Fuel, Actuation Porsche Cayenne S I

Tools

Designation Type Number Explanation Porsche System Tester ll commercially available tool 9588 pressure gauge commercially available tool p378 Pressure gauge commercially available tool p378a Connection line special tool P 9559 Measuring adapter special tool P 9705 Connecting lead special tool P 9705/1

Scheme 1

Scheme 2

Test conditions

1. The battery voltage must not be < 12 volts.
2. 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.
3. Fuel system parts must not get dirty.

Scheme 3

1. Pull the cover of the throttle body up and off.

2. Unscrew cap on the front right of the fuel gallery.

Scheme 4

3. Connect connection line P 9559 to the pressure gauge p378 . Screw the other end onto the fuel gallery.

Scheme 5

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.

> Replace scavenging valves after removing.

> Only use the special, Porsche-approved valves in the fuel gallery.

> Do not replace scavenging valves by tire valves.

> It is essential that the plastic cap is also replaced.

Note. 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.

Scheme 6

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

Preliminary work

1. Open the bonnet.

Scheme 7

2. Open lid of central electrics box. To do this, loosen the four fastening screws.

3. Remove fuses -3- for the ignition rod modules, -4- injection system and both fuel pump relays (left pump -1- and right pump -2- ). (Scheme 7)

Scheme 8

Scheme 9

4. Pull the design cover up and off.

Scheme 10

1. The battery voltage must not be < 12 volts.
2. Fuel system parts must not get dirty.

Checking fuel pressure

> 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.

> 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.

> In case of fire, use CO 2 or dry powder fire extinguishers.

Note. The ignition must be switched off when working on the fuel system. Absorb any escaping fuel using a suitable binding material or a cloth. Cloths which have absorbed fuel must be disposed of according to the applicable national laws. The fuel system must be depressurised before starting work on it. Only work on the fuel system in well-ventilated rooms. Any seals which have been removed must always be replaced.

Scheme 11

Note. The fuel gallery is pressurised. Place a cloth under the areas of the fuel gallery to be opened so that fuel does not drip on to hot engine parts.

1. Twist off the cap of the fuel scavenging valve -1-. (Scheme 10)

Note. Make sure that the switch on the adapter P 9479 is at 0 so that fuel is not pumped immediately when you connect the adapter.

2. Insert adapter P 9479 into both relay slots of the fuel pump relay for the fuel supply pumps at the same time (for details of relay assignment, see > 200201 Checking fuel pressure - section on "Preliminary work" ).

Scheme 12

Note. Proceed as follows to fit the adapter 1318/20 -2- to the scavenging valve: Turn the valve -4- anti-clockwise at the T-piece until the valve is closed. Place the adapter on the scavenging valve and use the knurled nut -3- to fit the adapter in a clockwise direction until the adapter is attached securely to the scavenging valve. To open the scavenging valve, turn the T-piece of the valve clockwise (the fuel is released immediately and flows out via the adapter 1318/20). If the T-piece touches the intake-air distributor when you turn it, shorten the cross-pin of the T-piece slightly so that it has sufficient clearance. The adapter 1318/20 includes a hose connection 1318/20-1 -1-, to which a suitable fuel hose can be fitted using a screw-type clamp. (Scheme 11)

3. Fit adapter 1318/20 to the scavenging valve (valve closed) -1-. Fit the tool set VAG 1318 to the adapter and support pressure gauge on the bonnet lock -3-. Keep the valve closed with the stop-cock -5- under the pressure gauge (stop-cock is positioned at a right angle to the flow direction). Fit hose connection 1318/20-1 -4- to the stop-cock and route a suitable fuel hose into a measuring cup using a clamp. The tool must be assembled as shown. (Scheme 12)

Scheme 13

Note. The steady-state pressure must be greater than 3.0 bar after 10 minutes.

4. Screw the valve (T-piece) in clockwise at the adapter 1318/20. Set the stop-cock under the pressure gauge VAG 1318 to flow direction. Switch on both fuel pumps for a short time using the adapter P 9479 in order to rinse out the air. Close the stop-cock under the pressure gauge VAG 1318 (stop-cock is positioned at a right angle to the flow direction). Switch on both fuel pumps using the adapter P 9479 and read the pressure on the pressure gauge. The fuel pressure should be approx. 4.0 bar. Then switch off both fuel pumps and check the steady-state pressure. The fuel pressure must not drop below 3.0 bar after 10 minutes.

Subsequent work

1. Insert fuses -3- for the ignition rod modules, -4- injection system and both fuel pump relays (left pump -1- and right pump -2- ). (Scheme 13)

2. Fit lid of central electrics box. To do this, fit the four fastening screws.

3. Fit the design cover.

Scheme 14

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 Equipment Manual 3.2.2. "WE 1262"

ohne Bezeichnung - Adapter adapter P 9479 (For controlling the fuel pumps); see Workshop Equipment Manual, Chapter 2.2.2

Scheme 15

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.)

Scheme 16

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. (Scheme 15)

2. Connect the suction hose (or fuel nozzle) to the connection -1- and then connect the venting device -2-. (Scheme 15)

Scheme 17

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.

Scheme 18

Note. Fuel can be removed directly through the fuel filler neck on older vehicles or vehicles from other manufacturers by removing the connecting piece.

Draining fuel (emptying the fuel tank)

> 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.

> 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.

> In case of fire, use CO 2 or dry powder fire extinguishers.

> Please observe the general warning notes and working regulations. --> 10 01 AW THE MOST IMPORTANT WORKING REGULATIONS AND WARNING NOTES - AS OF MY 2003 (ALL MODELS EXCEPT CAYENNE S TIO TITAN) .

> 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. All windows should be opened for better ventilation in the passenger compartment.

1. Fold rear seat forwards.

Scheme 19

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.

Scheme 20

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.

Scheme 21

5. Carefully pull off the fuel line -1-. Collect emerging fuel with a cloth. (Scheme 20)

6. Connect earth cable to the vehicle.

Scheme 22

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.

Scheme 23

9. Connect the connecting piece to the adapter.

10. Open lid of central electrics box. To do this, loosen the four fastening screws.

> 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. Use special tool 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. adapter P 9479 from the measurement tool box to activate the fuel pump.

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 P 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. see scheme 29

Scheme 24

12. Carry out any necessary repair work on the tank. Please observe the warning notes in --> 10 01 AW THE MOST IMPORTANT WORKING REGULATIONS AND WARNING NOTES - AS OF MY 2003 (ALL MODELS EXCEPT CAYENNE S TIO TITAN) .

13. Fit all connections (fuel lines, ventilation tubes and electric plugs).

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.

15. Tighten the seat-belt buckle fastening plates. Use three new fastening screws for this and tighten. For tightening torque Refer to 69 25 19 Removing and installing rear belt lock - as of MY 2003 (All Models) .

16. Fold rear seat down again.

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.

Designation Type Number Explanation Lifting platform commercially available tool - Keys VW-tool T10202

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) Refer to 42 05 19 Removing and installing rear axle housing - as of MY 2003 (All Models) .

Scheme 25

Group 20 - Fuel supply, control

> 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.

> 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.

> In case of fire, use CO 2 or dry powder fire extinguishers.

Note. The ignition must be switched off when working on the fuel system. Absorb any escaping fuel using a suitable binding material or a cloth. Cloths which have absorbed fuel must be disposed of according to the applicable national laws. The fuel system must be depressurised before starting work on it. Only work on the fuel system in well-ventilated rooms. Any seals which have been removed must always be replaced.

Removing fuel tank

Note. The repair procedure may vary depending on engine type and country equipment. This relates in particular to components in the right wheel housing. The description relates to ORVR vehicles. Sealing rings must generally be replaced.

Scheme 26

The following exploded drawing shows how the fuel tank is attached to the vehicle floor.

Scheme 27

1. Open filler flap.

Scheme 28

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.

3. Remove the fuel supply -1- at the connection unit and disconnect the 2 connection points -2 and 3-. (Scheme 28)

Scheme 29

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). see scheme 38

Scheme 30

5. Then, loosen the stone guard on the right side. Unscrew screws -2-. (Scheme 29)

Scheme 31

6. Remove line holder under the stone shield by pressing on the center plug -arrow-. Replace holder. (Scheme 30)

7. Remove the center underbody cover at the left and right of the longitudinal side members. Refer to 51 93 19 Removing and installing middle cover - as of MY 2003 (All Models) .

Scheme 32

8. Remove rear heat shield. To do so, undo the three speed nuts and the two screws.

Scheme 33

> 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. (Scheme 32)

Scheme 34

> 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.

Designation Type Number Explanation Lifting platform commercially available tool Keys VW-tool T10202

Required tools

> 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.

> 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.

> In case of fire, use CO 2 or dry powder fire extinguishers.

Note. The ignition must be switched off when working on the fuel system. Absorb any escaping fuel using a suitable binding material or a cloth. Cloths which have absorbed fuel must be disposed of according to the applicable national laws. The fuel system must be depressurised before starting work on it. Only work on the fuel system in well-ventilated rooms. Any seals which have been removed must always be replaced.

Installing fuel tank

Note. The repair procedure may vary depending on engine type and country equipment. This relates in particular to components in the right wheel housing. The description relates to ORVR vehicles. Sealing rings must generally be replaced.

The following exploded drawing shows how the fuel tank is attached to the vehicle floor.

Note. The top left cover must be fitted before the tank is installed. When installing the tank and rear axle, make sure that cables and lines are not damaged and are in the correct installation position. 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. 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-. see scheme 48

4. Lower the transmission jack and fit the center restraining strap. The arrow must be pointing forwards. Tighten fastening screws to the specified torque. --> Tightening torque: 17 ftlb.

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. Refer to 51 93 19 Removing and installing middle cover - as of MY 2003 (All Models) .

7. Replace holder and attach to side member. Clip in lines.

Scheme 35

8. Then, fit the stone guard on the right side. Mount nuts -arrows- and tighten to the specified torque. --> Tightening torque: 7.5 ftlb. see scheme 52

9. Mount the fuel supply -1- to the connection unit and connect the 2 connection points -2 and 3-. (Scheme 35)

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 Refer to 69 25 19 Removing and installing rear belt lock - as of MY 2003 (All Models) .

3. Fold rear seat down again.

4. Mount rear axle (spring struts and rear axle housing). Refer to 42 05 19 Removing and installing rear axle housing - as of MY 2003 (All Models) .

5. Mount carbon canister. > 202523 Installing carbon canister

6. Fill fuel tank (refuel). > Filling with fuel

Designation Type Number Explanation key VW-tool T10202

Component information

Note. The two senders have different shapes and may not be switched. The float installed in the left direction of travel is flat, while the float installed in the right direction of travel is spherical. The removal of both senders is explained in parallel in this description. If only one sender has to be removed, the other side of the tank can remain untouched.

Scheme 36

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.

Scheme 37

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.

Opening the tank

Note. If the tank must be opened for emptying, disconnect all connections.

Installation Location

1. Open filler flap.

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

> 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.

> 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.

> In case of fire, use CO 2 or dry powder fire extinguishers.

Note. The ignition must be switched off when working on the fuel system. Absorb any escaping fuel using a suitable binding material or a cloth. Cloths which have absorbed fuel must be disposed of according to the applicable national laws. The fuel system must be depressurised before starting work on it. Only work on the fuel system in well-ventilated rooms. Any seals which have been removed must always be replaced.

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. see scheme 61

Scheme 38

7. Open the relevant cap with the key T10202 and lift up the connection unit (cap).

Scheme 39

1. Disconnect electric connectors -1 and 2-. Then pull off the fuel lines -3 and 4- and remove the connection unit. (Scheme 38)

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.

Scheme 40

2. Press the retaining spring on the sender by hand while at the same time pulling the sender up.

Scheme 41

1. Install a new tank gauge. Press the sender into its mounting. The retaining spring must engage audibly.

Scheme 42

Scheme 43

1. Fit new seal in the opening of the 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.

2. Fit all connections (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, refer to 69 25 19 Removing and installing rear belt lock - as of MY 2003 (All Models) .

5. Fold rear seat down again.

6. Fill fuel tank (refuel). > Draining and filling fuel

1. Take up the vehicle at the jacking points provided using a platform lift. Refer to 40 V0 Lifting the vehicle - as of MY 2003 (Cayenne Turbo S, Cayenne S TIO Titan) . Refer to 40 V0 Lifting the vehicle - as of MY 2003 (Cayenne TIP, Cayenne MAN, Cayenne S TIP, Cayenne S MAN, Cayenne Turbo) .

2. Open filler flap.

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. Refer to 44 05 19 Removing and installing wheel - as of MY 2003 (All Models) .

Scheme 44

5. Remove right rear wheel housing liner. Refer to 53 69 19 Removing and installing rear wheel housing liners - as of MY 2003 (All Models) .

Scheme 45

Scheme 46

> 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.

> 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.

> In case of fire, use CO 2 or dry powder fire extinguishers.

Note. The ignition must be switched off when working on the fuel system. Absorb any escaping fuel using a suitable binding material or a cloth. Cloths which have absorbed fuel must be disposed of according to the applicable national laws. The fuel system must be depressurised before starting work on it. Only work on the fuel system in well-ventilated rooms. Any seals which have been removed must always be replaced.

> Make sure that the line runs below the valve.

Note. The repair procedure may vary depending on engine type and country equipment. This relates in particular to components in the right wheel housing. The description relates to ORVR vehicles.

The following exploded drawing shows the attachment of the tank filler neck and carbon canister in the right wheel housing.

Scheme 47

1 - Fastening screw, M6 x 28

2 - Fastening screw M6 x 20

3 - Fastening screw

4 - Fastening screw M6 x 28

5 - Fastening nut M6

6 - Carbon canister

7 - Degassing tank

Scheme 48

> Never leave carbon canister hanging freely on the lines.

> 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-. (Scheme 47)

Scheme 49

Note. 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. (Scheme 49)

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-. (Scheme 48)

Scheme 50

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.

Scheme 51

4. Remove hose connection on the degassing tank.

> 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 with a piece of wire -arrow- (figure shows degassing tank with carbon canister). (Scheme 51)

> 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.

> 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.

> In case of fire, use CO 2 or dry powder fire extinguishers.

Note. The ignition must be switched off when working on the fuel system. Absorb any escaping fuel using a suitable binding material or a cloth. Cloths which have absorbed fuel must be disposed of according to the applicable national laws. The fuel system must be depressurised before starting work on it. Only work on the fuel system in well-ventilated rooms. Any seals which have been removed must always be replaced.

Note. The repair procedure may vary depending on engine type and country equipment. This relates in particular to components in the right wheel housing. The description relates to ORVR vehicles.

The following exploded drawing shows the attachment of the tank filler neck and carbon canister in the right wheel housing.

1 - Fastening screw, M6 x 28

2 - Fastening screw M6 x 20

3 - Fastening screw

4 - Fastening screw M6 x 28

5 - Fastening nut M6

6 - Carbon canister

7 - Degassing tank

Installing carbon canister

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-. see scheme 87

4. Insert the hose on the degassing tank.

> Make sure that the line runs below the valve.

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. see scheme 89

Picture shows the correct position of the line. View from above without rear side panel.

Scheme 52

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-. --> Tightening torque: 7.5 ftlb. (Scheme 52)

1. Install the right rear wheel housing liner. Refer to 53 69 19 Removing and installing rear wheel housing liners - as of MY 2003 (All Models) .

2. Mount rear wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2003 (All Models) .

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.

5. Activate air suspension.

Information

Installation Location

Scheme 53

1 - Fuel pump, left

2 - Connection to fuel filter

3 - Fuel supply line connection

4 - Connection to fuel filter

5 - Fuel pump, right

6 - Fuel supply line connection

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

> 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.

> 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.

> In case of fire, use CO 2 or dry powder fire extinguishers.

Note. The ignition must be switched off when working on the fuel system. Absorb any escaping fuel using a suitable binding material or a cloth. Cloths which have absorbed fuel must be disposed of according to the applicable national laws. The fuel system must be depressurised before starting work on it. Only work on the fuel system in well-ventilated rooms. Any seals which have been removed must always be replaced.

1. Remove carbon canister and place it on a clean surface. > 202521 Removing carbon canister

Scheme 54

1 - Degassing tank

2 - Filler neck

3 - Pressure control valve

4 - Carbon canister

5 - Leakage diagnosis pump

Scheme 55

> Installation position of leakage diagnosis pump. (Scheme 54)

Scheme 56

1. Loosen three fastening screws on plastic support for pressure control valve. -Arrows-. (Scheme 55)

Scheme 57

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. (Scheme 56)

Scheme 58

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. (Scheme 57)

Scheme 59

3. Carefully lever the leakage diagnosis pump out of the bracket on the active carbon filter using a screwdriver. --> Levering out leakage diagnosis pump. (Scheme 58)

Scheme 60

4. Carefully lever the leakage diagnosis pump out of the rubber flange on the housing using a screwdriver. --> Rubber flange. (Scheme 59)

Scheme 61

5. Pull off the air hose. --> Pulling off air hose. (Scheme 60)

Scheme 62

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. (Scheme 61), (Scheme 62).

Scheme 63

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. (Scheme 63), see scheme 108.

Scheme 64

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.

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. (Scheme 64)

4. Fit air hose. --> Fitting air hose on leakage diagnosis pump. see scheme 111

5. Fit three fastening screws on the plastic support for the pressure control valve --> Tightening torque: 3 (2 ftlb.) Nm. -Arrows-. see scheme 112

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. see scheme 113

1. Install carbon canister. > 202523 Installing carbon canister

Designation Type Number Explanation key VW-tool T10202

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)

1. Empty the fuel tank. > Draining and filling fuel

Note. If the tank must be opened for emptying, disconnect all connections.

Installation Location

1. Open filler flap.

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

> 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.

> 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.

> In case of fire, use CO 2 or dry powder fire extinguishers.

Note. The ignition must be switched off when working on the fuel system. Absorb any escaping fuel using a suitable binding material or a cloth. Cloths which have absorbed fuel must be disposed of according to the applicable national laws. The fuel system must be depressurised before starting work on it. Only work on the fuel system in well-ventilated rooms. Any seals which have been removed must always be replaced.

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. see scheme 117

7. Open the relevant cap with the key T10202 and lift up the connection unit (cap).

Scheme 65

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. (Scheme 65)

Installing fuel filter

1. Fit new seal in the opening of the tank.

2. Connect filter unit. Mount the electric connector -1 and 2- and the hose connections -3 and 4-. see scheme 122

3. Place the connection unit into the tank. When doing so, make sure that the plastic lug is pointing forwards.

1. Close the tank. To do so, fit the sheetmetal ring and tighten using the key T10202 . --> Tightening torque: 104 ftlb.

2. Fit all connections (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, refer to 69 25 19 Removing and installing rear belt lock - as of MY 2003 (All Models) .

5. Fold rear seat down again.

6. Fill fuel tank (refuel). > Draining and filling fuel

1. Fill fuel tank (refuel). > Draining and filling fuel

Designation Type Number Explanation Porsche System Tester ll special tool 9588 Pressure gauge special tool P 378a Connection line special tool P 9559 measurement tool set special tool P 9684 Measuring adapter special tool P 9705 Connecting lead special tool P 9705/1

Special tools

1. The battery voltage must not be < 12 volts.
2. 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.
3. Fuel system parts must not get dirty.

Checking fuel delivery rate

1. Pull the cover of the throttle body up and off.

2. Unscrew cap on the front right of the fuel gallery.

> Secure the vehicle, e. g. with a warning sign.

> Wear protective gloves that are fuel-resistant.

> 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.

> Avoid contact with the skin and eyes.

Note. 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.

Scheme 66

Note. 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 P 9684 and use these to bridge the fuel pump. The exact assignment of the contacts can be obtained from Refer to 97 84 IN Fuse carrier - as of MY 2003 (All Models) .

Note. 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).

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.

> Only use the special, Porsche-approved valves in the fuel gallery.

> Do not replace scavenging valves by tire valves.

> It is essential that the plastic cap is also replaced.

9. Press the four rubber elements in the cover onto the four ball socket holders. The mounts must be felt to engage.

1. Open the bonnet.

2. Open lid of central electrics box. To do this, loosen the four fastening screws.

3. Remove fuses -3- for the ignition rod modules, -4- injection system and both fuel pump relays (left pump -1- and right pump -2- ). see scheme 133

4. Pull the design cover up and off.

5. Remove engine compartment cover at middle rear and left. Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .

Scheme 67

6. Loosen left cable guide of ignition coil cable at the plastic clips for the intake-air distributor --> Wiring for ignition rod modules and fold it up for better access to the fuel supply at the fuel distributor. see scheme 135

1. The battery voltage must not be < 12 volts.
2. Fuel system parts must not get dirty.

Checking quantity of fuel delivered

> 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.

> 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.

> In case of fire, use CO 2 or dry powder fire extinguishers.

Note. The ignition must be switched off when working on the fuel system. Absorb any escaping fuel using a suitable binding material or a cloth. Cloths which have absorbed fuel must be disposed of according to the applicable national laws. The fuel system must be depressurised before starting work on it. Only work on the fuel system in well-ventilated rooms. Any seals which have been removed must always be replaced.

Note. The fuel gallery is pressurised. Place a cloth under the areas of the fuel gallery to be opened so that fuel does not drip on to hot engine parts.

1. Twist off the cap of the fuel scavenging valve -1-. (Scheme 67)

Note. Proceed as follows to fit the adapter 1318/20 -2- to the scavenging valve: Turn the valve -4- anti-clockwise at the T-piece until the valve is closed. Place the adapter on the scavenging valve and use the knurled nut -3- to fit the adapter in a clockwise direction until the adapter is attached securely to the scavenging valve. To open the scavenging valve, turn the T-piece of the valve clockwise (the fuel is released immediately and flows out via the adapter 1318/20). If the T-piece touches the intake-air distributor when you turn it, shorten the cross-pin of the T-piece slightly so that it has sufficient clearance. The adapter 1318/20 includes a hose connection 1318/20-1 -1-, to which a suitable fuel hose can be fitted using a screw-type clamp. see scheme 138

Scheme 68

2. Relieve the fuel pressure. To do this, fit adapter 1318/20 -1- together with 1318/20-1 -2- and a suitable hose to the scavenging valve and relieve the fuel pressure into a cloth (screw T-piece on clockwise) --> Relieving the fuel pressure. Only a small quantity flows out. Close the T-piece on the adapter again (unscrew T-piece anti-clockwise). see scheme 139

Scheme 69

3. Pull fuel supply hose off the fuel gallery. To do this, place a cloth underneath, loosen the clamp and pull off the fuel supply hose --> Fuel supply. Catch any dripping fuel. see scheme 140

Scheme 70

Note. Make sure that the switch on the adapter P 9479 is at 0 so that fuel is not pumped immediately when you connect the adapter.

4. Hold fuel supply hose into measuring cup -2 and 3- and insert adapter P 9479 into the relay slot of the fuel pump relay for the left pump -1-. (For details of relay assignment, see -->Checking quantity delivered by fuel pump " Preliminary work " ). (Scheme 68)

Note. To avoid incorrect readings, ensure that the hoses are already filled with fuel when you start the test.

5. Switch fuel pump on using the adapter P 9479 until fuel emerges at the end of the hose. Then empty the measuring cup. This removes the remaining air from the hose.

Note. Get a second person to record the time for checking the quantity of fuel delivered.

6. Start the fuel supply in order to measure it. The left pump should supply at least 800 ml of fuel after around 15 seconds. The quantity of fuel delivered for both pumps should be at least 800 ml after around 10 seconds (insert adapter P 9479 into both relay slots at the same time and switch it on for this). Empty the measuring cup between measurements.

7. If the specified fuel quantities are not delivered, check the fuel lines for kinks and bends and check the fuel filter and power consumption of the pumps.

8. Fit the fuel supply hose after you have measured the fuel quantity. To do this, push the fuel supply hose on to the connection piece and fit a clamp --> Fuel supply. (Scheme 69)

9. Remove adapter 1318/20 and hose. To do this, turn the knurled nut anti-clockwise until the adapter comes off the scavenging valve.

1. Attach left cable guide for ignition coil cable to the plastic clips for the intake-air distributor --> Wiring for ignition rod modules. see scheme 144

2. Insert fuses -3- for the ignition rod modules, -4- injection system and both fuel pump relays (left pump -1- and right pump -2- ). see scheme 145

3. Fit lid of central electrics box. To do this, fit the four fastening screws.

4. Install engine compartment cover at middle rear and left. Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .

5. Fit the design cover.

Designation Type Number Explanation key VW-tool T10202

1. Empty the fuel tank. > Draining and filling fuel

General note

Note. The fuel pumps have different hose connections and must not be confused. The connections should be marked for identification when removing. 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

2 - Connection to fuel filter

3 - Fuel supply line connection

4 - Connection to fuel filter

5 - Fuel pump, right

6 - Fuel supply line connection

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

Note. If the tank must be opened for emptying, disconnect all connections.

Installation Location

1. Open filler flap.

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

> 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.

> 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.

> In case of fire, use CO 2 or dry powder fire extinguishers.

Note. The ignition must be switched off when working on the fuel system. Absorb any escaping fuel using a suitable binding material or a cloth. Cloths which have absorbed fuel must be disposed of according to the applicable national laws. The fuel system must be depressurised before starting work on it. Only work on the fuel system in well-ventilated rooms. Any seals which have been removed must always be replaced.

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. see scheme 151

7. Open the relevant cap with the key T10202 and lift up the connection unit (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). see scheme 153

Scheme 71

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).

Scheme 72

4. Turn the pump approx. 90° to the left until it disengages at the tank floor. Remove the pump from the tank.

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.

4. Turn the pump approx. 90° to the left until it disengages at the tank floor. Remove the pump from the tank.

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.

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.

2. Connect the fuel line from the right pump to the Y-piece.

3. Attach the sucking jet pump connection. This must engage audibly.

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.

6. Place the connection unit into the tank. When doing so, make sure that the plastic lug is pointing forwards.

1. Close the tank. To do so, fit the sheetmetal ring and tighten using the key T10202 . --> Tightening torque: 104 ftlb.

2. Fit all connections (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, refer to 69 25 19 Removing and installing rear belt lock - as of MY 2003 (All Models) .

5. Fold rear seat down again.

6. Fill fuel tank (refuel). > Draining and filling fuel

1. Fill fuel tank (refuel). > Draining and filling fuel

Poses Online

See also:
• 10 01 AW THE MOST IMPORTANT WORKING REGULATIONS AND WARNING NOTES - AS OF MY 2003 (ALL MODELS EXCEPT CAYENNE S TIO TITAN)
• 69 25 19 Removing and installing rear belt lock - as of MY 2003 (All Models)
• 42 05 19 Removing and installing rear axle housing - as of MY 2003 (All Models)
• 51 93 19 Removing and installing middle cover - as of MY 2003 (All Models)
• 40 V0 Lifting the vehicle - as of MY 2003 (Cayenne Turbo S, Cayenne S TIO Titan)
• 44 05 19 Removing and installing wheel - as of MY 2003 (All Models)
• 53 69 19 Removing and installing rear wheel housing liners - as of MY 2003 (All Models)
• 97 84 IN Fuse carrier - as of MY 2003 (All Models)
• 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models)
• Porsche System Tester ll 9588