Maintenance, Self Diagnostics: Other Porsche Cayenne I

Functional Check

Note. The following requirements must be met when fitting the seat belt If one of the requirements listed below is not met, the seat belt or the buckle must be replaced.

It must be possible to unroll the belt strap smoothly from the belt retractor via the deflector fitting by pulling evenly.

The tongue of the seat belt must engage audibly in the buckle.

An abrupt pull on the belt strap must lock the belt retractor.

Lifting the vehicle

> Align the vehicle evenly between the lifting platform columns.

> Lift the vehicle only at the take-up points provided.

> Check the correct seating of the support plates by raising the vehicle slightly and conducting a visual inspection.

> In order to ensure that the vehicle is not lifted off the support plates during assembly work, the vehicle must be secured on the lifting platform, or the shift in the center of gravity must be offset by a corresponding load in the vehicle, when units are removed or supported.

> In addition, the guidelines of the lifting platform manufacturers and the legal accident prevention regulations and those of the mutual indemnity association (VGB 14) must be observed.

> Lift the vehicle only at the approved take-up points.

Note. For Cayenne vehicles with air suspension/level control, the following work must also be performed before raising the vehicle: Adjusting car to normal level Switching off level control Switch on level control

After ending the repair or maintenance work, perform the steps for the following activity

Note. When driving onto the lifting platform, bear in mind the work to be carried out. If work has to be carried out in the front footwell, the vehicle should be positioned in such a way that the front doors can be opened far enough.

Scheme 14

Position the vehicle.

Adjusting car to normal level

Note. If air suspension accumulators of the air suspension are filled, only the ignition has to be switched on. If air pressure in accumulators is too low, compressor comes on and loads battery. In this case, a constanter (charging unit) must be connected or the engine must be started.

Stop vehicle and apply brake.

Close vehicle doors

Note. When the normal vehicle position has been reached, the middle indicator light next to the rocker switch is permanently on. If a further indicator light should come on, a different level is adjusted.

Tap the right-hand rocker switch on the center console in the appropriate direction until vehicle has reached normal level.

Switching off level control

Adjust car to normal level.

Switch on ignition.

Note. The message Car may now be lifted appears in the variable control display of the instrument panel.

Push --> time value: 5 s +5 s forwards.

Switch on level control

Note. Level control comes on automatically when setting off with the vehicle. As an alternative, the following steps can be performed.

Switch on ignition.

Push --> time value: 5 s +5 s forwards.

Checking bellows on steering gear

Note. The bellows on the steering gear can be damaged by outside influences, for example by stone damage or during assembly work. The steering gear can start to leak if dirt or moisture enters a leaky bellows.

Visually inspect the bellows for damage.

Tie rod joints: checking play and dust boots

1. Lift vehicle --> 40 V0 LIFTING THE VEHICLE - AS OF MY 2003 (CAYENNE TURBO S, CAYENNE S TIO TITAN) or 40 V0 LIFTING THE VEHICLE - AS OF MY 2003 (CAYENNE TIP, CAYENNE MAN, CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO) .

Note. The rubber dust boots and bellows on the steering gear and on the tie rods can be damaged by external influences, e. g. stone impact, or during assembly work. If a rubber dust boot leaks, the joint or tie rod must be replaced, because any dirt or moisture that seeps in will destroy the joint.

2. Check play and dust boots.

3. Check that dust boots, bellows and joints are functioning correctly and not leaking.

Axle joints: checking play and dust boots

1. Check play.

2. Visually inspect the dust boots for damage.

Note. When doing so, the rubber dust boots should be pressed down with the fingers to reveal hidden cracks. If a rubber dust boot leaks, the corresponding joint or control arm must be replaced, because any dirt or moisture that seeps in will destroy the joint.

3. Inspect the dust boots of the axle joints (ball joints) on the wheel suspension (front and rear) as follows

1. Place the vehicle on a lifting platform with the steering lock disengaged.
2. Perform a visual inspection after cleaning.

Note. Over a small area in the vicinity of the brake cover panels, no visual inspection is possible. Check this area by touch.

The procedure for the front axle is as follows

1. Turn the front wheels as far as they will go
2. Perform a visual inspection of the visible surfaces on the left and right
3. After turning the front wheels to the other steering stop, check the other half of each rubber dust boot.

Checking condition

Tires are a safety element that fulfil the demands placed on them only if they have the correct air pressure and a sufficient tread depth.

> The air pressure must never fall below the values specified (these are minimum pressures).

> The tread depth must never fall below the minimum.

> A visual inspection of the Tires (for cracks, pricks, bulges in the sidewall and/or foreign bodies) must be carried out.

Scheme 15

Note. For vehicles with a Tire pressure monitoring system, which can be identified by aluminum valves, the Tire pressure should be adjusted according to the filling information in the multi-function display. To do this, in the >> Main menu >> Tire pressure >> -Settings- << adjust the deviation values so that they are from 0.0 bar to +0.1 bar. Fill the Tires according to the display using the Tire-inflating device. Example: If the Tire-pressure display shows >> Settings << - 0.2 bar, then 0.2 bar must be added. (Scheme 15) Due to the pressure and temperature relationship (0.1 bar/10° C), the actual pressures displayed in the -Basic Tire pressure screen- in the multifunction display, or on the pressure gauge of the Tire-inflating device, may deviate from the required pressure specification at 20° C on the Tire pressure plate. This is particularly the case if the Tire air temperature is significantly above (higher values) or significantly below (lower values) 20° C. Changes in the Tire pressure are displayed for up to 1 minute in the >> Settings <<. (Scheme 16) For vehicles with the Tire pressure monitoring system, always use plastic valve caps. They protect the valve from dust, dirt, and moisture and therefore from damage (corrosion, etc.).

Scheme 16

1. Check condition and Tire pressure.

Valve caps protect the valve from dust and dirt and therefore from damage.

2. Always screw on valve caps tightly and replace missing valve caps.

Cold Tire pressures (at approx. 20° C)

Tire pressures apply to all-season, all-terrain, summer and winter Tires. They also apply only to Tires approved by Porsche.

Partial load: The Tire pressure is specified for a load of up to 3 people + 21 kg of luggage.

The collapsible spare wheel, or alternatively the spare wheel, is an option (standard: Tire sealant)

The spare wheel on the carrier is inflated to 3.4 bar gauge pressure max. During operation, Tires are to be adjusted to the gauge pressure specified for the particular vehicle axle and load condition.

Tire pressure - vehicle partially loaded

Values in bar gauge

Tire pressure - vehicle fully loaded

Values in bar gauge

Scheme 17

Note. The brake fluid level must not exceed the MAX mark. Observe brake fluid quality. Use only new DOT 4 brake fluid. This brake fluid is available under the following part numbers: container quantity 1 litre = 000.043.203.66; container quantity 30 litres = 000.043.203.67.

Scheme 18

Visually inspect brake fluid level. The brake fluid level must be between the MAX and MIN markings. The brake fluid reservoir is located under the left plenum panel cover -arrow-. (Scheme 18)

Tools

Designation Type Number Explanation piston resetting fixture (replaces P83) commercially available tool NR.144

Scheme 19

Foot-operated parking brake: Checking free play

The foot-operated parking brake, hereafter referred to as the FPB, is equipped with asbestos-free brake pads. The FPB pedal module is located on the left in the driver's footwell.

1. Lift vehicle --> 40 V0 LIFTING THE VEHICLE - AS OF MY 2003 (CAYENNE TURBO S, CAYENNE S TIO TITAN) or 40 V0 LIFTING THE VEHICLE - AS OF MY 2003 (CAYENNE TIP, CAYENNE MAN, CAYENNE S TIP, CAYENNE S MAN, CAYENNE TURBO) .

Note. An FPB that is equipped with asbestos-free brake pads must never be adjusted in such a way that the pad has to grind free during operation! Adjustment must only be done at the two adjustment devices on the rear wheels. Do not make adjustments at the pedal module or at the Z deflector on the center console. Ensure that the FPB cables are routed correctly.

Check free play at the pedal module

To do this, measure from the left seat rail up to the lower edge of the pedal plate of the FPB.

2. Depress pedal 40 mm (+ 5 mm). When this dimension is reached, the wheels must be able to turn without grinding the brake pads.

3. Depress pedal 75 mm (+ 5 mm). When this dimension is reached, the wheels must be fixed. If the wheels can still turn, the FPB must be adjusted!

Adjusting the foot-operated parking brake

The rear wheels must be removed to gain access to the adjustment device. Refer to 44 05 19 Removing and installing wheel - as of MY 2003 (All Models) .

Scheme 20

In the event of unfavourable tolerances, the brake pads may prevent the brake disc from turning freely. If this happens, the brake pads must be (evenly) pressed back a little with the piston resetting fixture (replaces P83) NR.144, see Workshop Equipment Manual, Chapter 2.4 -direction arrow-! (Scheme 19)

1. Release the FPB pedal so that the wheels and brake discs can turn freely.

The wheels may still grind slightly even then! If this happens, loosen the rear brake cables by moving them to and fro gently!

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

Scheme 21

3. Adjust the brake shoes (on both wheels). To do this, unscrew the plug -arrow- and turn the brake disc with the opening towards the adjustment device position. Using a screwdriver, adjust the adjustment device until the wheel can no longer be turned. Then unscrew by 6 teeth (wheels must be free to turn). (Scheme 20)

4. Check the free play on the pedal module once again.

5. Position disc brake pads by operating the brake several times.

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

Brake hoses and lines

Carry out visual inspection for leaks, damage, routing and corrosion.

Technical data, wear limits

Checking wheel mounting

Note. Use a suitable commercially available tool (wrench size 19 mm) together with a tested torque wrench, cover a range of 30-150 ftlb. Never use an impact bolter.

Do not undo the wheel bolts to check whether they are secure.

Re-tighten the wheel bolts and check they fit securely. --> Tightening torque: 118 ftlb.

Wheel electronics: reading out battery service life

The remaining service life of the wheel electronics can be read out with the Porsche System Tester. Before scheduled maintenance and/or changing a Tire, it is recommended to read out the remaining service life of the wheel electronics (due to battery capacity). It is always advisable to replace the wheel electronics if the expected remaining service life of the wheel electronics is shorter than that of the Tire. The battery for the wheel electronics cannot be replaced separately.

Scheme 22

1. Connect the -Porsche System Tester-. Read out the respective battery service life of the wheel electronics, FL, FR, RL, RR in months in the menu >> RDK >> Actual values >> Battery service life <<. see scheme 13

Scheme 23

2. If necessary, replace the -wheel electronics A-. Refer to 44 32 19 Removing and installing wheel electronics - as of MY 2003 (All Models). (Scheme 22)

Designation Type Number Explanation flexible screwdriver special tool P 9703

Scheme 24

Check lighting

Turn on ignition, switch on all vehicle lights one after another and check that the individual lights are working.

Lights to be checked

1. Main headlights
2. Fog lights
3. Side direction indicator light
4. Tail light
5. Number plate light
6. Additional brake light

Scheme 25

1- - Bulb for direction indicator light PY 21 W, 12 V (yellow bulb). (Scheme 23)

2- - Bulb for auxiliary high beam headlight. H7 (12 V, 55 W). (Scheme 23)

3- - Bulb for cornering light. H3 (12 V, 55 W). (Scheme 23)

4- - Installing bulb for parking light H6W (12V, 6W). (Scheme 23)

5- - 5 Xenon gas discharge lamp for dipped beam and high beam. D1S (12 V, 35 W). (Scheme 23)

Scheme 26

A- - Brake light. P 21 W. (Scheme 24)

B- - Direction indicator. P 21 W. (Scheme 24)

C- - Reverse light. P 21 W. (Scheme 24)

D- - Rear fog light and tail light. P 21/4 W. (Scheme 24)

E- - Tail light P 21/5 W. (Scheme 24)

Checking horn function

Press horn actuation on steering wheel and check the function and sound of horn.

Checking the clock

Check current time, adjust if necessary.

1. The clock is set in the multi-function display.

2. Press clock button on instrument cluster.

3. Set the time using the rocker switch on the wiper switch.

4. Press reset switch on the wiper switch.

Compare time displayed in instrument cluster with time displayed in PCM (if available) and adjust the time in PCM also if necessary.

Adjusting main headlights

The vehicle must be on a horizontal surface!

Make the adjustment with the regulator switch set to 0 (headlight beam adjustment)!

Use a flexible screwdriver P 9703 with a hexagon bit to adjust the headlights.

Using a headlight adjustment unit, make the adjustment with the vehicle ready for driving (fuel tank full, driver's seat occupied by a person or loaded with --> Mass: 75 kg ; Tire pressures must correspond to specified values).

Scheme 27

1. Press down cover -1- in engine compartment and remove it. (Scheme 25)

2. Turn on the ignition, turn on dipped beam and high beam headlights.

3. Check setting and adjust if necessary.

Adjusting

Set headlight adjustment unit to 10 cm/10 m (1%)!

With this alignment, preference must be given to the central zone around the salient point of the light/dark limit!

Note. The distance between the headlights and the adjustment unit should be as small as possible! It should not exceed 30 cm, because at greater distances it is no longer possible to define the formation of the light/dark limit in the adjustment unit clearly!

Scheme 28

The vertical/side adjustment of the dipped beam/high beam highlight is made first: adjustment -A- and -B-. (Scheme 26)

4. To do this, line up the light/dark borderline running upwards at an angle on the right-hand side with the dotted 15° line of the adjustment unit.

Scheme 29

5. The dipped beam headlight is then adjusted horizontally: adjustment -A- and -B-. (Scheme 27)

Scheme 30

To do this, line up the left, horizontal section of the light/dark limit (when driving on the right) with the dotted horizontal line of the adjustment unit.

Scheme 31

6. Check auxiliary high beam headlight and, if necessary, adjust the side setting using -A- and -B-. (Scheme 29)

7. In the case of Xenon headlights, the ignition must be switched off and on after the adjustment has been made with the lights switched on.

8. After this, the adjustment must be checked again.

9. Fit cap again.

Adjusting the main headlights, USA version

Vertical and horizontal adjustment must be carried out with a headlight adjustment unit.

Checking headlight washer

> Use only soapy water to clean the exterior lights and the plastic headlight lenses!

> Never use chemical cleaning agents!

> To avoid scratches, do not rub with cloths, paper towels or insect-removal sponges that are dry or just damp!

Note. The headlight washer nozzles are pre-set! Generally, it is not necessary to adjust them!

Check function, fluid levels and nozzle settings.

Adjusting spray nozzles

Note. The angle of the spray nozzle can be adjusted by hand. The recommended spraying range is in the central position. Sharp objects must not be placed in the nozzle bore as there is a risk of damaging the spray nozzle!

The bonnet must be closed.

Scheme 32

arrow- Spray nozzle adjustment. (Scheme 30)

Checking electrical equipment

Turn ignition key and check function of warning and indicator lights (visual inspection).

Actuate power windows and check operation.

Check that rear window heater is in working order.

Adjust heater blower and fans to high and low and check the air vents for air throughput.

Check operation of front seats.

Check audio function.

Check operation of door mirror, check adjustment options.

Check operation of orientation lights.

Actuate central locking and check operation.

Operate cigarette lighter and check that it is in working order.

Checking battery vent hose

Note. Make sure the vent hose -A- is not kinked or damaged. If in doubt, replace it. see scheme 28 Vent hose -A- must be inserted in the battery and in the battery box. see scheme 28

Checking battery vent hose under the driver's seat

1. Replace the battery box cover carefully. The ventilation channel must be mounted properly.

Scheme 33

2. Attach the four tension hooks in the battery case cover and close using the screwdriver.

> The fastening screws for seat and seat frame are coated and must be replaced after being unscrewed.

> Before screwing in the new fastening screws, clean the thread holes with an M10 x 1.5 tap!

3. Move the seat in its folded position towards the rear and then tip forward.

Scheme 34

4. Screw in fastening screws -1- and put back the carpet sections. --> Tightening torque: 33 ftlb. see scheme 30

5. Clip in front seat trim -C-. see scheme 30

Scheme 35

6. Push rear cover caps onto seat rails -arrows A- and press down the covers -arrows B- until these engage audibly. (Scheme 33)

Checking battery vent hose of the auxiliary battery

Note. The battery is located in the luggage compartment under the loadspace floor. If the vehicle contains a subwoofer or collapsible spare wheel, the relevant component must be removed before the auxiliary battery is removed.

Scheme 36

1. Remove collapsible spare wheel

1.1. Remove twist grip -A- and position it on the bolt -B-. (Scheme 34)

1.2. Unscrew the bolt and remove it together with the collapsible spare wheel.

Scheme 37

2. Removing subwoofer fastening

2.1. Remove Tire sealant -1- if it is present. (Scheme 35)

2.2. Unscrew both fastening screws -2-. (Scheme 35)

2.3. Unscrew the fastening screw -3-. (Scheme 35)

Scheme 38

3. Disconnect electrical plug connection and remove subwoofer

3.1. Remove plug connection from retaining bracket on the subwoofer and disconnect the plug connection.

3.2. Lift subwoofer up and out.

Scheme 39

4. Remove battery case cover

4.1. Unscrew the four fastening nuts -A-. (Scheme 37)

4.2. Unclip the four fastening clips -B- with a screwdriver. (Scheme 37)

4.3. Remove the cover for the housing by pulling it up.

4.4. Check vent hose.

5. Position battery case cover and screw it on

5.1. Put on the battery case cover, position it and clip in the four fastening clips -A- onto the cover. (Scheme 37)

5.2. Push the restraining straps across the four fastening bolts on the body floor and screw on the four fastening nuts -B-. --> tightening torque: 4.5 ftlb. (Scheme 37)

Scheme 40

6. Installing subwoofer

6.1. Position the subwoofer over the battery case.

6.2. Push the electrical plug connections together until the plug is felt to engage.

6.3. Position electrical plug connection on subwoofer.

Scheme 41

7. Fastening subwoofer

Note. If the vehicle contains a subwoofer or collapsible spare wheel the relevant component must be re-installed.

7.1.

7.2. Insert fastening screw -3- with washer and tighten. --> tightening torque: 3.5 ftlb. (Scheme 39)

7.3. Position both tightening nuts -2- and tighten them. --> tightening torque: 1.5 ftlb. (Scheme 39)

7.4. If present, place Tire sealant -1- in tray. (Scheme 39)

Scheme 42

8. Install collapsible spare wheel

Note. If the vehicle contains a subwoofer or collapsible spare wheel the relevant component must be re-installed.

8.1.

8.2. Insert collapsible spare wheel.

8.3. Screw in screw B -B-. (Scheme 40)

8.4. Position twist grip -A- and tighten fastening screw -B- hand tight. (Scheme 40)

Scheme 43

Note. To perform this check, a trailer with no faults in the wiring and lights, or a trailer test cable VAS 1537 A is required. Please note that, if a VAS 1537 A trailer test cable is used, only vehicles with a 13-pin plug can be checked. The test cable can be attached to the trailer socket to locate faults. The plug has 13 pins; adapters are required for 7-pin sockets. Because of the build-up of heat, ensure that a thermal circuit breaker is used in the test cable.

Checking electrically retractable trailer hitch

Note. The swivel action of the ball hitch is interrupted in the one-touch function of the rocker switch if resistance interferes with the movement sequence. The interruption is indicated by the rapid flashing of the red LED in the rocker switch. Overload protection is switched off by pressing the rocker switch for at least two seconds.

> Never swivel the hitch ball when a trailer is coupled or when, for example, bicycle racks are mounted or supported on the hitch ball.

> Only use the trailer coupling when the hitch ball is extended fully.

> Never insert tools of any kind into the hitch ball swivel mechanism. This could damage the locking mechanism; safe operation of the trailer hitch can then no longer be assured.

> Check that the hitch ball locks into position correctly before every journey.

Overload protection

Note. The vehicle must be stationary. Rear lid or rear window must be open. Trailer must be unhitched. Connectors (and any adapters) must be removed from the socket. There must not be any accessories on the hitch ball (e. g. ball protection cap, bicycle rack, etc.).

Scheme 44

1. Swivelling out the trailer coupling

1.1. Requirements

Note. The vehicle must be stationary. Rear lid or rear window must be open.

1.2.

1.3. To swivel out

1.4. Touch rocker switch -A-. see scheme 43

1.5. >> The hitch ball moves automatically into operating position.

1.6. The red LED in the rocker switch flashes until the operating position is reached.

Scheme 45

2. Retracting the trailer hitch

2.1. Requirements

Note. The vehicle must be stationary. Rear lid or rear window must be open. Trailer must be unhitched. Connectors (and any adapters) must be removed from the socket. There must not be any accessories on the hitch ball (e. g. ball protection cap, bicycle rack, etc.).

2.2.

2.3. To retract

2.4. Touch rocker switch -A-. see scheme 44

2.5. >> The hitch ball moves automatically into operating position.

2.6. The red LED in the rocker switch flashes until the operating position is reached.

Oil change service after 15,000 km/10,000 mls or 1 year

Note. Following fixed service interval display. Applies only for 6-cylinder models. An oil change service must be carried out at the latest after 15,000 km/10,000 mls or 1 year.

Oil change service after 30,000 km/20,000 mls or 2 years

Note. Following flexible service interval display. Applies only for 6-cylinder models. An oil change service must be carried out at the latest after 30,000 km/20,000 mls or 2 years.

Information

Note. The inspection must be carried out every 60,000 km (40,000 miles) in the first 10 years. After the first 10 years, the inspection must be carried out every 2 years, regardless of the mileage.

Checking airbag warning light

1. Function test of airbag warning light in instrument cluster

1.1. Switch on ignition.

Note. The airbag warning light must light up for approx. 3 seconds. If the warning light does not light up, check the light unit and power supply.

1.2.

Scheme 46

2. Function test of airbag warning light in center console

> Read out fault memory and correct the malfunction.

2.1.

2.2. Use the vehicle key to deactivate the passenger's airbag at the key-operated switch (cover of right fuse carrier).

2.3. Switch position ON - airbag active.

2.4. Switch position OFF - airbag deactivated.

2.5. Switch on the ignition; the warning light must light up continuously.