Fuel System, Electronic Injection: Other Porsche Cayenne I

Preliminary work

1. Remove throttle-housing cover. > 243519 Removing and installing throttle-housing cover (Y-shaped pipe)

2. Remove engine compartment covers on the left and right over the air cleaner housing. Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .

Replacing air-cleaner element - Cayenne S (type M48/00)

Note. In vehicles with air suspension, the compressor air tube on the air cleaner cover must be removed and installed.

Note. Under particularly difficult conditions (dusty environments) it may be necessary to change the filter element outside the maintenance intervals. The description only applies to changing one filter element. The second element is changed in the same way.

Scheme 15

Scheme 16

1. Remove the air tube on the right air cleaner cover. To do this, unclip the green cap. Insert a screwdriver into the notch of the cap and lever the cap off. --> Air line. (Scheme 16)

Scheme 17

2. Push the circlip into the flange -1- and then pull it off together with the flange -2-. (Scheme 17)

Scheme 18

3. Clip the green cap on again after disassembly.

Scheme 19

4. The coolant bleeder hose on the coolant expansion tank should be unclipped from the air cleaner housing cover of the cylinder bank 1 - 4.

Scheme 20

5. Open the two upper fastening clips on the air cleaner housing.

Scheme 21

6. Press the cover of the air cleaner housing in the direction of the engine, pulling it upwards at the same time.

Scheme 22

7. Remove the air-cleaner element from the air cleaner housing.

Scheme 23

8. Insert filter element in the housing.

Scheme 24

9. Place the cover on the air cleaner housing and run in from top to bottom. Make sure that the three fastening lugs run into the mounting points on the underside. The figure gives a clearer view of the dismantled air cleaner housing.

10. Push cover up against the air cleaner housing and release the 2 fastening clips

Scheme 25

11. Push the air suspension line onto the right air cleaner cover.

Scheme 26

12. The coolant bleeder hose and the coolant overflow hose must be clipped back onto the cylinder bank 1 - 4 on the air cleaner housing.

Subsequent work

1. Install throttle-housing cover. > 243519 Removing and installing throttle-housing cover (Y-shaped pipe)

2. Install engine compartment covers on the left and right over the air cleaner housing. Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .

1. Remove engine compartment covers on the left and right over the air cleaner housing. Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .

Replacing air-cleaner element - Cayenne Turbo (type M48/50)

Note. In vehicles with air suspension, the compressor air tube on the air cleaner cover must be removed and installed.

Note. Under particularly difficult conditions (dusty environments) it may be necessary to change the filter element outside the maintenance intervals. The description only applies to changing one filter element. The second element is changed in the same way.

Scheme 27

Scheme 28

1. Loosen connections on the air cleaner covers. To do this, turn the pins by 180° and pull them out. Pull off intake pipes.

2. Remove the air tube on the right air cleaner cover. To do this, unclip the green cap. Insert a screwdriver into the notch of the cap and lever the cap off.

3. Push the circlip into the flange -1- and then pull it off together with the flange -2-. see scheme 17

4. Clip the green cap on again after disassembly.

5. The coolant bleeder hose on the coolant expansion tank should be unclipped from the air cleaner housing cover of the cylinder bank 1 - 4.

6. Open the two upper fastening clips on the air cleaner housing.

7. Press the cover of the air cleaner housing in the direction of the engine, pulling it upwards at the same time.

8. Remove the air-cleaner element from the air cleaner housing.

9. Insert filter element in the housing.

10. Place the cover on the air cleaner housing and run in from top to bottom. Make sure that the three mounting elements run into the mounting points on the underside. The figure gives a clearer view of the dismantled air cleaner housing.

11. Push cover up against the air cleaner housing and release the 2 fastening clips

12. The coolant bleeder hose and the coolant overflow hose must be clipped back onto the cylinder bank 1 - 4 on the air cleaner housing.

13. Push the air suspension line onto the right air cleaner cover.

1. Install engine compartment covers on the left and right over the air cleaner housing. Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .

Replacing air-cleaner element - Cayenne

Note. Under particularly difficult conditions (dusty environments) it may be necessary to change the filter element outside the maintenance intervals.

Scheme 29

1. Remove the design cover -arrow A-. Unscrew the fixing clips -a- and remove both covers -arrows B-. (Scheme 29)

Scheme 30

2. Open the two upper fastening clips on the air cleaner housing.

> Only turn the fastening bolts in the correct direction of rotation for opening and closing.

> Turning the fastening bolts carefully ensures that the correct direction of rotation is maintained. The other direction of rotation can be checked using resistance.

3. Disconnect connection on the air cleaner cover. To do this, turn the fastening bolts through 180° and pull them out --> Diagram of fastening bolts (displayed for the V8). Then pull off the intake manifold. see scheme 29

4. Press the cover of the air cleaner element in the direction of the engine, pulling it upwards at the same time.

5. Remove the air-cleaner element from the air cleaner housing.

6. Insert air-cleaner element into air cleaner housing.

7. Place the cover on the air cleaner housing and run in from top to bottom. Make sure that the three mounting elements run into the mounting points on the underside. The figure gives a clearer view of the dismantled air cleaner housing.

8. Push cover up against the air cleaner housing and release the two fastening clips.

> Only turn the fastening bolts in the correct direction of rotation for opening and closing.

> Turning the fastening bolts carefully ensures that the correct direction of rotation is maintained. The other direction of rotation can be checked using resistance.

9. Fit intake manifold and air cleaner cover. To do this, insert fastening bolts and turn them through 180° to secure them.

Scheme 31

10. Push on design cover -arrow A-, until the locking tabs engage audibly. Fit the covers -arrows B- and secure with the fixing clips -a-. (Scheme 31)

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

2. Perform the steps required to replace the air-cleaner element. > 242455 Replacing air cleaner element

Scheme 32

1. On vehicles with air suspension, remove the air tube on the right air cleaner cover. To do this, unclip the green cap. Insert a screwdriver into the notch of the cap and lever the cap off.

2. Push the circlip into the flange -1- and then pull it off together with the flange -2-. see scheme 34

3. Clip the green cap on again after disassembly.

Scheme 33

4. Unscrew the fastening screw on the air cleaner housing.

Scheme 34

5. Pull the air guide of the air cleaner housing out of the wheel well. To do this take hold of the air guide in one hand and pull it forwards at an angle.

Scheme 35

6. Lift the air cleaner housing, tip it towards the engine and remove it from the engine compartment.

Installing air cleaner housing

Note. On vehicles with air suspension, push the compressor line on to the air cleaner cover.

1. Insert the air cleaner housing into the engine compartment at an angle from above.

Scheme 36

2. Introduce the two retaining bolts on the underside into the take-up bores in the body. Check the wheel well to make sure that the blue rubber discs are present and ensure that the bolts are properly fitted.

Scheme 37

3. Replace the air guide on the air cleaner housing from the wheel well. Check that the elements are installed correctly.

4. Tighten the fastening screw on the air cleaner housing. --> Tightening torque: 7.5 ftlb.

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

2. Perform the steps required to replace the air-cleaner element. > 242455 Replacing air cleaner element

Note. The description relates to one cylinder row. The air cleaner housing on the other cylinder row is removed and installed in the same way.

1. Perform the steps required to replace the air-cleaner element. > 242455 Replacing air cleaner element

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

Scheme 38

Removing air cleaner housing - Cayenne S (type M48/00)

1. Pull the air guide of the air cleaner housing out of the wheel well. To do this take hold of the air guide in one hand and pull it forwards at an angle.

2. Unscrew the fastening screw on the air cleaner housing.

Scheme 39

3. Unclip the electric cable from the coolant expansion tank on the cylinder bank 1 - 4. The cable is clipped in at 2 points.

4. Lift the air cleaner housing, tip it towards the engine and remove it from the engine compartment.

Installing air cleaner housing - Cayenne S (type M48/00)

1. Insert the air cleaner housing into the engine compartment at an angle from above.

2. Introduce the 2 retaining bolts on the underside into the take-up bores in the body. Check the wheel well to make sure that the blue rubber discs are present and ensure that the bolts are properly fitted.

3. Tighten the fastening screw on the air cleaner housing. --> Tightening torque: 7.5 ftlb.

4. Unclip the electric cable from the coolant expansion tank on cylinder bank 1 - 4. The cable is clipped in at two points.

5. Replace the air guide on the air cleaner housing from the wheel well. Check that the elements are installed correctly.

1. The steps required to replace the air-cleaner element are to be performed in the same way. > 242455 Replacing air cleaner element

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

Note. The description relates to one cylinder row. The air cleaner housing on the other cylinder row is removed and installed in the same way.

1. Perform the steps required to replace the air-cleaner element. > 242455 Replacing air cleaner element

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

Removing air cleaner housing - Cayenne Turbo (type M48/50)

1. Pull the air guide of the air cleaner housing out of the wheel well. To do this take hold of the air guide in one hand and pull it forwards at an angle.

2. Unscrew the fastening screw on the air cleaner housing.

3. Unclip the electric cable from the coolant expansion tank on the cylinder bank 1 - 4. The cable is clipped in at two points.

4. Lift the air cleaner housing, tip it towards the engine and remove it from the engine compartment.

Installing air cleaner housing - Cayenne Turbo (type M48/50)

1. Insert the air cleaner housing into the engine compartment at an angle from above.

2. Introduce the 2 retaining bolts on the underside into the take-up bores in the body. Check the wheel well to make sure that the blue rubber discs are present and ensure that the bolts are properly fitted.

3. Tighten the fastening screw on the air cleaner housing. --> Tightening torque: 7.5 ftlb.

4. Unclip the electric cable from the coolant expansion tank on cylinder bank 1 - 4. The cable is clipped in at two points.

5. Replace the air guide on the air cleaner housing from the wheel well. Check that the elements are installed correctly.

1. The steps required to replace the air-cleaner element are to be performed in the same way. > 242455 Replacing air cleaner element

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

Removing and installing fuel pipe

1. The steps involved in removing and installing the fuel pipe (fuel distributor pipe, pressure pipe) are identical to those involved in removing and installing the fuel injectors. > 244019 Removing and installing injection valve

Ignition is off, ignition key is removed.

1. Remove intake-air distributor. > 244619 Removing and installing intake-air distributor - section on "Removing"

Scheme 40

1 - Fastening screw M6

2 - Protective cap

3 - Bleeder valve

4 - Fuel injectors

5 - Sealing ring; replace

6 - Retaining clip; check that clip is seated securely

7 - Fuel supply connection

8 - Fuel distributor (or fuel distributor pipe)

9 - Cable plug; check that plug is seated securely

10 - Wiring harness for fuel injectors; clip into place

Removing fuel distributor pipe

> Gasoline is toxic.

> Inhaling vapors can cause irritation of the mucous membranes and eyes.

> It can be carcinogenic. It represents a serious risk to health when inhaled, touched or swallowed over longer periods.

> Only work on the fuel system in well-ventilated rooms.

> Wear protective gloves that are fuel-resistant.

> Wear a breathing mask with active charcoal filter; do not breathe in any fuel vapors.

> Ensure that there is adequate ventilation and extract all fuel vapors.

> Before opening the fuel lines or fuel hoses, relieve the fuel pressure.

> Collect escaping fuel, absorb it if necessary with a suitable binding material and dispose of properly.

> Pay attention to cleanliness when working on the fuel system.

> Keep clear of ignition sources.

> Do not smoke.

> Disconnect battery.

> Danger of fire due to naked flames and sparks, e. g. during welding or grinding work.

> Danger of fire due to escaping fuel, e. g. on hot engine components or due to electrostatic charge. Allow engine to cool down.

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

> Change any clothing soaked with fuel immediately.

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

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

Scheme 41

1. Release fuel injector connectors -arrows A- and pull them off -arrows B- .

Scheme 42

2. Use a screwdriver to press the locking hooks of the cable duct together -arrows A- , then press out in a downward direction -arrow B- and remove the cable duct from the fuel distributor pipe -arrow C- .

Scheme 43

3. Clamp the fuel hose in front of the fuel distributor pipe using a hose clamp -2- . Loosen the spring band clamp on the fuel hose using a spring-band pliers -1- and pull off the fuel hose.

Scheme 44

4. Loosen threaded joint of fuel distributor pipe -arrows- .

5. Carefully pull fuel distributor pipe out of the cylinder head using both hands and set it down on a clean surface.

6. Remove all fuel injectors. > 244019 Removing and installing fuel injector

Installing fuel distributor pipe

Note. Sealing rings on fuel injectors must be replaced!

1. Fit all fuel injectors. > 244019 Removing and installing fuel injector

Note. When installing the fuel distributor pipe, make sure that the fuel injectors do not become tilted!

2. Carefully insert the fuel distributor pipe into the cylinder head using both hands.

3. Tighten the fastening screws on the fuel distribution pipe hand-tight. Tighten fastening screws to the specified tightening torque. --> Tightening torque: 7.5 ftlb.

4. Fit fuel hose to the connection for the fuel distributor pipe and secure with a spring-band clamp -1- . Loosen and remove clamp -2- .

Scheme 45

5. Connect the line for the fuel injectors to the fuel distributor pipe -arrow A- and press it into the brackets -arrows B- until the locking lugs -C- engage audibly.

Scheme 46

6. Push connectors onto the fuel injectors -arrows A- until the locking lugs -B- are felt to engage.

1. Install intake-air distributor. > 244619 Removing and installing intake-air distributor - section on "Installing"

Removing cowl for throttle housing (intake manifold)

1. Remove the design cover -arrow A-. Unscrew the fixing clips -a- and remove both covers -arrows B-. see scheme 75

Scheme 47

2. Release the plug -arrow A- and pull it off -arrow B-. Release the air cleaner cover -arrows C- and lift it up and out -arrow D-. (Scheme 47)

Scheme 48

3. Release clamp -arrow A- and pull suction hose off throttle housing -arrow B-. Pull suction hose away to the right -arrow C-. Release breather hose -arrows D- and pull it off -arrow E-. (Scheme 48)

4. Remove air filter cover with suction hose.

> Only turn the fastening bolts in the correct direction of rotation for opening and closing.

> Turning the fastening bolts carefully ensures that the correct direction of rotation is maintained. The other direction of rotation can be checked using resistance.

5. Disconnect connection on the air cleaner cover. To do this, turn the fastening bolts through 180° and pull them out --> Diagram of fastening bolts (displayed for the V8). Then pull off the intake manifold. see scheme 78

Installing cowl for throttle housing (intake manifold)

> Only turn the fastening bolts in the correct direction of rotation for opening and closing.

> Turning the fastening bolts carefully ensures that the correct direction of rotation is maintained. The other direction of rotation can be checked using resistance.

1. Fit intake manifold and air cleaner cover. To do this, insert fastening bolts and turn them through 180° to secure them.

Scheme 49

2. Insert breather hose -arrow A- until the locking tabs -arrows B- are felt to engage. (Scheme 49)

3. Connect suction hose to throttle body -arrow A-. (Scheme 50)

4. Insert the cover for the air cleaner housing -arrow B- and secure with the retaining clips -arrows C-. (Scheme 50)

Scheme 50

5. Tighten clamp -arrow D-. (Scheme 50)

Scheme 51

6. Plug in connector -arrow A- until the locking tab -arrow B- is felt to engage. (Scheme 51)

7. Push on engine cover -arrow A- until locking tabs are felt to engage. see scheme 82

8. Fit covers -arrows B- and secure with fixing clips -a-. see scheme 82

Removing cowl for throttle housing (Y-shaped pipe) - Cayenne Turbo (type M48/50)

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

Scheme 52

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

Scheme 53

3. Pull off the electrical plugs on the throttle adjuster -1- and unclip the cable. Then pull off the plug on the boost pressure sensor -2-. Twist the two fastening bolts --> View shows the fastening bolts through approx. 45° in an anti-clockwise direction and pull out the bolts. (Scheme 53)and (Scheme 54).

Scheme 54

Scheme 55

4. Loosen the hose clamps to the left and right on the bellows and pull off the bellows.

Scheme 56

5. Pull off the Y pipe from the throttle body and pull off the hose on the Y pipe. To do this, press the button and pull off the hose.

Scheme 57

6. Unclip lines underneath the Y pipe and remove the middle section.

7. Undo intake manifold on the air cleaner cover. To do this, turn the two fastening bolts through 180° --> Fastening bolts and pull the bolts out in an upward direction. Then pull out the intake manifolds. see scheme 90

8. Remove the air tube on the right air cleaner cover. To do this, press off the green cap. Insert a screwdriver into the notch of the cap and lever the cap off.

9. Push the circlip into the flange -1- and then pull it off together with the flange -2-. see scheme 92

10. Clip the green cap on again after disassembly.

Scheme 58

11. Remove the air cleaner covers. To do so, loosen each of the two clamps -arrows- on the top side and remove the cover from the engine compartment in an upward direction. (Scheme 58)

Scheme 59

12. Loosen the two fastening screws of the pressure pipes on the lock support.

Scheme 60

Note. Depending on the routing, the electrical cable belonging to the fans may have to be disconnected on the left side and laid to one side in order to access the fastening screws of the Y pipe.

13. Disconnect the electrical plug of the hot-film mass air flow meter.

Scheme 61

14. To do so, loosen the hose clamp on the bottom of the left hot-film mass air flow meter and remove the component from the engine compartment.

Scheme 62

15. To do this, loosen the two hexagon socket head bolts (a/f 5) of the pressure pipes.

16. Remove the two pressure pipes from the vehicle.

Installing cowl for throttle housing (Y-shaped pipe) - Cayenne Turbo (type M48/50)

1. Insert the pressure pipe parts of the Y pipe into the charge air cooler to the left and right and tighten the two fastening screws. --> Tightening torque: 7.5 ftlb.

2. Install the left hot-film mass air flow meter. Position the lower hose clamp and tighten it. Then connect the electrical plug.

Scheme 63

3. Press the control lead on the bottom of the tubular pieces into the two fastening clips.

4. Connect the cables for the electric fans and clip into the holders.

5. Tighten the holders of the tubular pieces on the lock support.

6. Install the air cleaner covers. To do this, close the two fastening clips on the top side. Push the air line onto the right air cleaner cover.

Scheme 64

7. Press in the intake manifold on the air cleaner in the air cleaner cover. Then insert the two fastening bolts and turn them through 180°. --> Installation of fastening bolts. (Scheme 64)

8. Press the rubber T-piece into the plastic clip on the underside of the Y pipe. Then fit the hose at the bottom.

9. Attach the line to the underside of the Y pipe.

10. Slide the Y pipe onto the throttle body. Push in the two fastening bolts -3- and turn them clockwise through 45°. Fit the electrical plug for the boost pressure sensor -2- and the electrical plug for the throttle adjuster -1-. see scheme 108

11. Slide the bellows onto the tubular pieces to the left and right and tighten the hose clamps.

Scheme 65

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

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

Scheme 66

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

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

Scheme 67

3. 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.

4. Release the fastening bolts on the throttle body. To do this, twist bolts through 45° in an anti-clockwise direction. The spot on the bolts must lie as shown in the picture. --> Fastening bolts. see scheme 114

Scheme 68

5. Remove the fastening bolts. To do this, take hold of the bolt by the rubber ring with pliers and pull it out.

6. Pull off the Y-shaped pipe from the throttle body.

7. Disconnect the air flow sensor connections. To do this, undo the hose clamps to the left and right on the bellows and pull the bellows off the air flow sensors.

8. Remove the hose on the Y pipe. To do this, press the button and disconnect the vacuum line.

Installing cowl for throttle housing (Y-shaped pipe) - Cayenne S (type M48/00)

1. Attach the vacuum line to the underside of the Y-shaped pipe.

2. Slide the bellows onto the air flow sensors and tighten the hose clamps.

Scheme 69

3. Slide the Y-shaped pipe onto the throttle adjuster. Then insert the left and right fastening bolts. Turn the bolts 45° clockwise. --> Fastening bolts. (Scheme 69)

4. Connect the throttle adjuster. The plug must engage audibly. Clip the connecting cable into the sheetmetal holder.

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

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

Preliminary work for removing fuel injectors

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

2. Remove design covers from engine. Refer to 10 83 19 Removing and installing design cover. - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

Scheme 70

Scheme 71

1 - Intake-air distributor

2 - Positive crankcase ventilation (T flange)

3 - K50 x 12 lens-head screw --> Tightening torque: 1.6 ftlb.

4 - Cap; replace

5 - Valve insert

6 - M6 x 10 oval-head screw

7 - Fuel gallery; do not bend

8 - Fuel injector

9 - Safety clip

Removing injection valve

Ignition is off, ignition key is removed.

Scheme 72

> Gasoline is toxic.

> Inhaling vapors can cause irritation of the mucous membranes and eyes.

> It can be carcinogenic. It represents a serious risk to health when inhaled, touched or swallowed over longer periods.

> Only work on the fuel system in well-ventilated rooms.

> Wear protective gloves that are fuel-resistant.

> Wear a breathing mask with active charcoal filter; do not breathe in any fuel vapors.

> Ensure that there is adequate ventilation and extract all fuel vapors.

> Before opening the fuel lines or fuel hoses, relieve the fuel pressure.

> Collect escaping fuel, absorb it if necessary with a suitable binding material and dispose of properly.

> Pay attention to cleanliness when working on the fuel system.

> Keep clear of ignition sources.

> Do not smoke.

> Disconnect battery.

> Danger of fire due to naked flames and sparks, e. g. during welding or grinding work.

> Danger of fire due to escaping fuel, e. g. on hot engine components or due to electrostatic charge. Allow engine to cool down.

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

> Change any clothing soaked with fuel immediately.

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

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

1. Disconnect fuel line -1- and line -2- from the carbon canister on the radiator tank splash panel. (Scheme 72)

Scheme 73

2. Disconnect the electric connectors to the eight fuel injectors. To do this, press the metal clip on the plug and pull off the plug.

Scheme 74

3. Unscrew the four fastening screws on the fuel distribution pipe.

4. Remove fuel distribution pipe with the fuel injectors.

Scheme 75

5. Pull off the clamp on the fuel injector -A- and pull the fuel injector out of the fuel distribution pipe -B -. (Scheme 75)

Installing fuel injector

Note. If the fuel injectors are to be reused, the sealing rings should be replaced.

1. Replace sealing rings on the injection valves. Take care not to damage the fuel injector when removing the sealing rings.

Scheme 76

2. Insert injection valve into the fuel distribution pipe and align. The electric connector must be positioned opposite the lug on the distributor. Then fit sheetmetal clips -arrow-. (Scheme 76)

Scheme 77

3. Insert the fuel injector into the fuel distribution pipe -A- and insert the clamp on the fuel injector -B -. (Scheme 77)

Scheme 78

4. Check that the sheetmetal clip is correctly fitted. The sheetmetal clip must engage in the flanged edge on the fuel distribution pipe.

5. Insert fuel injectors into the openings in the intake module and press the fuel gallery down.

6. Tighten the four fastening screws to the specified torque. --> Tightening torque: 6 ftlb.

7. Connect the 8 electric connectors to the injection valves. The connectors must engage audibly.

8. Connect fuel line -1- and line -2- from the carbon canister on the radiator tank splash panel. see scheme 134

9. Switch on ignition and check the system for leaks.

Work subsequent to installing injection valves

1. Install design covers for engine. Refer to 10 83 19 Removing and installing design cover. - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

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

1. Ignition off, ignition key removed.
2. No sources of ignition in the vicinity.
3. Ensure adequate ventilation.

1. Remove fuel distributor pipe. > 243019 Removing and installing fuel distributor pipe - chapter on "Removing"

Removing fuel injectors

1. Pull clamp off fuel injector -A- and pull fuel injector out of fuel distributor pipe -B-. see scheme 136

Installing fuel injectors

Note. If the fuel injectors are to be reused, the sealing rings should be replaced.

1. Replace sealing rings on fuel injectors. Take care not to damage fuel injector when removing sealing rings.

2. Insert fuel injector into the fuel distributor pipe -A- and fit clamp on the fuel injector -B-. see scheme 137

3. Check that the sheetmetal clip is correctly fitted. The sheetmetal clip must engage in the flanged edge on the fuel distributor pipe.

1. Install fuel distributor pipe together with fuel injectors. > 243019 Removing and installing fuel distributor pipe

1. Remove Y-shaped pipe (intake manifold in front of throttle housing). > 243519 Removing and installing air box for throttle housing (Y-pipe) - section on "Removing" [9PAAE1 9PAAE7 9PAAK1] > 243519 Removing and installing air box for throttle housing (Y-pipe) - section on "Removing" [9PAAF1 9PAAJ1]

Scheme 79

1 - Intake-air distributor and throttle housing

2 - Seals for intake-air distributor; replace

3 - Seal for throttle adjuster; replace

4 - Throttle adjuster; do not actuate by hand

5 - Support for throttle body cover; secure with the fastening screws for the throttle adjuster

6 - Fastening screw, M6 x 45

7 - Fastening screws

1. Pull off cable plug on the throttle housing and pull cable out of the clip -Arrows-. see scheme 140

Scheme 80

2. Undo four screws on the throttle housing -Arrows-. Loosen sheetmetal reinforcement around the throttle housing. Remove throttle housing. (Scheme 80)

Scheme 81

3. Check condition of sealing ring. Replace sealing ring if necessary --> Sealing ring for throttle housing. (Scheme 81)

Installing throttle housing

1. Check condition of sealing ring. Replace sealing ring if necessary --> Sealing ring for throttle housing. see scheme 143

2. Move throttle housing into installation position and place sheetmetal reinforcement around the throttle housing. Insert and screw in four screws -Arrows-. --> Tightening torque: 8 (6 ftlb.) Nm. see scheme 144

3. Attach cable plug to throttle housing and insert cable into clip -Arrows-. see scheme 145

1. Install Y-shaped pipe (intake manifold in front of throttle housing). > 243519 Removing and installing air box for throttle housing (Y-pipe) - section on "Installing" [9PAAE1 9PAAE7 9PAAK1] > 243519 Removing and installing air box for throttle housing (Y-pipe) - section on "Installing" [9PAAF1 9PAAJ1]

Tools

1. Move bonnet to service position using bonnet stay P 9704 .

2. Disconnect battery. --> 90 IN WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY - AS OF MY 2003 (ALL MODELS EXCEPT CAYENNE S TIO TITAN) .

3. Put on the protection covers.

Scheme 82

4. Pull the design cover up and off.

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

Scheme 83

6. Remove connecting tube from air cleaner to engine. To do this, loosen the hose clamp on the engine, unplug the electric connector on the hot-film mass air flow meter and remove the two fastening pins on the air cleaner cover -arrows-. (Scheme 83)

Scheme 84

7. Remove vacuum line on throttle housing from connecting tube -arrow-. Then take the intake manifold out of the engine compartment. (Scheme 84)

Installing throttle body

1. Check condition of sealing ring for throttle housing. Replace sealing ring if necessary. Place throttle housing in installation position. Insert the four screws on the throttle housing and tighten -arrows-. --> Tightening torque: 10 (7.5 ftlb.) Nm. see scheme 152

2. Fit cable plug and cable to throttle housing -arrows-. see scheme 153

1. Place intake manifold in installation position. Connect vacuum line on throttle body to the connecting pipe.

2. Fit connector tube from air cleaner to engine. To do this, fasten the hose clamp on the engine, connect the electric connector on the hot-film mass air flow meter and insert the two fastening bolts on the air cleaner cover -arrows-. see scheme 155

Scheme 85

3. Press the design cover back on to the ball heads.

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

5. Remove protective covers, connect battery and fasten bonnet.

Removing air flow sensor - Cayenne Turbo (type M48/50)

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

2. Disconnect the relevant connection on the air cleaner cover. To do this, turn the pins through 180° and pull them out. Then pull off the intake manifolds.

Note. Items 3 to 5 must only be carried out on the right-hand air flow sensor.

3. Remove the air tube on the right air cleaner cover. To do this, unclip the green cap. Insert a screwdriver into the notch of the cap and lever the cap off.

4. Push the snap ring into the flange -1- and then pull it off together with the flange -2-. see scheme 161

5. Clip the green cap on again after disassembly.

6. The coolant bleeder hose on the coolant expansion tank should be unclipped from the air cleaner housing cover of the cylinder bank 1 - 4.

7. Remove the relevant air cleaner cover. To do so, loosen the two fastening clips on the top side and remove the cover from the engine compartment in an upward direction.

8. Disconnect the electrical plug of the air flow sensor.

9. Loosen the hose clamp on the bottom of the air flow sensor and remove the component from the engine compartment.

Scheme 86

10. Then undo the two fastening screws and remove the flange.

Installing air flow sensor - Cayenne Turbo (type M48/50)

1. Place the air flow sensor on the flange of the air cleaner and tighten the two fastening screws.

2. Insert the air flow sensor in the connection for the turbocharger and tighten the hose clamp. Connect the electrical plug to the air flow sensor.

3. Place the cover on the air cleaner housing and run in from top to bottom. Make sure that the three mounting elements run into the mounting points on the underside. The figure gives a clearer view of the dismantled air cleaner housing.

4. Push cover up against the air cleaner housing and release the two fastening clips.

5. The coolant bleeder hose and the coolant overflow hose must be clipped back onto the cylinder bank 1 - 4 on the air cleaner housing.

6. Push the air suspension line onto the right air cleaner cover.

7. Push the connections onto the cover of the air cleaner housing and mount and lock the fastening pins.

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

Removing air flow sensor - Cayenne S (type M48/00)

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

Scheme 87

2. Separate electric connections on the air flow sensor.

3. Disconnect the air flow sensor connections. To do this, undo the hose clamps to the left and right on the bellows and pull the bellows off the air flow sensors.

Scheme 88

4. Pull out retaining clip on the air flow sensor. --> Clamp for hot-film mass air flow meter. (Scheme 88)

5. Pull out air flow sensor.

Scheme 89

1. Insert air flow sensor in the pipe on the air cleaner housing cover. When doing so, observe the flow direction. There is a small arrow on the housing which must point towards the engine. Then connect the retaining clip.

2. Connect the bellows and tighten the hose clamps.

3. Connect electric connector to the air flow sensor.

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

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

2. Pull design cover straight up and off.

Removing air flow sensor

Note. The air flow sensor and air guide pipe are removed and installed as a single component.

1. Remove connecting tube from the air cleaner to the engine. To do so, loosen the hose clamp on the throttle adjuster and pull off the pipe. Disconnect cable plug from air flow sensor.

Scheme 90

2. Disconnect connections on air cleaner lid. To do this, turn the pins by 180° and pull them out -see illustration (V8 is shown here)-. Now pull off the connecting tube. see scheme 185

3. Remove vacuum line on throttle body from connector tube.

Scheme 91

4. Loosen hose clamp of connecting tube to the air flow sensor and carefully press in the two plastic clips on the air cleaner side. Disconnect air flow sensor from the connecting tube. If necessary, lever out with a small screwdriver. -arrow-. (Scheme 91)

Installing air flow sensor

1. Press air flow sensor onto connecting tube. Make sure the clip connections on the air cleaner side engage correctly. Fasten hose clamp.

2. Move connecting tube to installation position and connect vent line to throttle adjuster.

3. Press connecting tube onto throttle adjuster and tighten hose clamp. Push electric connector onto air flow sensor -arrow-. see scheme 189

4. Place intake manifold in installation position.

5. Lock the locking pins.

1. Press on design cover and check that it is seated correctly.

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

Scheme 92

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

2. Disconnect connection on the air cleaner lid. To do this, turn the pins by 180° and pull them out. Then pull off the intake pipe.

Required tools

1. Push the connections onto the cover of the air cleaner housing and mount and lock the fastening pins.

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

Preliminary work for removing intake distributor

1. Move bonnet to service position using bonnet stay P 9704 .

2. Disconnect battery. --> 90 IN WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY - AS OF MY 2003 (ALL MODELS EXCEPT CAYENNE S TIO TITAN) .

3. Put on the protection covers.

4. Pull the design cover up and off.

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

6. Remove connector tube from air cleaner to engine. To do this, loosen the hose clamp on the engine, unplug the electric connector on the hot-film mass air flow meter and remove the two fastening pins on the air cleaner cover -arrows-. see scheme 204

7. Remove the vacuum line on the throttle body from the connector tube. Then take the intake manifold out of the engine compartment.

8. Remove cover of air cleaner housing by loosening the clamps -arrows- and pulling off the cover. see scheme 206

9. Separate the six ignition coils from the wiring loom. To do this, press the connectors slightly downwards -arrow A-, release them using a suitable auxiliary tool (e. g. an angled wire) -arrow B- and remove them -arrow C-. (Scheme 93)

Scheme 93

Installing intake-air distributor

Note. The intake-air distributor seal must always be replaced.

1. Clean sealing surfaces and insert new seal into the intake distributor. Make sure that the dowel sleeves of the fastening screws are seated correctly in the seal.

Note. Make sure that the vacuum unit and the oil dip stick tube do not hinder the installation of the intake-air distributor.

2. First position the intake distributor on the inlet side and then press it down on the exhaust side.

Note. A mirror is very useful for inserting the fastening screws on the intake distributor.

3. Insert all nine hexagon socket head fastening screws (M7 x 40) into the intake distributor on the inlet side. Ensure that all screw holes are positioned correctly in front of their fastening points and that no components (e. g. wires) are jammed.

4. Tighten all nine hexagon socket head fastening screws (M7 x 40) on the inlet side. --> Tightening torque: 9.5 ftlb.

5. Fit vacuum unit into rubber mounts. Insert dipstick tube into the crankcase bore, while checking that the sealing ring on the tube is positioned correctly in the bore. Insert dipstick. Move dipstick tube into installation position and screw in two M6 nuts -1 and 2- into the vacuum unit support. --> Tightening torque: 7.5 ftlb.. see scheme 219

6. Insert vacuum line into the vacuum unit on the inlet side.

7. Fit three M8 hexagon socket head bolts on exhaust side -arrows- (two at the side and one fastening screw on center of heat shield). --> Tightening torque: 17 ftlb.. see scheme 221

8. Move vacuum lines into installation position.

9. Connect plastic connectors of vacuum lines to the flanges of the intake distributor -arrows-. see scheme 222

10. Connect cable plug on intake-air distributor flange -arrows-. see scheme 223

11. Connect positive crankcase ventilation plug on cylinder head cover -1-. see scheme 224

12. Press in plastic connectors on the flange and fit wires -3 and 4-. see scheme 224

13. Move vacuum unit into installation position and fit vacuum unit fastening screw (M6 x 20 hexagon socket head bolt) -2- to 7.5 ftlb. --> Tightening torque: 7.5 ftlb.. see scheme 224

14. Attach cable plugs and cable to throttle adjuster -arrows-. see scheme 225

15. Fit wiring harness to the left and right on the intake distributor. To do this, fasten the cable clips -arrows-. see scheme 226

Scheme 94

1. Re-connect ignition coil plugs to the ignition coils.

2. Install cover of air cleaner housing by clipping in the clamps -arrows-. see scheme 228

3. Fit connector tube from air cleaner to engine. To do this, fasten the hose clamp on the engine, connect the electric connector on the hot-film mass air flow meter and insert the two fastening bolts on the air cleaner cover -arrows-. see scheme 229

4. Then move the intake manifold to installation position. Connect vacuum line on throttle body to the connector tube.

5. Press the design cover back on to the ball heads.

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

7. Remove protective covers, connect battery and fasten bonnet.

1. Remove design cover. Refer to 10 83 19 Removing and installing design cover. - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

Scheme 95

I - Curved hose

II - Check valve

III - Hose

A - Vacuum line closed

B - Vacuum line closed

1 - Intake-air distributor and throttle housing

2 - Seals for intake-air distributor; replace

3 - Seal for throttle adjuster; replace

4 - Throttle adjuster; do not actuate by hand

5 - Support for throttle body cover; secure with the fastening screws for the throttle adjuster

6 - Fastening screw, M6 x 45

7 - Fastening screws

Removing intake-air distributor

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

1. 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.

> Only turn the fastening bolts in the correct direction of rotation for opening and closing.

2. Release the fastening bolts on the throttle body. To do this, twist the right and left pin through 45° in an anti-clockwise direction.

3. Remove the fastening bolts. To do this, take hold of the bolt by the rubber ring with pliers and pull it out.

4. Pull off the Y-shaped pipe from the throttle body.

5. Disconnect the air flow sensor connections. To do this, undo the hose clamps to the left and right on the bellows and pull the bellows off the air flow sensors.

6. Remove the vacuum line on the Y-shaped pipe. To do this, press the button and disconnect the vacuum line.

Scheme 96

7. Disconnect the vacuum line on the rear of the intake system.

Scheme 97

8. Disconnect positive crankcase ventilation line on the two valve covers. To do this press the plastic ring and pull the connections. Then remove the positive crankcase ventilation line from the retaining clip.

Scheme 98

Scheme 99

9. Then remove the line between the oil mist collector and the intake distributor.

> Keep clear of ignition sources.

> Do not smoke.

> Disconnect battery.

> Danger of fire due to naked flames and sparks, e. g. during welding or grinding work.

> Danger of fire due to escaping fuel, e. g. on hot engine components or due to electrostatic charge. Allow engine to cool down.

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

> Change any clothing soaked with fuel immediately.

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

> Gasoline is toxic.

> Inhaling vapors can cause irritation of the mucous membranes and eyes.

> It can be carcinogenic. It represents a serious risk to health when inhaled, touched or swallowed over longer periods.

> Only work on the fuel system in well-ventilated rooms.

> Wear protective gloves that are fuel-resistant.

> Wear a breathing mask with active charcoal filter; do not breathe in any fuel vapors.

> Ensure that there is adequate ventilation and extract all fuel vapors.

> Before opening the fuel lines or fuel hoses, relieve the fuel pressure.

> Collect escaping fuel, absorb it if necessary with a suitable binding material and dispose of properly.

> Pay attention to cleanliness when working on the fuel system.

Note. Before the lines are opened, place a cloth or a suitable container underneath them! Collect escaping fuel.

10. Disconnect fuel line -1- and line -2- to the carbon canister on the radiator tank splash panel. see scheme 244

11. Disconnect the electric connectors to the eight fuel injectors. To do this, press the metal clip on the plug and pull off the plug.

12. Unscrew the fastening screws on the intake distributor in the sequence shown below. --> Loosening order for suction module. (Scheme 100)

Scheme 100

13. Remove intake distributor from the engine in an upward direction.

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

Scheme 101

1. Replace intake distributor gaskets.

2. Place intake-air distributor on the engine and tighten the screws in the sequence shown below. --> Tightening sequence for suction module --> Initial tightening: 7.5 ftlb. --> Final tightening: 11 ftlb.. (Scheme 102)

Scheme 102

3. Connect the 8 electric connectors to the injection valves. The connectors must engage audibly.

4. Install positive crankcase ventilation line. The 2 connections must audibly engage. Then close the mounting clip.

5. Install line between intake distributor and oil mist collector.

> Gasoline is toxic.

> Inhaling vapors can cause irritation of the mucous membranes and eyes.

> It can be carcinogenic. It represents a serious risk to health when inhaled, touched or swallowed over longer periods.

> Only work on the fuel system in well-ventilated rooms.

> Wear protective gloves that are fuel-resistant.

> Wear a breathing mask with active charcoal filter; do not breathe in any fuel vapors.

> Ensure that there is adequate ventilation and extract all fuel vapors.

> Before opening the fuel lines or fuel hoses, relieve the fuel pressure.

> Collect escaping fuel, absorb it if necessary with a suitable binding material and dispose of properly.

> Pay attention to cleanliness when working on the fuel system.

> Keep clear of ignition sources.

> Do not smoke.

> Disconnect battery.

> Danger of fire due to naked flames and sparks, e. g. during welding or grinding work.

> Danger of fire due to escaping fuel, e. g. on hot engine components or due to electrostatic charge. Allow engine to cool down.

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

> Change any clothing soaked with fuel immediately.

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

6. Connect fuel line -1- and line -2- from the carbon canister on the radiator tank splash panel. see scheme 252

7. Connect vacuum line to the rear of the intake distributor. The plug must engage audibly.

8. Attach the vacuum line to the underside of the Y-shaped pipe.

9. Slide the bellows onto the air flow sensors and tighten the hose clamps.

> Only turn the fastening bolts in the correct direction of rotation for opening and closing.

10. Slide the Y-shaped pipe onto the throttle adjuster. Then insert the left and right fastening bolts. Turn the right and left bolts 45° clockwise.

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

Subsequent work for installing intake distributor

1. Install design cover. Refer to 10 83 19 Removing and installing design cover. - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

1. Remove intake-air distributor. > 244619 Removing and reinstalling intake-air distributor - section on "Removing"

Scheme 103

1. Remove three screws on the front bearing cover -1-. (Scheme 103)

Scheme 104

2. Remove two screws on the rear bearing cover -1-. (Scheme 104)

Scheme 105

3. Use a screwdriver to carefully lever the deflection lever off the roller shaft --> Levering off bearing cover. Only release the deflection lever as far as is necessary to allow it to disengage from the roller shaft catch --> Removing deflection lever. (Scheme 105), (Scheme 106).

Scheme 106

Scheme 107

4. Hold the bearing cover at the vacuum unit and lever it off -1-. Check sealing ring and replace if necessary. -2-. (Scheme 107)

Scheme 108

5. Carefully lever off the front bearing cover with a screwdriver --> Levering off front bearing cover and remove bearing cover. The bearing cover is very tight because of the sealing ring. Work carefully. Check sealing ring and replace if necessary. (Scheme 108)

Scheme 109

6. Push controller drum out to the rear. To do this, press firmly at the front and take the controller drum out through the rear opening -arrows-. Pull the controller drum out by pulling it firmly. If necessary, drive the controller drum out carefully with a rubber hammer. (Scheme 109)

7. Check sealing rings and replace if necessary -1-. The controller drum has two plastic bearings in the middle. Check these for smooth operation. (Scheme 110)

Scheme 110

1. Install intake-air distributor. > 244619 Removing and reinstalling intake-air distributor - section on "Installing"

Designation Type Number Explanation key VW-tool T10202

Note. The fuel filter is located under the left connection unit, and the pressure regulator is under the right connection unit. The procedure "Open tank" can be applied to both connection units (right pressure regulator, left fuel filter)

1. Empty the fuel tank. Refer to 20 03 Draining and filling fuel - as of MY 2003 (All Models) .

Opening the tank

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

Installation Location

Scheme 111

1. Open filler flap.

2. Fold rear seat forwards.

Scheme 112

3. Fold up the retaining brackets of the (right and left) seat-belt buckles. To do so, loosen the four fastening screws and fold up the bracket with the seat-belt buckle. Do not use the fastening screws again.

Scheme 113

4. Undo the caps (figure shows both). To do so, cut out the carpeted floor along the perforated lines using a carpet knife and fold it over. Then unscrew the four fastening nuts and remove the lid.

5. Empty the fuel tank if this has not already been done or if the fuel level in the fuel tank is very low. Refer to 20 03 Draining and filling fuel - as of MY 2003 (All Models) .

Scheme 114

> Gasoline is toxic.

> Inhaling vapors can cause irritation of the mucous membranes and eyes.

> It can be carcinogenic. It represents a serious risk to health when inhaled, touched or swallowed over longer periods.

> Only work on the fuel system in well-ventilated rooms.

> Wear protective gloves that are fuel-resistant.

> Wear a breathing mask with active charcoal filter; do not breathe in any fuel vapors.

> Ensure that there is adequate ventilation and extract all fuel vapors.

> Before opening the fuel lines or fuel hoses, relieve the fuel pressure.

> Collect escaping fuel, absorb it if necessary with a suitable binding material and dispose of properly.

> Pay attention to cleanliness when working on the fuel system.

> Keep clear of ignition sources.

> Do not smoke.

> Disconnect battery.

> Danger of fire due to naked flames and sparks, e. g. during welding or grinding work.

> Danger of fire due to escaping fuel, e. g. on hot engine components or due to electrostatic charge. Allow engine to cool down.

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

> Change any clothing soaked with fuel immediately.

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

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

6. Carefully remove the fuel supply -1- at the relevant connection unit (right connection unit here) and loosen the two disconnection points -2 and 3-. Also remove line (not shown here) in vehicles with auxiliary heating (auxiliary heater). Do the same at the left connection unit. Disconnect all connections on the connection unit. (Scheme 114)

Scheme 115

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

Scheme 116

1 - Fuel pressure line

2 - Electric connection for fuel pump

3 - Connection to fuel delivery unit right and left (unpressurized)

4 - Pressure regulator input from fuel filter

5 - Electric connection for fuel level indicator

6 - Fuel pressure regulator; 4 bar supply pressure

Scheme 117

1. Pull off electric connectors -1 and 2-. Then pull off the fuel lines -3 and 4- and remove the connection unit (pressure regulator). (Scheme 117)

Installing fuel pressure regulator

Note. The pressure regulator is integrated into the connection unit. The connection unit together with integrated pressure regulator is replaced as a complete unit and not disassembled.

Scheme 118

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

2. Connect the connection unit. Fit electric connector -1 and 2- and hose connections -3 and 4-. see scheme 277

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

Closing the tank

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

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

3. Fit the lid. Then tighten the four fastening nuts. --> Tightening torque: 7.5 ftlb. Refit carpeted floor and fix with double-sided adhesive tape.

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

5. Fold rear seat down again.

6. Fill fuel tank (refuel). Refer to 20 03 Draining and filling fuel - as of MY 2003 (All Models) .

1. Fill fuel tank (refuel). Refer to 20 03 Draining and filling fuel - as of MY 2003 (All Models) .

Designation Type Number Explanation Torque wrench, signal-transmitting with changeover ratchet commercially available tool NR.90 Only in combination with wrench inserts Accessory for torque wrench: Open ring wrench angled commercially available tool NR.96-3 various overall lengths, e. g. Hazet 4681-1 to 3 Accessory for torque wrench: Open ring wrench angled commercially available tool NR.97 various overall lengths, e. g. Hazet 4681-1 to 3 Accessory for torque wrench: Open ring wrench angled assembly commercially available tool NR.98 various overall lengths, e. g. Hazet 4681-1 to 3

Scheme 119

Preliminary work for removing oxygen sensors in front of catalytic converter - Cayenne S (M48/00)

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

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

3. Remove engine compartment cover above the oxygen sensor plugs. Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .

Scheme 120

4. Disconnect oxygen sensor plug for the oxygen sensor in front of catalytic converter at the right of the water splash panel and unclip the cable from the holder.

5. Remove air cleaner housing > 242519 Removing and installing air cleaner housing - "Removing" section .

> Only remove the exhaust system once it has cooled down.

> Wear protective gloves.

6. Release oxygen sensor wire from the cable guide and leave it at the oxygen sensor.

Scheme 121

> Special tools - oxygen sensors - Accessory for torque wrench: Open ring wrench angled NR.96-3. (Scheme 120)

> Special tools - oxygen sensors - Accessory for torque wrench: Open ring wrench angled NR.97. (Scheme 120)

> Special tools - oxygen sensors - Accessory for torque wrench: Open ring wrench angled assembly NR.98. (Scheme 120)

> Special tools - oxygen sensors - Torque wrench, signal-transmitting with changeover ratchet NR.90. (Scheme 120)

Removing oxygen sensors in front of catalytic converter - Cayenne S (M48/00)

> Always release oxygen sensor cable so that the wire can turn when unscrewing or screwing in the sensor.

> Do not kink cable.

Scheme 122

1 - Exhaust manifold, cylinders 1 -4

2 - Exhaust manifold, cylinders 5 - 8

3 - Seal for exhaust manifold; replace

4 - M8 hexagon nut; replace, coat thread of bolts with Microgleit

5 - Oxygen sensor ahead of catalytic converter

6 - Oxygen sensor ahead of catalytic converter

7 - Seal; replace

8 - M8 hexagon nut; replace

9 - Catalytic converter, front

10 - Catalytic converter, front

11 - Support

12 - Support

13 - Hexagon-head bolt M10 x 25

14 - Hexagon-head bolt, M8 x 15

15 - Stud M8 x 25

16 - Oxygen sensor behind catalytic converter

17 - Seal; replace

18 - Catalytic converter

19 - Catalytic converter

20 - Screw

21 - Bracket

22 - Bracket

23 - Bracket

24 - Hexagon-head bolt, M8 x 25

1. Remove the oxygen sensor in the exhaust manifold using a mirror. To do this, screw out the oxygen sensor with an open-ended wrench SW 22.

Scheme 123

> Always expose oxygen sensor cable so that the wire can turn when unscrewing or screwing in the sensor.

> Do not kink cable.

1. Preassemble the oxygen sensor in the exhaust manifold by hand using a mirror. Tighten oxygen sensor using a special tool. > 246919 Removing and installing oxygen sensor ahead of catalytic converter - "Tools and materials" section --> Tightening torque: 33 ftlb. +/-3.5 ftlb.

Scheme 124

Touching up for installing oxygen sensors in front of catalytic converter - Cayenne S (M48/00)

1. Push oxygen sensor wire into the cable guide.

2. Connect the oxygen sensor plug for the oxygen sensor in front of catalytic converter at the right of the water splash panel and clip the wires into the guide. Fit cable plug.

3. Install air cleaner housing > 242519 Removing and installing air cleaner housing - chapter on "installing" .

4. Fit engine compartment cover above the oxygen sensor plugs. Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .

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

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

Designation Type Number Explanation Torque wrench, signal-transmitting with changeover ratchet commercially available tool NR.90 Only in combination with wrench inserts Accessory for torque wrench: Open ring wrench angled commercially available tool NR.96-3 various overall lengths, e. g. Hazet 4681-1 to 3 Accessory for torque wrench: Open ring wrench angled commercially available tool NR.97 various overall lengths, e. g. Hazet 4681-1 to 3 Accessory for torque wrench: Open ring wrench angled assembly commercially available tool NR.98 various overall lengths, e. g. Hazet 4681-1 to 3

Scheme 125

> Only remove the exhaust system once it has cooled down.

> Wear protective gloves.

1. Loosen and bend primary catalytic converter (primary catalytic converter does not need to be removed completely). For details see. Refer to 26 76 19 Removing and installing primary catalytic converter - Cayenne Turbo - as of MY 2003 (Cayenne Turbo, Cayenne Turbo S) .

Tools - oxygen sensor

> Special tools - oxygen sensors - Accessory for torque wrench: Open ring wrench angled NR.96-3. see scheme 289

> Special tools - oxygen sensors - Accessory for torque wrench: Open ring wrench angled NR.97. see scheme 289

> Special tools - oxygen sensors - Accessory for torque wrench: Open ring wrench angled assembly NR.98. see scheme 289

> Special tools - oxygen sensors - Torque wrench, signal-transmitting with changeover ratchet NR.90. see scheme 289

Scheme 126

1 - Exhaust manifold

2 - Seal for exhaust manifold; replace

3 - M8 hexagon nut; replace

4 - M8 x 75 turbocharger fastening screw

5 - Seal for exhaust turbocharger; replace

6 - Oxygen sensor ahead of catalytic converter

7 - Seal; replace

8 - M8 hexagon nuts

9 - Primary catalytic converter

10 - Primary catalytic converter

11 - Support

12 - Support

13 - Fastening screw for support, M10 x 25

14 - Hexagon-head bolt, M8 x 15

15 - Oxygen sensor behind catalytic converter

16 - Seal; replace

17 - Main catalytic converter

18 - Main catalytic converter

19 - Stud

20 - Bracket for main catalytic converter

21 - Bracket for main catalytic converter

22 - Bracket for main catalytic converter

23 - Hexagon-head bolt, M8 x 25

> Always expose oxygen sensor cable so that the wire can turn when unscrewing or screwing in the sensor.

> Do not kink cable.

1. Carefully unscrew oxygen sensors on primary catalytic converter.

Installing oxygen sensors in front of catalytic converter - Cayenne Turbo (M48/50)

1. Position the oxygen sensor by hand and screw in as far as possible.

2. Tighten oxygen sensor using special tool > 247319 Removing and installing oxygen sensors behind catalytic converter - "Tools and materials section" . --> Tightening torque: 33 ftlb. +/-3.5 ftlb.

Subsequent work: installing oxygen sensors in front of catalytic converter - Cayenne Turbo (M48/50)

1. Install primary catalytic converter. Refer to 26 76 19 Removing and installing primary catalytic converter - Cayenne Turbo - as of MY 2003 (Cayenne Turbo, Cayenne Turbo S) .

Designation Type Number Explanation Torque wrench, signal-transmitting with changeover ratchet commercially available tool NR.90 Only in combination with wrench inserts Accessory for torque wrench: Open ring wrench angled commercially available tool NR.96-3 various overall lengths, e. g. Hazet 4681-1 to 3 Accessory for torque wrench: Open ring wrench angled commercially available tool NR.97 various overall lengths, e. g. Hazet 4681-1 to 3 Accessory for torque wrench: Open ring wrench angled assembly commercially available tool NR.98 various overall lengths, e. g. Hazet 4681-1 to 3 bonnet stay special tool P 9704

Scheme 127

1 - Cylinder head

2 - Exhaust manifold seal

3 - M8 fastening nut; replace

4 - Exhaust manifold

5 - Flange gasket; replace

6 - Primary catalytic converter, cylinders 1, 2 and 3

7 - Primary catalytic converter, cylinders 4, 5 and 6

8 - Oxygen sensor in front of catalytic converter, cylinders 1, 2 and 3

9 - Oxygen sensor in front of catalytic converter, cylinders 4, 5 and 6

10 - (Main) catalytic converter

11 - Fastening screws M8

12 - Oxygen sensor behind catalytic converter, cylinders 1, 2 and 3

13 - Oxygen sensor behind catalytic converter, cylinders 4, 5 and 6

14 - Heat shield

15 - Fastening screw M8

16 - Fastening screws M8 for intake distributor

17 - Support for intake distributor

18 - Side fastening screws M8 for intake distributor

> Only remove the exhaust system once it has cooled down.

> Wear protective gloves.

Note. Please read the most important working regulations and warning notes. Refer to 10 01 AW The most important working regulations and warning notes - as of MY 2003 (All Models Except Cayenne S TIO Titan) .

1. Move bonnet to service position using bonnet stay P 9704 .

2. Put on the protection covers.

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

4. Pull the design cover vertically upwards and off.

> Special tools - oxygen sensors - Accessory for torque wrench: Open ring wrench angled NR.96-3. see scheme 294

> Special tools - oxygen sensors - Accessory for torque wrench: Open ring wrench angled NR.97. see scheme 294

> Special tools - oxygen sensors - Accessory for torque wrench: Open ring wrench angled assembly NR.98. see scheme 294

> Special tools - oxygen sensors - Torque wrench, signal-transmitting with changeover ratchet NR.90. see scheme 294

Removing oxygen sensors ahead of catalytic converter

> The connector color of the oxygen sensor cable for the oxygen sensor behind the catalytic converter must match the color of the oxygen sensor cable plug of the oxygen sensor ahead of the catalytic converter in the same exhaust assembly (brown to brown and black to black).

> Do not interchange oxygen sensors.

Note. Cable plugs 1 and 2 belong to the oxygen sensors behind catalytic converter, while plugs 3 and 4 belong to the oxygen sensors in front of catalytic converter. The colors of the cable plugs are the same for each exhaust assembly.

Note. Mark oxygen sensors as you unscrew them so that the oxygen sensors are not confused.

Scheme 128

1 - Bore for oxygen sensor behind catalytic converter, cylinders 4, 5 and 6; brown cable plug for oxygen sensor

2 - Bore for oxygen sensor ahead of catalytic converter, cylinders 4, 5 and 6; brown cable plug for oxygen sensor

3 - Bore for oxygen sensor ahead of catalytic converter, cylinders 1, 2 and 3; black cable plug for oxygen sensor

4 - Bore for oxygen sensor behind catalytic converter, cylinders 1, 2 and 3; black cable plug for oxygen sensor (in this case oxygen sensor is fitted)

Scheme 129

> Always expose oxygen sensor cable so that the wire can turn when unscrewing or screwing in the sensor.

> Do not kink cable.

1. Disconnect cable plugs of oxygen sensors ahead of catalytic converter -3 and 4- and expose them. see scheme 296

Scheme 130

Scheme 131

2. Unscrew both oxygen sensors with a ring or open-ended wrench (a/f 22) -1-. (Scheme 128)

Installing oxygen sensors ahead of catalytic converter

> The connector color of the oxygen sensor cable for the oxygen sensor behind the catalytic converter must match the color of the oxygen sensor cable plug of the oxygen sensor ahead of the catalytic converter in the same exhaust assembly (brown to brown and black to black).

> Do not interchange oxygen sensors.

> Always expose oxygen sensor cable so that the wire can turn when unscrewing or screwing in the sensor.

> Do not kink cable.

Note. Cable plugs 1 and 2 belong to the oxygen sensors behind catalytic converter, while plugs 3 and 4 belong to the oxygen sensors in front of catalytic converter. The colors of the cable plugs are the same for each exhaust assembly.

Note. Mark oxygen sensors as you unscrew them so that the oxygen sensors are not confused.

1. Position oxygen sensors by hand and screw in as far as possible.

2. Position oxygen sensors behind catalytic converter -1- by hand and screw in as far as possible. (Scheme 129)

3. Tighten oxygen sensors using special tool > 246920 Removing and installing oxygen sensors ahead of catalytic converter - chapter on "Tools and materials" . --> Tightening torque: 37 ftlb.

4. Lay oxygen sensor cable and press into clips. Fit cable plug -3 and 4-. (Scheme 130)

Subsequent work: Installing oxygen sensors ahead of catalytic converter

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

2. Install design cover.

3. Fasten bonnet.

Information

Note. If the DME control module is replaced, it must be programmed using the Porsche System Tester. Thus, the DME control module can be adapted to the vehicle, the national variant and the equipment. The DME control module is located in the radiator tank near the right fender. If possible, before the DME control module is removed and replaced, a read-out of the vehicle data should be obtained from the Porsche System Tester. Symbol for the Tab key = -->| The Porsche System Tester instructions take precedence and in the event of a discrepancy these are the instructions that must be followed. Deviations may occur with later software versions.

Installation Location

Scheme 132

Exhaust-gas standard

Obtaining read-out and saving vehicle data from DME control module

1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on ignition. >> Continue.

2. Select vehicle type using the cursor keys.

3. Using the -->| key, move from the vehicle type to the control modules.

4. Select DME with the cursor keys and press the >> key.

5. Select Control unit programming with the cursor keys and press the >> key.

6. Select Read out control unit (vehicle data) with the cursor keys and press the >> key.

7. The message Vehicle data read-out complete will appear on the screen of the Porsche System Tester.

8. After replacement of the DME control module, the vehicle data is installed in the menu Program control module (see Section 6).

Removing DME control module

> Before removing the control unit, switch off the ignition.

Note. Unscrew the two fastening screws for the cowl panel cover and lift up the cover in this area. Refer to 66 44 19 Removing and installing cowl panel cover - as of MY 2003 (All Models) .

Scheme 133

1. Push the two retaining clips aside -arrows- and remove control unit to the front. see scheme 303

Scheme 134

2. Pull out latch on both connectors in -direction of arrow- and remove the connectors. see scheme 304

Scheme 135

1. Insert both connectors into the control unit and push in latch in -direction of arrow-. (Scheme 132)

Scheme 136

2. Insert control unit and secure with the two retaining clips -arrow-. (Scheme 133)

Programming new DME control module

Note. If a new DME control module is to be installed in a vehicle, the immobilizer code specified in IPAS must be entered in the DME control module. You can get the codes from IPAS or from your importer by specifying the vehicle identification number. During DME programming, it is essential to guarantee the power supply for the Porsche System Tester. It is essential to connect a battery charger with a current rating of at least 40 A to the vehicle battery. Symbol for the Tab key = -->|. The Porsche System Tester instructions take precedence and in the event of a discrepancy these are the instructions that must be followed. Deviations may occur with later software versions. The procedure described here has been structured in general terms; different text or additions may appear in the Porsche System Tester.

1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on ignition. Read out DME control module. > 247019 Removing and installing DME control module - "Reading out" section

2. Switch off ignition and replace DME control module with a new unit. > 247019 Removing and installing DME control module - "Removing" section

3. Change to the Control module programming menu and press >>.

4. Program control module and press >>.

5. Observe System Tester conditions >>.

6. Select vehicle type and press >>.

7. Select transmission type and press >>.

8. Select emission standard and press >>. > 247019 Removing and installing DME control module - "Information" section

9. Program control module and confirm with F8.

10. The data and programming status is then loaded on to the DME control module. Do not interrupt the programming sequence.

11. The System Tester indicates whether the control unit is programmable and the approximate programming time.

Note. During programming, the electric radiator fans may start.

12. Once the DME control module has been programmed successfully, switch to the Program immobilizer code menu and press >>.

13. Enter the new immobilizer code (IPAS), confirm with the >> key, check the code again and confirm with the F7 key.

14. When the programming period expires follow the instructions on the Porsche System Tester.

Note. In some countries (currently USA, Canada) the Ready status must be obtained following a test drive and/or by using the Porsche System Tester after a DME control module is programmed. If in doubt about this, contact the relevant importer. See On-Board Diagnosis Manual (DME 7.1.1) With all DME systems, the engine must run for several minutes before the engine control unit can relearn the idle speed and mixture adaptation values!

15. For the learning and adaptation routine of the throttle (E-gas), switch the ignition on for 30 seconds without starting the engine. Do not actuate accelerator pedal. This completes the adaptation of the throttle adjusting unit and the programming sequence is complete.

16. Read out the fault memory and delete the DME control module fault on every control unit connected to the CAN.

17. Carry out a test drive and read out fault memory.

Note. If faults are present, proceed in accordance with the DME 7.1.1 Manual. See On-Board Diagnosis Manual (DME 7.1.1)

Programming DME control module

Note. If a DME control module from a different vehicle with ME 7.1.1 is being used, proceed as follows. As a check, the immobilizer code of the vehicle in which the control unit is being installed (NEW) and of the vehicle from which the control unit has been removed (OLD) are required. During DME programming, it is essential to guarantee the power supply for the Porsche System Tester. It is essential to connect a battery charger with a current rating of at least 40 A to the vehicle battery. You can get the necessary codes from IPAS or from your importer by specifying the vehicle identification number. Symbol for the Tab key = -->| The Porsche System Tester instructions take precedence and in the event of a discrepancy these are the instructions that must be followed. Deviations may occur with later software versions. The procedure described here has been structured in general terms; different text or additions may appear in the Porsche System Tester.

1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on ignition. Read out DME control module. > 247019 Removing and installing DME control module - "Reading out" section

2. Switch off ignition and replace DME control module with a new unit. > 247019 Removing and installing DME control module - "Removing" section

3. Change to the Control unit programming menu and press >>.

4. Program control module >>.

5. Observe System Tester conditions >>.

6. Select vehicle type >>.

7. Select transmission type and press >>.

8. Select emission standard and press >>. > 247019 Removing and installing DME control module - "Information" section

9. Program control module and confirm with F8.

10. The data and programming status is then loaded on to the DME control module. Do not interrupt the programming sequence.

11. The System Tester indicates whether the control unit is programmable and the approximate programming time.

12. Once the DME control module has been programmed successfully, switch to the Program immobilizer code menu and press >>.

13. Enter the old immobilizer code (IPAS, vehicle - OLD), continue with the >> key, check the code again and confirm with F7.

14. Enter the new immobilizer code (IPAS, vehicle - NEW), continue with the >> key, check the code again and confirm with F7.

15. When the programming period expires follow the instructions on the Porsche System Tester.

Note. In some countries (currently USA, Canada) the Ready status must be obtained following a test drive and/or by using the Porsche System Tester after a DME control module is programmed. If in doubt about this, contact the relevant importer. See On-Board Diagnosis Manual (DME 7.1.1) With all DME systems, the engine must run for several minutes before the engine control unit can relearn the idle speed and mixture adaptation values!

16. For the learning and adaptation routine of the throttle (E-gas), switch the ignition on for 30 seconds without starting the engine. Do not actuate accelerator pedal. This completes the adaptation of the throttle adjusting unit and the programming sequence is complete.

17. Read out the fault memory and delete the DME control module fault on every control unit connected to the CAN.

18. Carry out a test drive and read out fault memory.

Note. If faults are present, proceed in accordance with the DME 7.1.1 Manual. See On-Board Diagnosis Manual (DME 7.1.1)

Note. If the DME control module is replaced, it must be programmed using the Porsche System Tester. Thus, the DME control module can be adapted to the vehicle, the national variant and the equipment. The DME control module is located in the radiator tank near the right fender. If possible, before the DME control module is removed and replaced, a read-out of the vehicle data should be obtained from the Porsche System Tester. Symbol for the Tab key = -->| The Porsche System Tester instructions take precedence and in the event of a discrepancy these are the instructions that must be followed. Deviations may occur with later software versions.

Installation Location

1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on ignition. >> Continue.

2. Select vehicle type using the cursor keys.

3. Using the -->| key, move from the vehicle type to the control modules.

4. Select DME with the cursor keys and press the >> key.

5. Select Control unit programming with the cursor keys and press the >> key.

6. Select Read out control unit (vehicle data) with the cursor keys and press the >> key.

7. The message Vehicle data read-out complete will appear on the screen of the Porsche System Tester.

8. After replacement of the DME control module, the vehicle data is installed in the menu Program control module (see Section 6).

> Before removing the control unit, switch off the ignition.

Note. Unscrew the two fastening screws for the cowl panel cover and lift up the cover in this area. Refer to 66 44 19 Removing and installing cowl panel cover - as of MY 2003 (All Models) .

1. Push the two retaining clips aside -arrows- and remove control unit to the front. (Scheme 135)

2. Pull out latch on both connectors in -direction of arrow- and remove the connectors. (Scheme 136)

Installing DME control module

1. Insert both connectors into the control unit and push in latch in -direction of arrow-. see scheme 310

2. Insert control unit and secure with the two retaining clips -arrow-. see scheme 311

Note. If a new DME control module is to be installed in a vehicle, the immobilizer code specified in IPAS must be entered in the DME control module. You can get the codes from IPAS or from your importer by specifying the vehicle identification number. During DME programming, it is essential to guarantee the power supply for the Porsche System Tester. It is essential to connect a battery charger with a current rating of at least 40 A to the vehicle battery. Symbol for the Tab key = -->|. The Porsche System Tester instructions take precedence and in the event of a discrepancy these are the instructions that must be followed. Deviations may occur with later software versions. The procedure described here has been structured in general terms; different text or additions may appear in the Porsche System Tester.

1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on ignition. Read out DME control module. > 247019 Removing and installing DME control module - "Reading out" section

2. Switch off ignition and replace DME control module with a new unit. > 247019 Removing and installing DME control module - "Removing" section

3. Change to the Control module programming menu and press >>.

4. Program control module and press >>.

5. Observe System Tester conditions >>.

6. Select vehicle type and press >>.

7. Select transmission type and press >>.

8. Select emission standard and press >>. > 247019 Removing and installing DME control module - "Information" section

9. Program control module and confirm with F8.

10. The data and programming status is then loaded on to the DME control module. Do not interrupt the programming sequence.

11. The System Tester indicates whether the control unit is programmable and the approximate programming time.

Note. During programming, the electric radiator fans may start.

12. Once the DME control module has been programmed successfully, switch to the Program immobilizer code menu and press >>.

13. Enter the new immobilizer code (IPAS), confirm with the >> key, check the code again and confirm with the F7 key.

14. When the programming period expires follow the instructions on the Porsche System Tester.

Note. In some countries (currently USA, Canada) the Ready status must be obtained following a test drive and/or by using the Porsche System Tester after a DME control module is programmed. If in doubt about this, contact the relevant importer. . See On-Board Diagnosis Manual (DME 7.1.1) With all DME systems, the engine must run for several minutes before the engine control unit can relearn the idle speed and mixture adaptation values!

15. For the learning and adaptation routine of the throttle (E-gas), switch the ignition on for 30 seconds without starting the engine. Do not actuate accelerator pedal. This completes the adaptation of the throttle adjusting unit and the programming sequence is complete.

16. Read out the fault memory and delete the DME control module fault on every control unit connected to the CAN.

17. Carry out a test drive and read out fault memory.

Note. If faults are present, proceed in accordance with the DME 7.1.1 Manual. See On-Board Diagnosis Manual (DME 7.1.1)

Note. If a DME control module from a different vehicle with ME 7.1.1 is being used, proceed as follows. As a check, the immobilizer code of the vehicle in which the control unit is being installed (NEW) and of the vehicle from which the control unit has been removed (OLD) are required. During DME programming, it is essential to guarantee the power supply for the Porsche System Tester. It is essential to connect a battery charger with a current rating of at least 40 A to the vehicle battery. You can get the necessary codes from IPAS or from your importer by specifying the vehicle identification number. Symbol for the Tab key = -->| The Porsche System Tester instructions take precedence and in the event of a discrepancy these are the instructions that must be followed. Deviations may occur with later software versions. The procedure described here has been structured in general terms; different text or additions may appear in the Porsche System Tester.

1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on ignition. Read out DME control module. > 247019 Removing and installing DME control module - "Reading out" section

2. Switch off ignition and replace DME control module with a new unit. > 247019 Removing and installing DME control module - "Removing" section

3. Change to the Control unit programming menu and press >>.

4. Program control module >>.

5. Observe System Tester conditions >>.

6. Select vehicle type >>.

7. Select transmission type and press >>.

8. Select emission standard and press >>. > 247019 Removing and installing DME control module - "Information" section

9. Program control module and confirm with F8.

10. The data and programming status is then loaded on to the DME control module. Do not interrupt the programming sequence.

11. The System Tester indicates whether the control unit is programmable and the approximate programming time.

12. Once the DME control module has been programmed successfully, switch to the Program immobilizer code menu and press >>.

13. Enter the old immobilizer code (IPAS, vehicle - OLD), continue with the >> key, check the code again and confirm with F7.

14. Enter the new immobilizer code (IPAS, vehicle - NEW), continue with the >> key, check the code again and confirm with F7.

15. When the programming period expires follow the instructions on the Porsche System Tester.

Note. In some countries (currently USA, Canada) the Ready status must be obtained following a test drive and/or by using the Porsche System Tester after a DME control module is programmed. If in doubt about this, contact the relevant importer. See On-Board Diagnosis Manual (DME 7.1.1) With all DME systems, the engine must run for several minutes before the engine control unit can relearn the idle speed and mixture adaptation values!

16. For the learning and adaptation routine of the throttle (E-gas), switch the ignition on for 30 seconds without starting the engine. Do not actuate accelerator pedal. This completes the adaptation of the throttle adjusting unit and the programming sequence is complete.

17. Read out the fault memory and delete the DME control module fault on every control unit connected to the CAN.

18. Carry out a test drive and read out fault memory.

Note. If faults are present, proceed in accordance with the DME 7.1.1 Manual. See On-Board Diagnosis Manual (DME 7.1.1)

Designation Type Number Explanation Torque wrench, signal-transmitting with changeover ratchet commercially available tool NR.90 Only in combination with wrench inserts Accessory for torque wrench: Open ring wrench angled commercially available tool NR.96-3 various overall lengths, e. g. Hazet 4681-1 to 3 Accessory for torque wrench: Open ring wrench angled commercially available tool NR.97 various overall lengths, e. g. Hazet 4681-1 to 3 Accessory for torque wrench: Open ring wrench angled assembly commercially available tool NR.98 various overall lengths, e. g. Hazet 4681-1 to 3

Preliminary work: Removing oxygen sensors behind catalytic converter

> Only remove the exhaust system once it has cooled down.

> Wear protective gloves.

1. Loosen and bend primary catalytic converter (primary catalytic converter does not need to be removed completely). For details see. Refer to 26 76 19 Removing and installing primary catalytic converter - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne S TIO Titan) .

Scheme 137

> Special tools - oxygen sensors - Accessory for torque wrench: Open ring wrench angled NR.96-3. see scheme 314

> Special tools - oxygen sensors - Accessory for torque wrench: Open ring wrench angled NR.97. see scheme 314

> Special tools - oxygen sensors - Accessory for torque wrench: Open ring wrench angled assembly NR.98. see scheme 314

> Special tools - oxygen sensors - Torque wrench, signal-transmitting with changeover ratchet NR.90. see scheme 314

Removing oxygen sensors behind catalytic converter - Cayenne S (M48/00)

1 - Exhaust manifold, cylinders 1 -4

2 - Exhaust manifold, cylinders 5 - 8

3 - Seal for exhaust manifold; replace

4 - M8 hexagon nut; replace, coat thread of bolts with Microgleit

5 - Oxygen sensor ahead of catalytic converter

6 - Oxygen sensor ahead of catalytic converter

7 - Seal; replace

8 - M8 hexagon nut; replace

9 - Catalytic converter, front

10 - Catalytic converter, front

11 - Support

12 - Support

13 - Hexagon-head bolt M10 x 25

14 - Hexagon-head bolt, M8 x 15

15 - Stud M8 x 25

16 - Oxygen sensor behind catalytic converter

17 - Seal; replace

18 - Catalytic converter

19 - Catalytic converter

20 - Screw

21 - Bracket

22 - Bracket

23 - Bracket

24 - Hexagon-head bolt, M8 x 25

> Always expose oxygen sensor cable so that the wire can turn when unscrewing or screwing in the sensor.

> Do not kink cable.

1. Carefully unscrew oxygen sensors on primary catalytic converter.

Installing oxygen sensors behind catalytic converter - Cayenne S (M48/00)

1. Position the oxygen sensor by hand and screw in as far as possible.

2. Tighten oxygen sensor using special tool > 247319 Removing and installing oxygen sensors behind catalytic converter - "Tools and materials" section . --> Tightening torque: 33 ftlb. +/-3.5 ftlb.

Subsequent work: Installing oxygen sensor behind catalytic converter

1. Install primary catalytic converter. Refer to 26 76 19 Removing and installing primary catalytic converter - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne S TIO Titan) .

Designation Type Number Explanation Torque wrench, signal-transmitting with changeover ratchet commercially available tool NR.90 Only in combination with wrench inserts Accessory for torque wrench: Open ring wrench angled commercially available tool NR.96-3 various overall lengths, e. g. Hazet 4681-1 to 3 Accessory for torque wrench: Open ring wrench angled commercially available tool NR.97 various overall lengths, e. g. Hazet 4681-1 to 3 Accessory for torque wrench: Open ring wrench angled assembly commercially available tool NR.98 various overall lengths, e. g. Hazet 4681-1 to 3

> Only remove the exhaust system once it has cooled down.

> Wear protective gloves.

1. Loosen and bend primary catalytic converter (primary catalytic converter does not need to be removed completely). For details see. Refer to 26 76 19 Removing and installing primary catalytic converter - Cayenne Turbo - as of MY 2003 (Cayenne Turbo, Cayenne Turbo S) .

> Special tools - oxygen sensors - Accessory for torque wrench: Open ring wrench angled NR.96-3. see scheme 320

> Special tools - oxygen sensors - Accessory for torque wrench: Open ring wrench angled NR.97. see scheme 320

> Special tools - oxygen sensors - Accessory for torque wrench: Open ring wrench angled assembly NR.98. see scheme 320

> Special tools - oxygen sensors - Torque wrench, signal-transmitting with changeover ratchet NR.90. see scheme 320

Removing oxygen sensors in front of catalytic converter - Cayenne Turbo (M48/50)

1 - Exhaust manifold

2 - Seal for exhaust manifold; replace

3 - M8 hexagon nut; replace

4 - M8 x 75 turbocharger fastening screw

5 - Seal for exhaust turbocharger; replace

6 - Oxygen sensor ahead of catalytic converter

7 - Seal; replace

8 - M8 hexagon nuts

9 - Primary catalytic converter

10 - Primary catalytic converter

11 - Support

12 - Support

13 - Fastening screw for support, M10 x 25

14 - Hexagon-head bolt, M8 x 15

15 - Oxygen sensor behind catalytic converter

16 - Seal; replace

17 - Main catalytic converter

18 - Main catalytic converter

19 - Stud

20 - Bracket for main catalytic converter

21 - Bracket for main catalytic converter

22 - Bracket for main catalytic converter

23 - Hexagon-head bolt, M8 x 25

> Always expose oxygen sensor cable so that the wire can turn when unscrewing or screwing in the sensor.

> Do not kink cable.

1. Carefully unscrew oxygen sensors on primary catalytic converter.

Installing oxygen sensors behind catalytic converter - Cayenne Turbo (M48/50)

1. Position the oxygen sensor by hand and screw in as far as possible.

2. Tighten oxygen sensor using special tool > 247319 Removing and installing oxygen sensors behind catalytic converter - "Tools and materials" section . --> Tightening torque: 33 ftlb. +/-3.5 ftlb.

1. Install primary catalytic converter. Refer to 26 76 19 Removing and installing primary catalytic converter - Cayenne Turbo - as of MY 2003 (Cayenne Turbo, Cayenne Turbo S) .

Designation Type Number Explanation Torque wrench, signal-transmitting with changeover ratchet commercially available tool NR.90 Only in combination with wrench inserts Accessory for torque wrench: Open ring wrench angled commercially available tool NR.96-3 various overall lengths, e. g. Hazet 4681-1 to 3 Accessory for torque wrench: Open ring wrench angled commercially available tool NR.97 various overall lengths, e. g. Hazet 4681-1 to 3 Accessory for torque wrench: Open ring wrench angled assembly commercially available tool NR.98 various overall lengths, e. g. Hazet 4681-1 to 3 bonnet stay special tool P 9704

1 - Cylinder head

2 - Exhaust manifold seal

3 - M8 fastening nut; replace

4 - Exhaust manifold

5 - Flange gasket; replace

6 - Primary catalytic converter, cylinders 1, 2 and 3

7 - Primary catalytic converter, cylinders 4, 5 and 6

8 - Oxygen sensor in front of catalytic converter, cylinders 1, 2 and 3

9 - Oxygen sensor in front of catalytic converter, cylinders 4, 5 and 6

10 - (Main) catalytic converter

11 - Fastening screws M8

12 - Oxygen sensor behind catalytic converter, cylinders 1, 2 and 3

13 - Oxygen sensor behind catalytic converter, cylinders 4, 5 and 6

14 - Heat shield

15 - Fastening screw M8

16 - Fastening screws M8 for intake distributor

17 - Support for intake distributor

18 - Side fastening screws M8 for intake distributor

Note. Please read the most important working regulations and warning notes. Refer to 10 01 AW The most important working regulations and warning notes - as of MY 2003 (All Models Except Cayenne S TIO Titan) .

> Only remove the exhaust system once it has cooled down.

> Wear protective gloves.

1. Move bonnet to service position using bonnet stay P 9704 .

2. Put on the protection covers.

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

4. Pull the design cover up and off.

> Special tools - oxygen sensors - Accessory for torque wrench: Open ring wrench angled NR.96-3. see scheme 326

> Special tools - oxygen sensors - Accessory for torque wrench: Open ring wrench angled NR.97. see scheme 326

> Special tools - oxygen sensors - Accessory for torque wrench: Open ring wrench angled assembly NR.98. see scheme 326

> Special tools - oxygen sensors - Torque wrench, signal-transmitting with changeover ratchet NR.90. see scheme 326

Removing oxygen sensors behind the catalytic converter

1 - Bore for oxygen sensor behind catalytic converter, cylinders 4, 5 and 6; brown cable plug for oxygen sensor

2 - Bore for oxygen sensor ahead of catalytic converter, cylinders 4, 5 and 6; brown cable plug for oxygen sensor

3 - Bore for oxygen sensor ahead of catalytic converter, cylinders 1, 2 and 3; black cable plug for oxygen sensor

4 - Bore for oxygen sensor behind catalytic converter, cylinders 1, 2 and 3; black cable plug for oxygen sensor (in this case oxygen sensor is fitted)

> Always expose oxygen sensor cable so that the wire can turn when unscrewing or screwing in the sensor.

> Do not kink cable.

Note. Cable plugs 1 and 2 belong to the oxygen sensors behind catalytic converter, while plugs 3 and 4 belong to the oxygen sensors in front of catalytic converter. The colors of the cable plugs are the same for each exhaust assembly.

1. Disconnect cable plugs of oxygen sensors behind catalytic converter -1 and 2- and expose them. see scheme 328

> The connector color of the oxygen sensor cable for the oxygen sensor behind the catalytic converter must match the color of the oxygen sensor cable plug of the oxygen sensor ahead of the catalytic converter in the same exhaust assembly (brown to brown and black to black).

> Do not interchange oxygen sensors.

Note. Mark oxygen sensors as you unscrew them so that the oxygen sensors are not confused.

2. Unscrew both oxygen sensors behind catalytic converter -2- with a ring or open-ended wrench (a/f 22) --> Releasing the oxygen sensor using an open-ended wrench. see scheme 329, see scheme 330.

Scheme 138

Installing oxygen sensors behind the catalytic converter

> The connector color of the oxygen sensor cable for the oxygen sensor behind the catalytic converter must match the color of the oxygen sensor cable plug of the oxygen sensor ahead of the catalytic converter in the same exhaust assembly (brown to brown and black to black).

> Do not interchange oxygen sensors.

> Always expose oxygen sensor cable so that the wire can turn when unscrewing or screwing in the sensor.

> Do not kink cable.

Note. Cable plugs 1 and 2 belong to the oxygen sensors behind catalytic converter, while plugs 3 and 4 belong to the oxygen sensors in front of catalytic converter. The colors of the cable plugs are the same for each exhaust assembly.

Note. Mark oxygen sensors as you unscrew them so that the oxygen sensors are not confused.

1. Position oxygen sensors behind catalytic converter -2- by hand and screw in as far as possible. see scheme 331

2. Tighten oxygen sensors using special tool > Tools - oxygen sensor . --> Tightening torque: 37 ftlb.

3. Lay oxygen sensor cable and press into clips. Fit cable plugs -1 and 2-. see scheme 332

Subsequent work: Installing oxygen sensors behind catalytic converter

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

2. Install design cover.

3. Fasten bonnet.

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