Ignition System: Other Porsche Cayenne I

Tools

Designation Type Number Explanation wrench VW-tool T10152

Preliminary work

1. Remove trim panel under dashboard on left. Refer to 70 19 19 Removing and installing trim under dashboard - as of MY 2003 (All Models) .

Removing ignition switch

Installation Location

Scheme 3

Scheme 4

1. Carefully lift rubber sleeve on the ignition starter switch -arrow A- using a screwdriver, for example, and remove it. (Scheme 4)

2. Carefully unclip molding for dashboard -arrow B- with a plastic spatula. Observe the two upper lugs when doing do. (Scheme 4)

Scheme 5

3. Turn union nut using a narrow plastic spatula, for example, or using the special wrench T10152 tool and unscrew the ring from the ignition starter switch.

4. Press ignition switch inwards and remove towards the bottom.

Scheme 6

5. Press connector -arrow- and pull off from ignition starter switch. (Scheme 6)

Scheme 7

1. Connect the connector to the ignition starter switch until it engages firmly.

Scheme 8

2. Position ignition starter switch in the dashboard. Position union nut, re-adjust switch and tighten union nut using wrench T10152 . --> Tightening torque: 1 ftlb.

Scheme 9

3. Check clips on the molding for the dashboard for damage and replace if necessary.

4. Position molding and press onto the dashboard until the clips engage.

Subsequent work

1. Install cover under instrument panel on left. Refer to 70 22 19 Removing and installing cover under dashboard - as of MY 2003 (All Models) .

Designation Type Number Explanation wrench VW-tool T10152

1. Remove trim panel under dashboard on left. Refer to 70 19 19 Removing and installing trim under dashboard - as of MY 2003 (All Models) .

Installation Location

1. Carefully lift rubber sleeve on the ignition starter switch -arrow A- using a screwdriver, for example, and remove it. see scheme 11

2. Carefully unclip molding for dashboard -arrow B- with a plastic spatula. Observe the two upper lugs when doing do. see scheme 11

3. Turn union nut using a narrow plastic spatula, for example, or using the special wrench T10152 tool and unscrew the ring from the ignition starter switch.

4. Press ignition switch inwards and remove towards the bottom.

5. Press connector -arrow- and pull off from ignition starter switch. see scheme 13

Installing ignition switch

1. Connect the connector to the ignition starter switch until it engages firmly.

2. Position ignition starter switch in the dashboard. Position union nut, re-adjust switch and tighten union nut using wrench T10152 . --> Tightening torque: 1 ftlb.

3. Check clips on the molding for the dashboard for damage and replace if necessary.

4. Position molding and press onto the dashboard until the clips engage.

1. Install cover under instrument panel on left. Refer to 70 22 19 Removing and installing cover under dashboard - as of MY 2003 (All Models) .

Designation Type Number Explanation Spark plug wrench VW-tool 3122 B Puller VW-tool T10095 A

Scheme 10

1. Pull engine cover vertically upwards and off.

Scheme 11

Removing ignition coils

1. Separate the six ignition coils from the wiring harness. To do this, press connector gently downwards -arrow A-, release using a suitable aid (e. g. angled piece of wiring) -arrow B- and pull off -arrow C-. (Scheme 12)

Scheme 12

Scheme 13

2. Remove ignition coils. For securely seated ignition coils, use the special tool puller T10095 A -A- to do this. (Scheme 13)

Scheme 14

1. Install the plug coils. When doing so, make sure that the straight surface is pointing to the intake pipes.

Scheme 15

2. Reconnect ignition coil. The plugs must engage audibly.

Scheme 16

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

1. Switch ignition off and remove ignition key

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

Scheme 17

1. Loosen the torque support. To do this unscrew the fastening screw on the torque support bracket.

Scheme 18

2. Loosen the torque support on the body and swivel upwards.

Scheme 19

3. Loosen the secondary air pump from cylinder row 1-4. To do this, unscrew the 3 fastening screws, pull the pump out of the support and lay it aside.

Scheme 20

Note. Place a cloth between design cover and support for secondary air pump to avoid scratching cover.

4. Loosen the 4 fastening screws on the ignition coil cover (picture shows side 5-8).

Scheme 21

5. Remove design cover from cylinder bank 1-4. Lift the cover slightly with both hands on the side pointing towards the intake system until it snaps out of the fastening points.

Scheme 22

6. Lift the cover at the front edge and slide the ignition coil cover of the second cylinder out of the torque support bracket. Pull out cover to the front.

Scheme 23

7. Remove torque support bracket. To do so, undo the 4 fastening screws and set bracket aside.

Scheme 24

8. Disconnect the ignition coil. To do this, press the button on the connector and pull off the connector.

Scheme 25

9. Loosen ignition coil. To do this, unscrew the fastening screw on the valve cover.

Scheme 26

10. Pull the ignition coil out and replace it.

11. Reconnect the new ignition coil. Tighten the fastening screws. --> Tightening torque: 7.5 ftlb.

12. Connect ignition coil. To do this slide on the connector until it locks with an audible click.

13. Install bracket for torque support. The M8 x 45 Torx screws are tightened on the upper screw points. --> Tightening torque: 17 ftlb. The M6 x 40 screws are tightened on the lower screw fastening points (center of the valve cover) --> Initial tightening: 3.5 ftlb. --> Final tightening: 7.5 ftlb.

Note. A rag should be placed between the secondary air pump support and the design cover to prevent the cover from being scratched.

14. Slide the design cover of cylinder row 1-4 under the secondary air pump support as shown in the illustration and then slide the cover of the second ignition coil through underneath the torque support bracket.

Scheme 27

15. Press down the two rubber mountings on the support. The rubber mountings must be felt to engage.

16. Tighten the four fastening screws on the ignition coils (illustration shows side 5-8). --> Tightening torque: 3.5 ftlb.

17. Reinstall secondary air pump. Tighten the 3 fastening screws. --> Tightening torque: 7.5 ftlb.

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

19. Tighten torque support fastening screw on the body (M10 x 70). --> Tightening torque: 44 ftlb.

Replacing ignition coils of cylinder row 5-8

Note. A rag should be placed between the secondary air pump and the design cover to prevent the cover from being scratched.

1. Unscrew the 4 fastening screws on the ignition coil cover.

Scheme 28

2. Remove design cover of cylinder bank 5-8. To do this, lift the cover slightly with both hands at the side pointing towards the intake system until it is released from its bracket.

Scheme 29

3. Lift the front of the design cover and remove it.

4. Disconnect the ignition coil. To do this, press the button on the connector and pull off the connector.

5. Loosen ignition coil. To do this, unscrew the fastening screw on the valve cover.

6. Pull the ignition coil out and replace it.

7. Reconnect a new ignition coil. Tighten the fastening screws. --> Tightening torque: 7.5 ftlb.

8. Connect ignition coil. To do this slide on the connector until it locks with an audible click.

Note. A rag should be placed between the secondary air pump and the design cover to prevent the cover from being scratched.

9. Slide the design cover under the secondary air pump as illustrated.

Scheme 30

10. Then press in the two rubber mountings on the support. The rubber mountings must be felt to engage.

11. Tighten the 4 fastening screws on the ignition coils. --> Tightening torque: 3.5 ftlb.

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

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

Removing hall sender

Note. The hall sensors are located behind the camshaft housing and point towards the intake system.

Note. Replace all seals and O-rings.

1. Disconnect connector on hall sender. To do so, push the button and remove.

Scheme 31

2. Loosen the fastening screw on the hall sender. Use a socket wrench with 1/4 inch drive and a joint.

3. Pull the hall sender out of the camshaft housing.

Installing hall sender

1. Push the hall sender into the camshaft housing and tighten the fastening screw. --> Tightening torque: 7.5 ftlb.

2. Push on electric connector. The connector must engage audibly.

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

Designation Type Number Explanation pressure sleeve VW-tool T10174

Scheme 32

1. Pull the design cover straight up and off.

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

Scheme 33

1 - Wiring arrangement

2 - M6 fastening nut

3 - M6 x 14 fastening screw

4 - Hall sender for exhaust camshaft; mark cable plug before removal

5 - Chain tensioner

6 - Sealing ring; replace

7 - M6 fastening screws for top chain case lid, thermostat housing, sheet-metal bracket

8 - Hydraulic valve sealing ring; drive out using a suitable socket and drive in using pressure sleeve T10174 .

9 - Bracket for coolant run-on pump and carbon canister solenoid valve

10 - Coolant regulator housing

11 - M8 fastening screw

12 - Sealing ring; replace

13 - Top chain case lid; prepare cylinder-head gasket and sealing surfaces

14 - Hall sender for inlet camshaft; mark cable plug before removal

15 - Sealing ring for oil duct seal; replace

Scheme 34

1. Open both plastic clips of the rear valve cover wiring harness and lay the wiring harness aside -1-. (Scheme 33)

Scheme 35

Note. Mark hall sender cable plugs according to position of exhaust and inlet camshafts.

2. Pull off cable plug on camshaft hall senders -top section of figure-. To do this, use an angled piece of wire to pull off the cable plug as described in > 282020 Removing and installing ignition coils - section on "Removing". Release the cable plugs on the inlet -2- and outlet -3- camshaft hall senders -arrows D- and pull them off -arrows E-. (Scheme 34)

Scheme 36

3. Unscrew the two fastening nuts for the engine wire harness on the top chain case lid -1- and push the engine wire harness to the plenum panel. (Scheme 35)

4. Unscrew the fastening screws for the hall senders -2- and carefully pull out the hall senders. (Scheme 36)

Note. Check the sealing rings on the hall senders and replace them if necessary or replace the hall sender.

1. Place hall sender in installation position and insert into the top chain case. Screw in fastening screw hand-tight. Tighten fastening screw. --> Tightening torque: 7.5 ftlb.

2. Fit engine wire harness to top chain case lid -1-. see scheme 63

3. Connect cable plugs for camshaft hall senders to the relevant hall senders.

4. Insert top wiring harness into the two plastic clips -1- and close clips. see scheme 64

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

2. Press the design cover on to the ball heads.

Designation Type Number Explanation Spark plug wrench VW-tool 3122 B Puller VW-tool T10095 A

Remove ignition coils. > 282020 Removing and installing cover - chapter on "removing"

Tools and materials

Replacing spark plugs

> Only check electrode gap of spark plugs, but do not bend them.

> Spark plugs with an incorrect electrode gap must be replaced.

Scheme 37

1. Remove spark plug using special tool spark plug wrench 3122 B .

Note. Check electrode gap before screwing in a new spark plug.

Scheme 38

2. Check electrode gap. The electrode gap of the spark plug must be 1.1 mm.

3. Tighten spark plugs using special tool spark plug wrench 3122 B . --> Tightening torque: 20 (15 ftlb.) Nm

Install ignition coils. > 282020 Removing and installing cover - chapter on "removing"

Designation Type Number Explanation spark plug wrench VW-tool 3122 B

1. Switch off ignition and remove ignition key.

Removing design cover of cylinder bank 1 -4

1. Remove engine compartment cover on the right and rear. To do this, undo the four bayonet screws and the fastening screw on the washer-fluid reservoir. Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .

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

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

4. Detach the secondary air pump from cylinder bank 1 -4. To do this, unscrew the three fastening screws, pull the pump out of the bracket and lay it aside.

Note. Place a cloth between design cover and support for secondary air pump to avoid scratching cover.

5. Unscrew the four fastening screws on the ignition coil cover (illustration shows side 5 - 8).

6. Remove design cover from cylinder bank 1 - 4. Lift the cover slightly with both hands on the edge pointing towards the intake system until it snaps out of the fastening points.

7. Lift the cover at the front edge and slide the ignition coil cover of the second cylinder out of the torque support bracket. Pull out cover to the front.

8. Remove torque arm bracket. To do so, undo the four fastening screws and set bracket aside.

Removing design cover of cylinder bank 5 - 8

Note. Place a cloth between secondary air pump and design cover to avoid scratching the cover.

1. Unscrew the four fastening screws on the ignition coil cover.

2. Remove design cover of cylinder bank 5 - 8. To do this, lift the cover slightly with both hands at the edge pointing towards the intake system until it is released from its holder.

3. Lift the front of the design cover and remove it.

1. Pull off lower hose from secondary air pump 5 - 8.

2. Separate the eight ignition coils from the wire harness. To do this, press on the button and, at the same time, pull off the plug.

3. Undo ignition coil. To do this, unscrew the fastening screw on the valve cover.

4. Pull out ignition coil and lay it aside.

Scheme 39

5. Undo spark plugs using special tool spark plug wrench 3122 B

> Only check electrode gap of spark plugs, but do not bend them.

> Spark plugs with an incorrect electrode gap must be replaced.

6. Check electrode gap in V8 naturally aspirated engine. --> Control value: 1.6 mm

Scheme 40

7. Check electrode gap in V8 turbo engine. --> Control value: 0.8 mm +/-0.05 mm

Note. Use only spark plugs approved by Porsche AG! Check electrode gap before screwing in a new spark plug.

8.

Tighten spark plugs using special tool spark plug wrench 3122 B . --> Tightening torque: 25 (19 ftlb.) Nm , --> Tightening torque: 30 (22 ftlb.) Nm

9. Reconnect the ignition coil. Tighten the fastening screws. --> Tightening torque: 10 (7.5 ftlb.) Nm

10. Connect ignition coil. To do this, push on the connector until it locks with an audible click.

11. Push lower hose onto secondary air pump 5 - 8.

Installing design cover of cylinder bank 5 - 8

Note. Place a cloth between secondary air pump and design cover to avoid scratching the cover.

1. Slide the design cover under the secondary air pump as illustrated.

2. Then press in the two rubber mountings on the bracket. The rubber mounts must be felt to engage.

3. Tighten the four fastening screws on the ignition coils. --> Tightening torque: 3.5 ftlb.

Installing design cover of cylinder bank 1 - 4

Note. Place a cloth between secondary air pump bracket and design cover to avoid scratching the cover.

1. Install bracket for the torque support. The M8 x 45 Torx screws are tightened at the upper screw points. --> Tightening torque: 23 ftlb. At the lower screw-mounting points (center of valve cover) the M6 x 40 are first tightened to --> Initial tightening: 3.5 ftlb. and then to --> Final tightening: 7.5 ftlb. .

2. Slide the design cover of cylinder bank 1 - 4 under the secondary air pump bracket as shown in the illustration and then slide the cover of the second ignition coil through underneath the torque support bracket.

3. Press down the two rubber mounts on the bracket. The rubber mounts must be felt to engage.

4. Tighten the four fastening screws on the ignition coils (illustration shows side 5 - 8). --> Tightening torque: 3.5 ftlb.

5. Reinstall secondary air pump. Tighten the three fastening screws. --> Tightening torque: 7.5 ftlb.

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

7. Tighten torque support fastening screw on the body (M10 x 70). --> Tightening torque: 44 ftlb.

8. Install the engine compartment cover at the right and rear. To do this, tighten the four bayonet screws and the sheetmetal screw on the washer-fluid reservoir. Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .

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

2. Remove and fold up cover for coolant regulator (thermostat). Refer to 19 58 19 Removing and installing coolant regulator (thermostat) - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

Scheme 41

1. Mark and note the installation position of the knock sensor and pull off cable plug.

2. Unscrew fastening screw and take knock sensor out of the crankcase.

Installing knock sensor

Note. The knock sensor and the cable plug must be aligned so that they never touch!

Scheme 42

> The precise tightening torque for the knock-sensor screw must be observed, otherwise the proper function of the knock sensor is not ensured.

> The knock sensors must a aligned so that the sensor housing and the cable plug do not touch anywhere, otherwise proper functioning of the knock sensor is not ensured.

1. Install knock sensor. Make sure that the knock sensors are aligned according to the illustrations -longer arrow points to alignment, smaller arrow points to fastening screw-. (Scheme 41)

Scheme 43

2. Tighten fastening screws. --> Tightening torque: 17 ftlb.

3. Push on cable plug and ensure that the cable plug does not touch.

1. Install cover for coolant regulator (thermostat). Refer to 19 58 19 Removing and installing coolant regulator (thermostat) - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

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

3. Fill and bleed the cooling system. Refer to 19 38 17 Draining and filling in coolant (includes bleeding) - as of MY 2003 (All Models) .

Removing right knock sensor

1. Pull off design cover.

2. Remove intake manifold. Refer to 24 35 19 Removing and installing cowl for throttle housing (intake manifold) - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

Scheme 44

3. Pull off the connector of the right knock sensor (under exhaust manifold) at the front of the cylinder head cover and expose socket -A, B and E in bottom figure-. see scheme 103

Scheme 45

4. Unscrew the right knock sensor (under exhaust manifold). To do this, loosen the fastening screw -arrow- and remove knock sensor. Unclip cable. Remove knock sensor. (Scheme 44)

Installing right knock sensor

> The precise tightening torque for the knock-sensor screw must be observed, otherwise the proper function of the knock sensor is not ensured.

> The knock sensors must a aligned so that the sensor housing and the cable plug do not touch anywhere, otherwise proper functioning of the knock sensor is not ensured.

Note. Clean attachment surfaces of knock sensor on the cylinder block with a cloth.

1. Position knock sensor on cylinder block and secure with a fastening screw. Lay the cable in such a way that it is pointing towards the front of the vehicle. Clip in cable. Tighten fastening screw. --> Tightening torque: 15 ftlb.

2. Fit cable plug.

3. Fit intake manifold. Refer to 24 35 19 Removing and installing cowl for throttle housing (intake manifold) - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

4. Fit design cover.

Removing left knock sensor

Note. This knock sensor is fitted half-hidden behind the water tube at the same level as the oil/water heat exchanger. It is difficult to reach.

1. Remove oil dip stick guide tube. Refer to 17 17 19 Removing and installing guide tube for oil dip stick - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

2. Loosen vacuum unit -9 to 16- and lay it to one side. To do this, loosen the fastening pin -8- and pull unit out of the perforated bracket. see scheme 107

Scheme 46

3. Use a long screwdriver to reach into the cable plug lock on the knock sensor and press this carefully towards the generator/air-conditioning compressor -arrow-. Expose cable plug using a pointed-nose pliers --> Installation position of left knock sensor. (Scheme 46), (Scheme 47).

Scheme 47

Scheme 48

Scheme 49

4. Grip the fastening screw on the knock sensor with a narrow angled tool and screw it out --> Tool recommendation. (Scheme 48)

5. Remove fastening screw and knock sensor.

Installing left knock sensor

> The precise tightening torque for the knock-sensor screw must be observed, otherwise the proper function of the knock sensor is not ensured.

> The knock sensors must a aligned so that the sensor housing and the cable plug do not touch anywhere, otherwise proper functioning of the knock sensor is not ensured.

Note. Clean attachment surfaces of knock sensor on the cylinder block with a cloth. The installation position is difficult to reach.

1. Place knock sensor in installation position and secure with a fastening screw.

2. Tighten fastening screw to the specified torque. A 1/4-inch tool with an angled ball head can be used here (this is necessary given the limited space and the narrowness of the tool). --> Tightening torque: 15 ftlb.

3. Connect knock sensor cable plug using a pointed-nose pliers.

4. Secure vacuum unit -9 to 16-. To do this, press rubber mountings into the corresponding holes on the bracket. Then secure the fastening pin -8-. --> Tightening torque: 6.0 ftlb.. see scheme 113

5. Install oil dip stick guide tube. Refer to 17 17 19 Removing and installing guide tube for oil dip stick - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

1. Pull the design cover straight up and off.

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

3. Remove air cleaner housing lid and air-cleaner element. Refer to 24 25 19 Removing and installing air cleaner housing - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

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

Scheme 50

1- - --> Tightening torque: 6 ftlb.. see scheme 115

2- - Guide tube for oil dipstick. see scheme 115

3- - Oil dipstick. see scheme 115

4- - Oil check valve, pay attention to direction of installation. see scheme 115

5- - Knock sensor; right with and left without cable. see scheme 115

6- - --> Tightening torque: 15 ftlb.. see scheme 115

7- - --> Tightening torque: 7.5 ftlb.. see scheme 115

8- - Cover for oil pump drive. see scheme 115

9- - O-ring; replace. see scheme 115

10- - Oil pump drive. see scheme 115

11- - Crankcase. see scheme 115

12- - Intermediate shaft. see scheme 115

13- - Thrust washer. see scheme 115

14- - --> Tightening torque: 7.5 ftlb., use impact bolter as needed; insert screws with screw locking agent. see scheme 115

15- - Drive shaft for oil pump; pay attention to the assembly of plastic washer see scheme 115

16- - Crankshaft reference mark sender. see scheme 115

17- - Oil pump, observe tightening sequence. see scheme 115

18- - --> Tightening torque: 17 ftlb.. see scheme 115

19- - --> Tightening torque: 6 ftlb.. see scheme 115

20- - Replacing --> Tightening torque: 22 ftlb.; see scheme 115

21- - Oil pan. see scheme 115

22- - Oil level sensor. see scheme 115

23- - Sealing ring; replace. see scheme 115

24- - --> Tightening torque: 9 ftlb.. see scheme 115

25- - Sealing ring; replace. see scheme 115

26- - Engine support arm/oil filter housing. see scheme 115

27- - --> Tightening torque: 15 ftlb.. see scheme 115

28- - To thermostat; replace O-ring. see scheme 115

29- - --> Tightening torque: 19 ftlb.. see scheme 115

30- - --> Tightening torque: 19 ftlb.. see scheme 115

31- - Secondary unit holder. see scheme 115

32- - Coolant pipe; replace O-ring. see scheme 115

33- - Knock sensor (without cable). see scheme 115

34- - Torsional vibration damper. see scheme 115

35- - --> Initial tightening: 74 ftlb. --> Final tightening: 90°; replace screw. see scheme 115

Scheme 51

1. Remove two fastening nuts for the hose holder and press the holder aside -arrows-. (Scheme 50)

Scheme 52

Note. The cable plug for the crankshaft pulse sender is secured in a difficult-to-reach position at the guide tube for the oil dip stick.

2. Press the cable plug for the crankshaft pulse sender at the guide tube for the oil dip stick towards the cylinder block (only pushed in) -arrow-. Then disconnect the cable plug. (Scheme 51)

Scheme 53

Note. The cable for the crankshaft pulse sender is installed between the cylinder block and the oil filter housing/engine support arm.

3. Remove crankshaft pulse sender by loosening the fastening screw -arrow-. Pull the crankshaft pulse sender out of the cylinder block. Carefully pull out the cable. (Scheme 52)

Scheme 54

Installing crankshaft pulse sender

Note. Check the sealing ring on the crankshaft pulse sender and replace it if necessary.

1. Fit crankshaft pulse sender into the cylinder block. Align and screw fastening screw in hand-tight.

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

3. Guide the cable for the crankshaft pulse sender in between the cylinder block and the oil filter housing/engine support arm using a piece of wire or other cable.

4. Connect cable plug and slide onto oil dip stick guide tube.

5. Fit hose holder back onto the intake-air distributor. To do this, fit the two fastening nuts. --> Tightening torque: 6 ftlb. .

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

2. Fit the air cleaner housing lid and air-cleaner element. Refer to 24 25 19 Removing and installing air cleaner housing - as of MY 2004 (Cayenne TIP, Cayenne MAN) .

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

4. Fit the design cover.

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

2. Remove secondary air pump with bracket on cylinder bank 5-8. For details, refer to 26 65 19 Removing and installing secondary air pump - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

Scheme 55

3. Disconnect cable connection for crankshaft pulse sender at rear of cylinder head. To do this, press the cable plug together -1- and pull it off -2-. see scheme 123

Scheme 56

4. Remove cable plug from the bracket. To do this, press the cable plug towards the plenum panel using a screwdriver. --> Released cable plug on crankshaft position sensor. (Scheme 55)

5. Remove underbody panel from transmission. -2-. For details, refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models). (Scheme 56)

Scheme 57

1 - Engine guard, front

2 - Engine guard

3 - M6 fastening screw

4 - Transverse strut

5 - M6 fastening nut

Scheme 58

1 - Cable plug for crankshaft pulse sender behind secondary air pump on cylinder bank 5-8

2 - Water guide housing

3 - Clip

4 - Coolant pipes

5 - Crankshaft pulse sender

6 - Fastening screw for crankshaft pulse sender, M6 --> Tightening torque: 10 (7.5 ftlb.) Nm

7 - Crankshaft pulse sender

8 - Sheetmetal clip

9 - Clip

Removing pulse sender (crankshaft reference mark sender)

Note. The installation position and cable routing for the crankshaft pulse sender is identical for both manual and automatic transmissions.

1. Loosen cable for crankshaft pulse sender out of the clips and release cable. Use a long screwdriver to do this if necessary.

Scheme 59

2. Remove fastening screw on crankshaft pulse sender and pull crankshaft pulse sender out carefully. --> Reference mark sender on manual transmission --> Reference mark sender on Tiptronic transmission. (Scheme 58), (Scheme 59).

Scheme 60

Installing pulse sender (crankshaft reference mark sender)

1. Move crankshaft pulse sender into installation position and insert screw.

2. Insert fastening screw on crankshaft pulse sender and tighten it. --> Reference mark sender on manual transmission --> Reference mark sender on Tiptronic transmission --> Tightening torque: 10 (7.5 ftlb.) Nm. (Scheme 60), see scheme 130.

3. Lay cable for crankshaft pulse sender and press it into the clips. Use a piece of wire, if necessary, to guide the cable plug upwards.

1. Push cable plug into the plastic holder at the rear of the cylinder head (cable plug engages securely). Insert cable plug.

2. Fit bracket for secondary air pump and secondary air pump. For details, refer to 26 65 19 Removing and installing secondary air pump - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .

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

4. Fit underbody panel on transmission. -2- For details, refer to 10 80 19 Removing and installing engine guard - as of MY 2003 (All Models). see scheme 131

1 - Engine guard, front

2 - Engine guard

3 - M6 fastening screw

4 - Transverse strut

5 - M6 fastening nut

Poses Online