Generators & Regulators: Removal & Installation Porsche Cayenne I

REMOVAL & INSTALLATION

Scheme 1

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Scheme 4

1. Turn ignition off. Disconnect negative battery cable. See «SERVICE PRECAUTIONS»(ref-165253-S33631525892004082300000) under TROUBLE SHOOTING.
2. Remove upper engine cover. Remove fasteners and remove left side engine cover.
3. Disconnect air flow meter harness connector. Release air cleaner cover housing and pull upwards. Loosen air intake hose clamp at throttle body, disconnect hose and push to right side.
4. Disconnect vent hose and remove air cleaner housing with intake hose.
5. Release serpentine belt tension by screwing a 8x50 mm bolt into threaded hole on belt tensioner. (Scheme 2) Remove belt from tensioning roller. Remove belt tensioner mounting bolts and remove tensioner.
6. Press and release connector (A) and pull of in direction of arrow (B). (Scheme 3) Remove protective cap (C). Remove B+ connector nut (2) and remove B+ cable.
7. Remove generator mounting bolts (3). (Scheme 4) Lever generator out of bracket.
8. Clamp generator coolant hoses "A" and "B" with appropriate hose clamps. (Scheme 5) Remove coolant hose connection fastener (4) from generator, and pull hoses away from generator. Remove generator in an upwards direction, carefully pushing upper coolant hose aside.
9. Before installing generator push threaded bushing towards rear of generator about.157" (4 mm). (Scheme 6) To install generator, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-165253-S17894539272004082300000).
10. Check and replace coolant hose connection seal as necessary. Fill and bleed cooling system. See «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-164288) article under COOLING SYSTEM MECHANICAL in ENGINES. Start vehicle and check belt running and generator operation.

Scheme 5

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Scheme 7

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Scheme 9

Scheme 10

1. Turn ignition off. Disconnect negative battery cable. See «SERVICE PRECAUTIONS»(ref-165253-S33631525892004082300000) under TROUBLE SHOOTING.
2. Raise and support vehicle. Remove right wheel. Remove right wheel housing liner. (Scheme 7)
3. Remove under body engine seal. Drain coolant. See «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-164288) article under COOLING SYSTEM MECHANICAL in ENGINES.
4. Remove air cleaner box, and related pipe and hoses.
5. Detach and move lock mount into service position. See «LOCK MOUNT»(ref-165253-S14273289562004082400000).
6. Remove 3 impact bracket bolts (8), and remove impact bracket. (Scheme 8)
7. Using a 30 mm open end wrench on serpentine belt tensioner, turn tensioner clockwise to release tension and remove belt from tensioning roller. (Scheme 9) After removing belt, release belt tensioner slowly.
8. Remove ground lead fastening screw, and remove ground lead. (Scheme 10)
9. Clamp generator coolant hoses "A" and "B" with appropriate hose clamps. (Scheme 11) Remove coolant connection fasteners from generator, and pull away from generator.
10. Remove generator mounting bolts (1,2). (Scheme 13) While supporting generator with hand, pull generator towards front of vehicle.
11. Remove the protective cap for generator harness connector. If necessary carefully cut cover with a knife. Press and release connector (B) and pull of in direction of arrow (C). (Scheme 14)
12. Remove B+ connector nut, and remove B+ lead. Remove generator through opening in wheelwell.
13. Installation is reverse of removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-165253-S17894539272004082300000). Fill and bleed cooling system. See «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-164288) under COOLING SYSTEM MECHANICAL article in ENGINES. Start vehicle and check belt running and generator operation.

Scheme 11

Scheme 12

Scheme 13

Scheme 14

1. Turn ignition off. Disconnect negative battery cable. See «SERVICE PRECAUTIONS»(ref-165253-S33631525892004082300000) under TROUBLE SHOOTING.
2. Raise and support vehicle. Remove right wheel. Remove right wheel housing liner. (Scheme 7)
3. Remove under body engine seal. Drain coolant. See «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-164288) under COOLING SYSTEM MECHANICAL article in ENGINES.
4. Remove air cleaner box, along with related pipes and hoses.
5. Detach and move lock mount into service position. See «LOCK MOUNT»(ref-165253-S14273289562004082400000).
6. Remove 3 impact bracket bolts (8), and remove impact bracket. (Scheme 8)
7. Using a 30 mm open end wrench on serpentine belt tensioner, turn tensioner clockwise to release tension and remove belt from tensioning roller. (Scheme 9) After removing belt, release belt tensioner slowly.
8. Remove ground lead fastening screw, and remove ground lead. (Scheme 10)
9. Unclip oil pressure switch and oil level sensor harness using release lever (A). (Scheme 15) Unclip pressure pipe (B). Press release plug and disconnect oil pressure switch harness connector (C).
10. Remove generator lead fastening screw (2). see scheme 17
11. Clamp generator coolant hoses "A" and "B" with appropriate hose clamps. (Scheme 11) Remove coolant connection fasteners from generator, and pull away from generator.
12. Remove generator mounting bolts (5,6). see scheme 18 While supporting generator with hand, pull generator towards front of vehicle.
13. Remove the protective cap for generator harness connector. If necessary carefully cut cover with a knife. Press and release plug (B) and pull of in direction of arrow (C). see scheme 19
14. Remove B+ connector nut, and remove B+ lead. Remove generator through opening in wheelwell.
15. Installation is reverse of removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-165253-S17894539272004082300000). Fill and bleed cooling system. See «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-164288) under COOLING SYSTEM MECHANICAL article in ENGINES. Start vehicle and check belt running and generator operation.

Scheme 15

1. Release front wheel housing liner fastening screws (8 and 9) from spoiler, inset circles Nos. 1 and 2. see scheme 20
2. Lifting up at lower corner of wheel housing liner (8) remove screws (4 and 6), inset circle No. 2. see scheme 20
3. Remove lower screws from front spoiler (7), inset circle No. 3. see scheme 20
4. Remove upper screws from front spoiler (5), inset circle No. 4. see scheme 20
5. With assistance from a helper, pull spoiler (1) forward and support. Remove left and right turn signal bulb holders (13) from direction indicator (13), inset circle No. 5. see scheme 20
6. Remove headlight cleaning system hose connection. Remove front spoiler.
7. Remove left and right side guide rail mounting nuts (14), inset circle No. 6. see scheme 20 Remove left and right side guide rails. Before installing, check expander nuts (2) replacing as necessary.
8. To install front spoiler, reverse removal procedure. When tightening front spoiler mounting bolts match existing marks on frame rails. Tighten lock mount bolts to specification. See «TORQUE SPECIFICATIONS»(ref-165253-S17894539272004082300000).