floor inner section.
Separating welded joints at the floor

inner section
8. Separate welded joints at the lower side member.
Separating welded joints at the lower

side member
9. Separate welded joints at the lower side member.
Separating welded joints at the lower

side member
10. Separate bracket for side member.
Separating bracket for side member

11. Separate bracket for side member.
11.1. Using a parting grinder, separate the bracket on the side member in
the area -N- .
Separating bracket for side member

12. Separate welded joints at the firewall lower section.

lower section
13. Separate welded joints at the firewall upper section.
13.1. Mill off the welded joints in area -P- and -U- using a spotweld
cutter.

upper section

13.2. Grind off the welded joints in area -Q- using a parting grinder.

upper section
14. Separate welded joints at the web plate.
14.1. In area -R- cut out a lid from the floor with a parting grinder.
14.2. Mill off the welded joints in area -S- using a spotweld cutter.
Separating welded joints at the web Cutting out a lid in the floor
plate
Separating welded joints at the web

plate
15. Separate welded joints at the side member lower section.
15.1. Mill off the welded joints in area -V- using a spotweld cutter.
Separating welded joints at the side

member lower section

16. Separate welded joints at the side member lower section.
16.1. Mill off the welded joints in area -Y- , -Y- and -Y- using a spotweld
cutter.

lower section
16.2. Grind off the welded joints in area -Z- and -Z- using a parting grinder.
17. Remove side member.



Preparing connection areas of body for installing front side member
1. Prepare connection areas of spring strut mount for installation.
Preparing connection areas of spring

strut mount for installation


4. Prepare connection areas of firewall lower section for installation.
Preparing connection areas of firewall

lower section for installation
5. Prepare connection areas of firewall lower section for installation.
Preparing connection areas of firewall

6. Prepare connection areas of floor inner section for installation.
Preparing connection areas of floor

Preparing front side member for installation
1. Prepare side member in area of bracket for installation.
Preparing side member in area of

bracket for installation
2. Prepare side member in area of spring strut mount for installation.
2.1. Grind both sides of the connection flanges of the new part in the
marked areas -B- until bare using a rotary brush.

spring strut mount for installation

frame head for installation
4. Prepare side member in area of frame head for installation.

frame head for installation
marked areas -E, F- until bare using a rotary brush.

spring strut mount for installation
6. Prepare side member in area of firewall for installation.
marked areas -G, H- until bare using a rotary brush.

firewall for installation
7. Prepare side member in area of floor front section for installation.
marked areas -I- until bare using a rotary brush.
Preparing side member in area of floor

front section for installation
8. Prepare side member in area of floor front section for installation.
marked areas -L, K- until bare using a rotary brush.
Preparing side member in area of floor

front section for installation
9. Prepare reinforcement for installation.
9.1. Cut back the new part to the area -M- .
Preparing reinforcement for installation

marked areas -N- until bare using a rotary brush.

9.3. Drill holes Ø 7 mm in the fastening flanges of the reinforcement (area -N- ). Maintain a distance of approx.
20 mm between the holes.
Installing front side members

1. Fit side member to the body.
1.1. Place the side member against the body and fasten to the
straightening set.
Note
z To fit the side member, the frame head (impact absorber mount) and
the top side member support must be secured to the straightening
attachments.
1.2. Install frame head and support for top side member.
2. Weld in side member in area of floor front section.
2.1. Plug-weld the side member in area -S- under shielding gas.
2.2. Weld the side member in area -T- with interrupted full weld under
shielding gas.
Welded joints in area of web plate

3. Weld in side member in area of floor front section.
Welded joints for floor inner section

4. Weld in side member in area of spring strut mount.
4.1. Plug-weld the spring strut mount in area -A- under shielding gas.
4.2. Weld the spring strut mount in area -B, C- with interrupted full weld
under shielding gas.
Welded joints for spring strut mount

5. Weld in side member in area of lower side member.
Welded conection at lower side

member front section
6. Weld in side member in area of lower side member.
Welded conection at lower side

member inner section
7. Weld in side member in area of firewall.
Welded joints at firewall lower section

8.1. Plug-weld the side member in area -P- and -U- under shielding gas.
Welded joints at firewall
Welded joints at top of side member

8.2. Weld the side member in area -Q- with interrupted full weld under shielding gas.
9. Weld in side member in area of floor lower section.
9.1. Plug-weld the side member in area -V- under shielding gas.
Welded joints at bottom of side Welded joints at bottom of side
member member
10.1. Plug-weld the side member in area -Y- , -Y- and -Y- under shielding
gas.
10.2. Weld the side member in area -Z- and -Z- with interrupted full weld under shielding gas.
Welded joints at firewall lower section
Welded joints at bottom of side

member
Welded joints at bottom of side

member
11. Weld in spring strut mount in area of firewall.

12. Weld in reinforcement for spring strut mount.

13. Weld in reinforcement at floor inner section.
13.1. Grinding the spot welds flat in area -S- .
13.2. Evacuate accessible cavities.

13.3. Prime the welds -T- .
13.4. Position the reinforcement and plug-weld in area -R- under shielding gas.
14. Install support and top side member.
14.1. → Replace side member for wheel housing upper section.
15. Install frame head (impact absorber mount).
15.1. → Replacing frame head (impact absorber mount)

Subsequent work
Welded joints for floor inner section

as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
50 79 55 Replacing side member (section) - as of MY 2003

- Preliminary work
- Removing side member
- Preparing connection areas of body for installing side member
- Preparing side member for installation
- Installing side member
- Subsequent work
Tools

special tool 00000

dimensions 1

1 mm cutting discs for high- commercially NR.129-

strength steel available tool 1
ATL InvertaSpot commercially we1194

available tool
MULTISPOT MI-100 commercially we1208

available tool
Preliminary work
Note
straightening set.
covers.
DANGER
Tools and materials
Removing side member
Removing side member

Note
1.1.
1.2. Cut the welded joint between the wing mounting point support and
the side member for the wheel housing upper section using the
spotweld cutter (areas -A- , -B- ).
1.3. Cut through the side member area -C- using an angle grinder. Use 1 mm cutting discs for high-strength
steel NR.129-1 for cutting. The dimension -X- must be maintained. → Cut dimension, old part: 400 mm
Preparing connection areas of body for installing side member
Preparing connection areas of body for installing side member
1. Fit side member to the body.

Note
z To fit the side member, the frame head (impact absorber mount) and the top side member support must be
secured to the straightening attachments.
Note
z Thick body panels (> 1.5 mm) must not be butt-welded without a welding gap.
z Always allow a welding gap of s = approx. 1x material strength when fitting new parts.
1.1. Fix inner side member -1- to frame head and secure support for
upper side member.
1.2. Mark the cut -D- in the area where the inner side member overlaps.
1.3. Fix inner side member -1- to frame head and secure support for upper side member.
1.4. Grind off the MIG welded joints on the outer side member in the area -G- using a parting grinder.
1.5. Fix outer side member -2- to inner side member.
1.6. Mark the cut -E- in the area where the outer side member overlaps.
1.7. Mill off the welded joints in area -F- using the spotweld cutter.
1.8. Remove new part and cut
remaining piece on the
body. Allow for welding gap
→ Welding gap: 2 mm and
do not damage internal
components!

2.1. Clean undersealing, adhesive residue and paint from the marked areas -H- of the body connection flanges
using a hot-air gun and rotary brush. Grind the connection flanges until bare.
Preparing side member for installation
Preparing side member for installation

1. Clean welding and sealing
areas.
1.1. Grind both sides of the

connection flanges of the
new parts in the marked
areas until bare using a
rotary brush.

2.1. Drill holes with a diameter of 8 mm in the overlapping area on the
fastening flange of the outer section (area -I- ). Maintain a
clearance of approx. 20 mm between the holes.
Installing side member
Installing side member
WARNING
Risk of material damage and personal injury if body repair work is not carried out correctly.
z On vehicles that have not been repaired correctly, an accident in the repair area can result in the
unintentional triggering of airbags and belt tensioners. As a result, optimal passenger safety can no
longer be assured.
→ Resistance spot welding on the side member may only be carried out using the welders approved in the
Workshop Equipment Manual: ATL InvertaSpot we1194 and MULTISPOT MI-100 we1208.
→ Set the welding parameters to the required thickness (approx. 2.5) and power (approx. 9000A).
→ Observe a point distance with regard to the original joint.
→ Thick body panels (> 1.5 mm) must not be butt-welded without a welding gap during inert-gas arc welding.
→ To achieve the required welding quality, maintain a welding gap of s = approx. 1x material strength.
→ Do not grind weld seams.
1. Fix inner side member to the body.
1.1. Fix side member to frame head and secure support for side member.
1.2. Fix the side member to the body using tensioning clamps.
2. Weld inner side member using inert gas.
2.1. Use an inert-gas arc welder to weld the inner side member in area
-J- to the inside of the carrier with a full weld.
3. Welding outer side member using inert gas
3.1. Plug-weld the outer side member in area -S- under shielding gas.
3.2. MIG weld the outer side member with a full weld in area -K- , -L- ,
-M and N- .
3.3. The seams -M und N- are applied in addition to the standard

welded joints.
4. Resistance spot-welding the side member
4.1. Fix outer side member to inner side member using tensioning
clamps.
4.2. Resistance spot-weld the side member in areas -O, P, Q- and -R- .
5. Install support for top side member.
5.1. The procedure is described in → Replacing side member for wheel housing upper section.
6. Install frame head (impact absorber mount).
6.1. → Replacing frame head (impact absorber mount)
Subsequent work

as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
51 01 55 Replacing ground pin for battery - as of MY 2003

- Overview of tools and materials
- Replacing ground pin
DANGER
→
Safety instructions for handling the air-conditioning system → 5000AW Safety instructions [9PAAD1
Overview of tools and materials
Overview of tools and materials
Metal inert-gas welder, see Workshop Equipment Manual, Chapter 3.5
Angle grinder, see Workshop Equipment Manual, Chapter 3.5
Cartridge gun V.A.G 1628 - see Workshop Equipment Manual, Chapter 3.5
Hot-air gun Leister-Electron, see Workshop Equipment Manual, Chapter 3.5
Rotary brush, see Workshop Equipment Manual, Chapter 3.5
Body sealant "Klebt und Dichtet" from Würth, see Parts Catalogue, Main Group 8
Replacing ground pin
Replacing ground pin
1. Remove accessories in the repair area
1.1. Place driver's seat in service position. → 270619 Removing and installing battery [9PAAE1 9PAAE7
9PAAF1]→ 270619 Removing and installing battery [9PAAJ1]→ 270619 Removing and installing
battery [9PAAD1 9PAAD7]
1.2. Lift floor carpet in area of ground pin.
2. Expose welding areas
2.1. Remove undersealing, paint, etc. from the welding areas of the body on upper and lower sides with a hot-
air gun or rotary brush.
2.2. If necessary, cut off damaged pin and grind flat.
3. Drill mounting hole
3.1. At the mounting position drill a hole with Ø 8 mm.

3.2. Deburr the drill hole.
4. Prepare ground pin for installation
4.1. Grind flat the bottom part of the ground pin.
5. Position ground pin

5.1. Grip ground pin with pliers and get an assistant to position and fix it
centrally over the drill hole
6. Weld in ground pin

6.1. From below, MIG weld the ground pin to the drill hole.
7. Grind the welded joints smooth
8. Clean welded joints and sheetmetal flanges with a wire brush
9. Prime welding area with 2K primer
10. Seal welding area with body sealant
11. Restore standard seal with body sealant
11.1. → Seam seals
12. Restore standard undersealing protection
12.1. → Undersealing
13. Install removed accessories in the repair area
14. Connect battery ground strap
14.1. → Remove main switch for power supply (battery disconnect switch) [9PAAD1 9PAAD7 9PAAE1 9PAAE7
9PAAF1]→ Remove main switch for power supply (battery disconnect switch) [9PAAJ1]
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
51 03 55 Replacing roof - as of MY 2003

- Preliminary work
- Removing roof
- Preparing connection areas of body for roof installation
- Preparing roof for installation
- Installing roof
- Subsequent work
Tools

special tool 00000

dimensions 1

Preliminary work
Preliminary work for body repairs
Note
z 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.
1.1. Remove accessories in the repair area according to the extent of damage on the vehicle.
2.1. Set up straightening bench with the straightening set according to the set-up drawings included with the
straightening set.
Note
3.1. Position vehicle on straightening bench, align to the reference holes and firmly bolt using the straightening
set..
4.1. Cover all accessories remaining on the vehicle and the neighbouring areas with fire-proof, protective covers.
DANGER
→ Safety instructions for handling the airbag system → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
→ Safety instructions for handling the air-conditioning system → 5000AW Safety instructions [9PAAD1 9PAAD7
Tools and materials
Tools and materials for replacing the roof

A - Double cartridge gun VAS 5237
B - Special electric cutter (fine) VAG 1561 A
C - Flashing knife, U-type 639.031.130.22
D - Saw blade
H - Adhesive set Terokal 5045 (includes set components H1-H4)
H1 - Cartridge, component A
H2 - Cartridge, component B
H3 - Mixing nozzle
H4 - Processing nozzle

Removing roof
Removing roof
1. Mill off the spot welds in the front and side roof areas.
1.1. Mill off the spot welds of the front roof cross member -A- and in the
area of the roof strips -B- using a spotweld cutter.
2. Cut off the roof.
2.1. Cut off the roof with the oscillating body saw in the area -C- on both
sides.
3. Mill off the spot welds in the rear roof area.
3.1. Mill off the spot welds in the rear roof area -D- and in the area of the
hinge mounting -E- .
4. Heat roof in area of the cross members and remove.
4.1. Heat roof bonding in area of the cross members -F- and -G- using a
hot-air gun.
4.2. Remove the roof.
5. Remove remaining pieces of the roof.
Note
z During separation make sure that the components beneath are not
damaged.
5.1. Cut off laser soldered joints on side panels (areas -H- ).
5.2. Remove the remaining pieces.
Preparing connection areas of body for roof installation
Preparing connection areas of body for installing roof

1. Loosen welded joints.
1.1. Separate metal inert-gas welds -L- between roof and roof frame with
an angle grinder.
2. Press side panels outwards.

2.1. Press side panels evenly by approx. → Installation dimension: 1
mm .
3. Check width of roof cut-out.
Note
z It must be possible to fit the roof without tension. There should be a
uniform gap with the side panels of approx. 0.5 - 1 mm on both sides.
3.1. Place roof on roof frame at front and swivel in towards the rear..
4. Fix side panels.

4.1. Fix side panels using tensioning clamps with the pre-tensioned
dimension -X- .
5. Weld in side panels.
5.1. MIG weld both side panels at the separated connection points to the roof frame -M- with a full weld.
6. Clean welding and bonding areas.
6.1. Clean the body connection flanges of paint in the marked areas using a hot-air gun. Grind the connection
flanges until bare.
Note
z Keep welding and bonding areas at connection points free of paint.
6.2. If necessary, touch up any paint damage in areas that will later no longer be accessible.
7. Grind bonding areas.

7.1. Grind adhesive flanges in area of side panels -N- and the hinge connection until bare using grain 150
sandpaper.
8. Clean bonding areas.
Note
z Leave cleaned areas to dry for approx. 1 - 2 minutes. Bonding areas must be completely dry.
z Ensure that clean gloves are
worn when touching cleaned
surfaces to avoid transferring
sweat from the hands and dirt
onto the bonding areas.
z Dispose of the used, acetone-

soaked cleaning cloth as
special-category waste.
8.1. Clean adhesive flanges in

area of side panels -N- with
acetone.
9. Stick on spacer pads.
Note
z The spacers are delivered as sub-parts. Individual pieces must be cut
to a width of approx.8 mm and affixed for the assembly.
z Three spacers are required for the installation.
9.1. Cut to length about 30 distance pieces.
9.2. Stick spacers on the roof support of the side panels approx. 150 mm
apart.
10.1. Coat spot-weld flange areas inside roof frame and roof cross members with zinc powder paint..
Preparing roof for installation
Preparing roof for installation
1. Prepare welding flanges front and side for the installation.
1.1. Grind bare the welding flanges in area of front roof cross member
-A- and in area of roof strips -B- using a rotary brush.
2. Prepare side adhesive flanges for the installation.

2.1. Grind bare the adhesive flanges in side roof area on the outside using grain 150 sandpaper.
3. Prepare rear welding and adhesive flanges for the installation.

3.1. Grind bare the welding flanges in area of rear roof cross member -D- on both sides using a rotary brush.
3.2. On the inside of the roof, grind bare the adhesive flanges in area of hinge mountings -E- using grain 150
sandpaper.
4. Coat front spot-weld flanges with zinc powder paint.
Note
z Do not apply zinc powder paint to the bonding areas -I- .
4.1. Coat all spot-weld flange areas with zinc powder paint -A, B-
5. Coat rear spot-weld flanges with zinc powder paint.
Note
z Do not apply zinc powder paint to the bonding areas -E- .
5.1. Coat spot-weld flange area -D- with zinc powder paint.
Installing roof
Installing roof
ATTENTION
cleaned.
container imprints.
eye doctor.
Note
z Minimum ambient and material temperatures during working and hardening → Working temperature: 18
deg. Celsius .
z Areas not treated with cathodic immersion painting and exposed body panels must be brushed or filled with
structural adhesive.
Note
z Bonding in the roof requires two people.
z Do not begin bonding work until all materials and tools necessary for later repair work are available. The roof
bonding process can only be carried out reliably when a smooth and swift sequence of operations is
guaranteed.
z Before final assembly, make sure you fully understand all the work steps involved and carry out a trial
assembly without application of adhesive.
z In addition to this instruction, also observe the general information for working with body structural adhesive
→ 501000 Working with body structural adhesive.
1. Glue on spacers.
Note
z To avoid undesirable displacement of the adhesive, two spacers must
be put in place on the front roof cross member before placing the roof
panel.
z As spacer material, thin wooden, plastic or metal pads (approx. 5 mm)

can be used.
z After fitting the roof these spacers must be completely removed.
1.1.
Fix two spacers with adhesive tape on the front cross member so that they project beyond the front edge of
the roof and can later be easily withdrawn from the gap.
1.2. Before assembling the roof, clean the adhesive flanges once more with acetone and leave to dry off for
approx. 1 – 2 min.
2. Apply adhesive to the roof cross members.
2.1. Apply Würth Klebt und Dichtet body sealant to the roof cross
members in the area of the bond with the roof outer panel using a
bead height of → Application depth: 15 mm .
3. Apply structural adhesive to the roof panel.
3.1. Apply structural adhesive Terokal 5045 to the roof outer edge and on
the inside of the roof panel in the area of the hinge connection points
and spread evenly with a brush or a wooden spatula.
4. Apply structural adhesive to the hinge mountings.
Note
The exposed sheetmetal areas must be completely coated with an even
adhesive film of → Application depth: 1 mm .
4.1. Apply structural adhesive Terokal 5045 to the hinge connection

points and spread evenly with a brush -Arrows- .
4.2. Additionally, in the area of the contact surface, apply structural

adhesive with a bead height -X- → Application depth: 8 mm .
5. Apply structural adhesive to the side panels.
Note
The exposed sheetmetal areas must be completely coated with an even
adhesive film of → Application depth: 1 mm .
5.1. Apply structural adhesive Terokal 5045 to the side panels and spread evenly with a brush -Arrows- .
5.2. Additionally, in the area of the contact surface, apply structural adhesive with a bead height -X- →
Application depth: 8 mm .
6. Position roof.
6.1. Place roof on roof frame at front and swivel in towards the rear.
7. Remove spacers.
7.1. Remove spacers completely on both sides.
8. Align roof.
9. Align roof.
9.1. Position roof panel in the roof channel at front and rear and at the hinge connection points using a suitable
round material (drift) and check for correct installation position.
10. Fix roof.

10.1. Fix roof panel to cross member front and rear using tensioning clamps.
Note
z By placing styropore pads or similar material under the tension straps, the tension can be increased at the
points required.
z The tensioning straps must remain on the vehicle until hardening of the structural adhesive is complete.
10.2. Fit tensioning straps to the outer surfaces of the roof and clamp the roof.
11. Clean surface of roof in area of side panels.
11.1. Remove most of the excess adhesive material with paper or cloth.
Note
z Have this work carried out by an assistant whilst at the same time starting with the welding work.
11.2. Finish cleaning visible surfaces with a cloth soaked in acetone.
12. Weld in roof.
12.1. Spot weld roof in area of front roof cross member -A- and at the roof
frame connection points -B- .
Illustration without tensioning straps

12.2. Resistance spot-weld in area of rear roof cross member -D- .
12.3. MIG weld roof in area of rear side panels -E- with full weld.
Note
z The body structural adhesive
used hardens at room
temperature.
z Hardening can be accelerated

by heat (e.g. with an infra-red
radiator in a painting booth).
z Do not load bonded parts until

hardening is complete.
z Information on accelerated
hardening can be obtained Illustration without tensioning straps Illustration without tensioning straps
from → 5000IN Working with
body structural adhesive.
Note
z After repairs with adhesive, allow at least ten hours before moving or carrying out further work on the vehicle
(leave standing overnight) to avoid damage to the bonded joint by premature loading.
13. Leave bonded joint to harden.
Subsequent work
1. Remove vehicle from the straightening bench.
4. Restore standard sealing with body sealant.

→ 5000IN Seam sealing

→ 5000IN Cavity preservation
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
51 45 55 Replacing outer lower side member - as of MY 2003

- Preliminary work
- Technical values
- Removing outer lower side member
- Preparing
- Installing
- Subsequent work
Tools

, apply body sealing compound commercially
Würth Klebt und Dichtet available tool .gif
special tool 00000

dimensions 1

Preliminary work
Note

straightening set.
Note
set..
DANGER
→
Safety instructions for handling the fuel tank → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
Tools and materials
Technical values
Gap dimensions
Note
z The figures showing the gap dimensions can be found in the section entitled → Diagram of gap dimensions.
Designation Dimension Note

Front door to rear door -k- 4.5 ±0.5 mm Rear door only lowered (max. 1
(3.7±0.5) mm)
(3.7±0.5) mm)
Removing outer lower side member
Removing outer lower side member
Note
1. Cut off the lower side member near the pillars.

1.2. Cut the laser welded joint between the lower side member and inner
lower side member using the parting grinder (areas -A- , -B and C- ).
1.3. Mill off the welded joint on the lower side member using the spotweld cutter (areas -D- , -E- , -K- ,
-I and J- ).
2. Remove lower side member.
2.1. In series production, the lower side member is sealed in the area of the pillars and wheel arch with
expanded foam sealing parts. These seals are destroyed when the lower side member is removed and must
be replaced when the member is reinstalled.
3. Shorten wing fastening rail.
3.1. Shorten wing fastening rail by the dimension -W- → Overlap: 50 mm .
3.2. Mill off the welded joint on the remaining piece of the fastening rail using the spotweld cutter.
3.3. Remove the remaining piece of the fastening rail.
Preparing
Preparing connection areas of body for installing lower side member

Fitting outer lower side member and preparing for installation
1. Produce repair part.
1.1. Cut off the connection areas to the pillar on the new lower side
member. Ensure that the repair part in the area of the cut overlaps
by -W- → Overlap: 50 mm over the remaining piece of the vehicle.
The overlap on the wheel arch is automatically defined when the cut
is made.
2. Adapt the lower side member to the body.
2.1. Fix the lower side member to the body with tensioning clamps. To fit, install the front and rear doors and
adjust the contours and gap dimensions between the doors and lower side member according to the
adjustment values.
→ Gap dimensions
3. Fit lower side member joints.
3.1. Use a body saw to cut the two sheetmetal plates -T- in the area of the overlap between the lower side
member and pillars. Do not damage the internal components.
4.1. Remove lower side member and remaining pieces from the pillars.
5.1. Grind both sides of the connection flange of the lower side member in the marked areas -A- ,
-B, C, D, E, I, J- , -F- , -G, H- and -K- until bare using a rotary brush.
6. Drilling holes for plug welding using inert gas
6.1. On the lower side member, drill holes with a diameter of 7 mm

( → see figure ) or use a hole punch (areas -I, J- ). Maintain spacing
as on the old part.
Installing
Installing seals
1. Install lower A-pillar seal -1- .
1.1. Apply a butyl sealing cord to the inner seal -4- .
1.2. Place the seal against the body and press into place -arrows- .
2. Install lower B-pillar seal -2- .
3. Install lower C-pillar seal -3- .
3.3. On the seal , apply body sealing compound Würth Klebt und
Dichtet -5- . Maintain the application depth -V- → Application
depth: 10 mm .
Installing outer lower side member
ATTENTION
Risk of damage if the processing time for the body adhesive sealant is not observed.
z The binding quality is affected if the processing time is not observed.
→ Observe the processing time of the body adhesive sealant (No. 1)!
→
The new part must be welded within 30 minutes in the area of the adhesive, otherwise the binding quality is
affected.
1. Apply body adhesive sealant to the lower side member.
1.1. Apply -L- Teromix-6700 two-component adhesive -U- →

Application depth: 6 mm to the wheel arch flange.
1.2. Apply -M- Teromix-6700 two-component adhesive thinly at the door hinge flange area.
2. Install lower side member.
2.1. Fit lower side member to the body. Adjust the contours and gap dimensions according to the previous fitting
process. Fix the lower side member with tensioning clamps.
3. Resistance spot-weld the lower side member.
3.1. Resistance spot-weld the lower side member in areas -A- , -B, C, E-
, -I- and -K- .
4. Inert gas arc weld the lower side member.

5. Grind the MIG seams until smooth.
Installing wing fastening rail
Note
In the case of the Cayenne Turbo, the undersealing in the area of the outer lower side member is painted in the
colour of the vehicle. This means that after priming the repair area on these vehicles, undersealing must also be
applied to this area.

1.1. Cut off the top part of the new
wing fastening rail. Ensure
that the repair part in the area
of the cut overlaps by -W- →
Overlap: 50 mm over the
remaining piece of the
vehicle.
2. Clean welding and sealing

areas.
2.1. Grind both sides of the

connection flange of the new
parts in the marked areas
until bare using a rotary
brush.
3.1. On the fastening flange in area -N- , drill holes with ø = 7 mm or

punch them with a hole punch. Maintain spacing as on the old part.
4. Fit the wing fastening rail.
4.1. Fix the wing fastening rail to the body.
4.2. Cut the two sheetmetal plates -T- using the oscillating body saw in
the area of the overlap with the fastening rail. Do not damage the
internal components when doing this.
5. Prepare the joints on the wing fastening rail for installation.
5.1. Remove the wing fastening rail at the top.
5.3. Grind down both sides of the welding areas in the area of the cuts on
the body and new part with a rotary brush.
6. Welding in the wing fastening rail
6.1. Plug-weld the wing fastening rail in area -N- under shielding gas.
Inert gas arc weld the wing fastening rail in area -M- with a full weld.
Subsequent work
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
51 49 55 Replacing lower side member reinforcement - as of MY

2003
- Preliminary work
- Removing lower side member reinforcement
- Preparing connection area of body for installing lower side member reinforcement
- Fitting outer lower side member reinforcement and preparing for installation
- Installing lower side member reinforcement
- Subsequent work
Tools

special tool 00000

dimensions 1
Preliminary work

Note
straightening set.
covers.

DANGER
Tools and materials
Removing lower side member reinforcement
Removing lower side member reinforcement
Note
1.1. → Replacing outer lower side member
2. Mill off the lower side member reinforcement in the area of the pillars.
3. Remove lower side member reinforcement.
Preparing connection area of body for installing lower side member

reinforcement
Preparing connection area of body for installing lower side member reinforcement
1.1. Clean the body connection flange of undersealing and paint in the marked areas using a hot-air gun or
Fitting outer lower side member reinforcement and preparing for installation
Fitting outer lower side member reinforcement and preparing for installation
1.1. Drill holes with ø = 7 mm -A- , -B- , -C- in the fastening flanges of the lower side member reinforcement.
2. Cleaning welding and sealing areas
2.1. Grind both sides of the connection flange of the lower side member in the marked areas until bare using a
rotary brush.
Installing lower side member reinforcement

Installing outer side member reinforcement
1. Fit lower side member reinforcement to the body.
1.1. Fit the lower side member reinforcement to the body and secure with tensioning clips. When fitting, align
the reference holes of the lower side member reinforcement and pillar reinforcement -arrow- .
2. Inert gas arc weld the lower side member.

2.1. Plug-weld the lower side member in the areas -A- , -B- and -C- under shielding gas.

5. Seal flange areas with body sealant.
6. Install lower side member.
6.1. → Replacing outer lower side member
Subsequent work

as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
51 70 55 Replacing threaded bushing for seat connection - as of

MY 2003
- Preliminary work
- Technical values
- Removing threaded bushing for seat connection
- Installing threaded bushing for seat connection
Tools

Hot-air gun commercially leister-
available tool electron
Conical shell reaming drill special tool NR.128
Spotweld drill special tool NR.129

Preliminary work

2. Covering the accessories adjacent to the area of the vehicle requiring repair.
covers.
Tools and materials
Item Designation
1 MIG welder
2 Angle grinder
3 Hot-air gun leister-electron
4 Rotary brush
5 Conical shell reaming drill NR.128
6 Spotweld drill NR.129
7 Body sealant "Klebt und Dichtet" from Würth
8 Threaded bushing
9 Plug ø 30 mm
Technical values
Diameter of outlet hole -x- 30 mm
Removing threaded bushing for seat connection
Removing threaded bush for seat connection
1. Drilling the drain hole out
1.1. On the extension of the seat cross member, use a conical shell reaming drill NR.128 to bore out the
diameter of the drain hole to the dimension -A- = 30 mm.
2. Remove burrs from the edges of the hole.
3. Separate welded joints
3.1. Drill out a connection between the seat cross member and the threaded insert using a spotweld cutter
NR.129.
4. Removing threaded bush.
Installing threaded bushing for seat connection
Installing threaded bush for seat connection
1. Preparing the threaded bush for installation
1.1. Grind the threaded bush -1- bright on the contact surface with the seat cross member.
2. Inserting threaded bush.
2.1. Insert a new threaded bush -1- fully into the seat cross member from below.
2.2. Set the threaded bush -1- at a slight angle.
2.3. Insert an M8 x 120 bolt -2- into the seat cross member from above.
2.4. Screw the bolt -2- approx. three revolutions into the threaded bush -1- .
2.5. Pull the threaded bush -1- with the screw -2- up to the seat cross member.
3. Position the threaded bush and weld it into place.
3.1. Align the threaded bush -1- in the middle.

3.2. Weld the threaded -1- insert into the existing holes using MIG
welding.
4. Grinding the spot welds flat
4.1. Unscrew the bolt and grind the spot welds flat.
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.
9.1. Close the drain hole by inserting a 30-mm diameter plug -3- from
below.
10. Restore standard seal with body sealant→ Seam seal

11. Restore standard underbody protection with underbody sealing
compound → underseal.
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
51 89 41 Repairing the threaded bush for suspension subframe

mount - as of MY 2003
- Installing the repair threaded bush
Tools

Time-Sert thread repair set special tool NR.122-
1
Spot facer for Time-Sert thread commercially NR.122-

repair set available tool 2
Tools and materials

Tools and materials
Note
z 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!
Installing the repair threaded bush
Installing repair threaded bush
Note
z 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. Drill out the old thread with a drill to the root of the thread.
2. Mill shoulder.
2.1. Mill out drill hole with spot facer -C- to dimension -X- . → Test and adjustment value: 10 mm Milling must
only be performed using tool Spot facer for Time-Sert thread repair set NR.122-2!
For milling, use an electronically controlled power drill set at a speed of approx. 250 1 /min.
3. Cut thread.
3.1. Cut thread using a cutting tool -D- up to dimension -Y- in the chassis bushing. → Test and adjustment
value: 40 mm Clean thread on chassis bushing (blow out swarf).
4. Position threaded bush on screw-in tool.
4.1. Clean thread on bush and on screw-in tool.
4.2. Oil the screw-in tool -E- .
4.3. Screw the threaded bush -A- onto the screw-in tool -E- by hand.
5. Screw in threaded bush

5.1. Fully screw in the threaded bush using the screw-in tool -E- .
Note
z 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.
6.1. Form and press the

threaded bush by turning
further with the screw-in tool
-E- in the base thread.
7. Unscrew the screw-in tool -E- from the threaded bush.
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
51 93 19 Removing and installing middle cover - as of MY 2003

- Removing middle cover
- Installing middle cover
Removing middle cover
Removing centre cover
1. Remove lifting platform holder.

1.1. Undo and unscrew fastening screws -1- .
1.2. Remove lifting platform holder -2- in a downward direction (
-Arrow A- ).
2. Remove cover.
3. Remove middle cover.
3.1. Loosen and unscrew fastening screws -5- .
3.2. Remove centre cover -4- in the rear area downwards from the body ( -Arrow D- ).
3.3. Pull out middle cover -4- in the front area under the wheel housing liner -6- ( -Arrow E- ).
3.4. Take off the middle cover.
Installing middle cover
Installing centre cover
1. Installing middle cover
1.1. Insert middle cover -4- in the front area under the wheel housing
liner -6- and push it forward ( -Arrow A- ).
1.2. Place centre cover -4- on the body -Arrow B- and position it.
1.3. Screw in fastening screws -5- and tighten to the specified tightening
torque → Tightening torque: 1.9 (1.5 ftlb.) Nm +/-0.14 (0.10 ftlb.)
Nm
2. Install cover.
3. Install lifting platform holder.
3.1. Place lifting platform holder -2- on the body -Arrow E- and position
it.
3.2. Screw in fastening screws -1- and tighten to the specified tightening
torque → Tightening torque: 9 (6.5 ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
53 05 55 Replacing end plate - as of MY 2003

- Preliminary work
- Removing end plate
- Preparing
- Installing end plate
- Subsequent work
Tools

special tool 00000

dimensions 1

Preliminary work
Note
straightening set.
Note
set..
DANGER
Tools and materials

Removing end plate
Abschlussblech ausbauen
Note
1. Cut off closing panel.
Preparing
Preparing connection areas of body for installing closing panel
brush. Grind the connection flange until bare.
2. Coat spot-weld flange areas
with zinc powder paint.
2.1. Coat all spot-weld flange

areas with zinc powder paint.
Fitting in closing panel and preparing for installation

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.
2.1. Coat all spot-weld flange areas with zinc powder paint (areas -A, B- , -C, D- ).
Installing end plate
Installing closing panel
1. Fit the closing panel to the body.
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.

2.1. Resistance spot-weld the closing panel in areas -A, B- ( -A, B- ) and
-C, D- .
3. Inert gas arc weld the closing panel.
3.1. Inset gas arc weld the closing panel in the area -E- ( -E- ) with a full weld.
Subsequent work
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
53 55 55 Replacing rear side panel - as of MY 2003

- Preliminary work
- Technical values
- Removing rear side panel
- Preparing
- Installing rear side panel
- Subsequent work
- Subsequent work
Tools

Teromix-6700 two-component commercially
adhesive available tool .gif
special tool 00000

dimensions 1

Preliminary work
Note

straightening set.
Note
set..
DANGER
→
Safety instructions for handling the fuel tank → 5000AW Safety instructions [9PAAD1 9PAAD7 9PAAE1
Tools and materials
Technical values
Gap dimensions
Note

Front door to rear door -k- 4.5 ±0.5 mm Rear door only lowered (max. 1
(3.7±0.5) mm)
(3.7±0.5) mm)
Rear window to outer side section -c- 4.5 ±0.5 mm
(3.7±0.5)
-d- 3 mm
Removing rear side panel
Removing rear side panel
Note
1. Cut out rear side panel in the area of the pillars.
1.1. Cut through the side panel in the areas -C- , -D- and -E- using the oscillating body saw. Maintain the
dimensions -X- → Cut dimension, old part: 220 mm , -Y- → Cut dimension, old part: 200 mm and -Z- →
Cut dimension, old part: 150 mm . Do not damage internal components.
1.3. Cut the laser-welded joint
between the rear side panel
and reinforcement on the C-
pillar using the parting grinder
(area -A- ).
2. Remove rear side panel
Preparing
Preparing connection area of body for installing rear side section

2.1. Coat all spot-weld flange areas on which there is no body adhesive
with zinc powder paint.
Fitting in rear side panel and preparing for installation

1.1. Cut the connection area to the roof on the new part. Ensure that the repair part in the area of the C and D-
pillars overlaps by -W- → Overlap: 50 mm over the remaining piece of the vehicle. The overlap on the
wheel arch is automatically defined owing to the cut dimension.
Note
z As a result of technical issues, it is not possible to provide a side section with a tail light holder with hole
pattern for repair work. In this case, a specially developed, adjustable
retainer plate is available which must also be installed.
2.1. Grind both sides of the connection flange of the side panel in the
marked areas -A, B, F, G- and -H, I- ( -I- ) until bare using a rotary
brush.
3.1. On the fastening flange in area -H- of the rear side panel, bore holes ø = 7 mm or punch them using a hole
punch. Maintain spacing between the bores as on the old part.

4.1. Coat all spot-weld flange areas on which there is no body adhesive (areas -A, F, G- and -I- ) with zinc
powder paint.
Installing rear side panel
Installing rear side panel
Note
z When fitting the side section using the alignment bench, the side portal can also be used.
1. Fit the rear side panel to the body.
1.1. To complete the fit, install the rear doors and lid and set the gap dimensions between the rear doors and lid
and the side panel according to the respective adjustment values.
1.2. Fix the rear side panel with tensioning clamps.
1.3. Mark the installation position of the side panel.
1.4. → Gap dimensions
2. Fit the side panel joints.
2.1. Use a body saw to cut the two sheetmetal plates in the area of the overlap between the side panel and
body. Do not damage the internal components.
2.2. Remove the accessories and side panel.
3. Applying body sealant to the wheel housing and in the area of the catch bar
ATTENTION
Risk of damage if the processing time is not observed!
z The binding quality of the adhesive (No. 1) is affected if the processing time is not observed!
→ Observe the processing time of the adhesive (No. 1)!

→ The new part must be welded within 30 minutes in the area of the adhesive, otherwise the adhesion of the
adhesive will be affected.
3.1. Apply Teromix-6700 two-component adhesive to the outside of
the wheel housing and close to the catch bar (areas -J, K- ).
-U- → Application depth: 6 mm
4. Fit side panel.

4.1. Fit side panel according to the markings and fix in place with
tensioning clamps.
5. Resistance spot-weld the side panel.
5.1. Resistance spot weld the side panel in the areas -A, B- ; -F- ; -G- and -I- ( -I- ).
6. Welding side panel using inert gas

6.1. MIG weld the side panel in the areas -C- , -D and E- with a full weld.
Plug-weld the side panel in area -H- using inert gas.

7. Flange edge of wheel arch → Flanging edges of wheel arch.
8. Grind inert gas arc weld areas, which are visible following installation, until bare, apply body solder to body
joints and align as required.
Subsequent work
Flanging edges of wheel arch

WARNING
Danger of tyre damage
z The tyres will be damaged if
wing folds are not reworked!
→ Flange the wheel arch edges.
Adjusting connection points for tail light
1. Mark drill holes on the bracket.
1.1. Put spacing plate -1- in position.
1.2. Mark the centre of the holes with a marking tool.
2. Drill holes in the bracket.
2.1. Drill holes -L, M- , → Bore: 8 mm .
2.2. Drill hole -K- , → Bore: 22 mm .

2.3. File out the transitions between the holes.
3. Fit retainer plate → 943119 Removing and installing tail light.
4. Mark drill holes on sealing channel.

4.1. Transfer the dimensions illustrated to the sealing channel. (The
centre of the illustrated control bore serves as the reference point)
-O = 50 mm- → Gap dimension: 50 mm
-P = 25 mm- → Gap dimension: 25 mm
-Q = 14,5 mm- → Gap dimension: 14.5 mm
-R = 4 mm- → Gap dimension: 4 mm
5. Drilling holes in sealing channel
5.1. Drill holes -S- , → Bore: 10 mm .
5.2. Drill holes -T- , → Bore: 10 mm .
Subsequent work

5. Restore standard undersealing with underbody sealant → 5000IN

Underbody protection.

→ 5000IN Cavity preservation.
as of MY 2003
WARNUNG
WARNING
AVERTISSEMENT
ATTENZIONE
immagine.
ADVERTENCIA
53 56 55 Replacing side panel bottom section - as of MY 2003

- Preliminary work
- Technical values
- Replacing side panel bottom section
- Preparing
- Installing side panel bottom section
- Subsequent work
Tools

special tool 00000

dimensions 1

Preliminary work
Note
straightening set.
Note
set..
DANGER
Tools and materials

Technical values
Gap dimensions
Note
Replacing side panel bottom section

Porsche Cayenne S 2006 (Completo) ENG

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PORSCHE CAYENNE 2003 2004 2005 2006 REPAIR MANUAL

01 01 00 Sales check - as of MY 2003

Work instruction for

Vehicle Ident. No.

→ Battery: checking charging condition [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1]

→ Alarm system: checking operation of monitoring devices [9PAAD1 9PAAD7

Test drive OK 1) Not OK 2)

Stamp of Official Porsche Centre

9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1, 9PAAJ1

01 01 01 Battery: checking charging condition - as of MY 2003

Designation Type Number Explanation

Battery: checking charging condition

Checking charge state with battery tester

z The tester must be connected directly to the battery.

1. Remove battery cover.

Evaluating the test results and further procedures:

– Open-circuit voltage: 12.7 - 12.5 V

– 1. Charge state: 100-80 %

– Open-circuit voltage: 12.5 - 12.2 V

– Open-circuit voltage: 12.2 - 11.6 V

– Open-circuit voltage: below 11.6 V

– 1. Charge state: below 10 %

– 2. Battery totally discharged; replace battery

9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1

01 01 01 Alarm system: Checking operation of indicators - as of

check operation of indicators

Alarm system: checking operation of indicators

9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1

01 01 23 Sales check: Fitting mobile phone console - as of MY

1 - Cover for interface box

Fitting mobile phone console

Overview of the single parts in the mobile phone console

Overview of installation of mobile phone console

Fastening holes in interface box

outer part -D- and the cable duct -C- .

3. Make sure that the wires are not pinched.

4. Engage the cable duct -C- in the outer part -D- .

5. Lift the assembled components -C, D, E- onto the centre console

Pushing components onto centre

Installing inner part

Screwing interface box onto upper part

Screwing on support for interface box

Pushing interface box into cradle

Routing line for the VDA interface and

Connecting line for the VDA interface

16. Move the seat to the position required by the customer.

9PAAD1, 9PAAD7, 9PAAE1, 9PAAE7, 9PAAF1

01 01 IN Diagnostic system: reading out fault memory and

Designation Type Number Explanation

Performing vehicle handover

2. Select Special functions using the cursor keys.

5. Switch on the ignition and start the function by pressing F8 .

7.1. Read out all fault memories.

9. Carry out an automatic search for control units.

2. Select the Special functions menu using the cursor keys.

3. Switch to Cayenne analysis and start it. Analysis is performed. Print

4. →| Select vehicle type. Switch to Cayenne handover .

5. Observe instructions on the Tester and code >> using F8 .

6. Enter the required chassis number >> .

Reading out fault memory

1. Select vehicle type. >>

1. Insert navigation CD into PCM and switch on PCM.

3. Disconnect Tester on vehicle.