Subsequent work
1. Fill and bleed the cooling system. Refer to 19 38 17 Draining and filling in coolant (includes bleeding) - as of MY 2003 (All Models) .
2. Bleed brake system. Refer to 47 01 07 Bleeding the brake system - as of MY 2003 (All Models Except Cayenne S TIO Titan) .
3. Connect battery. Refer to 90 IN Work instructions after disconnecting the battery - as of MY 2003 (All Models Except Cayenne S TIO Titan) .
4. Mount the wiper arms. Refer to 92 25 19 Removing and installing wiper arm - as of MY 2003 (All Models) .
5. Mount engine compartment covers. Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .
6. Check ATF level. Refer to 48 IN Test and assembly work on power steering - as of MY 2003 (All Models Except Cayenne S TIO Titan) .
7. Bleed power-assisted steering. Refer to 48 IN Test and assembly work on power steering - as of MY 2003 (All Models Except Cayenne S TIO Titan) .
8. Bleed offroad stabilizer if necessary. Refer to 40 26 07 Bleeding the Off-Road stabilizer System (ORS) - as of MY 2003 (All Models) . Refer to 40 26 07 Bleeding the Off-Road stabilizer System (ORS) - as of MY 2003 (All Models Except Cayenne Turbo S) .
9. Mount front wheels. Refer to 44 05 19 Removing and installing wheel - as of MY 2003 (All Models) .
10. If the engine has been replaced by a new one, the air conditioner must be filled in accordance with the instructions as a result of the change of air conditioning compressor. Refer to 87 34 19 Removing and installing air-conditioning compressor - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) and refer to 87 03 17 Adding refrigerant and removing by suction - as of MY 2003 (All Models) .
11. Perform suspension alignment. Refer to 44 IN Suspension alignment, complete - as of MY 2003 (All Models) .
12. Fit engine guard. > 108019 Removing and installing engine guard - "installing"
13. Perform a test drive with the vehicle. Check the fluid level in the reservoir after the coolant circuit has cooled again and, if necessary, fill up to the max marking with coolant.
14. Check engine oil level.
Designation Type Number Explanation Suspending device VW-tool 3033 Porsche System Tester ll special tool 9588 Circlip pliers for spring band clamps, Cayenne hose connections commercially available tool NR.72-1 Flexible screw driver a/f 7 commercially available tool NR.73-1 Filling device special tool P 9696 Transport eyebolt special tool P 9700/1
The following tools can be found in the Workshop Equipment Manual 3.0.13 "WE 1206" (exceptions are noted).
| Item | Designation | Source | Explanation |
|---|---|---|---|
| A- see scheme 303 | Assembly mandrel | Height can be adjusted; used for mounting in the engine cross member; equipped with a locking screw to prevent engine from tipping. | |
| B- see scheme 303 | Wheel hub holder | Secures the axles against falling out | |
| C- see scheme 303 | Assembly mandrel 1/11 | Height can be adjusted; for mounting at the front of the front-axle carrier. | |
| D- see scheme 303 | Oil pan support | Secures the engine against tipping after the transmission has been disconnected. Do not mount at the beginning of removal | |
| E- see scheme 303 | Steering knuckle bracket | In conjunction with -B- it protects the axles and spring struts from damage. see scheme 303 | |
| F- see scheme 303 | Assembly mandrel | For mounting on the rear front-axle carrier | |
| G- see scheme 303 | Assembly mandrel | Positioning guide of the elevating platform into the body | |
| D- see scheme 303 | Assembly mandrel | For mounting on the transmission cross member |
| Item | Designation | Source | Explanation |
|---|---|---|---|
| A- (Scheme 186) | Oil pan support | Prevents the engine tipping backwards. The support is mounted in the direction of travel towards the rear. | |
| B- (Scheme 186) | Wheel hub support | Prevents the spring struts from tipping to the side, thereby damaging the axles. | |
| 1/11- (Scheme 186) | Front mounting on front-axle carrier | Mounted on the base carrier at position 1. | |
| 1a- (Scheme 186) | Mounting with height adjustment | Is screwed into part 1/11. | |
| 2- (Scheme 186) | Lateral mounting mandrel for engine carrier | ||
| 2a- (Scheme 186) | Mounting with height adjustment | Screwed into part 2. | |
| 2b- (Scheme 186) | Protection against tipping | Screwed into part 2a. Prevents the engine from tipping forward. | |
| 3- (Scheme 186) | Rear front-axle carrier mounting | Mounted on the base carrier at position 3 | |
| 4- (Scheme 186) | Mounting in body | Mounted on the base carrier at position 4 | |
| 5- (Scheme 186) | Mounting for transmission cross member | Mounted on the base carrier at position 5 |
| Item | Designation | Source | Explanation |
|---|---|---|---|
| A- see scheme 305 | Suspending device 3033 | See Workshop Equipment Manual 2.2.3 | |
| B- see scheme 305 | Transport eyebolt P 9700/1 | See Workshop Equipment Manual 2.2.2 | Illustration deviates from the appearance of the "hook" (illustration shows V8 tool) -B- see scheme 305 |
| C- see scheme 305 | Flexible screw driver a/f 7 NR.73-1 | See Workshop Equipment Manual 2.4 | |
| D- see scheme 305 | Antifreeze testing device | See Workshop Equipment Manual, Chapter 3.0.6 "WE 1036" | Combined tool for testing antifreeze and electrolytes |
| E- see scheme 305 | Circlip pliers for spring band clamps, Cayenne hose connections NR.72-1 | See Workshop Equipment Manual 2.4 | |
| F- see scheme 305 | Filling device P 9696 | See Workshop Equipment Manual 2.2.2 | Used for vacuum filling of the cooling system |
| G- see scheme 305 | Porsche System Tester ll 9588 | See Workshop Equipment Manual 2.2.2 | |
| H- see scheme 305 | Lifting platform | Can be found in Workshop Equipment Manual, 3.0.13 "WE 1206" |
Special equipment-specific features are described in the notes.
1. Suspend the engine at the jacking points provided on a workshop crane and set down on the front-axle carrier. Refer to 10 01 IN Lifting the engine with a workshop crane - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .
2. Secure the engine against tipping. To do this, attach the safety locks on the engine cross member and raise the support under the oil pan until it touches the oil pan.
3. Install the transmission and mount it on the engine. Refer to 37 35 27 Removing and refitting transmission - as of MY 2003 (Cayenne TIP) or refer to 34 35 27 Removing and refitting transmission - as of MY 2003 (Cayenne MAN) .
4. Bolt the main catalytic converter holders onto the transmission cross member. --> Tightening torque: 17 ftlb.
5. Remove the support from under the oil pan and remove the tipping protection from the engine cross member.
6. Clip the oxygen sensor cable of the rear oxygen sensors into the supports and place the connector on the engine.
7. Pre-fit the drive belt. Mount the drive belt on the pulleys as far as possible. For details, refer to 13 78 19 Removing and installing drive belt - as of MY 2004 (Cayenne TIP, Cayenne MAN) .
8. Position the lifting platform under the engine/transmission combination.
9. Raise the body to a comfortable working height with the platform lift.
Note. Have a helper ensure the engine/transmission combination clearance when moving it into the body.
- When moving the unit into the body, ensure that the shift cable is on the transmission.
- When moving the unit into the body, fit the air-conditioning compressor at the same time.
10. Raise the engine/transmission combination into the body with the lifting platform. Ensure sufficient clearance. The insertion guides on the lifting platform must fit into the holes in the body. Fit the air-conditioning compressor when the engine is at half height. For details, refer to 87 34 19 Removing and installing V6 air-conditioning compressor - as of MY 2004 (Cayenne TIP, Cayenne MAN) .
11. Install power-steering pump (hydraulic pump). Refer to 48 98 19 Removing and installing hydraulic pump (Cayenne V6) - as of MY 2004 (Cayenne TIP, Cayenne MAN) .
12. Then insert the engine completely up into the engine compartment.
13. Tighten the 6 new front-axle carrier engine carrier screws. For details, refer to 40 06 19 Removing and installing front-axle carrier - as of MY 2003 (Cayenne TIP, Cayenne MAN) . --> Initial tightening: 89 ftlb. --> Final tightening - torque angle: 180 °
14. Install transmission cross member. For details, refer to 39 65 19 Removing and installing transfer box - as of MY 2003 (All Models). -A-. see scheme 312
15. Release the lateral supports on the wheel hubs.
16. Lower the lifting platform slowly and remove.
17. Connect electric connector -1, 2 and 3- to transmission. see scheme 314
18. Mount selector lever cable. For details, refer to 37 15 19 Removing and installing selector lever cable - as of MY 2003 (Cayenne TIP) .
Note. In vehicles with an offroad stabilizer, the electric lead must also be connected to the anti-roll bar.
- In addition, the two hydraulic lines (near the steering gear) must be screwed on.
19. Push the servo oil line onto the oil cooler and mount the spring band clamp.
Note. For vehicles with Servotronic, the electric connectors on the steering gear must also be connected.
Note. The slightly different illustrations between V8 and V6 show essentially the same actions.
20. Fit the steering column onto the steering gear. For details, refer to 48 90 19 Removing and installing steering gear - as of MY 2003 (All Models Except Cayenne S TIO Titan) .
21. Fit the heat protection shield on the steering gear by means of 2 fastening screws. --> Tightening torque: 7.5 ftlb.
22. Slide the heater coolant lines on the left side member and mount the space-saving clamps.
23. Push on the coolant connection piece on the lower left on the radiator. The connection piece must engage audibly.
24. Fit secondary air line to the secondary air pump. The connector must engage audibly.
25. Connect the ATF lines to the cooler. Remove the plugs and mount the lines. For details, refer to 38 62 19 Removing and installing line for ATF cooling - as of MY 2003 (Cayenne TIP) .
26. Mount the ground point of the generator on the right side member. --> Tightening torque: 15 ftlb.
Note. The slightly different illustrations between V8 and V6 show essentially the same actions.
27. Tighten the catalytic converter fastening on the body (Ill. shows two-train exhaust system for V8) --> Catalytic converter to body. For details, refer to 26 73 19 Removing and installing (main) catalytic converter - as of MY 2004 (Cayenne TIP, Cayenne MAN). see scheme 327
28. Remove and align cardan shaft. Refer to 39 35 19 Removing and installing rear cardan shaft - as of MY 2003 (Cayenne MAN) .
29. Push new exhaust clamps on catalytic converter.
Note. Use a transmission jack to support the exhaust system during installation.
30. Install the exhaust system. Move the exhaust system to its installation position using a transmission jack. Refer to 26 01 19 Removing and installing exhaust system - as of MY 2003 (All Models) .
31. Install the front cross member under the radiators. To do this, tighten the four fastening screws. --> Tightening torque: 17 ftlb.
32. Screw the front apron onto the transverse strut.
33. Lower the vehicle halfway.
Note. In the case of vehicles with air suspension, the compressed air lines must also be screwed on.
- Then connect the headlight levelling system sensor.
34. Tighten the brake lines on the left and right in the wheel housings.
35. Mount the electrical connections of the spring struts. To do this, connect cable -1- and then fasten supports -2 and 3-. see scheme 335
36. Lower the vehicle.
Note. If the fastening screws for the spring strut cannot be positioned, the spring strut can be pushed up slightly using a garage jack.
37. Mount the 3 fastening screws on the left and right spring struts from above (engine compartment side). -arrows-. Refer to 40 TW Tightening torques for front axle - as of MY 2003 (All Models). see scheme 337
38. Connect the 4 oxygen sensor connectors at the radiator tank splash panel.
39. Mount B+ transfer point on left spring dome. To do this, connect the two positive cables from the engine over the bolts. --> Tightening torque: 17 ftlb.
40. Connect the servo line to the reservoir and mount the spring band clamp. Then fill the container with Pentosin.
41. Tighten the line on the plenum panel splash panel from the carbon canister -2- and the fuel line -1-. --> Tightening torque: 26 ftlb.. Then mount the vacuum line. see scheme 341
42. Connect the vacuum line to the right spring dome and mount the spring band clamp. Then mount the 2 lines on the coolant reservoir and secure with spring band clamps.
43. Lay the engine wiring harness into the plenum panel. Mount the rubber sleeve into the middle opening. Then guide the control unit connector to the right. Connect the control unit, connector, and ground point. --> Tightening torque: 7.5 ftlb.
44. Plug in the 4 connectors (red, brown, white and black) in the left-hand central electrical system box. Then mount the cover using four Torx screws.
45. Check whether the wiring harness is laid correctly. Close all fixing clips.
46. Mount the plenum chamber cover. Do not forget the electric connector. Mount the 4 bayonet screws -A-. see scheme 345
47. Fit the drive belt and check that it is positioned correctly. Then remove the locking screw. For details, refer to 13 78 19 Removing and installing drive belt - as of MY 2004 (Cayenne TIP, Cayenne MAN) .
48. Connect the upper right coolant connection piece to the radiator. The connection piece must engage audibly.
Note. The slightly different illustrations between V8 and V6 show essentially the same actions.
49. Insert the air-cleaner element.
50. Insert the air cleaners into the housing and slide on the cover from the top downwards. Then close the two respective sheetmetal clips.
51. Push the air tube on the air cleaner cover.
52. Mount the intake manifold. To do this, push the intake manifold onto the throttle body and mount the vacuum line at the same time. Then attach the other end to the cover of the air cleaner housing.
53. Attach the hose clamp, the electric connector on the mass air-flow meter and the 2 fastening bolts on the air cleaner housing.
54. Press the 4 rubber elements in the cover onto the 4 ball head supports. The mounts must be felt to engage.
1. Fill and bleed the cooling system. Refer to 19 38 17 Draining and filling in coolant (includes bleeding) - as of MY 2003 (All Models) .
2. Bleed brake system. Refer to 47 01 07 Bleeding the brake system - as of MY 2003 (All Models Except Cayenne S TIO Titan) .
3. Connect battery. Refer to 90 IN Work instructions after disconnecting the battery - as of MY 2003 (All Models Except Cayenne S TIO Titan) .
4. Mount the wiper arms. Refer to 92 25 19 Removing and installing wiper arm - as of MY 2003 (All Models) .
5. Mount engine compartment covers. Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .
6. Check ATF level. Refer to 48 IN Test and assembly work on power steering - as of MY 2003 (All Models Except Cayenne S TIO Titan) .
7. Bleed power-assisted steering. Refer to 48 IN Test and assembly work on power steering - as of MY 2003 (All Models Except Cayenne S TIO Titan) .
8. Bleed offroad stabilizer if necessary. Refer to 40 26 07 Bleeding the Off-Road stabilizer System (ORS) - as of MY 2003 (All Models Except Cayenne Turbo S) .
9. Mount front wheels. Refer to 44 05 19 Removing and installing wheel - as of MY 2003 (All Models) .
10. Perform suspension alignment. Refer to 44 IN Suspension alignment, complete - as of MY 2003 (All Models) .
11. Fit engine guard. > 108019 Removing and installing engine guard - "Installing"
12. Perform a test drive with the vehicle. Check the fluid level in the reservoir after the coolant circuit has cooled again and, if necessary, fill up to the max marking with coolant.
13. Check engine oil level.
Designation Type Number Explanation Suspending device VW-tool 3033 Porsche System Tester ll special tool 9588 Circlip pliers for spring band clamps, Cayenne hose connections commercially available tool NR.72-1 Flexible screwdriver a/f 7 commercially available tool NR.73-1 Filling device special tool P 9696 Transport eyebolt special tool P 9700
The following tools are described in the Workshop Equipment Manual, Chapter 3.0.13 "WE 1206" (exceptions are noted).
| Item | Designation | Source | Explanation |
|---|---|---|---|
| A- see scheme 353 | Assembly mandrel | Height can be adjusted; used for mounting in the engine cross member; equipped with a locking screw to prevent engine from tipping. | |
| B- see scheme 353 | Wheel hub holder | Secures the axles against falling out | |
| C- see scheme 353 | Assembly mandrel 1/11 | Height can be adjusted; for mounting at the front of the front-axle carrier. | |
| D- see scheme 353 | Oil pan support | Secures the engine against tipping after the transmission has been disconnected. Do not mount at the beginning of removal | |
| E- see scheme 353 | Steering knuckle bracket | In conjunction with -B- it protects the axles and spring struts from damage. see scheme 353 | |
| F- see scheme 353 | Assembly mandrel | For mounting on the rear front-axle carrier | |
| G- see scheme 353 | Assembly mandrel | Positioning guide of the elevating platform into the body | |
| H- see scheme 353 | Assembly mandrel | For mounting on the transmission cross member |
| Item | Designation | Source | Explanation |
|---|---|---|---|
| A- see scheme 354 | Oil pan support | Prevents the engine tipping backwards. The support is mounted in the direction of travel towards the rear. | |
| B- see scheme 354 | Wheel hub support | Prevents the spring struts from tipping to the side, thereby damaging the axles. | |
| 1/11- see scheme 354 | Front mounting on front-axle carrier | Mounted on the base carrier at position 1. | |
| 1a- see scheme 354 | Mounting with height adjustment | Screwed into part 1/11. | |
| 2- see scheme 354 | Lateral mounting mandrel for engine carrier | ||
| 2a- see scheme 354 | Mounting with height adjustment | Screwed into part 2. | |
| 2b- see scheme 354 | Protection against tipping | Screwed into part 2a. Prevents the engine from tipping forward. | |
| 3- see scheme 354 | Rear front-axle carrier mounting | Mounted on the base carrier at position 3. | |
| 4- see scheme 354 | Mounting in body | Mounted on the base carrier at position 4. | |
| 5- see scheme 354 | Mounting for transmission cross member | Mounted on the base carrier at position 5 |
| Item | Designation | Source | Explanation |
|---|---|---|---|
| A- see scheme 355 | Suspending device 3033 | See Workshop Equipment Manual 2.2.3 | |
| B- see scheme 355 | Transport eyebolt P 9700 | See Workshop Equipment Manual 2.2.2 | |
| C- see scheme 355 | Flexible screwdriver a/f 7 NR.73-1 | See Workshop Equipment Manual 2.4 | |
| D- see scheme 355 | Antifreeze testing device | See Workshop Equipment Manual, Chapter 3.0.6 "WE 1036" | Combined tool for testing antifreeze and electrolytes |
| E- see scheme 355 | Circlip pliers for spring band clamps, Cayenne hose connections NR.72-1 | See Workshop Equipment Manual 2.4 | |
| F- see scheme 355 | Filling device P 9696 | See Workshop Equipment Manual 2.2.2 | Used for vacuum filling of the cooling system |
| G- see scheme 355 | Porsche System Tester ll 9588 | See Workshop Equipment Manual 2.2.2 | |
| H- see scheme 355 | Lifting platform | Can be found in Workshop Equipment Manual, 3.0.13 "WE 1206" |
Special features that are required for the equipment or relate to the Cayenne Turbo (M48/50) are described in the notes.
1. Suspend the engine at the jacking points provided on a workshop crane and set down on the front-axle carrier.
2. Secure the engine against tipping. To do this, attach the locks on the engine cross member and raise the support under the oil pan until it touches the oil pan.
3. Fit the transmission onto the engine. Refer to 37 35 27 Removing and refitting transmission - as of MY 2003 (Cayenne S TIP, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) or refer to 34 35 27 Removing and refitting transmission - as of MY 2003 (Cayenne S MAN) .
4. Install pre- and main catalytic converters. 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) . Refer to 26 76 19 Removing and installing primary catalytic converter - Cayenne Turbo - as of MY 2003 (Cayenne Turbo, Cayenne Turbo S) .
5. Tighten the fastening screw on the catalytic converter support. --> Tightening torque: 23 (17 ftlb.) Nm
6. Bolt the main catalytic converter supports onto the transmission cross member. For details, refer to 26 73 19 Removing and installing (main) catalytic converter - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .
7. Remove the support from under the oil pan and remove the tipping protection from the engine cross member.
8. Clip the oxygen sensor cable of the rear oxygen sensors into the supports and place the connector on the engine.
9. Pre-fit the drive belt. Mount the drive belt on the pulleys as far as possible.
10. Position the lifting platform under the body.
11. Raise the body to a comfortable working height with the platform lift.
Note. When moving the unit into the body, ensure that the shift cable is on the transmission.
- When moving the unit into the body, put the air-conditioning compressor into installation position.
- If the engine is to be replaced by a new one, make sure the air conditioner is evacuated before removing the engine and the new air-conditioning compressor is connected during installation of the engine as the replacement engine is delivered with the new compressor mounted. Refer to «87 34 19 Removing and installing air-conditioning compressor - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan)»(ref-274620-S10061287352007121900000) .
Note. Position the front-axle carrier back in the original, marked installation position and be careful not to damage adjacent parts.
12. Raise the engine/transmission combination into the body with the lifting platform. Ensure sufficient clearance. The insertion guides on the lifting platform must fit into the holes in the body.
13. Tighten the 6 new front-axle carrier engine carrier screws. For details, refer to 40 06 19 Removing and installing front-axle carrier - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo) . Refer to 40 06 19 Removing and installing front-axle carrier - as of MY 2003 (Cayenne Turbo S, Cayenne S TIO Titan) . --> Initial tightening: 120 (89 ftlb.) Nm --> Final tightening - torque angle: 180 °
14. Install transmission cross member. For details, refer to 39 65 19 Removing and installing transfer box - as of MY 2003 (All Models). -A-. see scheme 363
15. Loosen the lateral supports on the wheel hubs.
16. Lower the lifting platform slowly and remove.
17. Connect electric connector -1, 2 and 3- on the transmission and clip in the wiring harness. see scheme 365
18. Mount selector lever cable. For details, refer to 37 15 19 Removing and installing selector lever cable - as of MY 2003 (Cayenne S TIO Titan) . Refer to 37 15 19 Removing and installing selector lever cable - as of MY 2003 (Cayenne S TIP, Cayenne Turbo, Cayenne Turbo S) .
Note. In the Cayenne Turbo (M48/50), the hose connections on the turbochargers must also be fastened. To do this, connect pressure pipe -2- and tighten the hose clamp. Then fit the lead of the charge air cooler. The connection piece must engage audibly. Ensure that sheetmetal clip -1- is fitted correctly. see scheme 367
- Connect the hose line on the left charge air cooler. Ensure that locking clip -1- is mounted correctly. Then connect the line to the ambient air valve -2- and fit the spring-band clamp. see scheme 368
19. Push the servo oil line onto the oil cooler and mount the spring band clamp.
Note. For vehicles with Servotronic, the electric connector on the steering gear must also be connected.
20. Fit the steering column onto the steering gear. For details, refer to 48 90 19 Removing and installing steering gear - as of MY 2003 (All Models Except Cayenne S TIO Titan) . Refer to 48 90 19 Removing and installing steering gear - as of MY 2003 (Cayenne S TIO Titan) .
21. Fit the heat protection shield on the steering gear by means of 2 fastening screws. --> Tightening torque: 10 (7.5 ftlb.) Nm
22. Slide the heater coolant lines on the left side member and mount the clips.
23. Push on the coolant connection piece on the lower left on the radiator. The connection piece must engage audibly.
24. Connect the ATF lines to the radiator. Remove the plugs and mount the lines. For details, refer to 38 62 19 Removing and installing line for ATF cooling - as of MY 2003 (Cayenne S TIP, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .
25. Mount the ground point of the generator on the right side member. --> Tightening torque: 20 (15 ftlb.) Nm .
26. Tighten the catalytic converter fastening on the body. For details, refer to 26 73 19 Removing and installing (main) catalytic converter - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) .
27. Install cardan shaft. Refer to 39 35 19 Removing and installing rear cardan shaft - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S) . Refer to 39 35 19 Removing and installing rear cardan shaft - as of MY 2003 (Cayenne S TIO Titan) .
28. Install the exhaust system. Move the exhaust system to its installation position using a transmission jack. Refer to 26 01 19 Removing and installing exhaust system - as of MY 2003 (All Models) .
29. Install the front transverse strut under the radiators. To do this, tighten the four fastening screws. --> Tightening torque: 23 (7.5 ftlb.) Nm
30. Screw the front apron onto the transverse strut. --> Tightening torque: 5 (3.5 ftlb.) Nm
31. Lower the vehicle halfway.
Note. In the case of vehicles with air suspension, the compressed air lines must also be screwed on.
- Then connect the headlight levelling system sensor.
32. Tighten the brake lines on the left and right in the wheel housings.
33. Fit the electric connections of the spring struts. To do this, connect cable -1- and then fasten supports -2 and 3-. see scheme 384
34. Lower the vehicle.
35. Mount the three fastening screws on the left and right spring struts from above (engine compartment side). -arrows-. Refer to 40 TW Tightening torques for front axle - as of MY 2003 (All Models). see scheme 386
36. Mount B+ transfer point on left spring dome. --> Tightening torque: 23 (17 ftlb.) Nm
37. Connect the servo line to the reservoir and mount the spring band clamp. Then fill the container with Pentosin.
38. Connect the line from carbon canister -2- to the plenum panel splash panel until it audibly engages and tighten fuel line -1-. --> Tightening torque: 35 (26 ftlb.) Nm see scheme 389
39. On the left and right of the plenum panel splash panel, connect the oxygen sensor plug connections in front of and behind the catalytic converter and lay the cables so they are not subject to chafing.
Note. In the Cayenne Turbo, the support for the vacuum pump must also be screwed into position.
> Tightening torque: 7.5 ftlb.
40. Connect the vacuum line to the right spring dome and mount the spring band clamp. Then mount the 2 lines on the coolant reservoir and secure with spring band clamps.
41. Lay the engine wire harness into the plenum panel. Mount the rubber sleeve into the middle opening. Then guide the control unit connector to the right. Connect the control unit, connector, and ground point. --> Tightening torque: 10 (7.5 ftlb.) Nm
42. Plug in the 4 connectors (red, brown, white and black) in the left-hand central electrical system box. Then mount the cover using 4 Torx screws.
43. Check whether the wiring harness is laid correctly. Close all fixing clips.
44. Mount the plenum chamber cover. Do not forget the electric connector for the air-quality sensor. Mount the 4 bayonet screws -A-. see scheme 395
45. Position and tighten drive belt on all pulleys. Refer to 13 78 19 Removing and installing drive belt - as of MY 2003 (Cayenne S TIP, Cayenne S MAN) . Refer to 13 78 19 Removing and installing drive belt - as of MY 2003 (Cayenne S TIO Titan) . Refer to 13 78 19 Removing and installing drive belt - as of MY 2003 (Cayenne Turbo, Cayenne Turbo S) .
46. Connect the upper left coolant connection piece to the radiator. The connection piece must engage audibly.
47. Mount the torque support with new lock nuts. --> Tightening torque: 60 (44 ftlb.) Nm --> Tightening torque: 60 (44 ftlb.) Nm
48. Insert the air-cleaner element.
Note. In the case of vehicles with air suspension, the line of the air compressor must also be connected on the left air cleaner cover.
49. Mount both air cleaners with cover. Insert the air cleaners in the housings and slide on the covers from the top downwards. Then close the two respective sheetmetal clips. The coolant overflow hose must also be clipped onto the air cleaner housing of cylinder bank 1-4. Connect the electric connectors of the hot film mass air flow sensors.
Note. In the Cayenne Turbo (M48/50), the control lines of the ambient air valve on the T-piece must also be connected.
Note. Clip on the leads when mounting the Y-shaped pipe on the bottom.
50. Attach the vacuum line to the underside of the Y-shaped pipe.
51. Fit the Y-shaped pipe to the left and right and tighten the hose clamps.
Note. In the Cayenne Turbo (M48/50), the boost pressure sensor -3- must also be connected. see scheme 405
52. Slide the Y-shaped pipe onto the throttle adjuster. Then insert the left and right fastening bolts. Turn both bolts 45° clockwise.
53. Connect the throttle adjuster. The connector must engage audibly. Clip the connecting cable into the sheetmetal holder.
54. Press the 4 rubber elements in the cover onto the 4 ball head supports. The mounts must be felt to engage.
1. Fill and bleed the cooling system. Refer to 19 38 17 Draining and filling in coolant (includes bleeding) - as of MY 2003 (All Models) .
2. Bleed brake system. Refer to 47 01 07 Bleeding the brake system - as of MY 2003 (All Models Except Cayenne S TIO Titan) .
3. Connect battery. Refer to 90 IN Work instructions after disconnecting the battery - as of MY 2003 (All Models Except Cayenne S TIO Titan) .
4. Mount the wiper arms. Refer to 92 25 19 Removing and installing wiper arm - as of MY 2003 (All Models) .
5. Mount engine compartment covers. Refer to 70 02 19 Removing and installing front cover (engine compartment) - as of MY 2003 (All Models) .
6. Check ATF level. Refer to 48 IN Test and assembly work on power steering - as of MY 2003 (All Models Except Cayenne S TIO Titan) .
7. Bleed power-assisted steering. Refer to 48 IN Test and assembly work on power steering - as of MY 2003 (All Models Except Cayenne S TIO Titan) .
8. Bleed offroad stabilizer if necessary. Refer to 40 26 07 Bleeding the Off-Road stabilizer System (ORS) - as of MY 2003 (All Models) . Refer to 40 26 07 Bleeding the Off-Road stabilizer System (ORS) - as of MY 2003 (All Models Except Cayenne Turbo S) .
9. Mount front wheels. Refer to 44 05 19 Removing and installing wheel - as of MY 2003 (All Models) .
10. If the engine has been replaced by a new one, the air conditioner must be filled in accordance with the instructions as a result of the change of air conditioning compressor. Refer to 87 34 19 Removing and installing air-conditioning compressor - as of MY 2003 (Cayenne S TIP, Cayenne S MAN, Cayenne Turbo, Cayenne Turbo S, Cayenne S TIO Titan) and refer to 87 03 17 Adding refrigerant and removing by suction - as of MY 2003 (All Models) .
11. Perform suspension alignment. Refer to 44 IN Suspension alignment, complete - as of MY 2003 (All Models) .
12. Fit engine guard. > 108019 Removing and installing engine guard - "installing" .
13. Perform a test drive with the vehicle. Check the fluid level in the reservoir after the coolant circuit has cooled again and, if necessary, fill up to the max marking with coolant.
14. Check engine oil level.