Cooling: Maintenance Porsche Cayenne I

Draining coolant

> Swallowing coolant additives and cleaning liquids must be urgently avoided.

> Do not consume any food or drink while working (danger of accidental mixing).

> If swallowed, observe the warning information on the containers and contact a doctor. If necessary, show the doctor the warning information on the packaging.

> Never open the cooling system when it is hot. Emerging coolant may be very hot and can cause scalding.

> The cooling system must be depressurized before being opened.

> Allow engine to cool down.

> The power supply to the fans must be disconnected before starting work on the radiator, radiator fans, or the belt drive. Refer to 97 84 IN Fuse carrier - as of MY 2003 (All Models) or battery. Refer to 90 IN Work instructions after disconnecting the battery - as of MY 2003 (All Models Except Cayenne S TIO Titan) .

> Do not relieve the system pressure of the cooling system and then run the engine.

> Relieving the system pressure and subsequently starting the engine can cause severe damage to components in the cooling system. If the cooling system must be opened when it is hot, allow the cooling system to cool down before starting the engine again.

Note. The coolant filled in at the factory is intended to suffice for the entire service life. As long as the coolant is not contaminated by foreign bodies or other fluids it need not be changed. Different coolant additives must not be mixed and doing so may damage the cooling system. Only use original Porsche coolant additives. The coolant must be set to antifreeze protection of -37 °C. This corresponds to a mixing ratio of 50 : 50 (coolant additive : water). This mixing ratio provides optimum corrosion and antifreeze protection. Coolant additives, coolants and cleaning agents must be disposed of according to the respective, applicable national laws. Seals in the cooling system must be replaced by new ones following disassembly.

1. Open maintenance cover.

2. Carefully open the cap on the coolant reservoir. Unscrew the cap in an anti-clockwise direction.

3. Open cap on the reservoir and remove.

Scheme 10

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

Scheme 11

5. Release the front apron on the underside.

Scheme 12

6. Remove the support plate under the radiator. To do this, loosen the 4 fastening screws.

7. Drain cooling system. If present, remove the drain plug from the radiator, otherwise open the lowest coolant hose on the radiator, and drain the coolant into a container and dispose of it according to the applicable national laws if no longer required.

8. Fit a new drain plug on the radiator and tighten it. If removed, fasten coolant hose.

9. Install the support plate under the radiator. Tighten the four fastening screws. --> Tightening torque: 17 ftlb.

1. Screw the cap adapter for the coolant reservoir (K 60) onto the reservoir.

2. Connect the flexible extension (Fz 100) to the cap.

3. Connect the vacuum pressure gauge of the bleeder tool to the flexible extension. When doing so, ensure that both shut-off valves are closed (positioned at 90° to flow direction).

Scheme 13

4. Connect the Venturi nozzle to the vacuum pressure gauge.

Note. The coolant amount provided must be approx. 2 liters more than the amount which has to be filled. Refer to 10 01 IN Tightening torques for Cayenne S (M48/00) and Cayenne Turbo (M48/50) - as of MY 2003 (Cayenne S TIP, Cayenne S MAN) . Refer to 10 01 IN Tightening torques for Cayenne S (M48/00) and Cayenne Turbo (M48/50) - as of MY 2003 (Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) . Refer to 10 01 IN Technical data for BFD engine (Cayenne) - as of MY 2004 (Cayenne TIP, Cayenne MAN) . Because differing quantities of coolant can drain away for different types of repairs, the filling capacities can vary greatly. Recommendation: To be on the safe side, fill the canister to 30 l, then bleed the cooling system. The difference after bleeding is the suctioned-in coolant quantity. Observe volume scale on the canister. An antifreeze content of -35°C corresponds to a mixture of 50:50 (antifreeze: water).

5. Place a canister with a sufficient amount of coolant and with an antifreeze content of -35°C beside the vehicle near the reservoir.

Note. The bleeding process is completed more quickly if the canister is positioned at roughly the same height as the coolant expansion tank.

6. Push the filler hose -5- of the vacuum pressure gauge onto the canister connection. Lay the return line -6- from the Venturi nozzle to a second container (bucket). see scheme 49

Scheme 14

Note. A hissing sound after connecting the compressed air supply is usual.

7. Connect the compressed air supply.

Scheme 15

8. Open both shut-off valves on the vacuum pressure gauge until the transparent filler hose -5- has completely filled with coolant. see scheme 49

Scheme 16

9. Close the left shut-off valve (V1) on the vacuum pressure gauge and allow a vacuum to build up in the cooling system.

Scheme 17

Note. If no vacuum is generated (the pointer does not move to the green area), there is a leak in the cooling system. Deformation of the rubber hoses of the cooling system is normal. When the pressure gauge pointer is in the green area of the display scale, a sufficient vacuum has been built up. After both shutoff valves on the vacuum pressure gauge have been closed and the compressed air supply has been disconnected, the vacuum must not drop. If the vacuum drops within approx. 30 seconds, there is a leak in the coolant circuit.

10. When there is a sufficient vacuum in the cooling system (indicator is in the green area), close the right shut-off valve (V2) and then disconnect the compressed air supply.

11. Re-open the left shut-off valve (V1) on the vacuum pressure gauge. The cooling system is then filled.

12. When there is no trace of vacuum present or the coolant is no longer drawn from the canister, open the right shut-off valve (V2).

13. Then remove the complete filling tool (including the cap K 60).

14. If necessary, fill the coolant reservoir with coolant to the maximum marking.

Note. If necessary, the system can be checked for leaks. > 190101 Checking cooling system - chapter on "Checking"

15. Screw on the cover of the reservoir in a clockwise direction.

16. Close the maintenance cover.

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

18. Conduct a test drive with the vehicle, check the fluid level in the reservoir after the cooling system has cooled again and, if necessary, fill up to the max marking with coolant.