Generators & Regulators Porsche Cayenne S I

DESCRIPTION & OPERATION

Generator as installed on Cayenne, Cayenne S and Cayenne Turbo is an internally regulated, three-phase generator driven by engine accessory drive belt. Generator is water cooled and has a maximum output of 220 amps.

BELT TENSION

Serpentine belt tension is automatically adjusted by tensioner and no adjustment is required.

DRIVE BELT ROUTING

Serpentine belt is self-adjusting. (Scheme 1)or (Scheme 2).

Scheme 1

TESTING

Note. Charge indicator in instrument cluster receives a signal from DF terminal on generator via CAN-bus system. No testing is available from manufacturer. Check circuits using wiring diagrams. See WIRING DIAGRAMS .

SERVICE PRECAUTIONS

The following precautionary measures must be taken before disconnecting or total discharge of the battery or serious electrical damage can occur

1. Never disconnect battery with engine running.
2. Ensure battery is securely connected before starting.
3. Do not use a boost charger to start engine.
4. When jump starting use jumper cables with overvoltage protection.
5. Always disconnect the battery before performing any welding.
6. Turn ignition to OFF position. Wait one minute before disconnecting negative lead.
7. Always disconnect negative lead first. When reconnecting battery connect negative lead last.
8. Before beginning testing, perform «PRELIMINARY INSPECTION»(/porsche/cayenne-s/i-2002-2007/remont/charging-system/#generators-regulators__preliminary-inspection) .

PRELIMINARY INSPECTION

Verify customer complaint by operating system. Visually inspect for obvious signs of mechanical and electrical damage. Check generator belt tension and condition. Ensure that battery voltage is within specifications. Following manufacturers instructions for load tester, load test battery. Inspect for blown fuses and damaged relays. For fuse and/or relay identification, see WIRING DIAGRAMS .

Verify ground connection integrity between engine, body, battery and generator. Check for damaged wiring harnesses and/or switches. Check for a broken or partially broken wire inside insulation, which could cause system malfunction but prove good in a continuity/voltage check with system disconnected. Ensure any aftermarket electronic equipment is properly installed. If fault is found, repair as necessary. If no fault is found, check for conditions that might cause an intermittent situation.

BATTERY DISCONNECT PRECAUTIONS

After disconnecting battery or replacing ECM, drive vehicle to enable ECM to relearn driveability. Inform your customer that they may experience driveability different from what they are accustomed to until ECM completes relearn function.

Ready Status

After battery is disconnected and reconnected, The "Ready Status" must be obtained following a test drive or using a Porsche System Tester (or equivalent aftermarket scan tool).

Idle Relearn

After disconnecting the power supply, the idle speed might change or fluctuate briefly until the throttle adjusting unit readapts. The mixture adaption is also lost.

To readapt the DME control unit (PCM), perform the following procedure

1. Turn ignition on, with engine off for 30 seconds. Do NOT touch accelerator pedal. This completes the adaption of the throttle adjusting unit.
2. The engine must run for several minutes before the PCM can relearn the idle speed and mixture adaption values.

Tire Pressure Monitoring

Tire pressure monitoring values will be lost after the battery is disconnected. After reconnecting the battery, drive the vehicle for a short distance. The actual tire pressures will start to display again.

Steering Angle Sensor

The steering angle sensor must be re-initialized after battery is disconnected and connected.

1. Turn steering wheel to straight ahead position.
2. Turn ignition off then on again twice (do not start the engine yet).
3. Start engine.
4. From the straight-ahead position, turn steering wheel about 20 degrees to the left and 20 degrees to the right (past the straight-ahead position).
5. Drive the vehicle straight ahead for at least one second at a speed above 2.5 MPH.
6. The stored fault code in the Porsche Stability Management (PSM) control unit should now be cleared automatically. The PSM indicator light in the instrument cluster should now go out.

Sliding Roof Electric Motor

The sliding roof limit positions are lost when battery is disconnected and connected. To restore settings, turn ignition on (engine off) and press the rocker switch upwards. The roof opens and closes completely. The limit positions are now stored in the control unit.

Power Windows

The limit positions of the power windows are deleted from the control unit when the battery is disconnected and connected.

To restore the settings, manually close each power window as far as it will go. Open it completely, and then press the rocker switch for closing the window again. The power window limit positions are now stored in the control unit.

Supply Voltage Fault Entry

A "supply voltage" entry may be stored in various electronic control units if the battery is completely discharged. This will have to erased from fault memory using a scan tool.

REMOVAL & INSTALLATION

Scheme 2

Scheme 3

Scheme 4

Scheme 5

1. Turn ignition off. Disconnect negative battery cable. See «SERVICE PRECAUTIONS»(/porsche/cayenne-s/i-2002-2007/remont/charging-system/#generators-regulators__service-precautions) under TROUBLE SHOOTING.
2. Remove upper engine cover. Remove fasteners and remove left side engine cover.
3. Disconnect air flow meter harness connector. Release air cleaner cover housing and pull upwards. Loosen air intake hose clamp at throttle body, disconnect hose and push to right side.
4. Disconnect vent hose and remove air cleaner housing with intake hose.
5. Release serpentine belt tension by screwing a 8x50 mm bolt into threaded hole on belt tensioner. (Scheme 3) Remove belt from tensioning roller. Remove belt tensioner mounting bolts and remove tensioner.
6. Press and release connector (A) and pull of in direction of arrow (B). (Scheme 4) Remove protective cap (C). Remove B+ connector nut (2) and remove B+ cable.
7. Remove generator mounting bolts (3). (Scheme 5) Lever generator out of bracket.
8. Clamp generator coolant hoses "A" and "B" with appropriate hose clamps. (Scheme 6) Remove coolant hose connection fastener (4) from generator, and pull hoses away from generator. Remove generator in an upwards direction, carefully pushing upper coolant hose aside.
9. Before installing generator push threaded bushing towards rear of generator about.157" (4 mm). (Scheme 7) To install generator, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(/porsche/cayenne-s/i-2002-2007/remont/charging-system/#generators-regulators__torque-specifications).
10. Check and replace coolant hose connection seal as necessary. Fill and bleed cooling system. See «SPECIFICATIONS & DRIVE BELT ROUTING»(/porsche/cayenne-s/i-2002-2007/remont/accessory-drive-belts/#specifications-drive-belt-routing) article under COOLING SYSTEM MECHANICAL in ENGINES. Start vehicle and check belt running and generator operation.

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

1. Turn ignition off. Disconnect negative battery cable. See «SERVICE PRECAUTIONS»(/porsche/cayenne-s/i-2002-2007/remont/charging-system/#generators-regulators__service-precautions) under TROUBLE SHOOTING.
2. Raise and support vehicle. Remove right wheel. Remove right wheel housing liner. (Scheme 8)
3. Remove under body engine seal. Drain coolant. See «SPECIFICATIONS & DRIVE BELT ROUTING»(/porsche/cayenne-s/i-2002-2007/remont/accessory-drive-belts/#specifications-drive-belt-routing) article under COOLING SYSTEM MECHANICAL in ENGINES.
4. Remove air cleaner box, and related pipe and hoses.
5. Detach and move lock mount into service position. See «LOCK MOUNT»(/porsche/cayenne-s/i-2002-2007/remont/charging-system/#generators-regulators__lock-mount).
6. Remove 3 impact bracket bolts (8), and remove impact bracket. (Scheme 9)
7. Using a 30 mm open end wrench on serpentine belt tensioner, turn tensioner clockwise to release tension and remove belt from tensioning roller. (Scheme 10) After removing belt, release belt tensioner slowly.
8. Remove ground lead fastening screw, and remove ground lead. (Scheme 11)
9. Clamp generator coolant hoses "A" and "B" with appropriate hose clamps. (Scheme 12) Remove coolant connection fasteners from generator, and pull away from generator.
10. Remove generator mounting bolts (1,2). (Scheme 14) While supporting generator with hand, pull generator towards front of vehicle.
11. Remove the protective cap for generator harness connector. If necessary carefully cut cover with a knife. Press and release connector (B) and pull of in direction of arrow (C). (Scheme 15)
12. Remove B+ connector nut, and remove B+ lead. Remove generator through opening in wheelwell.
13. Installation is reverse of removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(/porsche/cayenne-s/i-2002-2007/remont/charging-system/#generators-regulators__torque-specifications). Fill and bleed cooling system. See «SPECIFICATIONS & DRIVE BELT ROUTING»(/porsche/cayenne-s/i-2002-2007/remont/accessory-drive-belts/#specifications-drive-belt-routing) under COOLING SYSTEM MECHANICAL article in ENGINES. Start vehicle and check belt running and generator operation.

Scheme 12

Scheme 13

Scheme 14

Scheme 15

1. Turn ignition off. Disconnect negative battery cable. See «SERVICE PRECAUTIONS»(/porsche/cayenne-s/i-2002-2007/remont/charging-system/#generators-regulators__service-precautions) under TROUBLE SHOOTING.
2. Raise and support vehicle. Remove right wheel. Remove right wheel housing liner. (Scheme 8)
3. Remove under body engine seal. Drain coolant. See «SPECIFICATIONS & DRIVE BELT ROUTING»(/porsche/cayenne-s/i-2002-2007/remont/accessory-drive-belts/#specifications-drive-belt-routing) under COOLING SYSTEM MECHANICAL article in ENGINES.
4. Remove air cleaner box, along with related pipes and hoses.
5. Detach and move lock mount into service position. See «LOCK MOUNT»(/porsche/cayenne-s/i-2002-2007/remont/charging-system/#generators-regulators__lock-mount).
6. Remove 3 impact bracket bolts (8), and remove impact bracket. (Scheme 9)
7. Using a 30 mm open end wrench on serpentine belt tensioner, turn tensioner clockwise to release tension and remove belt from tensioning roller. (Scheme 10) After removing belt, release belt tensioner slowly.
8. Remove ground lead fastening screw, and remove ground lead. (Scheme 11)
9. Unclip oil pressure switch and oil level sensor harness using release lever (A). (Scheme 16) Unclip pressure pipe (B). Press release plug and disconnect oil pressure switch harness connector (C).
10. Remove generator lead fastening screw (2). (Scheme 17)
11. Clamp generator coolant hoses "A" and "B" with appropriate hose clamps. (Scheme 12) Remove coolant connection fasteners from generator, and pull away from generator.
12. Remove generator mounting bolts (5,6). (Scheme 18) While supporting generator with hand, pull generator towards front of vehicle.
13. Remove the protective cap for generator harness connector. If necessary carefully cut cover with a knife. Press and release plug (B) and pull of in direction of arrow (C). (Scheme 19)
14. Remove B+ connector nut, and remove B+ lead. Remove generator through opening in wheelwell.
15. Installation is reverse of removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(/porsche/cayenne-s/i-2002-2007/remont/charging-system/#generators-regulators__torque-specifications). Fill and bleed cooling system. See «SPECIFICATIONS & DRIVE BELT ROUTING»(/porsche/cayenne-s/i-2002-2007/remont/accessory-drive-belts/#specifications-drive-belt-routing) under COOLING SYSTEM MECHANICAL article in ENGINES. Start vehicle and check belt running and generator operation.

Scheme 16

1. Release front wheel housing liner fastening screws (8 and 9) from spoiler, inset circles Nos. 1 and 2. (Scheme 20)
2. Lifting up at lower corner of wheel housing liner (8) remove screws (4 and 6), inset circle No. 2. (Scheme 20)
3. Remove lower screws from front spoiler (7), inset circle No. 3. (Scheme 20)
4. Remove upper screws from front spoiler (5), inset circle No. 4. (Scheme 20)
5. With assistance from a helper, pull spoiler (1) forward and support. Remove left and right turn signal bulb holders (13) from direction indicator (13), inset circle No. 5. (Scheme 20)
6. Remove headlight cleaning system hose connection. Remove front spoiler.
7. Remove left and right side guide rail mounting nuts (14), inset circle No. 6. (Scheme 20) Remove left and right side guide rails. Before installing, check expander nuts (2) replacing as necessary.
8. To install front spoiler, reverse removal procedure. When tightening front spoiler mounting bolts match existing marks on frame rails. Tighten lock mount bolts to specification. See «TORQUE SPECIFICATIONS»(/porsche/cayenne-s/i-2002-2007/remont/charging-system/#generators-regulators__torque-specifications).

LOCK MOUNT

Note. Servicing generator as well as other components located at front of engine compartment is made easier by moving lock mount into service position.

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

1. Remove front spoiler. See «FRONT SPOILER»(/porsche/cayenne-s/i-2002-2007/remont/charging-system/#generators-regulators).
2. Remove front lid seal. (Scheme 21)
3. Disconnect front lid lock cable. see scheme 22
4. Remove rubber covers (1) and (2), inset circle No. 1. see scheme 23
5. On Turbo models only, remove side air guides.Disconnecting air sensor harness connector (14), inset circle No. 2. see scheme 23 Slide air guide (15) outwards to remove.
6. On all models, remove lock mount fastening screws (3), inset circle No. 3. see scheme 23
7. Install lock mount service mount bolts (4), inset circle No. 4. No bolt size is given by manufacturer, but bolts provide support for lock mount as it is moved into service position.
8. Remove lock mount fastening screws (5), inset circle No. 5. see scheme 23
9. Remove lock mount fastening screws (6 and 7), inset circle No. 6. see scheme 24
10. Release air intake guides (8) at air filter, inset circle No. 7. see scheme 24
11. Disconnect in-line harness connector (9), inset circle No. 8. see scheme 24
12. On Turbo models only, remove charge air cooler (intercooler) mount screws (16), inset circle No. 8. see scheme 24 Remove spacers (17).
13. On all models, remove front spoiler guide rails. See «FRONT SPOILER»(/porsche/cayenne-s/i-2002-2007/remont/charging-system/#generators-regulators).
14. Pull lock mount into service position, inset circle No. 10. see scheme 24 To prevent damage to the headlights and accessories pull lock mount forward on both sides by an equal mount.
15. To secure lock mount, reverse procedure. When tightening lock mount mounting bolts match existing marks on frame rails and body. Tighten lock mount bolts to specification. See «TORQUE SPECIFICATIONS»(/porsche/cayenne-s/i-2002-2007/remont/charging-system/#generators-regulators__torque-specifications). Connect and check function of front lid lock cable. see scheme 25

GENERATOR SPECIFICATIONS

Normal output (for all models) is 1,680 Watts.

TORQUE SPECIFICATIONS

GENERATOR & GENERATOR BRACKET TORQUE SPECIFICATIONS

WIRING DIAGRAMS

Note. See STARTING/CHARGING in appropriate SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

Poses Online

See also:
• SPECIFICATIONS & DRIVE BELT ROUTING
• DISABLING/ENABLING ELECTRONIC LEVEL CONTROL
• WIRING DIAGRAMS
• PRELIMINARY INSPECTION
• BATTERY DISCONNECT PRECAUTIONS
• SERVICE PRECAUTIONS
• TORQUE SPECIFICATIONS
• LOCK MOUNT
• FRONT SPOILER