Maintenance, Self Diagnostics Porsche Cayenne S I

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

Visual inspection of all rubber mountings for damage.

Functional Check

Note. The following requirements must be met when fitting the seat belt If one of the requirements listed below is not met, the seat belt or 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.

If it displays evidence of damage in the form of cuts, fraying, seam tears etc., the seat belt must be replaced.

Lifting the vehicle

> 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 center 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.

> Lift the vehicle only at the approved take-up points.

Note. For Cayenne vehicles with air suspension/level control, the following work must also be performed before raising the vehicle: Adjusting car to normal level Switching off level control Switch on level control

After ending the repair or maintenance work, perform the steps for the following activity

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.

Scheme 1

Position the vehicle.

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 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.

Switch on ignition.

Push --> time value: 5 s +5 s forwards.

Power steering: Checking fluid level

> 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. Refer to 48 IN TEST AND ASSEMBLY WORK ON POWER STEERING - AS OF MY 2003 (ALL MODELS EXCEPT CAYENNE S TIO TITAN) .

Scheme 2

The reservoir is located in the engine compartment, front left under the engine compartment cover -arrow-. (Scheme 2)

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.

Scheme 3

A dipstick with a MIN/MAX marking is mounted on the closure cap of the expansion tank. The marks are for a fluid level with a cold engine (approx. 20 °C)!

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 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.

Checking bellows on steering gear

Note. The bellows on the steering gear can be damaged by outside influences, for example by stone damage or during assembly work. The steering gear can start to leak if dirt or moisture enters a leaky bellows.

Visually inspect the bellows for damage.

Tie rod joints: checking play and dust boots

1. Lift vehicle --> 40 V0 LIFTING THE VEHICLE - AS OF MY 2003 (CAYENNE TURBO S, CAYENNE S TIO TITAN) or 40 V0 LIFTING THE VEHICLE - AS OF MY 2003 (CAYENNE TIP, CAYENNE MAN, CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO) .

Note. 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. 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 play and dust boots

1. Check play.

2. Visually inspect the dust boots for damage.

Note. When doing so, the rubber dust boots should be pressed down with the fingers to reveal hidden cracks. 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

1. Place the vehicle on a lifting platform with the steering lock disengaged.
2. Perform a visual inspection after cleaning.

Note. Over a small area in the vicinity of the brake cover panels, no visual inspection is possible. Check this area by touch.

The procedure for the front axle is as follows

1. Turn the front wheels as far as they will go
2. Perform a visual inspection of the visible surfaces on the left and right
3. After turning the front wheels to the other steering stop, check the other half of each rubber dust boot.

Drive shafts: visual inspection of boots

Perform a visual inspection of the boots for leaks and damage.

Checking condition

Tires are a safety element that fulfil the demands placed on them only if they have the correct air pressure and a sufficient tread depth.

> 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 Tires (for cracks, pricks, bulges in the sidewall and/or foreign bodies) must be carried out.

Scheme 4

Note. For vehicles with a Tire pressure monitoring system, which can be identified by aluminum valves, the Tire pressure should be adjusted according to the filling information in the multi-function display. To do this, in the >> Main menu >> Tire pressure >> -Settings- << adjust the deviation values so that they are from 0.0 bar to +0.1 bar. Fill the Tires according to the display using the Tire-inflating device. Example: If the Tire-pressure display shows >> Settings << - 0.2 bar, then 0.2 bar must be added. (Scheme 4) Due to the pressure and temperature relationship (0.1 bar/10° C), the actual pressures displayed in the -Basic Tire pressure screen- in the multifunction display, or on the pressure gauge of the Tire-inflating device, may deviate from the required pressure specification at 20° C on the Tire pressure plate. This is particularly the case if the Tire air temperature is significantly above (higher values) or significantly below (lower values) 20° C. Changes in the Tire pressure are displayed for up to 1 minute in the >> Settings <<. (Scheme 5) For vehicles with the Tire pressure monitoring system, always use plastic valve caps. They protect the valve from dust, dirt, and moisture and therefore from damage (corrosion, etc.).

Scheme 5

1. Check condition and Tire 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 Tire pressures (at approx. 20° C)

Tire pressures apply to all-season, all-terrain, summer and winter Tires. They also apply only to Tires approved by Porsche.

Partial load: The Tire 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: Tire sealant)

The spare wheel on the carrier is inflated to 3.4 bar gauge pressure max. During operation, Tires are to be adjusted to the gauge pressure specified for the particular vehicle axle and load condition.

Tire pressure - vehicle partially loaded

Values in bar gauge

Tire pressure - vehicle fully loaded

Values in bar gauge

Scheme 6

Note. The brake fluid level must not exceed the MAX mark. Observe brake fluid quality. Use only new DOT 4 brake fluid. This brake fluid is available under the following part numbers: container quantity 1 litre = 000.043.203.66; container quantity 30 litres = 000.043.203.67.

Scheme 7

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-. (Scheme 7)

Changing the brake fluid

Note. Observe brake fluid quality. Use only new DOT 4 brake fluid. The brake fluid change interval is two years using Super DOT 4 brake fluid. 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. Drain brake fluid from every brake caliper at both bleeder valves. Bleed the outer bleeder valve first.

Scheme 8

1. Open threaded cover of brake fluid reservoir -arrow-. (Scheme 8)

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 cm 3 ).

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. Refer to 47 TW TIGHTENING TORQUES FOR BRAKE HYDRAULICS - AS OF MY 2003 (ALL MODELS EXCEPT CAYENNE S TIO TITAN) .

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.

Tools

Designation Type Number Explanation piston resetting fixture (replaces P83) commercially available tool NR.144

Scheme 9

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.

1. Lift vehicle --> 40 V0 LIFTING THE VEHICLE - AS OF MY 2003 (CAYENNE TURBO S, CAYENNE S TIO TITAN) or 40 V0 LIFTING THE VEHICLE - AS OF MY 2003 (CAYENNE TIP, CAYENNE MAN, CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO) .

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

Scheme 10

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-! (Scheme 9)

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

Scheme 11

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). (Scheme 10)

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

Brake hoses and lines

Carry out visual inspection for leaks, damage, routing and corrosion.

Brake system: visual inspection of brake pads and brake discs for wear

> 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. If brake pad wear is indicated by the warning light, the warning contact (sender including line and plug connection) must also be replaced. Replacement of the warning contact can be avoided by replacing the brake pads no later than when the pad thickness is approx. 2.5 mm -arrows-. (Scheme 11) Warning contacts must be replaced if the core of the line is worn. However, if only the plastic part of the warning contact is worn, there is no need to replace it.

Scheme 12

1. To check the brake pads, remove the wheels.

2. Visually inspect the brake pads for wear. Refer to > Running gear maintenance: visual inspection - brake lines/brake pads/brake discs [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1] .

3. Carry out visual inspection of the brake discs for wear. Refer to > Running gear maintenance: visual inspection - brake lines/brake pads/brake discs [9PAAD1 9PAAD7 9PAAE1 9PAAE7 9PAAF1] .

Technical data, wear limits

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.

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 Tire, 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 Tire. The battery for the wheel electronics cannot be replaced separately.

Scheme 13

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 <<. (Scheme 12)

Scheme 14

2. If necessary, replace the -wheel electronics A-. Refer to 44 32 19 Removing and installing wheel electronics - as of MY 2003 (All Models). (Scheme 13)

Designation Type Number Explanation flexible screwdriver special tool P 9703

Scheme 15

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

1. Main headlights
2. Fog lights
3. Side direction indicator light
4. Tail light
5. Number plate light
6. Additional brake light

Scheme 16

1- - Bulb for direction indicator light PY 21 W, 12 V (yellow bulb). (Scheme 14)

2- - Bulb for auxiliary high beam headlight. H7 (12 V, 55 W). (Scheme 14)

3- - Bulb for cornering light. H3 (12 V, 55 W). (Scheme 14)

4- - Installing bulb for parking light H6W (12V, 6W). (Scheme 14)

5- - 5 Xenon gas discharge lamp for dipped beam and high beam. D1S (12 V, 35 W). (Scheme 14)

Scheme 17

A- - Brake light. P 21 W. (Scheme 15)

B- - Direction indicator. P 21 W. (Scheme 15)

C- - Reverse light. P 21 W. (Scheme 15)

D- - Rear fog light and tail light. P 21/4 W. (Scheme 15)

E- - Tail light P 21/5 W. (Scheme 15)

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 headlights

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 P 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 ; Tire pressures must correspond to specified values).

Scheme 18

1. Press down cover -1- in engine compartment and remove it. (Scheme 16)

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. The distance between the headlights and the adjustment unit should be as small as possible! 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!

Scheme 19

The vertical/side adjustment of the dipped beam/high beam highlight is made first: adjustment -A- and -B-. (Scheme 17)

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.

Scheme 20

5. The dipped beam headlight is then adjusted horizontally: adjustment -A- and -B-. (Scheme 18)

Scheme 21

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.

Scheme 22

6. Check auxiliary high beam headlight and, if necessary, adjust the side setting using -A- and -B-. (Scheme 20)

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.

Checking headlight washer

> 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. The headlight washer nozzles are pre-set! Generally, it is not necessary to adjust them!

Check function, fluid levels and nozzle settings.

Adjusting spray nozzles

Note. The angle of the spray nozzle can be adjusted by hand. The recommended spraying range is in the central position. 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.

Scheme 23

arrow- Spray nozzle adjustment. (Scheme 21)

Mix ratio of fluids for windscreen washer system

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.

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.

Scheme 24

2. Release the covers -arrows A- and remove rear seat rail cover caps -arrows B-. (Scheme 22)

3. Move front left seat back and up as far as possible. Move backrest fully forward.

Scheme 25

4. Unclip the front seat trim forwards -A-. (Scheme 23)

5. Fold the carpet sections forward and unscrew both fastening screws -1-. (Scheme 23)

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.

Scheme 26

7. Open the four tension hooks on the battery case cover using a screwdriver.

8. Remove the battery case cover with ventilation channel.

Scheme 27

Note. The maintenance-free battery has an inspection glass. The charge state and acid level of the battery can be checked through the inspection glass -B-. (Scheme 26) If a battery is more than 5 years old and the indicator of the inspection glass is colorless, replace the battery. 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 color indications are possible

Check low-maintenance battery

> 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. Use a commercially available battery filling bottle. The correct acid level of the battery is an important factor for a long service life of the battery. 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. 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. Make sure the vent hose -A- is not kinked or damaged. If in doubt, replace it. (Scheme 27) Vent hose -A- must be inserted in the battery and in the battery box. (Scheme 27)

Checking battery vent hose under the driver's seat

1. Replace the battery box cover carefully. The ventilation channel must be mounted properly.

Scheme 28

2. Attach the four tension hooks in the battery case cover and close using the screwdriver.

> 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.

Scheme 29

4. Screw in fastening screws -1- and put back the carpet sections. --> Tightening torque: 33 ftlb. see scheme 30

5. Clip in front seat trim -C-. see scheme 30

Scheme 30

6. Push rear cover caps onto seat rails -arrows A- and press down the covers -arrows B- until these engage audibly. (Scheme 28)

Checking battery vent hose of the auxiliary battery

Note. The battery is located in the luggage compartment under the loadspace floor. If the vehicle contains a subwoofer or collapsible spare wheel, the relevant component must be removed before the auxiliary battery is removed.

Scheme 31

1. Remove collapsible spare wheel

1.1. Remove twist grip -A- and position it on the bolt -B-. (Scheme 29)

1.2. Unscrew the bolt and remove it together with the collapsible spare wheel.

Scheme 32

2. Removing subwoofer fastening

2.1. Remove Tire sealant -1- if it is present. (Scheme 30)

2.2. Unscrew both fastening screws -2-. (Scheme 30)

2.3. Unscrew the fastening screw -3-. (Scheme 30)

Scheme 33

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.

Scheme 34

4. Remove battery case cover

4.1. Unscrew the four fastening nuts -A-. (Scheme 32)

4.2. Unclip the four fastening clips -B- with a screwdriver. (Scheme 32)

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. (Scheme 32)

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. (Scheme 32)

Scheme 35

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.

Scheme 36

7. Fastening subwoofer

Note. 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. (Scheme 34)

7.3. Position both tightening nuts -2- and tighten them. --> tightening torque: 1.5 ftlb. (Scheme 34)

7.4. If present, place Tire sealant -1- in tray. (Scheme 34)

Scheme 37

8. Install collapsible spare wheel

Note. If the vehicle contains a subwoofer or collapsible spare wheel the relevant component must be re-installed.

8.1.

8.2. Insert collapsible spare wheel.

8.3. Screw in screw B -B-. (Scheme 35)

8.4. Position twist grip -A- and tighten fastening screw -B- hand tight. (Scheme 35)

Scheme 38

Note. To perform this check, a trailer with no faults in the wiring and lights, or a trailer test cable VAS 1537 A is required. Please note that, if a VAS 1537 A trailer test cable is used, only vehicles with a 13-pin plug can be checked. The test cable can be 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.

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.

Scheme 39

Test procedure

Note. The LED for permanent positive -9- is lit for the entire duration of the test. (Scheme 38)

Scheme 40

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 (Scheme 39) -4- and the direction indicator in the instrument cluster should not now light up. (Scheme 39)

2. Actuate brake pedal - LEDs -6- should light up. (Scheme 39)

3. Switch on parking light - LEDs -5, 7- should light up. (Scheme 39)

4. Switch on parking light and rear fog light. Switch on parking light - LEDs -5, 7- should light up. (Scheme 39)

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 (Scheme 39)

11- Ground for charge positive (Scheme 39)

12- Trailer detection (Scheme 39)

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. (Scheme 39)

Checking electrically retractable trailer hitch

Note. The swivel action of the ball hitch is interrupted in the one-touch function of the rocker switch if resistance interferes with the movement sequence. The interruption is indicated by the rapid flashing of the red LED in the rocker switch. Overload protection is switched off by pressing the rocker switch for at least two seconds.

> 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. The vehicle must be stationary. Rear lid or rear window must be open. Trailer must be unhitched. Connectors (and any adapters) must be removed from the socket. There must not be any accessories on the hitch ball (e. g. ball protection cap, bicycle rack, etc.).

Scheme 41

1. Swivelling out the trailer coupling

1.1. Requirements

Note. The vehicle must be stationary. Rear lid or rear window must be open.

1.2.

1.3. To swivel out

1.4. Touch rocker switch -A-. (Scheme 40)

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.

Scheme 42

2. Retracting the trailer hitch

2.1. Requirements

Note. The vehicle must be stationary. Rear lid or rear window must be open. Trailer must be unhitched. Connectors (and any adapters) must be removed from the socket. 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-. see scheme 44

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.

Test drive - maintenance

Note. 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.

Maintenance every 2 years

Note. 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.

Maintenance every 4 years

Note. 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.

Maintenance after 4 then every 2 years

Note. 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.

Maintenance after 10 then every 2 years

Note. 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.

Oil change service after 15,000 km/10,000 mls or 1 year

Note. Following fixed service interval display. Applies only for 6-cylinder models. An oil change service must be carried out at the latest after 15,000 km/10,000 mls or 1 year.

Oil change service after 30,000 km/20,000 mls or 2 years

Note. Following flexible service interval display. Applies only for 6-cylinder models. An oil change service must be carried out at the latest after 30,000 km/20,000 mls or 2 years.

03 Cardan shaft maintenance - as of MY 2004 (Cayenne TIP, Cayenne MAN, Cayenne S TIP, Cayenne S MAN, Cayenne Turbo)

Note. The air bellows of the cardan shafts may be damaged by external influences e. g. during off-road use or similar operation. Consequence: loss of a large amount of grease, ingress of dirt into the universal joint. 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. Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

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. Refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models) .

Visual inspection of center bearing (rear cardan shaft)

1. Inspect air bellows of center bearing for damage. To do this, rotate the cardan shaft in steps through 180°.

Scheme 43

The Porsche System Tester is connected to the vehicle via a 16-pin 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-. (Scheme 41)

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

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.

Information

Note. The inspection must be carried out every 60,000 km (40,000 miles) in the first 10 years. After the first 10 years, the inspection must be carried out every 2 years, regardless of the mileage.

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.

Note. 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.

Scheme 44

2. Function test of airbag warning light in center console

> 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.

> 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 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. When you perform the drive link test: The cutoff relay is activated. The cutoff relay must be activated again. To activate the cutoff relay: Press on the colored area of cutoff relay (located in power distributor). The engine is switched off. The hazard warning lights are activated. 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.

>

1.13.

Scheme 45

2. Simulate the fault

2.1. Simulate the fault using the side airbag, for example. Move seat all the way forward.

Note. 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-. (Scheme 43)

2.4. Connect the battery and switch on ignition.

2.5. Read out fault memory. Static fault present.

Scheme 46

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. (Scheme 44)

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. Fault memory shows a sporadic fault.

4.2.

4.3. Erase fault memory.

Carry out work instruction after disconnecting the battery. --> 90 IN WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY - AS OF MY 2003 (ALL MODELS EXCEPT CAYENNE S TIO TITAN) .

Additional maintenance, replacing spark plugs

Note. 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.

Additional maintenance every 120,000 km/80,000 mls or every 4 years

Note. 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.

Additional maintenance every 240,000 km/160,000 miles or every 16 years

Note. 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.

Minor maintenance

Note. 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. If the mileage for scheduled maintenance is not reached, minor maintenance must be carried out after 2, 6, 10...... years. 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. The maintenance item > Replacing spark plugs < depends on the engine type. Please refer to the "Additional maintenance" chapter. Refer to 28 70 55 Replacing spark plugs - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

Note. 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. If the mileage for scheduled maintenance is not reached, minor maintenance must be carried out after 2, 6, 10...... years. 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. The maintenance item > Replacing spark plugs < depends on the engine type. Please refer to the "Additional maintenance" chapter. Refer to 28 70 55 Replacing spark plugs - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) . Refer to 28 70 55 Replacing spark plugs - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

Major maintenance

Note. 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. If the mileage for scheduled maintenance is not reached, major maintenance must be carried out after 4, 8, 12...... years. 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. The maintenance item > Replacing spark plugs < depends on the engine type. Please refer to the "Additional maintenance" chapter. Refer to 28 70 55 Replacing spark plugs - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

Note. 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. If the mileage for scheduled maintenance is not reached, major maintenance must be carried out after 4, 8, 12...... years. 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. The maintenance item > Replacing spark plugs < depends on the engine type. Please refer to the "Additional maintenance" chapter. Refer to 28 70 55 Replacing spark plugs - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) . Refer to 28 70 55 Replacing spark plugs - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

Poses Online

See also:
• 48 IN TEST AND ASSEMBLY WORK ON POWER STEERING - AS OF MY 2003 (ALL MODELS EXCEPT CAYENNE S TIO TITAN)
• 40 V0 LIFTING THE VEHICLE - AS OF MY 2003 (CAYENNE TURBO S, CAYENNE S TIO TITAN)
• 47 TW TIGHTENING TORQUES FOR BRAKE HYDRAULICS - AS OF MY 2003 (ALL MODELS EXCEPT CAYENNE S TIO TITAN)
• 44 05 19 Removing and installing wheel - as of MY 2003 (All Models)
• 17 01 17 Engine oil and oil filter change - as of MY 2004 (Cayenne TIP, Cayenne MAN)
• 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models)
• 69 AW SAFETY REGULATIONS FOR HANDLING AIRBAGS AND... - AS OF MY 2003 (ALL MODELS)
• 90 IN WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY - AS OF MY 2003 (ALL MODELS EXCEPT CAYENNE S TIO TITAN)
• 28 70 55 Replacing spark plugs - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan)
• 24 24 55 Replacing air-cleaner element - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne S TIO Titan)
• 39 90 55 Changing oil for transfer box - as of MY 2003 (All Models)
• 37 02 55 Changing ATF - as of MY 2003 (Cayenne Turbo, Cayenne Turbo S)
• 13 78 01 Checking drive belt - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan)
• 19 01 01 Checking cooling system - as of MY 2003 (All Models)
• 60 06 AN Teaching control unit of Panorama roof system - as of MY 2004 (All Models)
• 85 15 19 Removing and installing heater/air-conditioning unit - as of MY 2003 (All Models)
• piston resetting fixture (replaces P83) NR.144
• > Cardan shaft maintenance