Cooling: Other Porsche Cayenne I

Tools

Scheme 18

A - Cooling system leak tester (pump), see Workshop Equipment Manual, Chapter 3 "WE1069"

B - Hose extension FZ 100

C - K22 cap adapter (for sports cars)

D - K60 cap adapter included (in scope of delivery Filling device P 9696 )

Coolant: Checking the level and antifreeze content

> 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.

> 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.

Scheme 19

1. Open maintenance cover.

Scheme 20

> 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.

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

Scheme 21

3. Check antifreeze content with a commercially available antifreeze tester. If it is lower than -37 °C, it must be adjusted accordingly. The coolant level must not drop below the minimum mark.

Note. The following table specifies how much coolant must be replaced by pure antifreeze in order to adjust the freezing point to -37 °C.

Checking the antifreeze content of the coolant using a refractometer

Note. The following diagram shows the scale used by Leitenberger. The scale can vary slightly, depending on the manufacturer. The ETHYLENE scale must be used for Porsche antifreeze.

Scheme 22

1. Using a pipette, take a sample from the coolant reservoir.

Scheme 23

2. Deposit a few drops on the test surface.

Scheme 24

3. Close the light-diffusing lens. A closed film must form.

4. Using the refractometer, view against a very bright light source. A very clear light/dark limit emerges. The point of intersection between this line and the display scale marks the freezing point of the coolant.

5. A freezing point that is too low must be adjusted accordingly.

Note. The following table specifies how much coolant must be replaced by pure antifreeze in order to adjust the freezing point to -37°C.

Scheme 25

1. Check the cooling system for leaks. To do this, apply a test pressure of approx. 1.5 bar using the cooling system test device and check hose connections for leakage. The pressure must not drop.

Scheme 26

2. Check the coolant level. A graduated disc with a "min" and "max" marking is located in the opening of the reservoir. The "min" level must be covered with coolant.

3. Screw on the cap of the coolant reservoir again until it locks with an audible click.

4. Close the maintenance flap.

5. Check radiator for external dirt. The radiators should not be excessively dirty. If necessary, they can be cleaned using a vacuum cleaner with a brush attachment.

> 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.

> 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.

Scheme 27

1. Drain cooling system. > 193817 Draining and filling coolant (includes bleeding)

Note. The cleaning work steps must be repeated until no more oil rises to the surface in the coolant reservoir. The radiator cleaning agent mixture must be approx. 23 liters in the filling canister of the filling device filling device P 9696 . The cleaning agent is mixed with water at a ratio of 50:50 (Frostox R Spezial).

2. Fill the cooling circuit with the cleaning agent mixture. To do this, proceed with the cooling system analogously to filling the coolant. > 193817 Draining and filling in coolant (includes bleeding) - chapter on "Filling in"

3. Start the vehicle.

4. After the vehicle has been bled and the coolant temperature is > 80 °C, let the stationary vehicle run at medium engine speed for at least 15 minutes.

5. Switch off engine.

> 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.

6. Open coolant reservoir carefully and slowly in an anti-clockwise direction with gloves and a cloth.

7. Drain cooling system. > 193817 Draining and filling coolant (includes bleeding)

8. Use hot water to rinse out any oil which has adhered inside the coolant reservoir.

9. Close the cooling system and fill the coolant circuit with water only and then bleed the cooling system according to regulations. > 193817 Draining and filling coolant (includes bleeding)

10. Start engine.

11. After the vehicle has been bled and the coolant temperature is > 80 °C, let the stationary vehicle run at medium engine speed for at least 15 minutes.

12. Switch off engine.

> 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.

13. Open coolant reservoir carefully in an anti-clockwise direction with gloves and a cloth and relieve any residual pressure.

14. Drain cooling system. > 193817 Draining and filling coolant (includes bleeding)

15. Close the cooling system and bleed with the approved antifreeze mixture according to regulations. > 193817 Draining and filling coolant (includes bleeding)

Scheme 28

Note. The big fan is for the engine cooling, the small fan is for the air conditioning The sheetmetal clips on the fans are for balancing the fans and must not be pulled off.

1. Remove the radiator frame. > 192019 Removing and installing cooling fan housing (radiator frame) - chapter on "Removing"

Scheme 29

1. Unclip the electric plug on the radiator frame.

Scheme 30

2. Undo the 3 fastening screws on fan and pull fan down and out.

Removing fan for air conditioning

1. Unclip the electric plug on the radiator frame.

Scheme 31

2. Undo the 3 fastening screws on fan and pull fan down and out. When doing so, guide the cables and control unit.

Scheme 32

Installing fan for air conditioning

1. Push fan cable with control module from underneath through the radiator frame.

2. Tighten the three fastening screws. --> Tightening torque: 3 ftlb.

3. Route cables correctly and clip electric plug into the frame at the top.

Installing engine fan

1. Push fan from the bottom into the frame and tighten the 3 fastening screws to 4 Nm (3 ftlb.).

2. Route connecting cables correctly and clip electric connector into the radiator frame at the top.

Subsequent work

Note. The big fan is for the engine cooling, the small fan is for the air conditioning The sheetmetal clips on the fans are for balancing the fans and must not be pulled off.

1. Install the radiator frame. > 192019 Removing and installing cooling fan housing (radiator frame) - chapter on "Installing"

Preliminary work

1. Removing the front engine compartment cover. Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .

2. Remove Y-shaped pipes. Refer to 24 35 19 Removing and installing cowl for throttle housing (Y-shaped pipe) - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne S TIO Titan) . Refer to 24 35 19 Removing and installing cowl for throttle housing (intake manifold) - as of MY 2004 (Cayenne TIP, Cayenne MAN) . Refer to 24 35 19 Removing and installing cowl for throttle housing (Y-shaped pipe) - as of MY 2003 (Cayenne Turbo, Cayenne Turbo S) .

Removing radiator fan housing (radiator frame)

> 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) .

Note. The repair instructions differ slightly in the illustrations for the V6. The work steps are essentially identical.

Scheme 33

1. Disconnect the electric plugs on the fans.

Scheme 34

2. Unclip the cable harness fixed to the vehicle from the clips on the radiator frame.

Scheme 35

3. Loosen the two upper fastening screws of the radiator module on the lock carrier.

4. Press the radiator module towards the engine until the frame can be pulled up and out.

Scheme 36

5. Release the catch springs to the left and right on the radiator module and pull the frame up and out.

Scheme 37

If the radiator frame is stuck, it can be released carefully by means of a crowbar.

Installing radiator fan housing (radiator frame)

1. Slide the radiator frame from the top to the bottom along the radiator into the engine compartment.

2. Check whether the installation is correct. To do this, check whether the catch springs on the left and right have engaged properly and that the four fastening projections on the underside have engaged in the plastic clamps.

3. Tighten the two upper fastening screws of the radiator module on the lock carrier.

4. Join the two electric connectors on the top side.

5. Press the wiring harness into the 4 fastening clips.

1. Install Y-shaped pipes. Refer to 24 35 19 Removing and installing cowl for throttle housing (Y-shaped pipe) - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne S TIO Titan) . Refer to 24 35 19 Removing and installing cowl for throttle housing (intake manifold) - as of MY 2004 (Cayenne TIP, Cayenne MAN) . Refer to 24 35 19 Removing and installing cowl for throttle housing (Y-shaped pipe) - as of MY 2003 (Cayenne Turbo, Cayenne Turbo S) .

2. Install front engine cover. Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .

Scheme 38

A- - Flexible screwdriver a/f 7 (for loosening or tightening screw hose clamps) Flexible screwdriver a/f 7 NR.73-1

B- - Antifreeze protection testing device (for checking the antifreeze content in the cooling system. The design can deviate from that shown in the picture.)

C- - Spring band clamp pliers (for opening and closing spring band clamps) Assembly tools for spring band clamps NR.72

Scheme 39

Filling device P 9696

1- - Canister (canister with lifting tube, capacity approx. 30 l, with volume scale)

2- - Hose extension

3- - Adapter K 22 (included in the scope of delivery of radiator vacuum filling device)

4- - Venturi nozzle (included in the scope of delivery of radiator vacuum filling device)

5- - Adapter K 60 (included in the scope of delivery of radiator vacuum filling device)

6- - Pressure gauge (included in the scope of delivery of radiator vacuum filling device)

Components of the radiator vacuum filling device

Note. Pay attention to the special features in the corresponding chapter for vehicles with auxiliary heater. > 193817 Draining and filling coolant (includes bleeding) - chapter on "Bleeding"

Scheme 40

Filling device P 9696

1- - Adapter K 22 (installed in place of the cap on the coolant reservoir.)

2- - Hose extension FZ 100 (installed between K22 and KVB 01.)

3- - KVB 01 (vacuum pressure gauge with two shut-off valves)

V1- - Shut-off valve V1 (shutoff valve for the filler hose.)

V2- - Shut-off valve V2 (shutoff valve for the filler hose.)

4- - Venturi nozzle (a vacuum is produced in this component by means of compressed air. A pressure between 6 and 10 bar must be present.)

5- - Filler hose (the cooling system is refilled via this hose.)

6- - Return lines (the compressed air and the extracted coolant are drawn off via this hose.)

Bleeding vehicles with auxiliary heater

1. Fill and bleed the vehicle as described in the previous chapter using the vacuum filling device. > 193817 Draining and filling coolant (includes bleeding)

2. Warm engine to operating temperature ([>=] 90 °C).

Note. Do not activate the 2/3 directional-control valve with the Porsche System Tester above 1500 rpm. Activate the 2/3 directional-control valve with the Porsche System Tester below 1500 rpm.

3. Operate engine for 5 minutes with changing engine speeds. When doing this, run the engine for 10 seconds in idle and then for 10 seconds at 4,000 rpm. In the speed transition from higher engine speeds (1500 to 4000 rpm) to idle (approx. 600), the directional-control valve should be activated with the Porsche System Tester below 1500 rpm. Note that the 2/3 directional-control valve is not activated with the Porsche System Tester above 1500 rpm.

4. Let the vehicle cool down.

5. Open maintenance cover.

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

7. Check coolant level and, if necessary, fill the coolant reservoir with coolant to the maximum marking.

8. Screw on the cover of the reservoir.

9. Close the maintenance cover.

1. Drain cooling system. > 193817 Draining and filling coolant (includes bleeding) - chapter on "Draining"

2. Remove the right-hand headlight. Refer to 94 15 19 Removing and installing main headlight - as of MY 2003 (All Models) .

3. Remove engine compartment cover on the right and rear. Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .

Scheme 41

1. Remove electric connector from coolant reservoir.

Scheme 42

2. Pull off the 3 coolant hoses shown.

Scheme 43

3. Loosen the coolant reservoir fastening screw.

Scheme 44

4. Pull coolant reservoir towards engine and take out of the bracket.

Scheme 45

1. Insert coolant reservoir into the bracket and push in the direction of the wing.

2. Tighten fastening screw. --> Tightening torque: 7.5 ftlb.

3. Mount and tighten the three coolant hoses.

4. Connect electric plug to reservoir.

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

2. Install right headlight. Refer to 94 15 19 Removing and installing main headlight - as of MY 2003 (All Models) .

3. Fill and bleed the cooling system. > 193817 Draining and filling coolant (includes bleeding) - chapter on "Filling"

1. Drain cooling system. > 193817 Draining and filling coolant (includes bleeding) - chapter on "Draining"

2. Remove the right-hand headlight. Refer to 94 15 19 Removing and installing main headlight - as of MY 2003 (All Models) .

3. Remove engine compartment cover on the right and rear. Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .

Removing coolant expansion tank

1. Remove electric connector from coolant reservoir.

2. Pull off the three coolant hoses shown.

Scheme 46

3. Detach the torque support. To do this, unscrew the fastening screw on the torque support bracket and pull it out.

Scheme 47

4. Detach the torque support from the body and swivel upwards.

Scheme 48

5. Undo torque support bracket fastening screw from the body. One fastening screw is loosened through the headlight opening. The second screw is accessible from the top.

Scheme 49

Scheme 50

6. Remove body bracket. When doing this, unclip the electric cable (2 x).

7. Loosen the secondary air pump from cylinder row 1-4. Refer to 26 65 19 Removing and installing secondary air pump - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

8. Undo the coolant reservoir fastening screw.

9. Pull coolant reservoir towards engine and take out of the holder.

Installing coolant expansion tank

1. Insert coolant reservoir into the holder and push in the direction of the wing.

2. Tighten fastening screw. --> Tightening torque: 7.5 ftlb.

3. Tighten the secondary air pump from cylinder row 1-4. Refer to 26 65 19 Removing and installing secondary air pump - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

4. Reinstall body bracket for the torque support. Clip on electric cable for coolant reservoir (2 x).

5. Tighten fastening screw (M10 x 20) through the headlight opening. --> Tightening torque: 44 ftlb.

6. Tighten fastening screw (M10 x 37) from the engine compartment. --> Initial tightening: 37 ftlb. --> Final tightening: 90°

7. Reinstall torque support. Install the fastening screw (M10 x 85) with a new fastening nut on the bracket. --> Tightening torque: 44 ftlb.

8. Tighten the fastening screw of the torque support onto the body (M10 x 70). --> Tightening torque: 44 ftlb.

9. Mount and tighten the three coolant hoses.

10. Connect electric plug to reservoir.

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

2. Install right headlight. Refer to 94 15 19 Removing and installing main headlight - as of MY 2003 (All Models) .

3. Fill and bleed the cooling system. > 193817 Draining and filling coolant (includes bleeding) - chapter on "Filling"

1. Drain cooling system. > 193817 Draining and filling coolant (includes bleeding)

Scheme 51

2. Remove front left wheel housing liner. Refer to 50 56 19 Removing and installing front wheel housing liner - as of MY 2003 (All Models) .

Scheme 52

1. Undo sheetmetal holder of coolant line by removing fastening screw (M6 x 16) on the body. Unclip the coolant line from the holder. Carefully pull the additional coolant pump forward under the wing. Pull off electric connector -1- on the pump. Then open the coolant hoses -2 and 3- and remove the pump by loosening the screw-type hose clamp. (Scheme 52)

Installing additional coolant pump

1. Insert the additional coolant pump in the screw-type hose clamp and screw in the fastening screw hand-tight. Install the coolant hoses -2 and 3-, position the spring-band clamps and then connect the electric connector -1-. Clip coolant lines into holder and fasten sheetmetal holder of coolant line by mounting the fastening screw on the body. --> Tightening torque: 7.5 ftlb. see scheme 92

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

1. Fill and bleed the cooling system. > 193817 Draining and filling coolant (includes bleeding) - chapter on "Filling"

2. Install front left wheel housing liner. Refer to 50 56 19 Removing and installing front wheel housing liner - as of MY 2003 (All Models) .

1. Drain coolant > 193817 Draining and filling coolant (includes bleeding) - chapter on "Draining"

Scheme 53

2. Pull the design cover vertically upwards and off.

3. Remove right engine compartment covers and center plenum panel Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .

Removing the additional coolant pump

Note. Cover the engine. For this work, the worker must lie on the engine. The additional coolant pump is difficult to reach.

1. Cover the intake-air distributor with covers.

Scheme 54

2. Open both plastic clips of the rear valve cover wiring harness and lay the wiring harness aside -1-. (Scheme 54)

3. Loosen both fastening nuts of the engine wire harness on the top chain case lid and push the engine wire harness to the side.

Scheme 55

4. Disconnect cable plug of the additional coolant pump. Pull out additional coolant pump laterally from the rubber mountings. Pull off spring band clamps -1 and 2- of the coolant hoses. (Scheme 55)

Scheme 56

Note. If one or more rubber sleeves slide out of the sheetmetal holder when inserting the additional coolant pump, grab the rubber sleeves with a pointed-nose pliers and pull them up through the holes in the sheetmetal holder.

1. Mount the coolant hoses and spring band clamps on the additional coolant pump -1 and 2-. Connect the additional coolant pump laterally into the rubber mounting. Push on cable plug. see scheme 97

2. Mount wiring harnesses. Tighten fastening nuts --> Tightening torque: 6 ftlb. . Clip in the component.

1. Fill coolant and bleed system > 193817 Draining and filling coolant (includes bleeding) - chapter on "Filling"

2. Mount right engine compartment covers and center plenum panel Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .

Scheme 57

3. Mount design cover.

1. Drain cooling system. > 193817 Draining and filling coolant (includes bleeding)

2. Remove the radiator frame. > 193817 Draining and filling coolant (includes bleeding)

Scheme 58

Scheme 59

1 - Coolant pump

2 - Seal for coolant pump (replace seal)

3 - 2 dowel sleeves (do not remove)

4 - 8 M6 x 25 fastening screws (tightening torque 10 Nm (7.5 ftlb.))

5 - Support for cable duct (fit with the two upper fastening screws)

Scheme 60

1. Separate the electric connection from the throttle adjuster. To do this, press on the plug at the top and bottom and, at the same time, pull it off. Unclip the cable from the sheetmetal holder.

Scheme 61

2. Remove the throttle adjuster.

Scheme 62

Note. To ease removal, spray the pulley from the rear side with an anti-corrosion agent.

3. Unscrew the three fastening screws on the coolant pump pulley. Wrench size is T 40.

Scheme 63

4. Remove the drive belt from the coolant pump pulley. Mark the direction of running of the drive belt with chalk.

Scheme 64

5. Use an open-ended wrench (a/f 30) to turn the belt tensioner clockwise and, at the same time, remove the drive belt from the tensioning roller. Relieve the belt tensioner carefully. Remove the drive belt from the coolant pump.

> The pulleys of the engine accessories are made of plastic. Do not use damaged pulleys.

> The pulley is sensitive to impacts.

> Do not pry off the pulley with a screwdriver.

6. Remove the 3 loosened fastening screws on the pulley and remove the pulley.

Scheme 65

7. Remove the eight fastening screws on the coolant pump and remove the pump. If the pump is stuck, loosen it by gently tapping with a plastic hammer.

Scheme 66

Installing coolant pump

> The pulleys of the engine accessories are made of plastic. Do not use damaged pulleys.

> The pulley is sensitive to impacts.

> Do not pryoff the pulley with a screwdriver.

Scheme 67

1. Clean sealing surfaces. Mount new sheetmetal seal on the coolant pump. Slide the new sheetmetal seal over the dowel pins.

Scheme 68

2. Tighten the 8 fastening screws. --> Tightening torque: 7.5 ftlb. Mount the sheetmetal holder for the cable duct using the two upper fastening screws.

3. Fit the pulley on the coolant pump. Screw in the three fastening screws by hand.

4. Mount drive belt -as shown in the following-. To do this, turn the belt tensioner clockwise and thread the drive belt around all the pulleys. Then carefully relieve the tensioning roller. Refer to 13 78 19 Removing and installing drive belt - as of MY 2003 (Cayenne S TIP, Cayenne S MAN). Refer to 13 78 19 Removing and installing drive belt - as of MY 2003 (Cayenne Turbo, Cayenne Turbo S). (Scheme 69)

Scheme 69

5. Check whether the drive belt is correctly installed.

6. Tighten the three fastening screws of the coolant pump pulley. --> Tightening torque: 17 ftlb.

7. Tighten the throttle adjuster with new seal. --> Tightening torque: 17 ftlb.

8. Connect the throttle adjuster. The connector must engage audibly. Clip the connecting cable into the sheetmetal holder.

1. Install the radiator frame. > 192019 Removing and installing cooling fan housing (radiator frame) - chapter on "Installing"

2. Fill and bleed the cooling system according to instructions. > 193817 Draining and filling coolant (includes bleeding) - chapter on "Filling"

1. Drain cooling system. > 193817 Draining and filling coolant (includes bleeding)

Scheme 70

1- - Coolant pipe. (Scheme 70)

2- - Wiring for reservoir. (Scheme 70)

3- - Thermostat housing. (Scheme 70)

4- - Connection wires on cylinder block. (Scheme 70)

5- - Connections on oil/water heat exchanger. (Scheme 70)

6- - Coolant pipe. (Scheme 70)

7- - Coolant hose; flange must engage with an audible click. (Scheme 70)

8- - --> Tightening torque: 2 ftlb.. (Scheme 70)

9- - O-ring; replacing. (Scheme 70)

10- - Fuel feed direction of coolant pump. (Scheme 70)

11- - --> Tightening torque: 15 ftlb.. (Scheme 70)

12- - Pulley (Scheme 70)

13- - --> Tightening torque: 6 ftlb.. (Scheme 70)

14- - Coolant pump; check for smooth operation. (Scheme 70)

15- - Direction of flow - coming from radiator. (Scheme 70)

16- - Hose line - coming from radiator. (Scheme 70)

17- - --> Tightening torque: 6 ftlb.. (Scheme 70)

Scheme 71

1. Mark the rolling direction of the drive belt with chalk.

Scheme 72

2. Relieve and remove drive belt. To do this, screw an M8 screw into the belt tensioner.

Scheme 73

Scheme 74

3. Turn the drive wheel for the coolant pump in such a way that the fastening screws can be reached through the holes in the belt pulley -arrows-. (Scheme 74)

Scheme 75

4. Pull coolant pump out of the crankcase.

Scheme 76

1. Clean sealing face and install new O-ring on coolant pump.

2. Tighten the 3 fastening screws. --> Tightening torque: 6 ftlb.

3. Fit drive belt. Refer to 13 78 19 Removing and installing drive belt - as of MY 2004 (Cayenne TIP, Cayenne MAN) .; then remove the screw from the belt tensioner and tension the belt. Check whether the drive belt is correctly installed.

1. Fill and bleed cooling system according to regulations. > 193817 Draining and filling coolant (includes bleeding)

1. Drain cooling system. > 193817 Draining and filling coolant (includes bleeding)

2. Remove intake-air distributor. Refer to 24 46 19 Removing and installing intake-air distributor - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

Scheme 77

Scheme 78

1 - Thermostat housing (observe loosening and tightening sequence)

2 - Fastening screw M6 x 25

3 - O-rings, 22 x 3, replacing

4 - Coolant pipe for heater

5 - Fastening screw M6 x 16

6 - O-rings, 28 x 3, replacing

7 - Seal for thermostat housing; replacing

8 - Fastening screw M6 x 16

9 - Molded seal; replacing

10 - Thermostat well

11 - O-ring, 50 x 3, replacing

12 - O-ring, 20 x 2.65, replacing

Scheme 79

1. Remove the two coolant lines on the thermostat housing cover. To do this, remove the spring-band clamps and pull off the hoses.

Scheme 80

2. Pull off the cable duct upwards over the coolant pump.

3. Release the upper fastening screw of the oil dipstick.

Scheme 81

4. Loosen the fastening screw on the cable duct.

Scheme 82

5. Disconnect the coolant outlet on the generator. To do this, open the spring-band clamps and pull off the hose. Collect the draining coolant.

Scheme 83

6. Remove the coolant return line on the thermostat housing. To do this, loosen the fastening screw and pull off the line.

Scheme 84

7. Disconnect vent line for cylinder heads. To do this, press the ribbed surfaces of the buttons and pull off the plugs.

Scheme 85

8. Undo the 3 rear fastening screws of the heater pipes.

9. Undo the thermostat housing cover. The sequence shown must be observed when doing so.

Scheme 86

Scheme 87

10. Lift the housing cover. Remove the thermostat using assembly aid P 9627 .

Installing thermostat

Note. All seals between opened sealing surfaces must be replaced.

Scheme 88

1. Insert thermostat in the cover and turn it until the two sheetmetal edges are lying to the left and right of the holder.

2. Replace inner and outer seal in thermostat housing cover.

3. Position thermostat housing cover and tighten the fastening screws (M6 x 25) according to the sequence shown. --> Tightening torque: 7.5 ftlb.

Scheme 89

4. Tighten the three rear fastening screws (M6 x 16) on the heater pipes. --> Tightening torque: 7.5 ftlb.

5. Connect vent lines for cylinder heads. The connectors must engage audibly.

6. Fit coolant line leading to the generator. Insert the line in the thermostat housing cover and tighten the fastening screw. --> Tightening torque: 7.5 ftlb.

7. Push coolant line onto generator and fit the spring-band clamp.

8. Push the holder onto the timing case cover below the cable duct and tighten the fastening screw. --> Tightening torque: 7.5 ftlb.

Scheme 90

9. Tighten the upper fastening screw of the oil dipstick. --> Tightening torque: 7.5 ftlb.

Scheme 91

10. Push the cable duct onto the retaining bracket over the coolant pump.

11. Check whether the drive belt is correctly installed.

12. Fit coolant supply and return hose on thermostat housing cover.

1. Install intake distributor. Refer to 24 46 19 Removing and installing intake-air distributor - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

2. Fill coolant system and check for leaks. > 193817 Draining and filling coolant (includes bleeding) - chapter on "Filling"

1. Remove transmission. Refer to 37 35 19 Removing and installing transmission - as of MY 2003 (Cayenne TIP) or refer to 34 35 19 Removing and installing transmission - as of MY 2003 (Cayenne MAN) .

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

3. Drain cooling system. > 193817 Draining and filling coolant (includes bleeding)

Scheme 92

1- - O-ring; replacing. (Scheme 92)

2- - Clamp; replace if damaged. (Scheme 92)

3- - Thermostat housing. (Scheme 92)

4- - --> Tightening torque: 6 ftlb. fastening screw. (Scheme 92)

5- - Coolant regulator; pay attention to the direction of installation --> Start of opening temperature: 80 °C --> End of opening temperature: 107 °C --> Opening stroke: 7 mm. (Scheme 92)

6- - Adapter; pay attention to the installation position. (Scheme 92)

7- - Molded seal; replacing. (Scheme 92)

8- - Temperature sensor for coolant temperature. (Scheme 92)

9- - Plug. (Scheme 92)

Coolant pump components

1- - Coolant pipe. see scheme 153

2- - Wiring for reservoir. see scheme 153

3- - Thermostat housing. see scheme 153

4- - Connection wires on cylinder block. see scheme 153

5- - Connections on oil/water heat exchanger. see scheme 153

6- - Coolant pipe. see scheme 153

7- - Coolant hose; flange must engage with an audible click. see scheme 153

8- - --> Tightening torque: 2 ftlb.. see scheme 153

9- - O-ring; replacing. see scheme 153

10- - Fuel feed direction of coolant pump. see scheme 153

11- - --> Tightening torque: 15 ftlb.. see scheme 153

12- - Pulley. see scheme 153

13- - --> Tightening torque: 6 ftlb.. see scheme 153

14- - Coolant pump; check for smooth operation. see scheme 153

15- - Direction of flow - coming from radiator. see scheme 153

16- - Hose line - coming from radiator. see scheme 153

17- - --> Tightening torque: 6 ftlb.. see scheme 153

Scheme 93

1. Pull hoses off the thermostat housing from below (transmission area) and then loosen the -3 fastening screws-. (Scheme 93)

Scheme 94

2. Carefully take off the cover. Coolant emerges.

Scheme 95

3. Note or mark position of bleeder valve -arrow-. (Scheme 95)

Scheme 96

4. Remove thermostat from the housing.

Installing coolant regulator

1. Insert thermostat with spring up into the housing.

2. Align bleeder valve -arrow-. see scheme 159

3. Position housing cover with new seal.

4. Tighten the 3 fastening screws -arrows-. --> Tightening torque: 6 ftlb. see scheme 161

5. Connect coolant hoses and fit spring-band clamps.

1. Install transmission. Refer to 37 35 19 Removing and installing transmission - as of MY 2003 (Cayenne TIP) or refer to 34 35 19 Removing and installing transmission - as of MY 2003 (Cayenne MAN) .

2. Fill and bleed the cooling system according to instructions. > 193817 Draining and filling coolant (includes bleeding) - chapter on "Filling"

Technical Values

Information

1. The engine does not need to be removed in order to remove the large coolant pipe at the bottom.
2. The large one-piece coolant pipe (at the bottom) will be damaged irreparably during removal and is replaced by a multi-piece coolant pipe comprising a pipe, connection piece, two clips and a hose.
3. If the old plastic coolant pipes (heater pipes and lower coolant pipe) are leaking, all pipes must always be replaced (not just the sealing rings).
4. When removing the old plastic coolant pipes, replace them with the metal coolant pipes.

1. Drain cooling system. «> 193817 Draining and filling coolant (includes bleeding)»(ref-274617-S13698919752007121900000)
2. Disconnect the battery.
3. Remove intake-air distributor. Refer to «24 46 19 Removing and installing intake-air distributor - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan)»(ref-274612-S23373008862007121900000) .
4. Close off intake openings to prevent dirt or small parts from falling in.

Scheme 97

Scheme 98

Scheme 99

1. Open both cable holders and press wire harness to one side -arrows- .

Scheme 100

2. Unclip vent line and remove three screws -arrows- .

3. Remove holder for the three coolant pipes. To do this, remove the top part of the plastic holder by releasing the locking lugs (press them together) and pull it up and off -arrows- .

Scheme 101

4. Loosen connected coolant hoses on the upper coolant pipes and pull them off.

5. Remove housing cover on coolant regulator. Remove housing cover with the attached heater pipes. See 19 58 19 Removing and installing coolant regulator (thermostat) - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) . The thermostat insert remains fitted.

6. Set down housing cover for coolant regulator with the attached heater pipes.

7. Pull the coolant pipes -4- out of the housing cover -1-. (Scheme 97)

Removing lower coolant pipe

1. Remove heater pipes. See Removing upper coolant pipes (heater pipes) .

2. Cut plastic coolant pipe close to the coolant guide using a metal saw blade. A pneumatic or electric body saw can be used if necessary.

Scheme 102

3. Turn the coolant pipe up. Use a suitable pliers if necessary.

Scheme 103

4. Remove both parts of the coolant pipe by turning them. Use a suitable pliers if necessary. Clean the bore fittings in the crankcase and in the coolant guide. Use a cloth to absorb all remaining coolant.

Scheme 104

Installing coolant pipes

Note. For exploded view (Scheme 98)

1. The metal pipe, connection piece, two clips, sealing rings and the coolant hose are required for carrying out repairs. Check the sealing rings and make sure they are fitted correctly. Never twist sealing rings during installation.

Scheme 105

Note. 000 043 204 68 (Status 02/07) "Kluber Syntheso GLEP 1" is a neutral-reaction assembly grease for connection pieces and sealing rings in oily or water-carrying areas. Use "Kluber Syntheso GLEP 1" very sparingly. Components and lubrication points must only be coated lightly and excess grease must be removed. Excess grease can result in leaks. "Kluberplus S06-100" is a water-soluble assembly gel with the number 000 043 205 93 (status 06/08). This must always be used for the sealing rings on the intake socket between the water pump and thermostat housing. It must be diluted 50:50 with water.

2. Coat the sealing rings and the inside of the coolant hose lightly with the recommended grease.

3. Press the connection piece with the sealing rings as far as it will go into the rear coolant guide.

Scheme 106

4. Slide both clips and the piece of hose onto the coolant pipe. Push on the screw-type clamps in an offset position. Slide piece of hose on fully so that it does not project out. Insert coolant pipe with the greased sealing rings into the crankcase.

Scheme 107

5. Turn the coolant pipe towards the connection piece and slide the coolant hose onto the connection piece. When removing it later, the coolant hose should be cut open and replaced if it is seated very securely.

6. Press all components into the correct position and move the clips so that they can be fitted without colliding. Move clip locks into an offset installation position -8- and tighten them. (Scheme 98)

Installing upper coolant pipes (heater pipes)

Note. 000 043 204 68 (Status 02/07) "Kluber Syntheso GLEP 1" is a neutral-reaction assembly grease for connection pieces and sealing rings in oily or water-carrying areas. Use "Kluber Syntheso GLEP 1" very sparingly. Components and lubrication points must only be coated lightly and excess grease must be removed. Excess grease can result in leaks. "Kluberplus S06-100" is a water-soluble assembly gel with the number 000 043 205 93 (status 06/08). This must always be used for the sealing rings on the intake socket between the water pump and thermostat housing. It must be diluted 50:50 with water.

1. Apply a thin coat of grease on the sealing rings on the coolant pipes -3 and 8-. Carefully press the coolant pipes -4- into the thermostat housing cover -1-. (Scheme 97)

2. Fit thermostat housing cover with the attached heater pipes. See 19 58 19 Removing and installing coolant regulator (thermostat) - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

3. Fit coolant hoses for the upper coolant pipes. Secure clips.

4. Fit holder for the coolant pipes.

5. Screw in three fastening screws -arrows- . Clip in vent line. Tightening torque: 10 Nm (7.5 ftlb.)

6. Fit engine wire harness on coolant pipe holders -arrows- .

1. Fit intake-air distributor. See 24 46 19 REMOVING AND INSTALLING INTAKE-AIR DISTRIBUTOR - AS OF MY 2004 (CAYENNE TIP, CAYENNE MAN) .

2. Fill in coolant and bleed the system. See > 193817 Draining and filling coolant (includes bleeding) .

1. Insert thermostat with spring up into the housing.

2. Align bleeder valve -arrow-. see scheme 159

3. Position housing cover with new seal.

4. Tighten the 3 fastening screws -arrows-. --> Tightening torque: 6 ftlb. see scheme 161

5. Connect coolant hoses and fit spring-band clamps.

1. Install transmission. Refer to 37 35 19 Removing and installing transmission - as of MY 2003 (Cayenne TIP) or refer to 34 35 19 Removing and installing transmission - as of MY 2003 (Cayenne MAN) .

2. Fill and bleed the cooling system according to instructions. > 193817 Draining and filling coolant (includes bleeding) - chapter on "Filling"

1. Disconnect battery. Refer to 90 IN Work instructions after disconnecting the battery - as of MY 2003 (All Models Except Cayenne S TIO Titan) .

2. Drain cooling system. > 193817 Draining and topping up with coolant (includes bleeding) - chapter on "Draining"

3. Remove lock mount. Refer to 50 38 19 Removing and installing lock carrier - as of MY 2003 (All Models) .

4. Remove the radiator frame. > 192019 Removing and installing cooling fan housing (radiator frame) - chapter on "Removing"

Scheme 108

Scheme 109

Scheme 110

1 - Radiator module (If at all possible, do not open the air-conditioning system. Do not bend the lines.

2 - Lock carrier

3 - Front bumper

4 - 2 clamps

5 - Safety clip

Removing radiator

Do not open the air conditioner if at all possible when removing the - radiator module . Do not bend the lines

When installing the - radiator module do not bend the lines.

Scheme 111

Note. The retaining clips should be mounted again immediately so that they are not confused.

1. Remove coolant hoses on the radiator. To do this, pull out the retaining clips on the two coolant flanges and pull off the hoses. Then fit the retaining clips again so that they are not confused.

Scheme 112

2. Pull off the top right vent hose on the radiator.

Scheme 113

3. Unscrew both fastening screws -C- for securing condenser to the coolant radiator (left direction of travel). (Scheme 113)

Scheme 114

4. Unscrew the fastening screw -D- (left direction of travel) for securing power steering radiator lines to coolant radiator. (Scheme 114)

Scheme 115

5. Unclip the radiator for the power steering system. To do this, unclip the wiring to the front out of the holder -A- and push it to the left out of the support -B-. Hang the radiator carefully downwards. (Scheme 115)

Scheme 116

6. Lift both locks for the ATF cooler and air-conditioning condenser with a screwdriver -1- and push down -arrow-. (Scheme 116)

Scheme 117

Note. Fix the remaining radiators in the installation position using tie wraps.

7. Lift up the radiator and take it out of the vehicle by moving it up and to the right. When doing this, watch out for the connection lines of the air-conditioning system on the left side.

Scheme 118

Installing radiator

Note. The retaining clips should be mounted again immediately so that they are not confused.

Do not open the air conditioner if at all possible when removing the - radiator module . Do not bend the lines

When installing the - radiator module do not bend the lines.

Scheme 119

1. Insert the radiator from above on the right between the ATF cooler and the air-conditioning condenser.

Scheme 120

2. Move the ATF cooler into the installation position and push on the metal clips to fasten it.

Scheme 121

3. Fasten servo oil cooler. To do this, push the servo oil cooler from left to right into the support -A- and clip the lines into the support -B-. (Scheme 121)

4. Tighten the fastening screw on the servo oil cooler line with a fastening screw. --> Tightening torque: 7.5 ftlb.

Scheme 122

5. Screw in both fastening screws -C- for securing condenser to the coolant radiator (left direction of travel). --> Tightening torque: 6 ftlb. (Scheme 122)

6. Push on the cooler vent line onto the right radiator side and fit the spring-band clamp.

Scheme 123

7. Push on the two coolant lines. The retaining clips on the flange must engage audibly.

1. Install the radiator frame. > 192019 Removing and installing cooling fan housing (radiator frame) - chapter on "Installing"

2. Install lock mount. Refer to 50 38 19 Removing and installing lock carrier - as of MY 2003 (All Models) .

3. Fill and bleed the cooling system. > 193817 Draining and filling in coolant (includes bleeding) - chapter on "Filling in"

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

5. Connect the battery. Refer to 90 IN Work instructions after disconnecting the battery - as of MY 2003 (All Models Except Cayenne S TIO Titan) .

1. Drain coolant completely. > 193817 Draining and filling coolant (includes bleeding) - chapter on "Draining"

2. Remove intake-air distributor. Refer to 24 46 19 Removing and installing intake-air distributor - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

Removing coolant temperature sensor

> 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.

Scheme 124

1. Pull off cable plug of the coolant temperature sensor -arrow-. (Scheme 124)

Scheme 125

Note. Even when the coolant has been completely drained, coolant emerges from the open bore on the coolant temperature sensor!

2. Unscrew the coolant temperature sensor using a ring wrench (a/f 22). Absorb emerging coolant. (Scheme 125)

Installing coolant temperature sensor

1. Clean sealing surfaces and screw in coolant temperature sensor with a new sealing ring into the distributor pipe. --> Tightening torque: 22 ftlb.

2. Fit cable plug again -arrow-. see scheme 209

1. Install intake-air distributor. Refer to 24 46 19 Removing and installing intake-air distributor - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

2. Fill up completely with coolant and bleed system. > 193817 Draining and filling coolant (includes bleeding) - chapter on "Filling" .

Poses Online